Electrically conductive busbar structure with preloaded screws

Abstract

This invention relates to the field of new energy electrical connection and conductive busbar assembly technology, and discloses a conductive busbar structure with pre-installed screws, including a conductor, a plastic part, and screws. The plastic part is assembled at the end of the conductor, and the screws are disposed inside the plastic part. This conductive busbar structure with pre-installed screws utilizes the plastic part to pre-install the screws above the conductor holes and maintain them at a high position. This allows the screws to be stably held in the corresponding position of the conductor's through holes before assembly, eliminating the need for operators to manually pick up, hold, and align the small screws on-site. It is particularly suitable for battery pack and electrical control box assembly scenarios where thick protective gloves are worn. It fundamentally avoids problems such as screws falling off, misalignment, and repeated adjustments caused by the inconvenience of gloves, making the fastening operation one step, significantly improving assembly speed and positioning accuracy, and greatly improving the overall assembly efficiency of the production line.

Description

Technical Field

[0001] This invention relates to the field of new energy electrical connection and conductive busbar assembly technology, specifically a conductive busbar structure with pre-installed screws. Background Technology

[0002] Conductive busbars, as core components for power transmission in electrical, mechanical manufacturing, new energy vehicles, and battery packs, are typically made of conductive metals such as copper and aluminum. They require screws for fastening to their counterparts to ensure a stable and reliable conductive path. In the assembly of various integrated electrical equipment, the installation efficiency and positioning accuracy of conductive busbars directly affect the overall assembly progress, electrical performance, and safety of the product.

[0003] In actual assembly operations, operators must manually place each screw into the corresponding hole of the conductive connector bar before tightening it with a torque wrench. Because the screws are small and operators often wear thick protective gloves on the production floor, it is difficult to grip and accurately align them. This easily leads to screws falling off, misalignment, and repeated adjustments, reducing assembly efficiency and posing risks such as lost screws and improper assembly. This fails to meet the demands of efficient, rapid, and stable industrial assembly.

[0004] Therefore, a conductive connector structure with pre-installed screws is proposed to solve the above-mentioned problems. Summary of the Invention

[0005] Technical problems to be solved To address the shortcomings of existing technologies, this invention provides a conductive connector structure with pre-installed screws, which solves the problems of small-volume screws being difficult to handle, difficult to align, inconvenient to operate while wearing thick gloves, easy to fall off, and low installation efficiency during the assembly of conductive connectors.

[0006] Technical solution To achieve the above objectives, the present invention provides the following technical solution: a conductive connector structure with pre-installed screws, comprising a conductor, a plastic component, and screws; the plastic component is assembled at the end of the conductor, the screws are disposed inside the plastic component, the plastic component holds the screws above the holes in the conductor, and the screws are arranged corresponding to the holes in the conductor.

[0007] Preferably, the conductor is made of conductive metal, the conductor has a plate-like structure, and a through hole for assembly connection is provided at the end of the conductor.

[0008] Preferably, the through hole of the conductor matches the size of the screw shank, and the screw can pass through the through hole of the conductor to connect and fix with an external fitting.

[0009] Preferably, the plastic part is an injection-molded structural part, and the plastic part and the end of the conductor are nested together, with the plastic part covering a local area of ​​the conductor end.

[0010] Preferably, the plastic part has a rib structure inside, the rib structure is arranged around the outer wall of the screw, and the rib structure is adapted to the external dimensions of the screw.

[0011] Preferably, the rib structure clamps and positions the screw, keeping it in a high position under the constraint of the rib structure, and the screw will not detach from the plastic part.

[0012] Preferably, the head of the screw is located inside the plastic part, the shank of the screw extends toward the through hole of the conductor, and a predetermined distance is left between the screw and the conductor.

[0013] Preferably, the plastic part has an operating opening at the position corresponding to the screw head, and the operating opening allows an external tool to be inserted and act on the screw head.

[0014] Preferably, the conductor, plastic parts, and screws are assembled into an integrated pre-assembled structure, which can be directly and quickly fastened to external components.

[0015] Beneficial effects Compared with the prior art, the present invention provides a conductive connector structure with pre-installed screws, which has the following advantages: 1. This conductive connector structure with pre-installed screws uses plastic parts to pre-install the screws above the conductor holes and keep them in a high position. This allows the screws to be stably held in the corresponding position of the conductor through holes before assembly, eliminating the need for operators to manually pick up, hold, and align the small screws on-site. It is especially suitable for battery pack and electrical control box assembly scenarios where thick protective gloves are worn. It fundamentally avoids problems such as screws falling off, misalignment, and repeated adjustments caused by the inconvenience of gloves, making the fastening operation one step, significantly improving assembly speed and positioning accuracy, and greatly improving the overall assembly efficiency of the production line.

[0016] 2. This conductive connector structure with pre-installed screws utilizes the internal rib structure of the plastic parts to clamp and limit the screws. The rib structure, which is adapted to the screw's external dimensions, provides elastic clamping and radial positioning for the screw. This ensures that the screw will not fall off, deviate, jam, or be lost under conditions such as transportation, transfer, shaking, and vibration. It always maintains a standard high position that can be directly installed, eliminating the need for parts inspection and screw retrieval before assembly. This ensures a continuous and stable production process and effectively reduces material loss and on-site defect rate.

[0017] 3. This conductive connector structure with pre-installed screws utilizes a pre-assembled component consisting of conductors, plastic parts, and screws, integrating the conductive and fastening parts into a single unit. It eliminates the need for additional bolts, washers, clips, or other auxiliary parts, as well as special positioning tooling. The structure is simple in design, easy to manufacture, and has a lower assembly threshold. It can be adapted to automated and manual assembly lines in various fields such as new energy, electrical, and automotive. While simplifying the operation process, it improves operational safety and expands the applicability of conductive connectors in high-density, high-paced assembly scenarios. Attached Figure Description

[0018] Figure 1 This is a front view schematic diagram of a conductive connector structure with pre-installed screws proposed in this invention; Figure 2 This is a schematic diagram of a conductive copper busbar structure with pre-installed screws proposed in this invention. Figure 3 This is a schematic diagram of a conductive connector bar structure with pre-installed screws proposed in this invention. Figure 4 This is a schematic diagram of a conductive connection bar structure with pre-installed screws proposed in this invention. Figure 5 This is a schematic cross-sectional view of a conductive connector structure with pre-installed screws for quick screw installation proposed in this invention. Figure 6 This is a schematic diagram of the overall connection structure of a conductive connector with pre-installed screws proposed in this invention.

[0019] In the diagram: 1. Conductor; 2. Plastic part; 3. Screw; 10. Through hole; 11. Operating opening; 13. Rib structure. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] Please see Figure 1 - Figure 6 A conductive connector structure with pre-installed screws includes a conductor 1, a plastic part 2, and a screw 3; the plastic part 2 is assembled at the end of the conductor 1, the screw 3 is disposed inside the plastic part 2, the plastic part 2 holds the screw 3 above the hole of the conductor 1, and the screw 3 is arranged corresponding to the hole of the conductor 1.

[0022] First, conductor 1 is made of conductive metal and has a plate-like structure. A through hole 10 for assembly connection is provided at the end of conductor 1. By selecting copper, aluminum, or other metals with high conductivity and high mechanical strength as the base material of conductor 1, the core functional requirements of low loss and high conductivity during power transmission are ensured. The plate-like structure design effectively increases the contact area between conductor 1 and external components, improving the stability of the conductive connection and the structural load-bearing capacity. The precisely opened through hole 10 at the end provides a standardized and positioned passage for screw 3, allowing screw 3 to accurately pass through conductor 1 to achieve coaxial locking with the component. This ensures consistent connection positions at each assembly station, avoiding assembly misalignment and poor connection due to hole deviation, ultimately ensuring that the overall structure remains stable and unbroken during long-term operation.

[0023] Secondly, the through hole 10 of conductor 1 matches the size of the shank of screw 3. Screw 3 can pass through the through hole 10 of conductor 1 to connect and fix with the external clamp. By precisely matching the hole diameter of the through hole 10 with the outer diameter of the shank of screw 3, the radial clearance of screw 3 when passing through the through hole 10 is eliminated, effectively avoiding problems such as screw 3 shaking, offset, jamming or eccentricity. This ensures that screw 3 always remains coaxial with conductor 1 and external clamp during the tightening process, so that the tightening force can be evenly transmitted and avoid deformation or damage to conductor 1 caused by local stress concentration. At the same time, the size matching design ensures the tight fit between screw 3 and through hole 10, ultimately achieving a firm mechanical connection and reliable electrical conduction between conductor 1 and external clamp, meeting the requirements of high current, high vibration and multi-condition application scenarios.

[0024] Furthermore, plastic part 2 is an injection-molded structural component. Plastic part 2 and the end of conductor 1 are assembled in a nested manner. Plastic part 2 wraps a local area of ​​the end of conductor 1. By using an integrated injection molding process to manufacture plastic part 2, the external dimensions, internal structural precision, and assembly tolerances of plastic part 2 can be precisely controlled, making it suitable for mass production and ensuring the structural consistency and performance stability of each product. The nested assembly method between plastic part 2 and the end of conductor 1 achieves a tight, gapless connection between the two, eliminating the need for additional glue, bolts, or clips to form an inseparable integral structure. The partial wrapping design of plastic part 2 on the end of conductor 1 not only avoids the risk of scratches to operators caused by the sharp corners of conductor 1, but also reduces deformation and damage to conductor 1 caused by collisions and compression during transportation and assembly. At the same time, it provides protection and isolation for the connection area between conductor 1 and screw 3, improving the safety and durability of the overall structure.

[0025] Furthermore, the plastic part 2 has a rib structure 13 inside, which is arranged around the outer wall of the screw 3. The rib structure 13 is adapted to the outer dimensions of the screw 3. By integrally molding the rib structure 13 in a ring-shaped distribution inside the plastic part 2, the rib structure 13 and the cylindrical outer wall contour of the screw 3 are perfectly fitted. Utilizing the elastic deformation characteristics of the rib structure 13 itself, a uniform and stable ring-shaped clamping constraint is formed on the outer wall of the screw 3. Compared with single-point limiting, this ring-shaped fitting structure can more comprehensively limit the shaking, deflection and displacement of the screw 3, ensuring that the screw 3 can maintain accurate axial positioning under any installation angle, transportation posture and vibration environment, avoiding locking failure caused by the positional deviation of the screw 3, and providing core structural support for the high-level pre-installation and stable positioning of the screw 3.

[0026] Furthermore, the rib structure 13 clamps and positions the screw 3. Under the constraint of the rib structure 13, the screw 3 remains in a high position and will not detach from the plastic part 2. The moderate elastic clamping force provided by the rib structure 13 reliably restricts the screw 3 to the preset high position, ensuring that the screw 3 can move downward smoothly to complete the locking when subjected to external torque, and ensuring that the screw 3 is always fixed in this position under normal conditions without external force, and will not slip due to its own weight, transportation vibration, changes in product handling angle, etc. At the same time, the clamping and limiting function of the rib structure 13 completely avoids the screw 3 from falling off, being lost, or shifting during non-assembly stages such as product transfer, warehousing, and production line loading, ensuring that when the product arrives at the assembly station, the screw 3 is always in a standard pre-assembled state that can be directly operated, without the need for manual searching, reinstallation, or correction before assembly, ensuring the continuous and stable production process.

[0027] Furthermore, the head of screw 3 is confined inside the plastic part 2, and the shank of screw 3 extends toward the through hole 10 of conductor 1. A preset distance is left between screw 3 and conductor 1. The limiting structure inside the plastic part 2 axially restricts the head of screw 3, preventing screw 3 from sinking excessively or completely penetrating the plastic part 2 when not assembled. This ensures that the head of screw 3 is always within the operating space of the plastic part 2, facilitating precise gripping and operation by external tools. The reasonable distance reserved between screw 3 and conductor 1 provides sufficient downward stroke for the tightening operation of screw 3, avoiding premature contact between the shank of screw 3 and the upper surface of conductor 1, which could lead to failure to continue screwing downwards or incomplete locking. At the same time, this distance design also prevents premature contact between screw 3 and conductor 1, avoiding accidental operation before locking that could cause scratches or electrical short circuits on the surface of conductor 1, ensuring a continuous and smooth locking process, and improving the assembly success rate and product insulation safety.

[0028] Furthermore, the plastic part 2 has an operating opening 11 corresponding to the head of the screw 3. The operating opening 11 allows external tools to be inserted and act on the head of the screw 3. By opening a dedicated operating opening 11 on the plastic part 2 corresponding to the head of the screw 3, a standardized and direct operating channel is provided for external assembly tools such as torque wrenches and electric screwdrivers. This allows the tools to be quickly and accurately aligned with the head of the screw 3 without the need for manual assistance in aligning the screw 3, greatly simplifying the operation steps. The size and shape of the operating opening 11 are adapted to the specifications of commonly used assembly tools, which can effectively limit the operating range of the tools and avoid the screw head from slipping or the plastic part 2 from tool deviation. It is especially suitable for industrial site operation scenarios where operators wear thick protective gloves, reducing the difficulty of operation and improving assembly speed and positioning accuracy.

[0029] Finally, conductor 1, plastic part 2, and screw 3 are assembled into an integrated pre-assembled structure. This integrated pre-assembled structure can be directly and quickly fastened to external components. By integrating the three core components of conductor 1, plastic part 2, and screw 3 before leaving the factory, a single, independent, complete, and directly usable assembly is formed, replacing the traditional decentralized parts assembly mode. This integrated pre-assembled structure eliminates the tedious steps of picking up and placing screws 3 on-site, manual alignment, and individual assembly, achieving a rapid assembly effect of "pick up and install, tighten to fit". It does not require additional positioning fixtures and auxiliary accessories, significantly lowering the threshold for assembly operations. At the same time, this structure can significantly improve the overall assembly efficiency of products such as battery packs, electrical cabinets, and new energy equipment, reduce manual operation time and defect rate, adapt to automated production lines and high-efficiency mass production, and expand the application scope of conductive connectors in multiple fields.

[0030] Working principle: This structure uses three high-position screws, elastic clamping of ribs, integrated design, and quick locking without manual intervention as its core working mechanism. It maintains stability and reliability throughout the entire process of parts transfer, production line material handling, on-site assembly, and torque locking, completely solving the problems of low assembly efficiency, difficult alignment, and easy screw drop of traditional conductive connectors. The overall operation is stable, the movement is smooth, and the positioning is accurate.

[0031] This structure mainly consists of three core components: conductor 1, plastic part 2, and screw 3. Conductor 1 has a through hole 10, plastic part 2 has an operating opening 11, and plastic part 2 has an integrally formed rib structure 13. The components work together to form a complete pre-assembly and locking system. In the pre-assembly stage, the injection-molded plastic part 2 is first assembled into the end of conductor 1 in a nested manner, so that plastic part 2 and conductor 1 are firmly combined into an inseparable whole, ensuring that there will be no loosening, displacement, or misalignment during subsequent transportation and assembly.

[0032] Then, screw 3 is pressed into the interior through the operating opening 11 at the top of plastic part 2. The rib structure 13 on the inner wall of plastic part 2 is precisely matched with the outer wall size of screw 3. The rib structure 13 forms a uniform and stable elastic clamping and radial limit for screw 3, so that screw 3 is reliably held in a high position. The shank of screw 3 is vertically downward and strictly aligned with the through hole 10 of conductor 1. At the same time, a reasonable preset gap is maintained between the lower end of screw 3 and the upper surface of conductor 1, which provides sufficient downward pressure stroke for subsequent locking action and avoids premature contact of screw 3, which would prevent it from being properly tightened.

[0033] During non-assembly stages such as product transfer, warehousing, and loading, the rib structure 13 continuously provides clamping force, resisting external interference such as equipment vibration, handling shaking, and angular tilting. This ensures that the screws 3 will not loosen, deflect, slip, or be lost, and will always remain in a standard position ready for direct installation. No manual inspection, reinstallation, or correction is required before assembly, significantly improving production line efficiency. When assembling battery packs, electrical cabinets, or other equipment on-site, operators do not need to pick up, hold, or align the small screws 3. They only need to place the entire structure at the installation position of the component, aligning the through hole 10 of the conductor 1 with the threaded hole of the component. Then, a torque wrench is inserted through the operating opening 11, directly contacting the head of the screw 3 and applying downward pressure and rotational torque. Under the action of external force, screw 3 overcomes the clamping force of rib structure 13 and moves downward. The rod smoothly passes through the through hole 10 and is screwed into the threaded hole of the matching part. As the torque is continuously applied, screw 3 gradually completes the locking, realizing a stable conductive connection between conductor 1 and the external matching part. The entire locking process does not require holding screw 3 by hand, repeated alignment, or worrying about screw 3 falling off. Installation can be completed in one action, significantly improving assembly speed and consistency, while reducing the difficulty of operation. It is suitable for industrial field operations with thick gloves. It solves the industry pain points of low assembly efficiency, inaccurate positioning, easy screw falling off, and improper installation of traditional conductive connectors from the structural root, ensuring assembly quality and production efficiency.

[0034] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

Claims

1. A conductive connector structure with pre-installed screws, characterized in that: It includes a conductor (1), a plastic part (2) and a screw (3); the plastic part (2) is assembled at the end of the conductor (1), the screw (3) is disposed inside the plastic part (2), the plastic part (2) holds the screw (3) above the hole of the conductor (1), and the screw (3) is arranged corresponding to the hole of the conductor (1).

2. The conductive connector structure with pre-installed screws according to claim 1, characterized in that: The conductor (1) is made of conductive metal and has a plate-like structure. A through hole (10) for assembly and connection is provided at the end of the conductor (1).

3. The conductive connector structure with pre-installed screws according to claim 1, characterized in that: The through hole (10) of the conductor (1) matches the size of the shank of the screw (3), and the screw (3) can pass through the through hole (10) of the conductor (1) to connect and fix with the external fitting.

4. The conductive connector structure with pre-installed screws according to claim 1, characterized in that: The plastic part (2) is an injection-molded structural part. The plastic part (2) and the end of the conductor (1) are nested together. The plastic part (2) wraps a local area of ​​the end of the conductor (1).

5. The conductive connector structure with pre-installed screws according to claim 1, characterized in that: The plastic part (2) has a rib structure (13) inside. The rib structure (13) is arranged around the outer wall of the screw (3). The rib structure (13) and the external dimensions of the screw (3) are compatible.

6. A conductive connector structure with pre-installed screws according to claim 5, characterized in that: The rib structure (13) clamps and positions the screw (3), and the screw (3) remains in a high position under the restriction of the rib structure (13), and the screw (3) will not come out of the plastic part (2).

7. The conductive connector structure with pre-installed screws according to claim 1, characterized in that: The head of the screw (3) is located inside the plastic part (2), the shank of the screw (3) extends toward the through hole (10) of the conductor (1), and a preset distance is left between the screw (3) and the conductor (1).

8. A conductive connector structure with pre-installed screws according to claim 1, characterized in that: The plastic part (2) has an operating opening (11) at the position corresponding to the head of the screw (3), and the operating opening (11) allows an external tool to be inserted and act on the head of the screw (3).

9. A conductive connector structure with pre-installed screws according to claim 1, characterized in that: The conductor (1), plastic part (2) and screw (3) are assembled to form an integrated pre-assembled structure, which can be directly fastened to external parts.

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