Electrical contact element and method of producing a hard-soldered, electrically conductive connection to a mating contact by means of a pressed-in soldering body made from hard solder

{
  "publication_number": "US11145995B2",
  "country": "US",
  "kind": "B2",
  "title": "Electrical contact element and method of producing a hard-soldered, electrically conductive connection to a mating contact by means of a pressed-in soldering body made from hard solder",
  "abstract": "An electrical contact for forming a materially bonded, electrically conductive connection to a mating contact comprises a contact surface and a soldering body. The contact surface has a recess extending into the contact surface. The soldering body is formed of a hard solder material and is pressed into the recess. The soldering body protrudes out from the recess beyond the contact surface.",
  "claims": [
    "1. An electrical contact for forming a materially bonded, electrically conductive connection to a mating contact, comprising: a contact body including: a top surface and a contact surface arranged opposite the top surface, the contact surface configured to be joined with the mating contact; a passage extending through the contact body from the top surface; a recess extending into the contact surface in the direction of the top surface and adjacent the passage; and a soldering body formed of a hard solder material pressed into the recess and protruding out from the recess beyond the contact surface prior to a soldering operation, wherein the contact surface, the recess, and the soldering body have an annular shape.",
    "2. The electrical contact of claim 1, wherein the soldering body is a molded part.",
    "3. An electrical connection, comprising: a contact having a contact surface with a recess extending into the contact surface and a soldering body formed of a hard solder material disposed in the recess; a mating contact hard-soldered to the contact surface of the contact by the hard solder material of the soldering body; and a screw pushing the contact and the mating contact together.",
    "4. The electrical contact of claim 1, wherein the contact body has a protrusion projecting from the contact surface in a direction opposite the top surface and parallel to the soldering body, the protrusion including a first side defining the passage and a second side at least partially defining the recess.",
    "5. The electrical contact of claim 4, wherein the protrusion projects beyond the soldering body.",
    "6. An electrical connection, comprising: a contact having: a top surface and a contact surface arranged opposite the top surface; a passage extending through the contact from the top surface; a recess extending into the contact surface in the direction of the top surface and adjacent the passage; a protrusion extending from the contact surface in a direction opposite the top surface; and a soldering body formed of a hard solder material disposed in the recess; and a mating contact hard-soldered to the contact surface of the contact by the hard solder material of the soldering body, the mating contact including a receptacle into with the protrusion of the contact engages to position the contact with respect to the mating contact.",
    "7. The electrical connection of claim 6, wherein the hard solder material is disposed between the protrusion and the receptacle.",
    "8. The electrical connection of claim 3, wherein the contact surface, the recess, and the soldering body have an annular shape.",
    "9. A cell connector, comprising: an electrical connection including: a contact having: a planar contact surface with a recess extending into the contact surface; a soldering body formed of a hard solder material disposed in the recess; a passage defined through the contact; and a protrusion projecting from the contact surface; and a mating contact abutting the planar contact surface and engaging with the protrusion, the mating contact hard-soldered to the contact surface of the contact by the hard solder material of the soldering body.",
    "10. The cell connector of claim 9, wherein the recess extends into the contact surface in a direction parallel to the direction of the passage through the contact.",
    "11. The cell connector of claim 10, wherein the protrusion includes a first side defining the passage and a second side at least partially defining the recess.",
    "12. The cell connector of claim 11, wherein the mating contact comprises a receptacle receiving the protrusion.",
    "13. The electrical connection of claim 6, wherein the protrusion includes a first side defining the passage and a second side defining the recess.",
    "14. The electrical connection of claim 13, wherein the first side comprises an interior wall of the protrusion, and the second side comprises an exterior wall of the protrusion opposite the interior wall.",
    "15. The electrical connection of claim 14, wherein the recess surrounds the passage.",
    "16. The electrical connection of claim 15, wherein the passage comprises a through hole, and wherein the recess comprises an annular recess.",
    "17. The electrical connection of claim 16, wherein the protrusion comprises a cylindrical protrusion and the receptacle comprises a hole sized to receive the protrusion.",
    "18. The electrical contact of claim 4, wherein the first side comprises an interior wall of the protrusion, and the second side comprises an exterior wall of the protrusion opposite the interior wall.",
    "19. The electrical contact of claim 4, wherein the recess surrounds the passage."
  ],
  "description_excerpt": "The present invention relates to an electrical contact and, more particularly, to an electrical contact soldered to a mating contact.\n\nBatteries of electric vehicles commonly have a plurality of cells that generate a high current and are connected in series. The cells are often also referred to as modules. The wires which contact the single cells are connected by cell connectors. Due to the high currents, the conductors of the wires have large cross-sections such that large forces are necessary for their connection. The conductors of the wires are commonly pushed against each other by a screw and a contact mounted between the two conductors. In some designs, the screw penetrates the conductor and the contact.\n\nA higher contact pressure is necessary not only to move the electrical conductors, which are typically heavy and rigid for high direct currents, but also to level out unevenness of the surface and to achieve an overlay which is as extensive as possible through an elastic deformation of the contact surfaces of the conductor and of the contact. The larger the surface via which the electrical contact and the electrical conductors, which serve as mating contacts, abut each other, the lower the transition resistance. With a low transition resistance, electrical losses can be reduced, and the cell connector does not heat up excessively. There is a need in the art to reduce or limit the transition resistance as much as possible.\n\nAn electrical contact for forming a materially bonded, electrically conductive connection to a mating contact comprises a contact surface and a soldering body.",
  "cpc": [
    "H01R 4/027",
    "B23K 2101/38",
    "H01M 2/206",
    "H01M 2220/20",
    "H01M 50/502",
    "H01M 50/528",
    "H01R 11/12",
    "H01R 11/16",
    "H01R 11/281",
    "H01R 2201/26",
    "H01R 25/006",
    "H01R 4/022",
    "H01R 4/028",
    "H01R 4/34",
    "H01R 4/38",
    "H01R 4/44",
    "H01R 43/02",
    "H01R 43/0235",
    "H01R 43/0263",
    "Y02E 60/10"
  ],
  "ipc": [
    "H01M 50/528",
    "H01R 4/02",
    "H01R 43/02",
    "B23K 1/00"
  ],
  "assignees": [
    "TE Connectivity Germany GmbH"
  ],
  "inventors": [
    "Rudi Blumenschein",
    "Frank Kaehny",
    "Kai Kioschis",
    "Andre Martin Dressel"
  ],
  "filing_date": "2018-03-29",
  "publication_date": "2021-10-12",
  "grant_date": "2021-10-12",
  "priority_date": "2017-03-29",
  "application_number": "US-201815939723-A",
  "family_id": "61763842",
  "cited_by_count": 4,
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