Function module for electrical applications

Patent metadata

Field	Value
Publication number	US-11949178-B2
Application number	US-202117551290-A
Country	US
Kind code	B2
Filing date	Dec 15, 2021
Priority date	Dec 15, 2021
Publication date	Apr 2, 2024
Grant date	Apr 2, 2024

Abstract

A function module for electrical applications and method of making a function module for electrical applications. The function module includes: a functional member having a piercing area with at least one aluminum conductor trace; and an electrical connector having at least one piercing member. The at least one piercing member is configured to pierce through the at least one aluminum conductor trace in an electrically conductive manner and provide a form-fit connection between the functional member and the electrical connector within the piercing area. The functional member and the electrical connector are joined together within the piercing area by means of a solder connection.

First claim

The invention claimed is:

1. A function module for electrical applications, comprising:
a functional member having a piercing area with at least one aluminum conductor trace; and
an electrical connector having at least one piercing member, wherein the at least one piercing member is configured to pierce through the at least one aluminum conductor trace and to provide a form-fit connection between the functional member and the electrical connector within the piercing area;
wherein the functional member and the electrical connector are joined together within the piercing area by a solder connection, and
wherein the solder connection is based on a surface activation composition comprising: an aqueous solvent or a mixed aqueous solvent; and/or an organic amine; and/or a fatty acid; and/or a filler selected from a group consisting essentially of SN, Ag, Zn, Co, In, Sb, Bi, Au, Cd, A, Si, Ge, Co, Ni, P, Cr, Se, Te, oxides thereof or combinations thereof, in an amount less than 25% weight basis.

2. The function module according to claim 1 , wherein the electrical connector is a crimp connector.

3. The function module according to claim 1 , wherein the functional member is a foil composite and/or comprises one or more foil layers.

4. The function module according to claim 1 , wherein the at least one aluminum conductor trace is a mechanical structured trace.

5. The function module according to claim 1 , wherein the solder connection prevents or delays formation of an oxide layer on the at least one aluminum conductor trace within the piercing area.

6. The function module according to claim 1 , wherein the form-fit connection is formed between the functional member and the electrical connector within the piercing area to provide a mechanical strain relief for the solder connection; and/or the solder connection between the functional member and the electrical connector within the piercing area provides a mechanical strain relief for the form-fit connection.

7. The function module according to claim 1 , wherein the solder connection comprises solder material positioned between the functional member and the electrical connector, wherein the solder material seals gaps at penetration edges between the at least one piercing member and the at least one aluminum conductor trace.

8. The function module according to claim 1 , wherein the function module is a cell connector for electrical energy storage cells.

9. The function module according to claim 1 , wherein the function module is an electrical heating device.

10. A method for producing the function module according to claim 1 , comprising steps of:
piercing the at least one piercing member of the electrical connector through the at least one aluminum conductor trace within the piercing area such that the form-fit connection between the piercing member of the electrical connector and the at least one aluminum conductor trace is established; and
soldering together the functional member and the electrical connector within the piercing area using a solder material and the surface activation composition.

11. The method according to claim 10 , wherein the method comprises:
depositing or printing, the surface activation composition onto the functional member and/or onto the at least one aluminum conductor trace within the piercing area; and/or
depositing or printing the solder material onto the surface activation composition within the piercing area.

12. The method according to 11 , wherein the method comprises: heating the piercing area after the surface activation composition and/or the solder material is deposited; and/or heating the piercing area after the at least one piercing member of the electrical connector is pierced through the least one aluminum conductor trace.

13. The method according to claim 10 , wherein the at least one piercing member of the electrical connector is pierced through the surface activation composition and/or the solder material before or at the same time the at least one piercing member of the electrical connector is pierced through the at least one aluminum conductor trace.

14. The method according to claim 10 , wherein the surface activation composition comprises: aqueous solvent or the mixed aqueous solvent; and/or the organic amine; and/or the fatty acid.

15. A method for producing a function module comprising: piercing at least one piercing member of an electrical connector through at least one aluminum conductor trace within a piercing area of a functional member such that the form-fit connection is established between the piercing member of the electrical connector and the at least one aluminum conductor trace of the functional member; and soldering together the functional member and the electrical connector within the piercing area using a solder material and a surface activation composition, wherein the surface activation composition comprises: an aqueous solvent or a mixed aqueous solvent; and/or
an organic amine; and/or a fatty acid.

16. The method according to claim 15 , wherein the method comprises:
depositing or printing, the surface activation composition onto the functional member and/or onto the at least one aluminum conductor trace within the piercing area; and/or
depositing or printing the solder material onto the surface activation composition within the piercing area.

17. The method according to claim 16 , wherein the method comprises: heating the piercing area after the surface activation composition and/or the solder material is deposited; and/or heating the piercing area after the at least one piercing member of the electrical connector is pierced through the at least one aluminum conductor trace.

18. The method according to claim 15 , wherein the at least one piercing member of the electrical connector is pierced through the surface activation composition and/or the solder material before or at the same time the at least one piercing member of the electrical connector is pierced through the at least one aluminum conductor trace.

Assignees

• Gentherm Gmbh

Inventors

• Ciaccio Michael Peter
• Weiss Michael

Classifications

• H01R12/68 Primary

  comprising deformable portions · CPC title

• H01R12/707

  Soldering or welding · CPC title

• H01R43/0256

  for soldering or welding connectors to a printed circuit board · CPC title

• H01R12/675 Primary

  with contacts having at least a slotted plate for penetration of cable insulation, e.g. insulation displacement contacts for round conductor flat cables · CPC title

• H01R4/2407

  having saw-tooth projections · CPC title