Electrical Connection Arrangement, Connection System and Method for Producing an Electrical Connection Between two Electrical Conductors

Abstract

The invention relates to an electrical connection arrangement (4) for the electrical and mechanical connection of a first electrical conductor (2) to a second electrical conductor (3), having an electrical connection element (8) with a first end and with a second end, wherein a press portion (9) is arranged at the first end, the press portion having at least one lateral contact surface (11) for electrical contact with an inner lateral surface (12) of a contact recess (13) of the first electrical conductor (2), and wherein a bearing portion (10) is arranged at the second end, the bearing portion having a bearing surface (14) for non-positive connection to a side surface (15) of the second electrical conductor (3). A connection bore (16) extends at least between the bearing portion (10) and the press portion (9) so that the connection element (8) can receive a first fastening means (17) or forms a first fastening means (17) itself, and can receive a second fastening means (18) which can be connected to the first fastening means (17) so that the non-positive connection is produced between the bearing surface (14) of the bearing portion (10) and the side surface (15) of the second electrical conductor (3). It is provided that the press portion (9) can be radially spread apart by the first fastening means (17) and/or by the second fastening means (18) in order to bring about a non-positive connection between the at least one lateral contact surface (11) and the inner lateral surface (12) of the contact recess (13), by the two fastening means (17, 18) being connected together.

Claims

1. Electrical connection arrangement (4) for the electrical and mechanical connection of a first electrical conductor (2) to a second electrical conductor (3), having an electrical connection element (8) with a first end and with a second end, wherein a press portion (9) is arranged at the first end, the press portion having at least one lateral contact surface (11) for electrical contact with an inner lateral surface (12) of a contact recess (13) of the first electrical conductor (2), and wherein a bearing portion (10) is arranged at the second end, the bearing portion having a bearing surface (14) for non-positive connection to a side surface (15) of the second electrical conductor (3), wherein a connection bore (16) extends at least between the bearing portion (10) and the press portion (9) so that the connection element (8) can receive a first fastening means (17) or forms a first fastening means (17) itself, and can receive a second fastening means (18) which can be connected to the first fastening means (17) so that the non-positive connection is produced between the bearing surface (14) of the bearing portion (10) and the side surface (15) of the second electrical conductor (3), and wherein the press portion (9) can be radially spread apart by the first fastening means (17) and/or by the second fastening means (18) in order to bring about a non-positive connection between the at least one lateral contact surface (11) and the inner lateral surface (12) of the contact recess (13), by the two fastening means (17, 18) being connected together.

2. Electrical connection arrangement (4) according to claim 1, characterized in that the connection element (8) is primarily configured to be sleeve-shaped, wherein the connection bore (16) extends entirely through the connection element (8).

3. Electrical connection arrangement (4) according to claim 1 or 2, characterized in that the bearing portion (10) is configured in one piece with the press portion (9).

4. Electrical connection arrangement (4) according to one of claims 1 to 3, characterized in that the connection element (8), preferably the bearing portion (10) of the connection element (8), has a mechanical interface (26) for a rotationally fixed mechanical connection to at least one of the electrical conductors (2, 3).

5. Electrical connection arrangement (4) according to one of claims 1 to 4, characterized in that the press portion (9) is configured to receive the first fastening means (17) in a rotationally fixed manner.

6. Electrical connection arrangement (4) according to one of claims 1 to 5, characterized in that the press portion (9) is slotted in the longitudinal direction in order to form the at least one lateral contact surface (11) in each case between two longitudinal slots, wherein preferably a plurality of lateral contact surfaces (11) are configured in the manner of spring tabs of a spring cage.

7. Electrical connection arrangement (4) according to one of claims 1 to 6, characterized in that the at least one lateral contact surface (11) has a convex bulge.

8. Electrical connection system (1), in particular electrical connection system (1) for high voltage technology, having an electrical connection arrangement (4) according to one of claims 1 to 7, and the first fastening means (17), wherein the first fastening means (17) is received in the press portion (9) inside the connection bore (16).

9. Electrical connection system (1) according to claim 8, characterized in that for bringing about the spreading apart of the press portion (9) as a result of the connection of the two fastening means (17, 18), a) the first fastening means (17) tapers on the outer lateral surface and/or b) the press portion (9) tapers on the inner lateral surface inside the connection bore (16), in the direction of the second end of the connection element (8), preferably conically.

10. Electrical connection system (1) according to claim 8 or 9, characterized in that the first fastening means (17) has an internal thread for forming a threaded connection with the second fastening means (18).

11. Electrical connection system (1) according to one of claims 8 to 10, having the second fastening means (18), wherein the second fastening means (18) is received at least in some portions in the bearing portion (10) inside the connection bore (16).

12. Electrical connection system (1) according to claim 11, characterized in that the second fastening means (18) has a screw element a) with a screw shank (19) which can be passed through a fastening recess (20) of the second electrical conductor (3) and which extends at least in some portions through the connection bore (16), wherein the screw shank (19) has an external thread for forming a threaded connection with the first fastening means (17); and b) with a screw head (21) which is supported directly or indirectly on a side surface of the second electrical conductor (3) facing away from the bearing surface (14) of the bearing portion (10).

13. Electrical connection system (1) according to one of claims 8 to 12, having the first electrical conductor (2) and the second electrical conductor (3), wherein the electrical conductors (2, 3) are preferably configured in each case as conductor rails.

14. Electrical connection system (1) according to claim 13, characterized in that a fastening recess (20) of the second electrical conductor (3), through which the second connection means (18) is passed, has a larger cross-sectional extent than the portion of the second connection means (18) running through the fastening recess (20), for compensating for mechanical tolerances.

15. Method for producing an electrical and mechanical connection between a first electrical conductor (2) and a second electrical conductor (3), having at least the following method steps: arranging an electrical connection element (8) with a press portion (9) arranged on a first end, a bearing portion arranged on a second end and a connection bore (16), which extends at least between the bearing portion (10) and the press portion (9), between the electrical conductors (2, 3); introducing a first fastening means (17) into the connection bore (16) or designing the connection element (8) such that it forms a first fastening means (17) itself; introducing a second fastening means (into the connection bore (16); and connecting the two fastening means (17, 18) so that a bearing surface (14) of the bearing portion (10) comes into contact with a side surface (15) of the second electrical conductor (3) and the first fastening means (17) or the second fastening means (18) radially spreads apart the press portion (9) in order to bring about a non-positive connection between at least one lateral contact surface (11) of the press portion (9) and an inner lateral surface (12) of a contact recess (13) of the first electrical conductor (2).

Description

[0124] Exemplary embodiments of the invention are described in more detail hereinafter with reference to the drawings.

[0125] The figures show in each case preferred exemplary embodiments in which individual features of the present invention are shown in combination with one another. Features of an exemplary embodiment are also able to be implemented separately from the other features of the same exemplary embodiment, and can be accordingly combined together with features of other exemplary embodiments in a simple manner by a person skilled in the art to form further meaningful combinations and sub-combinations.

[0126] Elements which are function the same are provided with the same reference signs in the figures.

[0127] In the figures schematically:

[0128] FIG. 1 shows a connection system in an unconnected state according to an exemplary embodiment of the invention in a lateral sectional view;

[0129] FIG. 2 shows the connection system of FIG. 1 in a preassembled state in a lateral sectional view;

[0130] FIG. 3 shows the connection system of FIG. 1 in a partially assembled state in a lateral sectional view;

[0131] FIG. 4 shows the connection system of FIG. 1 in a fully assembled state in a lateral sectional view;

[0132] FIG. 5 shows a connection element according to the invention and a corresponding first fastening means in a perspective view:

[0133] FIG. 6 shows the connection element of FIG. 5 in a further perspective view;

[0134] FIG. 7 shows a connection system in the fully assembled state with a housing shell for the first electrical conductor in a lateral sectional view;

[0135] FIG. 8 shows a perspective individual view of the housing shell and the connection element of the connection system of FIG. 7;

[0136] FIG. 9 shows a connection system in the fully assembled state according to a further exemplary embodiment of the invention in a lateral sectional view;

[0137] FIG. 10 shows a connection element in one piece with the first fastening means according to a further exemplary embodiment of t invention in a perspective view;

[0138] FIG. 11 shows an anti-rotation device between a one-piece connection element and the first electrical conductor in a perspective view;

[0139] FIG. 12 shows a connection system with the connection element according to FIG. 10 in a fully assembled state in a lateral sectional view;

[0140] FIG. 13 shows a connection element in one piece with the first fastening means and a second fastening means configured as a bolt, according to a further exemplary embodiment of the invention in a perspective view;

[0141] FIG. 14 shows a connection system with the connection element according to FIG. 13 in a partially assembled state in a lateral sectional view; and

[0142] FIG. 15 shows the connection system according to FIG. 14 in a fully assembled state in a lateral sectional view.

[0143] An electrical connection system 1 according to a first exemplary embodiment of the invention is shown in different states in a lateral sectional view in FIGS. 1 to 4.

[0144] The electrical connection system 1 has a first electrical conductor 2 and a second electrical conductor 3, which in the exemplary embodiment are configured in each case as conductor rails and which can be connected by means of an electrical connection arrangement 4 according to the invention. The state of the connection system 1 when not yet connected is shown in FIG. 1.

[0145] The first electrical conductor 2 can be, for example, a connector panel or the first electrical conductor 2 can be part of a connector panel which is connected to one or more electrical consumers via one or more electrical outputs 5, for example to a main unit or secondary unit of an electric vehicle. The second electrical conductor 3 can be, for example, a conductor rail which is connected in the load path or charging path to a high voltage battery 8 and which can be directly or indirectly connected to the high voltage battery 6 (for example via an electrical sub-assembly) which is indicated in FIG. 1 as a black box 7.

[0146] The connection arrangement 4 has an electrical connection element 8 with a press portion 9 arranged on a first end and a bearing portion 10 arranged on a second end. The connection element 8 is primarily configured to be sleeve-shaped and extends along a longitudinal axis L from its first end to its second end. In the exemplary embodiment, the bearing portion 10 and the press portion 9 are configured in one piece.

[0147] The press portion 9 has at least one lateral contact surface 11 for electrical contact with an inner lateral surface 12 of a contact recess 13 of the first electrical conductor 2. In order to form at least one lateral contact surface 11 the press portion 9 is preferably slotted in the longitudinal direction, wherein a lateral contact surface 11 in the manner of a spring tab of a spring cage is formed in each case between two longitudinal slots. In the exemplary embodiment, specifically four lateral contact surfaces 11 or spring tabs are provided, as can be identified particularly clearly by the perspective view of the connection element 8 in FIGS. 5 and 6.

[0148] The bearing portion 10 of the connection element 8 has a front bearing surface 14 for a non-positive, electrical contact with a side surface 15 of the second electrical conductor 3. In this case, in particular, a flat contact can be provided.

[0149] A connection bore 16 extends through the connection element 3, from the second end through the bearing portion 10 into the press portion 9. In the exemplary embodiment, the connection bore 16 extends entirely through the whole connection element 8. Due to the connection bore 16, the press portion 9 can receive a first fastening means 17 and the bearing portion 10 can receive a second fastening means 18. The two fastening means 17, 18 can be screwed together via a common threaded connection. For example, in the exemplary embodiment the first fastening means 17 is configured as a screw nut which has an internal thread for forming the common threaded connection with the second fastening means 18.

[0150] Also by way of example, the second fastening means 18 is configured as a screw element with a screw shank 19 which can be passed through a fastening recess 20 of the second electrical conductor 3 and which extends at least in some portions through the connection bore 18 and has an external thread for forming the threaded connection with the first fastening means 17.

[0151] In FIG. 2 a preassembled state of the electrical connection system 1 or the electrical connection arrangement 4 is shown. In the preassembled state shown, the connection arrangement 4 is captively connected to the second electrical conductor 3, by the first fastening means 17 and the second fastening means 18 already being partially screwed together.

[0152] In order to simplify the screwing process for the technician, it can be provided that the press portion 9 is configured to receive the first fastening means 17 captively. To this end, for example, the press portion 9 can have a polygonal cross-sectional path on the inner face and the first fastening means 17 can have a polygonal cross-sectional path on the outer face, which can be clearly identified, in particular, when viewing FIGS. 5 and 6 together.

[0153] A partially assembled state of the electrical connection system 1 is shown in FIG. 3. The two fastening means 17, 18 have been screwed together further so that the first fastening means 17 moves further along the longitudinal axis L of the connection element 8 in the direction of the second end of the connection element 8. In this manner, the connection element 8 can be initially pressed with the front bearing surface 14 of the bearing portion 10 axially against the corresponding side surface 15 of the second electrical conductor 3 and a corresponding non-positive mechanical and electrically stable connection can be produced thereby with the second electrical conductor 3. To this end, the second fastening means 18 or the screw element has a screw head 21 which is supported on the second electrical conductor 3, for example by the bearing flange 22 shown, which in the exemplary embodiment is in one piece with the screw head 21. Alternatively, however, an indirect support can also be provided, for example via a washer.

[0154] For tolerance compensation, the fastening recess 20 is configured to be oversized relative to the screw shank 19, as can be clearly identified in FIGS. 1 to 4. As an alternative to an oversized bore, for example, an elongated hole or an elliptical fastening recess 20 can also be provided.

[0155] FIG. 4 finally shows a fully assembled state of the electrical connection system 1. The two fastening means 17, 18 have been screwed together further, which due to the axial movement of the first fastening means 17 in the direction of the second end of the connection element 8 ultimately leads to a radial spreading apart of the press portion 9, whereby a non-positive connection is brought about between the lateral contact surfaces 11 and the inner lateral surface 12 of the contact recess 13, as is indicated by the arrows shown in FIG. 4.

[0156] The aforementioned longitudinal slots between the lateral contact surfaces 11 are advantageous in order to bring about a non-destructive and releasable spreading apart, the longitudinal slots being able to provide the press portion 9 with a certain degree of elasticity. In order to bring about the spreading apart, starting from the axial movement of the first fastening means 17, the press portion 9 on the inner lateral surface, i.e. inside the connection bore 16, and the first fastening means 17 on the outer lateral surface, have in each case surface portions 23, 23′ tapering in the direction of the second end of the connection element 8. The tapering surface portions 23, 23′ preferably have the same slope, but can also differ in terms of their 16 slope and design. In principle, it can be sufficient if only one of the two connecting partners, consisting of the first fastening means 17 and the press portion 9, has a corresponding tapering surface portion 23, 23′.

[0157] In particular, the combination of an axial connection with the second electrical conductor 3 and a radial connection with the first electrical conductor 2 can result in a particularly advantageous electrical connection arrangement 4. If the depth of the contact recess 13 were not to be sufficient for a stable mechanical connection with suitable tolerance compensation, a sleeve-shaped body 24 can be positioned on the first electrical conductor 2, which correspondingly lengthens the contact recess 13 (shown in dashed lines in FIG. 4).

[0158] For compensating for tolerances it can be advantageous if the lateral contact surfaces 11 have a convex bulge as indicated in the exemplary embodiment. Thus the connection element 8 itself can then produce a mechanically and electrically stable connection with the first electrical conductor 2 when the connection element 8 tilts inside the contact recess 13, in order to compensate for a relative rotation of the electrical conductors 2, 3, for example.

[0159] In FIGS. 7 and 8 a further connection system 1 according to the present invention is shown in a fully assembled state, in order to illustrate a further optional optimization of the ease of assembly of the connection system 1.

[0160] The electrical conductors 2, 3, in particular the electrical conductors 2, 3 of a high voltage system, are occasionally provided with one or more housing shells 25 for protection against contact or other reasons, for example as indicated in FIGS. 7 and 8. By means of the housing shells 25 it is possible to provide, on the one hand, a captive retaining means for the connection element 8 (optionally together with the first fastening means 17) and also a further anti-rotation device. Thus, for example, it can be provided that the connection element 8, in particular the bearing portion of the connection element 8, has a mechanical interface 26 (see also FIGS. 5 and 6) for a rotationally fixed mechanical connection with the first electrical conductor 2 or the second electrical conductor 3. A rotationally fixed connection to the first electrical conductor 2 indirectly via the housing shell 25 is indicated in FIG. 7. The mechanical interface 26, as can be identified clearly in FIG. 8, has a polygonal cross section.

[0161] The exemplary embodiments and variants of the invention described above are merely to be understood by way of example. In principle, the combination of an axial and radial connection in a connection system 1 according to the invention can be implemented in many different ways, which is to be illustrated by way of example with reference to the following figures.

[0162] In FIG. 9 the second fastening means 18 is not configured as a screw element but as a purely shank-shaped body which extends from the second electrical conductor 3 transversely, or at right angles, from the side surface 15 provided for the connection and produces the threaded connection with the first fastening means 17. The drive for the screw connection, for example, can be produced via the first fastening means 17 or can be permitted by rotating the connection element 8 together with the first fastening means 17 (for example via a rotationally fixed mechanical interface 26 in the region of the bearing portion 10, comparable with the mechanical interface 26 in FIGS. 7 and 8).

[0163] With reference to FIGS. 10 to 12, a variant of the invention is to be illustrated in which the connection element 8 is configured in one piece with the first fastening means 17 in the manner of a expansion dowel.

[0164] As above, the connection element 8 has a press portion 9 on a first end and a bearing portion 10 on a second end. In the assembled state, the connection element 8 can be non-positively supported with its front bearing surface 14 on the side surface 15 of the second electrical conductor 3 facing the first electrical conductor 2 (see FIG. 12). The lateral contact surfaces 11 of the press portion 9 also serve for the non-positive connection to the inner lateral surface 12 of the contact recess 13 (see also FIG. 12). The connection bore 16 extends entirely through the connection element 8 so that the second fastening means 18 can be passed through from the second end of the connection element 8 to the first end of the connection element 8.

[0165] A first fastening means 17 which is functionally configured in one piece with the press portion 9 extends from the first end of the connection element 8. The first fastening means 17 has an internal thread 27 inside the connection bore 16 (see FIG. 10) in order to be able to be screwed to the second fastening means 18, which is in turn a screw element. The press portion 9 has in the exemplary embodiment of FIGS. 10 to 12 slotted portions in the manner of spring tabs attached on both sides, wherein each spring tab forms one of the lateral contact surfaces 11. The spring tabs are configured to be convex or bulging and represent a defined weakened point in the connection element 8. If the second fastening means 18 or the screw element is now screwed to the internal thread 27 of the first fastening means 17, the axial force component applied during the screwing process to the connection element 8 causes the spring tabs to spread apart as soon as the connection element 8 is supported with its front bearing surface 14 on the second electrical conductor 3. The principle is known primarily from expansion dowels in drywall construction and is surprisingly very suitable for use in the context of the present invention.

[0166] A development of the connection element 8 in one piece with the first fastening means 17 can be an anti-rotation device between the press portion 9 and the contact recess 13 of the first electrical conductor 2, as shown in FIG. 11. For example, the contact recess 13 can have a polygonal cross section, as already mentioned above, in order to cooperate in a rotationally fixed manner with an axial region of the press portion 9 which is also configured to be polygonal.

[0167] A further exemplary embodiment of the invention is shown in FIGS. 13 to 15.

[0168] Similar to the above exemplary embodiment, the connection element 8 is configured in one piece with the first fastening means 17. In contrast to the above exemplary embodiments, however, a screw connection or threaded connection is not provided between the fastening means 17, 18, but rather a press connection.

[0169] To this end, the second fastening means 18 is configured as a bolt, with a bolt head 21′ and a bolt shank 19″. Accordingly, the connection bore 16 of the connection element 8 is configured to receive the bolt shank 19″ with an interference fit so that the fastening means 17, 18 can be pressed together with sufficient force. As can be seen with reference to FIGS. 14 and 15, the bearing flange 22 in this case is advantageously configured on the connection element 8. In other words, the connection element 8 is supported with its bearing surface 14 on the side surface of the second, electrical conductor 3 facing away from the first electrical conductor 2, after the bolt or the second fastening means 18 has been connected to the connection element 8.

[0170] So that in turn the press portion 9 can be spread apart, the connection element 8 has a tapering portion 28 in its upper end portion facing the second electrical conductor 3. By pressing in the bolt shank 19′, the connection element 8 widens in the lower press portion 9 facing the first electrical conductor 2 and brings about the non-positive connection inside the contact recess 13.

[0171] At this point it should be mentioned that it is also possible to provide the insertion of the second fastening means 18, i.e. for example the pressing-in of the bolt in FIGS. 13 to 15, starting from the first electrical conductor 2. In this case, it can be advantageous to ensure that the first fastening means 17 is not pushed out of the second electrical conductor 3. This can be implemented, for example, by an additional or alternative bearing flange 22 or another bearing portion on the side surface of the second electrical conductor 3 facing the first electrical conductor 2 and/or on the side surface of the first electrical conductor 2 facing away from the second electrical conductor 3 or by a corresponding latching means, such as a latching hook, which correspondingly engages behind at least one of the electrical conductors 2, 3. For example, the spring tabs of the press portion 9 can have a latching hook at their ends or be correspondingly re-shaped in order to form a latching hook.