WO2022215936A1

WO2022215936A1 - Contact assembly for transferring an electric voltage and connecting module with contact assembly

Info

Publication number: WO2022215936A1
Application number: PCT/KR2022/004515
Authority: WO
Inventors: Bernd Guntermann; Oliver Gormanns; Michael Haag
Original assignee: Hanon Systems
Priority date: 2021-04-09
Filing date: 2022-03-30
Publication date: 2022-10-13
Also published as: DE102021108916A1

Abstract

The invention, which relates to a contact assembly for transferring an electric voltage and a connecting module with contact assembly, is based on the object of providing a solution for achieving a reliable electrical connection of an electrical load disposed in a sealed housing to a voltage source disposed outside the housing.

Description

CONTACT ASSEMBLY FOR TRANSFERRING AN ELECTRIC VOLTAGE AND CONNECTING MODULE WITH CONTACT ASSEMBLY

The invention relates to a contact assembly for transferring an electric voltage to an electrical load disposed in a housing.

The invention also relates to a connecting module having at least one contact assembly and being disposed on a housing. An electrical load to be supplied with an electric voltage is disposed inside the housing.

Such an electrical load includes, for example, a motor or an electrical component such as an inverter, with which a motor can be driven, for example.

Compressors for mobile applications, in particular for air conditioning systems of motor vehicles, for conveying refrigerant through a refrigerant circuit, also referred to as refrigerant compressors, are known from the prior art. Such compressors are driven either by a pulley being connected by a belt to a drive unit of the motor vehicle, or electrically.

In addition to an electric motor for driving the respective compression mechanism, an electrically driven compressor usually also has a so-called inverter, which is also referred to as an inverted rectifier.

The inverter is used to convert a DC voltage of a vehicle battery disposed in the on-board network into an AC voltage used for driving the electric motor of the compressor. Corresponding control of the inverter allows for controlled operation of the electric motor, in particular in motor vehicles with on-board network voltages of 48　V or above 60　V.

The present invention relates in particular to electrical contact assemblies and connecting modules in vehicles in which DC voltages of, for example, 48　V, 60　V or more are required for operation of electrical components, as may be the case in particular with electrically driven vehicles or vehicles with a so-called hybrid drive.

The use of an inverter or inverted rectifier for driving electric motors at high voltages, especially in vehicles with on-board network voltages above 60　V, involves so-called high-voltage applications, or HV applications for short, particularly in the automotive sector. One such high-voltage application or high-voltage component is, for example, an inverter for an electrically driven refrigerant compressor in a motor vehicle.

Designs of electrically driven refrigerant compressors with a housing in which both the inverter and the electric motor of the refrigerant compressor are disposed are known. As such, the housing, in particular the compressor housing, is designed to be sealed against moisture and dirt. Since the inverter disposed in the housing is to be supplied for operation with a voltage from an on-board network with, for example, 48　V or 60　V and above, so-called passages are to be provided that, on the one hand, allow for transferring voltage into the housing and, on the other hand, do not affect the tightness of the housing.

An electrical passage includes, for example, an electrical conductor or similar means for electrically connecting an electrical load disposed in a sealed housing to an electrical conductor of an on-board network of a motor vehicle disposed outside the housing. In this way, for example, a voltage from a battery located in the on-board network of the motor vehicle is transferred to an electrical load disposed in a sealed housing. The load disposed in the housing can be an electrical component such as the inverter for driving an electric motor.

Transfer can be carried out with insulated leads and/or lead wires being disposed with an appropriate seal, such as an O-ring, inside a passage opening in the housing. The dimensions of the passage opening, the seal designed as an O-ring and the cable, in particular the diameters, are matched to each other so that the passage and/or voltage passage through the housing is sealed to prevent moisture and/or dirt from entering the housing. The lead wires are soldered or crimped to a supply line from the on-board network, for example.

In order to improve the connection possibilities of a supply line from the on-board network at a passage, it is known to provide a connecting module on the compressor housing or in a corresponding opening of the compressor housing. The connecting module has at least one passage and is sealed to the housing. In addition, such a connecting module can be designed with fixed clamping connection options or bolt connection options, for example, in order to firmly connect a voltage-supplying line from the on-board network to the clamping connection options or bolt connection options by means of corresponding eyes or cable lugs. The connection should be easy to disconnect for service purposes, for example. Typically, such a connecting module has two passages.

The bolt connection options can be designed as bolts or threaded bolts, which are connected to the connecting module on one side, for example firmly. The bolts or threaded bolts are electrically conductively coupled to the passage. The line of the on-board network, which is designed with eyes and/or cable lugs, can be attached to the bolts or threaded bolts.

The term contact assembly refers to the components for transferring an electric voltage from outside the housing to an electrical load disposed inside the housing. Such contact assembly, which also includes a passage, may be the insulated lead, which is disposed with a seal, such as an O-ring, within a corresponding passage opening in the housing. When using a connecting module, as explained above, the contact assembly has the bolts or threaded bolts and electrical conductors connected to the bolts or threaded bolts, which are guided into the interior of the sealed housing in the form of a passage.

Connecting modules known from the prior art often require a large number of various components to be connected in several steps in order to be subsequently mounted on the housing or in an opening in the housing of an electrical component of a motor vehicle.

A large number of components of such a connecting module with corresponding contact assemblies leads to high material costs and, because of a plurality of assembly steps, also to high production costs.

In addition, the connecting modules known from the prior art are not arbitrarily compatible so that the connecting modules are to be provided with various connection possibilities for the lines of the on-board network. Thus, for example, a refrigerant compressor with a special connecting module and/or a connecting module with a special contact assembly cannot be connected to every on-board network of a motor vehicle.

According to the prior art, contacts, for example in refrigerant compressors with a supply voltage of 48 V, are designed in such a way that a printed circuit board of the inverter disposed in the housing of the refrigerant compressor is electrically connected via lines or rigid busbars. This is also intended to achieve an axial compensation of manufacturing tolerances between the current-transferring elements. However, lateral compensation of the manufacturing tolerances of the individual current-transferring elements is not possible in this way. This implementation involves high manufacturing efforts and assembly efforts and hardly can be automated.

In such solutions, it is intended to provide two passages by inserting two bolts into the connecting module through two adjacently disposed openings in the connecting module, which are to be fixed with fitted-on counter-sleeves for fastening. Simultaneously with the insertion of the bolts, one conductor provided with a cable lug is to be placed in a radial alignment with each bolt in order to also guide the bolt through the opening in the cable lug when inserting the bolt into the opening of the connecting module. When both elements are placed, the bolt heads are cast in the connecting module and the cast area is covered with a cover element. The actual passages are formed by the two conductors provided with the cable lugs, which are guided in a sealed manner through the connecting module into the interior of the housing. The part of the conductor projecting into the interior of the housing is to be contacted with the electrical load disposed in the housing. Known methods such as soldering, bolting or pressing are suitable for joining.

Consequently, there is a need for a uniform, universal and improved contact assembly, in particular for an improved contact assembly in a connecting module.

The aim of the invention is to provide a contact assembly or a connecting module with a contact assembly by means of which an electrical load disposed in a sealed housing can be reliably electrically connected to a voltage source disposed outside the housing. In particular, the contact assembly and/or the connecting module with a contact assembly should not affect the tightness of the housing. In addition, material costs and time expenditure for manufacture and assembly of the contact assembly and/or the connecting module with a contact assembly and thus the costs for manufacturing are to be reduced. A further aim of the contact assembly and/or the connecting module with a contact assembly is to ensure tolerance compensation when assembling the individual components.

The aim is achieved by an object with the features according to claim 1 and by an object with the features according to claim 7. Further developments are indicated in the dependent claims.

The invention provides a contact assembly and a connecting module with a contact assembly through which correspondingly high currents, for example for operating an electrically driven refrigerant compressor in a motor vehicle, can be conducted. The currents can be in the range from -150　A to 150　A. As such, the components of the contact assembly are designed with a suitable cross section.

According to the design of the invention, the contact assembly has at least one bifurcated contact being U-shaped and flat at a first end and having a cylindrical contact surface at the second end opposite the first end.

Using the first U-shaped and flat end, the bifurcated contact is advantageously pushed onto a fastening element disposed in the connecting module, such as a bolt or a threaded bolt, in a radial direction. In this case, the fastening element is at least partially enclosed by the U-shaped and flat first end of the bifurcated contact.

A supply line from the on-board network with corresponding cable lugs can be plugged onto the fastening element. By using a corresponding counterpart to the fastening element, such as a nut to the bolt, the respective cable lug of the supply line can be connected, in particular bolted, to the first end of the bifurcated contact, and a fixed and electrically conductive connection can be produced in this way.

Such a bifurcated contact can be punched out of a sheet metal as a punched part in a first working step. In a subsequent step, the bifurcated contact bent, in particular rolled, at the second end to become a cylinder so that the embossed sheet metal part has the desired cylindrical contact surface at the second end.

According to an alternative embodiment, such a bifurcated could also be composed of two parts, such as a U-shaped and flat first part and a second part having the cylindrical contact surface. The cylindrical contact surface could be provided, for example, by a wire with a corresponding diameter, while the U-shaped flat first part is provided as a punched sheet-metal part. Both parts can be joined together by a soldering process or a welding process.

According to the invention, at least the U-shaped and flat first part of the bifurcated contact is disposed in the connecting module and outside the sealed housing, while the second part of the bifurcated contact with the cylindrical contact surface is disposed in the connecting module and inside the housing.

According to a further development of the invention, the bifurcated contact between the first part and the second part has a transition zone in which the U-shaped flat first part gradually merges into the cylindrical contact surface of the second part. The transition zone of each bifurcated contact can be disposed tightly in a partition wall of the connecting module. Such a partition wall of the connecting module can be designed as a separate component of the connecting module. After disposing the bifurcated contacts with the transition zone in the partition wall, the partition wall can be connected to the other elements of the connecting module and the connecting module can thus be completed. The partition wall may be provided with corresponding openings into which the bifurcated contacts are inserted with sealing means in order to form the sealed passage.

According to an advantageous embodiment of the invention, the bifurcated contact is disposed by means of suitable sealing means, which is disposed in particular in an oval or round transition zone of the bifurcated contact so as to seal and surround the bifurcated contact, in openings of the connecting module or through a partition wall of the connecting module. The sealing means is designed to seal the opening. This provides a passage allowing for a current line to an electrical load in a sealed housing.

Alternatively, the sealing means can also sealingly surround the bifurcated contact in a first part being flat and having a rectangular cross section and can be disposed in the opening of the connecting module or in the partition wall of the connecting module.

In order to produce an electrically conductive connection between the bifurcated contact and an electrical load in a housing, such as an inverter in an electrically driven refrigerant compressor, the cylindrical contact surface of the bifurcated contact is advantageously surrounded by a spring contact element with elastically deformable lamellar contact springs, in particular the spring contact element is disposed plugged onto the cylindrical contact surface.

A further advantage of the invention is that the unit consisting of the cylindrical contact surface of the bifurcated contact with the plugged-on spring contact element is inserted or pressed into a hollow cylindrical contact sleeve being disposed on or in a circuit board and/or printed circuit board of an electrical load.

The hollow cylindrical contact sleeve is preferably disposed in a passage bore of the circuit board and/or printed circuit board. In this case, the contact sleeve is electrically contacted with conductor tracks of the circuit board and/or printed circuit board. The electrical contact can be produced by means of a soldering process.

The unit consisting of the cylindrical contact surface with the plugged-on spring contact element is inserted or pressed into the hollow cylindrical contact sleeve, which is soldered on the printed circuit board, so that an electrically conductive connection is formed from the first flat and U-shaped part of the bifurcated contact via the transition zone to the second part, the cylindrical contact surface and via the plugged-on spring contact element to the hollow cylindrical contact sleeve with the connected conductor track.

In addition to the bifurcated contact, the contact assembly preferably also has the plugged-on spring contact element and the hollow cylindrical contact sleeve. The contact assembly thus represents a passage for supplying an electric voltage from the outside to an electrical load disposed in a sealed housing.

The spring contact element advantageously has elastically deformable lamellar contact springs made of an electrically conductive and elastic material. In this case, the lamellar contact springs of the spring contact element are designed strip-shaped in the axial direction of the spring contact element and are preferably connected to one another at opposite ends. The connections of the lamellar contact springs each can be designed as a circular ring in the region of the ends and/or end faces of the spring contact element.

The outer diameter of the circular ring is preferably smaller than the inner diameter of the hollow cylindrical contact sleeve so that the spring contact element can be inserted into the hollow cylindrical contact sleeve. The outer diameter of the circular ring is dimensioned in such a way that the lamellar contact spring fixes the spring contact element securely and firmly in the hollow-cylindrical contact sleeve in a state of elastic deformation within the contact sleeve. As such, the hollow cylindrical contact sleeve has an inner diameter being constant along its length.

In an initial state, the lamellar contact springs of the spring contact element are preferably designed to bulge outwards or partially inwards in the region between the ends in a radial direction, in particular uniformly along the length. The initial state is understood to be the unmounted state of the spring contact element.

The circular rings of the spring contact element advantageously have a slit-shaped opening extending in the axial direction. With the design of the slit-shaped opening, the inner diameter of the circular rings of the spring contact element can be slightly smaller than the outer diameter of the cylindrical contact surface of the bifurcated contact. When pushing the spring contact element onto the cylindrical contact surface of the bifurcated contact, the circular rings can widen and thus ensure a secure hold of the spring contact element on the cylindrical contact surface of the bifurcated contact in the end position. The spring contact element is clamped onto the contact surface of the bifurcated contact.

A circular ring of the spring contact element can have a locking device forming a stop when the spring contact element is pushed onto the cylindrical contact surface of the bifurcated contact.

In addition, the hollow cylindrical contact sleeve advantageously has a flange-shaped and/or bead-like circumferential formation. When inserting the hollow cylindrical contact sleeve into the passage bore of the printed circuit board, the formation serves as a stop, in particular in a state before soldering the hollow cylindrical contact sleeve.

According to a further development of the invention, the cylindrical contact surface of the bifurcated contact and the spring contact element disposed on the contact surface are coaxially aligned with one another and consequently have a common longitudinal axis. In addition, the cylindrical contact surface of the bifurcated contact, the spring contact element disposed thereon and the hollow cylindrical contact sleeve are aligned coaxially with one another on a common longitudinal axis. The spring contact element makes it possible to compensate for manufacturing tolerances in such a way that, for example, a deviation of the longitudinal axis of the cylindrical contact surface of the bifurcated contact from the longitudinal axis of the hollow cylindrical contact sleeve is compensated for, since the lamellar contact springs produce a reliable electrical contact of the bifurcated contact with the contact sleeve even in the event of deviations of the longitudinal axes from one another.

The reliable electrical contact with one another is also obtained in the case that the cylindrical contact surface of the bifurcated contact with the spring contact element disposed thereon cannot be pushed completely into the hollow cylindrical contact sleeve, which can also occur due to manufacturing tolerances.

Thus, the contact assembly allows for electrical connection in the form of a passage and simultaneously both an axial and a lateral tolerance compensation of the individual components.

The object of the invention is also achieved by a connecting module according to the invention with at least one contact assembly. Preferably, two of the contact assemblies are provided for in a connecting module.

According to the concept, the connecting module has a partition wall in which the at least one contact assembly is disposed, preferably in the form of a sealed passage. When two or more contact assemblies are designed, the contact assemblies are placed at a distance from one another.

The partition wall is designed as a single element being connected to the connecting module, in particular to a rear wall of the connecting module. Such a partition wall can, for example, also form a surface, such as the rear wall of the connecting module. The partition wall is preferably bolted to the connecting module or fastened to the connecting module by means of a click mechanism.

The connecting module is advantageously disposed with the partition wall on a housing enclosing the load to be supplied with electric voltage via the passage to be formed. The connecting module is sealingly disposed on the housing.

According to the invention, the connecting module has at least one formation, especially a recess, in which a head of a fastening element, in particular a hexagonal threaded bolt, is introduced and fixed. The fastening element provided in the formation makes it possible to produce an electrically conductive and firm connection between the U-shaped first end of the bifurcated contact and a cable lug of a supply line from the on-board network of a motor vehicle, for example using a nut complementary to the hexagonal threaded bolt. To prevent an unintentional release of such a connection, in particular a bolt connection, corresponding securing means can be used.

The object is also achieved by a method according to the invention for mounting the connecting module.

When assembling the connecting module, the fastening element, in particular, for example, a hexagonal threaded bolt or two hexagonal threaded bolts, is introduced into the respective formation, in particular a recess, and fixed. Subsequently, the partition wall, in which, for example, two bifurcated contacts with corresponding sealing means have been disposed and fixed, can be joined as a rear wall with the connecting module. In this case, the U-shaped first end of the bifurcated contact is pushed over the fastening element, in particular the thread of the hexagonal threaded bolt, and the hexagonal threaded bolt is locked in such a way that it is held in the respective formation, even in the case that the orientation and/or position of the connecting module is changed. This is achieved by pushing the U-shaped first end of the bifurcated contact in the radial direction over the thread of the hexagonal threaded bolt. The U-shaped first end of the bifurcated contact is preferably disposed in a region close to the respective head of the hexagonal threaded bolt.

Subsequently, the connecting module with the partition wall having the passage and/or the at least one bifurcated contact is disposed on the housing, which preferably takes place using further sealing means and, for example, bolts being guided through prepared passage openings of the connecting module and are bolted to the housing. In this way, an opening provided in the housing for the passages is closed correspondingly tightly, the passages being formed in the form of the bifurcated contacts introduced tightly into the connecting module.

Further details, features and advantages of embodiments of the invention will become apparent from the following description of embodiments with reference to the associated drawings.

Figs. 1a to 1c: show a connecting module according to the prior art, each in perspective views,

Fig. 2a: shows a connecting module according to the invention with bifurcated contacts in a perspective view, and

Fig. 2b: shows a detailed representation of recesses formed in a bottom of the connecting module,

Fig. 3: shows two bifurcated contacts of the connecting module of Fig. 2a in a perspective view,

Fig. 4: shows the connecting module of Fig. 2a in a further perspective view,

Fig. 5: shows an exemplary embodiment of a spring contact element,

Fig. 6: shows an embodiment of a hollow cylindrical contact sleeve, and

Fig. 7: shows the connecting module in the assembled state with two complete contact assemblies.

Figs. 1a, 1b, and 1c, respectively, represent a connecting module 1’ from the prior art in perspective views. The connecting module 1’ has a bottom 2, two side surfaces 3 and a rear wall 4 and/or a rear surface. For spatial separation of the electrical connections from one another, the connecting module 1′ is formed with a partition wall 5. In addition, the partition wall 5 allows for separate disposal of fastening elements 6, such as threaded bolts or hexagonal threaded bolts, by means of which an electrical connection to a supply line (not shown) of an on-board network of a motor vehicle can be produced.

In the connecting module 1′, the passage is formed by means of a contact 7 having an eye at a first end. The eye is disposed in a guided manner via the fastening element 6. The contact 7 is formed at a second end disposed in the interior of a sealed housing so that a connection with an electrical load can be made by soldering, bolting, or pressing. The connecting module 1′ is attached to the housing by means of the rear wall 4. The contact 7 is disposed in a sealed manner in the rear wall 4 of the connecting module 1’, for example using appropriate sealing means (not shown), so that a correspondingly sealed passage is formed.

Fig. 1a shows, by way of example, two passage openings 8 for receiving fastening elements, such as bolts, by means of which the connecting module 1’ can be bolted onto the housing (not shown).

When assembling the connecting module 1′, the two contacts 7 are introduced with the eyes first into the connecting module 1′ through corresponding openings provided in the rear wall 4, as is shown in Fig. 1b. Fig. 1b shows the connecting module 1’ in a perspective differing from Fig. 1a. Subsequently, the fastening elements 6, which are designed as hexagonal threaded bolts, each are introduced through an opening provided in the bottom 2 of the connecting module 1′ and the eye of the contact 7 in the direction represented by an arrow.

For fixing the fastening elements 6 and for sealing the bottom 2 of the connecting module 1’, the region of the heads of the fastening elements 6 is cast-sealed and a cover 9 is attached in the region of the step-shaped bottom 2.

Fig. 1c shows the individual parts of the connecting module 1’ from the prior art in an exploded view. In addition to the components of the connecting module 1′ already explained, two sleeves 10 are shown that, depending on the design of the connecting module 1′, can be configured as spacer elements, securing elements, or bolt elements, such as a nut.

Manufacturing of such a connecting module 1′ is very complicated and requires a large number of assembly steps, which usually cannot be automated or can only be automated with considerable effort.

Fig. 2a shows a connecting module 1 according to the invention with two bifurcated contacts 11 in a perspective view. Fig. 2b shows a detailed representation of recesses 12 formed in a bottom 2 of the connecting module 1.

The connecting module 1 has the bottom 2, two side surfaces 3, and a partition wall 5. Instead of having openings for feeding through fastening elements 6, the bottom 2 is closed and thus tightly formed and has correspondingly shaped recesses 12 for receiving one fastening element 6 at a time. Fastening elements 6 designed as hexagonal threaded bolts are introduced with the hexagonal head 13 into the recesses 12. Such a fastening element 6 can be, for example, a so-called machine bolt with a metric thread.

During assembly, the fastening elements 6 are moved with the heads 13 first in the direction of the bottom 2 of the connecting module 1, as shown by means of the arrows in Fig. 2b, and are disposed with corresponding alignment in the associated hexagonal recesses 12. The shape and the inner dimensions of the recess 12 and the shape and the outer dimensions of the head 13 of the fastening element 6 correspond to one another.

The inner dimensions of the recess 12 may be slightly smaller than the outer dimensions of the head 13 so that the head 13 is pressed into the recess 12 during assembly and the fastening element 6 is fixed in the bottom 2 of the connecting module 1. The fastening element 6 is disposed with the head 13 correspondingly firmly in the recess 12 and is connected to the connecting module 1 so that detachment of the fastening element 6 from the connecting module 1 is prevented, for example during further assembly steps.

The rear wall 4 of the connecting module 1 is designed to be partially or completely removable. In the case of a design of the rear wall 4 that is only partially removable, the rear wall 4 is provided with one or two openings. The design of the rear wall 4 with two openings 14 is shown in particular in Fig. 4.

The removable component of the rear wall 4 is designated as partition wall 15 of the connecting module 1, which is firmly connected to the rear wall 4, for example by bolts, adhesive bonding or a click mechanism, and in this way the complete housing of the connecting module 1 can be formed.

The partition wall 15 is provided for receiving, for example, two bifurcated contacts 11 being disposed parallel and spaced apart from one another in the partition wall 15, as shown in Fig. 2a. The bifurcated contacts 11 each have a first U-shaped and flat-formed end 16 and a second end 17 disposed opposite the first end and having a cylindrical contact surface.

The bifurcated contacts 11 are guided through the partition wall 15 and are disposed in a sealed manner within the partition wall 15. Corresponding sealing means 18 are provided between the bifurcated contacts 11 and the respective associated opening within the partition wall 15.

Figs. 2a and 2b also show passage openings 8 for receiving fastening means, such as bolts, by means of which the connecting module 1 can be fastened, in particular bolted, to a housing (not shown).

In a first assembly step, the heads 13 of the fastening elements 6, which are designed as hexagonal threaded bolts, are inserted and/or pressed into the recesses 12 during assembly of the connecting module 1. Parallel to the first mounting step, the bifurcated contacts 11 are sealingly inserted with corresponding sealing means 18 into the provided openings of the partition wall 15. Subsequently, the unit consisting of the partition wall 15 with the bifurcated contacts 11 is pushed with the first ends 16 first into the connecting module 1 by moving the unit into the connecting module 1 in the direction shown by the arrows in Fig. 2a. The U-shaped and flat-formed first end 16 of the bifurcated contacts 11 is guided first through the openings 14 formed in the rear wall 4 of the connecting module 1, which are clearly shown in Fig. 4, and subsequently over the fastening elements 6, in particular the hexagonal threaded bolts.

In addition to the sealing means 18 described, Fig. 2a shows further annular sealing means 18a that can be used additionally or alternatively to the sealing means 18 and ensure sealing of the connecting module 1 in the region of the partition wall 15 to the housing (not shown).

Fig. 3 shows two bifurcated contacts 11 of the connecting module 1 of Fig. 2a in a perspective view.

Each bifurcated contact 11 has a first U-shaped and flat-formed end 16. A second end 17 of the respective bifurcated contact 11 is formed with a cylindrical contact surface. Between the first end 16 and the second end 17 there is a respective transition zone 19 in which the flat shape of the bifurcated contact 11 merges into the cylindrical shape.

In a first working step, the bifurcated contact 11 is punched out of a sheet metal as a punched part. The U-shaped and flat first end 16 of the bifurcated contact 11 is completely shaped already. In a subsequent step, the bifurcated contact 11 at the second end 17 is correspondingly deformed, in particular rolled, so that the embossed sheet metal part is formed at the second end 17 with the desired cylindrical contact surface. Thus, the bifurcated contact 11 is produced in a few working steps and at reduced costs. When producing such a bifurcated contact from a plurality of components, a further working step of joining the elements together would be necessary and the manufacturing efforts would be correspondingly higher.

The bifurcated contact 11 presented in Fig. 3 also has a ribbing between the first end 16 and the transition zone 19, improving the stability of the bifurcated contact 11 and permitting better shaping of the second end 17.

Fig. 4 represents the components of the connecting module 1 shown in Fig. 2a in a further perspective view. In this case, the openings 14 formed in the rear wall 4 of the connecting module 1 are clearly visible, into which the bifurcated contacts 11 with the first ends 16 first are introduced.

The housing (not shown) on which the connecting module 1 is disposed has two passage openings for feeding through the bifurcated contacts 11. The respective second end 17 of the bifurcated contacts 11 is guided through passage openings into the interior of the housing. In addition, a cylindrical section 20 of a formation of the partition wall 15 is received in the respective passage opening of the housing so that the partial area 21 shown in Fig. 4 is disposed inside the housing or inside the passage opening of the housing. Each passage through the housing is sealed by means of the annular sealing means 18a. Regarding the further elements of the connecting module 1 shown in Fig. 4, reference is made to the explanations of Fig. 2a.

Fig. 5 shows an exemplary embodiment of a spring contact element 22. The spring contact element 22 has several elastically deformable lamellar contact springs 23 extending in the direction of the longitudinal axis of the spring contact element 22. The lamellar contact springs 23 of the spring contact element 22 are designed strip-shaped in the axial direction of the spring contact element 22 and are preferably connected to one another at opposite ends. In this case, the connections of the lamellar contact springs 23 each are in the form of a circular ring 24 in the region of the ends and/or end faces of the spring contact element 22.

The circular rings 24 of the spring contact element 22 have a slit-shaped opening 25 extending in the axial direction. This opening 25 makes it possible that the inner diameter of the circular rings 24 of the spring contact element 22 can be slightly smaller than the outer diameter of the cylindrical contact surface 17 of the bifurcated contact 11. When pushing the spring contact element 22 onto the second end 17, in particular the cylindrical contact surface of the bifurcated contact 11, the circular rings 24 can widen and thus ensure a secure hold of the spring contact element 22 on the cylindrical contact surface 17 of the bifurcated contact 11 in their end position.

A circular ring 24 of the spring contact element 22 can have a locking device 26 forming a stop when the spring contact element 22 is pushed onto the cylindrical contact surface 17 of the bifurcated contact 11.

Fig. 6 shows an exemplary embodiment of a hollow cylindrical contact sleeve 27. Such a contact sleeve 27 can be disposed on a printed circuit board (not shown) and, for example, be soldered electrically conductively to a conductor strip. In this case, the contact sleeve 27 can be inserted into a passage bore formed in the printed circuit board. The passage bore within the printed circuit board is formed in such a way so that the diameter is slightly larger than the outer diameter of the contact sleeve 27.

The hollow cylindrical contact sleeve 27 has a flange-shaped and/or bead-like circumferential formation 28. When inserting the hollow cylindrical contact sleeve 27 into the passage bore formed in the printed circuit board, the formation 28 serves as a stop, in particular in a state before soldering the hollow cylindrical contact sleeve 27 to a conductor strip.

In Fig. 7, the connecting module 1 is shown in the assembled state with two complete contact assemblies 29. Regarding the description of the individual elements of the connecting module 1, reference is made to the explanations of Figs. 2a and 4.

The contact assemblies 29 each having a bifurcated contact 11 with the first end 16, the transition zone 19 and the second end 17 are also formed in each case with the spring contact element 22 plugged onto the respective second end 17 and the hollow-cylindrical contact sleeve 27. Thus, the contact assemblies 29 each represent an electrically conductive connection and a passage for supplying an electric voltage to an electrical load disposed in the sealed housing.

The two parallel and spaced contact assemblies 29 are disposed in the connecting module 1. The design of three or more contact assemblies 29 in a connecting module 1 is likewise possible.

With the U-shaped design of the first end 16 of the bifurcated contacts 11, the contact assemblies 29 allow for axial compensation 30 of assembly tolerances and manufacturing tolerances.

In addition, the contact assemblies 29 with the lamellar contact springs 23 formed on the spring contact elements 22 and disposed in the hollow cylindrical contact sleeves 27 each allow for lateral compensation 31 of assembly tolerances and manufacturing tolerances.

List of reference numerals

1, 1' connecting module

2 bottom

3 side surface

4 rear wall

5 separating wall

6 fastening element

7 contact

8 passage opening

9 cover

10 sleeve

11 bifurcated contact

12 recess

13 head

14 opening

15 partition wall

16 first end, U-shaped and flat-formed part

17 second end, cylindrical contact surface

18, 18a sealant

19 transition zone

20 cylindrical section of partition wall 15

21 partial area

22 spring contact element

23 lamellar contact spring

24 circular ring

25 slit-shaped opening

26 locking device

27 hollow cylindrical contact sleeve

28 formation

29 contact assembly

30 axial tolerance compensation

31 lateral tolerance compensation

Claims

A contact assembly for transferring an electric voltage to an electrical load disposed in a housing, characterized in that the contact assembly (29) has at least one bifurcated contact (11), having a first U-shaped and flat-formed end (16) as well as a second end (17) disposed opposite the first end (16) and having a cylindrical contact surface, wherein the bifurcated contact (11) is disposed with the first end (16) outside of and with the second end (17) inside of the housing.
The contact assembly according to claim 1, characterized in that the bifurcated contact (11) has a transition zone (19) between the first end (16) and the second end (17).
The contact assembly according to claim 1 or 2, characterized in that the bifurcated contact (11) is disposed with the second end (17) within a spring contact element (22).
The contact assembly according to claim 3, characterized in that the bifurcated contact (11) is disposed with the second end (17) and the spring contact element (22) in a hollow cylindrical contact sleeve (27).
The contact assembly according to claim 4, characterized in that the hollow cylindrical contact sleeve (27) is disposed on or in a printed circuit board which is disposed in the housing connected to the electrical load.
The contact assembly according to claim 5, characterized in that the printed circuit board is formed as a control unit of an inverter which is connected to an electric motor of a refrigerant compressor.
A connecting module, which has at least one contact assembly according to any one of claims 1 to 6 and which is disposed on a housing in which an electrical load to be supplied with an electric voltage is disposed, characterized in that the connecting module (1) has a bottom (2) which is formed with at least one recess (12), wherein, in the recess (12), a head (13) of a fastening element　(6), in particular a bolt head of a hexagon threaded bolt, is disposed, and in that the connecting module (1) has a partition wall (15) connectable to a rear wall (4), wherein at least one bifurcated contact (11) is disposed in the rear wall (4).
The connecting module according to claim 7, characterized in that a sealant　(18) is disposed between the bifurcated contact (11) and the partition wall　(15).
The connecting module according to claim 7 or 8, characterized in that the first end (16) of the bifurcated contact (11) is disposed on the fastening element　(6), wherein the U-shaped and flat first end (16) of the bifurcated contact　(11) is disposed radially from a longitudinal axis of the fastening element　(6), and wherein the U-shaped first end (16) of the bifurcated contact (11) at least partially encloses the fastening element (6).
The connecting module according to any one of claims 7 to 9, characterized in that the fastening element (6) of the connecting module (1) is connected to a supply line, in particular a cable lug of the supply line, of an on-board network of a motor vehicle.
A method of mounting the connecting module according to any one of claims 7 to 10, having the following steps:

- introducing a head (13) of a fastening element (6) into a recess (12) formed in the bottom (2) of the connecting module (1), and fixing the fastening element　(6),

- disposing at least one bifurcated contact (11) in a partition wall (15) with sealants (18) as well as fixing the bifurcated contact (11) in the partition wall　(15),

- inserting the partition wall (15) with the at least one bifurcated contact (11) into the connecting module (1), wherein a U-shaped first end (16) of the bifurcated contact (11) is pushed through an opening (14) formed in a rear wall (4) of the connecting module (1) as well as over the fastening element (6), in particular a thread of a hexagon threaded bolt,

- locking the fastening element (6) and joining the partition wall (15) to the connecting module (1), as well as

disposing the connecting module (1) with the partition wall (15) having at least one bifurcated contact (11) on a housing, in particular on an outer surface of the housing, as well as fixing the connecting module (1) to the housing and sealing the connecting module (1) towards the housing.
The method according to claim 11, characterized in that the head (13) of the fastening element (6) is pressed into the recess (12).
The method according to claim 11 or 12, characterized in that the U-shaped first end (16) of the bifurcated contact (11) is pushed over the fastening element (6) in the radial direction.
The method according to any one of claims 11 to 13, characterized in that the U-shaped first end (16) of the bifurcated contact (11) is disposed in an area of the head (13) of the fastening element (6).
The method according to any one of claims 11 to 14, characterized in that the connecting module (1) is guided into the interior of the housing with a second end　(17) of the bifurcated contact (11) through a passage opening formed in the housing, wherein a cylindrical section (20) of a formation of the partition wall (15) is received in the passage opening of the housing and the passage is sealed with a sealant (18a).