Busbar assembly with electroplated electrical contact surfaces

Abstract

A bus assembly includes a bus formed of a first conductive material having a planar contact portion. The bus defines a first aperture extending through the contact portion. The bus assembly also includes a contact insert formed of a second conductive material having a higher hardness than the first conductive material. The contact insert defines a first surface mechanically and electrically connected to the contact portion of the bus. The contact insert defines a second surface plated with a third conductive material different from the second conductive material. The contact insert defines a smooth second aperture coaxial with the first aperture and extending from the first surface to the second surface.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Patent Application No. 17 / 852,854, filed June 26, 2022, which claims priority to U.S. Provisional Patent Application No. 63 / 226,925, filed July 29, 2021, and U.S. Provisional Patent Application No. 63 / 270,670, filed October 22, 2021, the entire disclosure of each of which is incorporated herein by reference. Technical Field

[0003] This patent application relates to a busbar assembly having an electroplated electrical contact surface. Background Technology

[0004] By electroplating conductive materials, such as tin or silver, onto the contact areas of the busbar, the resistance of the electrical connection to the busbar can be reduced and stabilized. The electroplating material can be applied directly to the contact area of ​​the busbar. However, directly electroplating the busbar has several disadvantages in terms of processing costs. Selectively electroplating the contact areas requires specialized tools and additional processing, which increases production costs. Electroplating the entire busbar is a simpler process, but requires more expensive tin or silver plating materials. Therefore, there is still a need for a busbar with a lower-cost electroplated electrical contact surface. Summary of the Invention

[0005] According to one or more aspects of this disclosure, a busbar assembly includes a busbar formed of a first conductive material having a planar contact portion. The busbar defines a first hole extending through the contact portion. The busbar assembly also includes a contact insert formed of a second conductive material, the material having a higher hardness than the first conductive material. The contact insert defines a first surface that is mechanically and electrically connected to the contact portion of the busbar. The contact insert further defines a second surface plated with a third conductive material different from the second conductive material. The contact insert additionally defines a smooth second hole coaxial with the first hole and extending from the first surface to the second surface.

[0006] In one or more embodiments of the busbar assembly according to the preceding paragraph, an annular ring surrounding the second hole is electroplated on the second surface.

[0007] In one or more embodiments of the busbar assembly according to any of the preceding paragraphs, the third conductive material is silver or tin.

[0008] In one or more embodiments of the busbar assembly according to any of the preceding paragraphs, the first hole has a generally cylindrical shape.

[0009] In one or more embodiments of the busbar assembly according to any of the preceding paragraphs, the contact plug has a generally cylindrical shape.

[0010] In one or more embodiments of the busbar assembly according to any of the preceding paragraphs, the contact insert defines a cylindrical collar extending from a second surface and defining an annular groove therein. The collar is interference-fitted with the inner wall of the first bore, causing a portion of the busbar to deform and be disposed within the annular groove.

[0011] In one or more embodiments of the busbar assembly according to any of the preceding paragraphs, the collar includes a lip extending above the slot.

[0012] In one or more embodiments of the busbar assembly according to any of the preceding paragraphs, the diameter of the lip is smaller than the diameter of the collar.

[0013] In one or more embodiments of the busbar assembly according to any of the preceding paragraphs, the second surface defines a plurality of alternating protrusions and indentations extending radially from the collar.

[0014] In one or more embodiments of the busbar assembly according to any of the preceding paragraphs, the busbar defines a cylindrical indentation in the contact portion surrounding the first hole.

[0015] In one or more embodiments of the busbar assembly according to any of the preceding paragraphs, the busbar defines a cylindrical indentation in the contact portion surrounding the first hole.

[0016] The outer surface of the contact portion located between the first and second surfaces defines a plurality of serrations extending from the outer surface. These serrations are interference-fitted with a recess, causing a portion of the busbar to deform and be positioned between the serrations.

[0017] In one or more embodiments of the busbar assembly according to any of the preceding paragraphs, the plurality of serrations are not parallel to the axis of the second hole and are not perpendicular to the axis of the second hole.

[0018] In one or more embodiments of the busbar assembly according to any of the preceding paragraphs, the second surface defines a plurality of alternating protrusions and indentations extending radially from the second hole.

[0019] In one or more embodiments of the busbar assembly according to any of the preceding paragraphs, the first surface of the contact plug is welded to the contact portion of the busbar.

[0020] In one or more embodiments of the busbar assembly according to any of the preceding paragraphs, the contact insert defines a cylindrical collar extending from a second surface and defining a plurality of serrations therein. The collar is interference-fitted with the inner wall of the first bore, causing a portion of the busbar to deform and be positioned within the plurality of serrations.

[0021] In one or more embodiments of the busbar assembly according to any of the preceding paragraphs, a plurality of serrations extend along the collar in a direction parallel to the axis of the second hole.

[0022] In one or more embodiments of the busbar assembly according to any of the preceding paragraphs, the collar and the second hole have an elongated cylindrical shape.

[0023] According to one or more aspects of this disclosure, a method of manufacturing a busbar assembly includes the following steps: A busbar formed of a first conductive material is provided, the busbar having a planar contact portion and defining a smooth first hole extending through the contact portion; A contact insert is provided, which is formed of a second conductive material with a hardness greater than that of a first conductive material. The contact insert defines a first surface and a second surface opposite to the first surface. The second surface is plated with a third conductive material different from the second conductive material and defines a smooth second hole. Arrange the contact plug on the contact portion so that the second hole is coaxial with the first hole; and The first surface of the contact plug is mechanically and electrically attached to the contact portion of the busbar.

[0024] In one or more embodiments of the method according to any of the preceding paragraphs, the method further includes the following steps: Insert the alignment tool into the second hole of the contact plug; Use the alignment tool to align the axis of the second hole with the axis of the first hole; and The contact plug is attached to the contact portion using a welding process.

[0025] In one or more embodiments of the method according to any of the preceding paragraphs, the welding process is selected from a list including acoustic welding, laser welding, resistance welding, spin welding, brazing and soldering processes.

[0026] In one or more embodiments of the method according to any of the preceding paragraphs, the welding process is a torsional acoustic welding process.

[0027] In one or more embodiments of the method according to any of the preceding paragraphs, the contact insert defines a cylindrical collar extending from a second surface and defines an annular groove therein. The method further includes the step of forming an interference fit between the collar extending from the contact insert and the inner wall of the first hole, such that a portion of the busbar deforms and is disposed within the annular groove.

[0028] In one or more embodiments of the method according to any of the preceding paragraphs, the busbar defines a cylindrical indentation in the contact portion surrounding the first hole. The outer surface of the contact portion, located between the first and second surfaces, defines a plurality of serrations extending from the outer surface. The method further includes the step of forming an interference fit between the plurality of serrations on the outer edge of the contact insert and the first hole, such that a portion of the busbar deforms and is disposed between the plurality of serrations. Attached Figure Description

[0029] The invention will now be described by way of example with reference to the accompanying drawings, in which: Figure 1 A side view of a busbar assembly including electrical contact plugs according to some embodiments is shown.

[0030] Figure 2A A perspective view of an electrical contact plug according to some embodiments is shown.

[0031] Figure 2B A cross-sectional perspective view of the busbar of a busbar assembly according to some embodiments is shown.

[0032] Figure 2C Illustrations based on some embodiments Figure 2A Electrical contact plugs and Figure 2B Assembly view of the busbars.

[0033] Figure 3A Illustrations based on some embodiments Figure 2A A bottom view of the electrical contact plug.

[0034] Figure 3B Illustrations based on some embodiments Figure 2A A top view of the electrical contact plug.

[0035] Figure 3C Illustrations are shown according to some embodiments Figure 2A A partial sectional side view of the electrical contact plug.

[0036] Figure 4 A side view of a bus assembly according to some embodiments is shown.

[0037] Figure 5A This is a cross-sectional view of a busbar assembly according to some embodiments.

[0038] Figure 5B This is an enlarged cross-sectional view of a busbar assembly according to some embodiments.

[0039] Figure 6A A perspective view of an electrical contact plug according to some embodiments is shown.

[0040] Figure 6B A cross-sectional perspective view of the busbar of a busbar assembly according to some embodiments is shown.

[0041] Figure 6C Illustrations are shown according to some embodiments Figure 6A Electrical contact plugs and Figure 6B Assembly view of the busbars.

[0042] Figure 7 This is an enlarged cross-sectional view of a busbar assembly according to some embodiments.

[0043] Figure 8A This is a top view of an electrical contact plug according to some embodiments.

[0044] Figure 8B This is a side view of an electrical contact plug according to some embodiments.

[0045] Figure 8C According to some embodiments Figure 8A and 8B A side view of the process of attaching the contact plug to the busbar.

[0046] Figures 9A to 9C This is a perspective view of an electrical contact plug according to some embodiments.

[0047] Figures 10A to 10C According to some embodiments, including Figures 9A to 9C A three-dimensional view of the busbar assembly of the electrical contact plug.

[0048] Figure 11A According to some embodiments, including Figures 9A to 9C A three-dimensional view of the busbar assembly of the electrical contact plug.

[0049] Figure 11B According to some embodiments Figure 11A A cross-sectional view of the busbar assembly.

[0050] Figure 12 This is a flowchart of a method for manufacturing a busbar assembly according to some embodiments. Detailed Implementation

[0051] Figure 1 A non-limiting example of a busbar assembly 10 is shown. This busbar assembly (busbar assembly) includes busbars (busbars) 12. Busbar 12 is a strip or band formed of a robust conductive metal, such as a copper or aluminum-based alloy, constructed to carry high currents, for example, exceeding 100 amperes. Busbars are commonly used in high-power electrical applications such as power plants, industrial power distribution, and electric vehicles. Busbar assembly 10 also includes electrical contact plugs, hereinafter referred to as plugs 14, constructed to provide mechanical and electrical connections between busbar 12 and electrical devices 16, such as batteries or motors. Plugs 14 are molded parts of conductive copper material, which are more rigid than the busbars.

[0052] Figure 2A-5B A first example of plug 14A is shown. Plug 14A has a cylindrical shape with a smooth through-hole or hole 18 passing through its center. This hole is configured to receive a fastener 20, such as a bolt or threaded stud, to attach the busbar assembly 10 to the electrical device 16. Plug 14A can be used for bolted connections where a plated contact surface is desired between the busbar 12 and the electrical device 16. Plug 14A is plated with a conductive metallic material, such as tin or silver, preferably only on the device contact surface 22. Figure 2A , Figure 2C , Figure 3A and Figure 4-5B On the bottom surface shown, the smooth hole 18 allows the fastener 20 to pass through easily and avoids the potential problem of misthreading that may occur with threaded through holes.

[0053] The plug-in 14A also includes a collar 24 protruding from the busbar contact surface 26, which is generally arranged opposite to the device contact surface 22. Figure 2A , Figure 2C , Figure 3A and Figure 4-5B The top surface of the insert 14A is shown in the figure. The collar 24 has an annular groove 28 that defines a plurality of stepped surfaces or layers around the periphery of the collar 24.

[0054] from Figure 2B As can be seen, the busbar 12 also has a cylindrical through-hole or aperture 30 extending through the contact portion 32 of the busbar 12. The busbar 12 also defines a cylindrical recess 34 that surrounds the busbar aperture 30 and is coaxial with the busbar aperture 30. The collar 24 and the recess 34 are sized such that they are in an interference fit or press-fit state when the collar 24 is inserted into the recess 34. The annular groove 28 includes a lip 36 extending above the groove 28, thereby forming a top edge 38, an inner edge 40, and a bottom edge 42 within the groove 28. Figure 5A As can be seen, the diameter of the lip 36 is smaller than the diameter of the collar 24. The top edge 38 is not perpendicular to the inner edge 40, nor parallel to the bottom edge 42. Figure 5A and 5B As shown, when the collar 24 of the plug 14A is pressed into the recess 34, the sidewall 44 of the recess 34 in the busbar 12 deforms, and at least some of the material displaced from the sidewall 44 enters and preferably fills the groove 28 in the collar 24, thereby fixing the plug 14A in the recess 34.

[0055] The busbar contact surface 26 also defines a plurality of alternating protrusions and recesses 46 extending radially from the collar 24. These alternating protrusions and recesses 46 displace some material on the bottom surface 48 of the recess 34, thereby inhibiting the twisting of the insert 14A within the recess 34 when torque is applied to the busbar assembly 10, for example, when torque is applied by the threaded fastener 20 within the hole 18 of the insert 14A.

[0056] Figure 6A-7 A second example of plug-in 14B is shown. The plug-in also has a cylindrical shape with a smooth through-hole or bore 18 passing through the center of plug-in 14A. This bore is configured to receive fasteners 20, such as bolts or threaded studs, to attach the busbar assembly 10 to the electrical device 16. Plug-in 14B can be used for bolted connections where an electroplated contact surface is desired between the busbar 12 and the electrical device 16. Plug-in 14B is plated with a conductive metallic material, such as tin or silver, preferably only on the device contact surface 22. Figure 6A , Figure 6C and Figure 7 On the bottom surface shown, the smooth hole 18 allows the fastener 20 to pass through easily and avoids the potential problem of misthreading that may occur with threaded through holes.

[0057] Insert 14B defines a plurality of serrations 50 that protrude from the outer edge 52 of insert 14B. The plurality of serrations 50 are arranged at an angle on the outer edge 52 of insert 14B such that they are neither parallel to nor perpendicular to the axis X of the hole 18 in insert 14B.

[0058] from Figure 6B As can be seen, the busbar 12 also has a cylindrical through-hole or aperture 30 extending through the contact portion 32 of the busbar 12. The busbar 12 also defines a cylindrical recess 34 that surrounds and is coaxial with the busbar aperture 30. The plurality of serrations 50 and the recess 34 are sized such that they are in an interference fit or press-fit state when the insert 14B is placed within the recess 34. Figure 5A and 5B As shown, when the insert 14B is pressed into the recess 34, the sidewall 44 of the recess 34 in the busbar 12 deforms due to the plurality of serrations 50. At least some of the material removed from the sidewall 44 enters and preferably fills the space between the serrations 50, thereby fixing the insert 14B within the recess 34. Furthermore, the angled plurality of serrations 50 cause the insert 14B to rotate slightly when pressed into the recess 34.

[0059] Multiple serrations 50 have sharp edges that provide a broaching feature to break through the surface oxides on the busbar 12, thereby improving electrical performance and mechanical retention.

[0060] The device contact surface 22 also defines a plurality of alternating protrusions and indentations 46 in the busbar contact surface 26, which is generally arranged opposite to the device contact surface 22. Figure 6A , Figure 6C and Figure 7 The top surface of the insert is shown in the diagram. Multiple alternating protrusions and recesses 46 extend radially from the hole 18. These multiple alternating protrusions and recesses 46 displace some material on the bottom surface 48 of the recess 34, thereby inhibiting the twisting of the insert 14B within the recess 34 when torque is applied to the busbar assembly 10, for example, when torque is applied by the threaded fastener 20 within the hole 18 of the insert 14B.

[0061] While the foregoing example of busbar 12 shows a hole 18 extending through busbar 12 surrounded by recess 34, alternative embodiments of the busbar may simply have holes extending through the counting portion in a uniform diameter, and collars or serrations may deform the inner wall of the hole to secure the insert to the busbar.

[0062] The third example of plugin 14C is in Figures 8A-8C As shown in the diagram. The plug 14C also has a cylindrical shape with a smooth through-hole or bore 18 passing through its center. This bore is configured to receive a fastener 20, such as a bolt or threaded stud, to attach the busbar assembly 10 to the electrical device 16. Where a plated contact surface is desired between the busbar 12 and the electrical device 16, the plug 14C can be used for bolted connections. The plug 14C is plated with a conductive metallic material, such as tin or silver, preferably only on the inner portion 56 of the device contact surface 22, such as... Figures 8A-8C As shown, the contact surface 22 of the device is the top surface. The smooth hole 18 allows the fastener 20 to pass through easily and avoids the potential problem of misthreading that may occur with threaded through holes.

[0063] The busbar contact surface 26 of plug-in 14C is generally flat and is welded to the contact portion 32 of busbar 12, thereby mechanically and electrically connecting plug-in 14C to the contact portion 32 of busbar 12. Welding is preferably performed using a torsional sonic welding process; however, other sonic welding, laser welding, resistance welding, spin welding, brazing, or soldering processes may also be used in some busbar applications. Welding plug-in 14C to the contact portion 32 also suppresses torsion of plug-in 14C when torque is applied to busbar assembly 10, for example, by the torque applied by the threaded fastener 20 within the hole 18 of plug-in 14C.

[0064] The fourth example of Plugin 14D is in Figures 9A-9CAs shown in the diagram. The insert 14D has a circular or oblong cylindrical shape with a smooth through-hole or bore 18 extending through the center of the insert 14D. This bore is configured to receive a fastener 20, such as a bolt or threaded stud, to attach the busbar assembly 10 to the electrical device 16. The bore may also have a circular or oblong shape. The outer surface of the collar 18 defines a plurality of serrations 60 extending in a direction generally parallel to the bore 18. The serrations 60 are sized such that when the insert 14D is placed within the busbar bore 30, the serrations 60 are in an interference fit or press-fit state. Figures 10A-10C As shown, insert 14D is pressed into busbar hole 30, the sidewall of busbar hole 30 being deformed by a plurality of serrations 60. At least some of the material displaced from the sidewall enters and preferably fills the space between the serrations 60, thereby securing insert 14D within busbar hole 30. The plurality of serrations 60 have sharp edges that provide a broaching feature to break through surface oxides in busbar hole 30, thereby improving electrical performance and mechanical retention.

[0065] Where an electroplated contact surface is desired between busbar 12 and electrical installation 16, insert 14D can be used for bolted connection, such as Figure 11A and 11B As shown. The smooth hole 18 allows the fastener 20 to pass through easily and avoids the potential problem of misthreading that may occur with threaded through holes.

[0066] The plug-in 14D can be mechanically pressed into the busbar hole 30 to provide a friction fit, or it can be twisted and welded to the busbar 12.

[0067] Figure 12 A method 200 for manufacturing a busbar assembly, such as the busbar assembly 10 described above, is shown. The method 200 includes the following steps: Step 202, providing a busbar formed of a first conductive material, the busbar having a planar contact portion and defining a smooth first hole extending through the contact portion, this step includes providing a busbar 12 formed of the first conductive material, the busbar 12 having a planar contact portion 32 and defining a smooth first hole 30 extending through the contact portion 32, such as Figure 2B and 6B As shown; Step 204 involves providing a contact insert formed of a second conductive material having a higher hardness than a first conductive material. The contact insert defines a first surface and a second surface opposite the first surface, and defines a smooth second hole. The second surface is plated with a third conductive material different from the second conductive material. This step includes providing a contact insert 14 formed of the second conductive material having a higher hardness than the first conductive material. The contact insert 14 defines a first surface 26 and a second surface 22 opposite the first surface 26, the second surface 22 being plated with a third conductive material different from the second conductive material. Figure 1 As shown, the contact plug 14 defines a smooth second hole 18 extending through it; Step 206: Arrange contact inserts on the contact portion so that the second hole is coaxial with the first hole. This step includes arranging contact inserts 14 on the contact portion 32 so that the second hole 18 is coaxial with the first hole 30, such as... Figure 1 As shown; Step 208 involves attaching the first surface of the contact plug to the contact portion of the busbar. This step includes attaching the first surface 26 of the contact plug 14 to the contact portion 32 of the busbar 12, such as... Figure 1 As shown; Step 210, inserting an alignment tool into the second hole of the contact plug. This step is optional and includes inserting the alignment tool 58 into the second hole 18 of the contact plug 14C, such as... Figure 8C As shown; Step 212, using an alignment tool to align the axis of the second hole with the axis of the first hole. This step is optional and includes using alignment tool 58 to align the axis X of the second hole 18 with the axis X of the first hole 30, such as... Figure 8C As shown; Step 214, attaching the contact plug to the contact portion using a soldering process. This step is optional and includes attaching the contact plug 14C to the contact portion 32 using a soldering process, such as... Figure 8C As shown. The welding process can be laser welding, resistance welding, rotary welding, brazing, soldering, or acoustic welding, and is preferably a torsional acoustic welding process; Step 216, forming an interference fit between the collar extending from the contact plug and the inner wall of the first hole, causing partial deformation of the busbar and its placement within the annular groove. This step is optional and may include forming an interference fit between the collar 18 of the contact plug 14A and the inner wall 44 of the recessed portion 34 of the first hole 30, causing partial deformation of the busbar 12 and its placement within the annular groove 28 defined in the collar 18. See [link to relevant documentation]. Figure 5A and 5B ;as well as Step 218: An interference fit is formed between the multiple serrations on the outer edge of the contact plug and the first hole, causing a portion of the busbar to deform and be positioned between the multiple serrations. This step is optional and includes forming an interference fit between the multiple serrations 50 on the outer edge 52 of the contact plug 14B and the recessed portion 34 of the first hole 30, causing a portion of the busbar 12 to deform and be positioned between the multiple serrations 50. See [link to previous steps]. Figure 7 .

[0068] While the invention has been described according to preferred embodiments, it is not intended to be limited thereto, but rather to be limited only by the scope set forth in the following claims. For example, the embodiments described above (and / or aspects thereof) may be used in combination with each other. Furthermore, various modifications may be made to adapt situations or materials to the teachings of the invention without departing from its main scope. The dimensions, types, orientations of the various components, and the number and position of the various components described herein are intended to define parameters of particular embodiments and are not intended to be limiting, but merely prototypical embodiments.

[0069] Having read the above description, many other embodiments and variations within the spirit and scope of the claims will be apparent to those skilled in the art. Therefore, the scope of the invention is defined only by the appended claims and the full scope of their equivalents.

[0070] As used herein, “one or more” includes functions performed by a single element, functions performed by more than one element in a distributed manner, functions performed by a single element, functions performed by several elements, or any combination of the above.

[0071] It should also be understood that although the terms "first," "second," etc., are used in some cases to describe various elements herein, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, without departing from the scope of the various described embodiments, a first contact may be referred to as a second contact, and similarly, a second contact may be referred to as a first contact. Both the first and second contacts are contacts, but they are not the same contact.

[0072] The terminology used in the description of the various embodiments herein is for descriptive purposes only and is not intended to be limiting. As used in the specification and appended claims of the various described embodiments, the singular forms “a,” “an,” and “the” are intended to equally include the plural forms unless the context clearly indicates otherwise. It should also be understood that the term “and / or” as used herein refers to and covers all possible combinations of one or more associated listed items. It should also be understood that the term “includes” as used herein specifically refers to the presence of the stated features, integrals, steps, operations, elements, and / or components, but does not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components, and / or combinations thereof.

[0073] As used herein, the term "if" may optionally be interpreted as "when" or "in response to determination" or "in response to detection," depending on the context. Similarly, depending on the context, the phrases "if determination" or "if [the stated condition or event] is detected" may optionally be interpreted as "in response to the decision" or "[when the condition or event is detected]" or "in response to the detection of [the stated condition or event]."

[0074] Furthermore, while this document may use terms of regulation or orientation, these elements should not be limited by such terms. Unless otherwise stated, all regulations or orientations are for the purpose of distinguishing one element from another and, unless otherwise stated, do not indicate any order, direction, or orientation of operation.

Claims

1. A busbar assembly (10), comprising: Busbar (12), the busbar being formed of a first conductive material and having a planar contact portion (32), wherein the busbar (12) defines a first hole (18) extending through the contact portion (32); and A contact insert (14) is formed of a second conductive material with a hardness greater than that of the first conductive material. The contact insert (14) defines a first surface (26) that is mechanically and electrically connected to the contact portion (32) of the busbar (12). The contact insert (14) also defines a second surface (22) plated with a third conductive material different from the second conductive material. The contact insert (14) defines a smooth second hole (30) coaxial with the first hole (18) and extending from the first surface (26) to the second surface (22). The contact insert (14) defines a cylindrical collar (24) extending from the first surface (26) and defining an annular groove (28) therein, wherein the collar (24) includes a lip (36) extending above the annular groove (28), and wherein the first surface (26) defines a plurality of alternating protrusions and indentations (46) extending radially beyond the lip (36) and the collar (24).

2. The busbar assembly (10) according to claim 1, characterized in that, The annular ring surrounding the second hole (30) on the second surface (22) is electroplated.

3. The busbar assembly (10) according to claim 1, characterized in that, The diameter of the lip (36) is smaller than the diameter of the collar (24).

4. The busbar assembly (10) according to claim 1, characterized in that, The collar (24) is press-fitted with the inner wall (44) of the first hole (18), causing a portion of the busbar (12) to deform and be disposed within the annular groove (28).

5. The busbar assembly (10) according to claim 1, characterized in that, The busbar (12) defines a cylindrical recess (34) in the contact portion (32) surrounding the first hole (18).

6. The busbar assembly (10) according to claim 1 or 2, characterized in that, The busbar (12) defines a cylindrical recess (34) in the contact portion (32) surrounding the first hole (18), wherein the outer surface of the contact portion located between the first surface (26) and the second surface (22) defines a plurality of serrations (50) extending from the outer surface, and wherein the plurality of serrations (50) are interference-fitted with the cylindrical recess (34) such that a portion of the busbar (12) is deformed and disposed between the plurality of serrations (50).

7. The busbar assembly (10) according to claim 6, characterized in that, The plurality of serrations (50) are not parallel to the axis (X) of the second hole (30) and are not perpendicular to the axis (X) of the second hole (30).

8. The busbar assembly (10) according to claim 6, characterized in that, The first surface (26) defines a plurality of alternating protrusions and indentations (46) extending radially from the second hole (30).

9. The busbar assembly (10) according to claim 1 or 2, characterized in that, The first surface (26) of the contact plug (14) is welded to the contact portion (32) of the busbar (12).

10. The busbar assembly (10) according to claim 1, characterized in that, The contact insert (14) defines a cylindrical collar (24) extending from the contact portion (32) and defining a plurality of serrations (60) therein, wherein the collar (24) is interference-fitted with the inner wall (44) of the first hole (18) such that a portion of the busbar (12) is deformed and disposed within the plurality of serrations (60).

11. The busbar assembly (10) according to claim 6, characterized in that, The plurality of serrations (60) extend along the collar (24) in a direction parallel to the axis (X) of the second hole (30).

12. The busbar assembly according to claim 6, characterized in that, The collar (24) and the second hole (30) have an elongated cylindrical shape.

13. A method of manufacturing a busbar assembly (10), comprising: A busbar (12) formed of a first conductive material is provided, the busbar (12) having a planar contact portion (32) and defining a smooth first hole (18) extending through the contact portion (32). A contact insert (14) is provided, formed of a second conductive material with a hardness greater than that of the first conductive material. The contact insert (14) defines a first surface (26) and a second surface (22) opposite to the first surface (26). The second surface (22) is plated with a third conductive material different from the second conductive material and defines a smooth second hole (30). The contact insert (14) defines a cylindrical collar (24) extending from the first surface (26) and defining an annular groove (28) therein. The collar (24) includes a lip (36) extending above the annular groove (28). The first surface (26) defines a plurality of alternating protrusions and indentations (46) extending radially beyond the lip (36) and the collar (24). The contact plug (14) is arranged on the contact portion (32) such that the second hole (30) is coaxial with the first hole (18); and The first surface (26) of the contact plug (14) is mechanically and electrically attached to the contact portion (32) of the busbar (12).

14. The method as described in claim 13, characterized in that, The method further includes: An alignment tool is inserted into the second hole (30) of the contact plug (14); Use the alignment tool to align the axis (X) of the second hole (30) with the axis of the first hole (18); and The contact plug (14) is attached to the contact portion (32) using a welding process.

15. The method according to claim 14, characterized in that, The welding process is selected from a list including acoustic welding, laser welding, resistance welding, rotary welding, brazing and soldering processes.

16. The method according to claim 14, characterized in that, The welding process described is a torsional acoustic welding process.

17. The method according to claim 13, characterized in that, The busbar (12) defines a cylindrical recess (34) in the contact portion (32) surrounding the first hole (18), wherein the outer surface of the contact portion located between the first surface (26) and the second surface (22) defines a plurality of serrations (50) extending from the outer surface, and wherein the method further includes: An interference fit is formed between a plurality of serrations (50) on the outer edge (52) of the contact plug (14) and the first hole (18), such that a portion of the busbar (12) is deformed and positioned between the plurality of serrations (50).

18. The method according to claim 13, characterized in that, The method further includes forming an interference fit between a collar (24) extending from the contact plug (14) and the inner wall (44) of the first hole (18), such that a portion of the busbar (12) is deformed and disposed within the annular groove (28).

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