Insert with screw and contact assembly including insert with screw

Abstract

To provide an insert 1 with a screw to be screwed into a bus bar, in particular, a bus bar of a battery module.SOLUTION: Regarding the insert 1 with the screw to be screwed into a bus bar 64, in particular, a bus bar of a battery module 102, the insert with the screw comprises a male screw for self-tapping or self-forming. The present invention relates to a contact assembly 62 including the insert with the screw, the bus bar and a contact screw 44 which can be screwed into the insert with the screw. Preferably, the insert with the screw comprises a touch protection part and is screwed into a bus bar, in particular, a thread of a bus bar which is cut by the male screw of the insert with the screw.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present invention relates to a threaded insert for screwing into a busbar, and to a contact assembly having a threaded insert. [Background technology]

[0002] A reliable electrical connection of battery modules, for example in e-mobility, is essential. High currents need to be transmitted with as few losses as possible. The components and contact assemblies used for this purpose need to provide reliable and safe transmission regardless of changing environmental conditions and in environments prone to vibration. To meet these requirements, threaded connections are used in some applications to connect the busbars that connect the battery modules. Due to the high voltages, the threaded connections must be touch-protected and protected from contact as soon as personnel begin working on them. Whether touch-protected or touch-protected, the threaded connections should be easy to assemble. Summary of the Invention [Problem to be solved by the invention]

[0003] The underlying problem of the present invention is therefore to provide a threaded connection for connecting several busbars in a contact-protected manner, which can withstand highly fluctuating environmental influences, which reliably connects the busbars to one another even in environments subject to vibration loads, and which is easy to assemble. [Means for solving the problem]

[0004] The invention solves this problem on the one hand by a threaded insert for screwing into a busbar, in particular a busbar of a battery module, which threaded insert has a self-tapping or self-forming external thread, and on the other hand by a contact assembly having a threaded insert, a busbar and a contact screw that can be screwed into the threaded insert.

[0005] This solution simplifies the manufacture of the contact assembly, since it is not necessary to pre-thread the base material of the busbar or battery module, e.g., copper. Another advantage of the threaded insert is that its material can be optimally matched to the material of the busbar and the material of the screw that is to be screwed into the threaded insert. This allows for a high-strength connection that is easy to manufacture.

[0006] The invention can be further improved by the following features, each of which is preferred alone, independent of each other and which can be combined with each other in any way.

[0007] For example, according to the first configuration, the threaded insert may have or consist of a material with high strength, particularly a strength higher than that of copper. Due to the higher strength of the material, a higher pretensioning force can be achieved in the threaded connection. In addition, the threaded insert is subject to less wear during tapping or thread formation.

[0008] The threaded insert may be made from the same material as the contact screw or from a material that has greater strength than the contact screw.

[0009] Preferably, the threaded insert is made from steel, especially stainless steel, which, together with the contact thread made from steel, provides a high strength and corrosion resistant steel-on-steel thread combination.

[0010] In another configuration, the threaded insert may be made from aluminum or an aluminum-containing material, which provides high corrosion resistance.

[0011] The threaded insert may be configured as a hollow cylinder and may have a through opening that passes through the entire threaded insert and has an internal thread. It may also have a closed bottom. The internal thread may preferably be metric, for example, and may receive a complementary metric thread. This simplifies the procurement of compatible contact threads, making the threaded insert more accessible and versatile.

[0012] The female thread may extend over a longer area in the longitudinal direction of the threaded insert than the male thread. This allows for a larger contact surface between the threaded insert and the fastening element, e.g., the contact screw, that is screwed into the threaded insert. The larger contact surface reduces contact resistance and losses. The longitudinal direction in this example corresponds to the axial direction of the threaded insert and thus the direction in which the threaded insert is screwed in.

[0013] In another configuration, the female threads of the threaded insert may extend over a shorter area than the male threads of the threaded insert, which embodiment offers the potential for faster assembly since fewer turns are required to form a connection between the threaded insert and the component into which it is to be threaded.

[0014] The threaded insert may have a head provided with a screw drive, in which case the head may be configured as a flat head with a flange. Other configurations include, for example, a round head, an external hexagon, an internal hexagon, and / or a countersunk head.

[0015] The screw drive may be used to attach an instrument for turning the threaded insert, preferably around the circumference of the threaded insert in the longitudinal or threading direction, from the head to the other free end of the threaded insert, i.e., the end facing the face of the component into which the threaded insert is inserted.

[0016] The shape of the screw driver can be as desired, for example, an internal hexagon. The shape of the complementary tool is then a hex wrench having a hexagonal profile that can engage with the internal hexagon of the threaded insert to turn it. This configuration is particularly preferred for reaching difficult to access heads.

[0017] In another configuration, the screw driver can be an external hexagon. Preferably, the head is then configured as a hexagonal head. An instrument can then grip the head or the screw driver. Thus, the drive or connection geometry can be any and can have other shapes. As with an internal hexagon or Torx drive, an instrument can be inserted into a recess in the threaded insert or grip the outer periphery or outer contour of the threaded insert.

[0018] One configuration may provide both an internal recess and an external contour in the head that can be gripped by the tool, for example, the head comprising both an internal hexagon and an external hexagon, for greater flexibility in tool selection for better accessibility, power transfer, and ease of management during assembly.

[0019] In another configuration, during assembly, the threaded insert may be held and aligned with a screw that threads into the internal threads of the threaded insert.

[0020] The head may further comprise an undercut, i.e., an unthreaded area below the head, such as a narrow recess, groove or depression.

[0021] The threaded insert may have a flange that projects radially beyond the head and is located between the male thread and the head. The flange allows the head to lie flush and flat against the component into which the threaded insert is inserted. The flange provides good force transmission and a defined threading depth.

[0022] The internal threads of the threaded insert may extend to the end opposite the head.

[0023] The threaded insert may have a touch protection portion, which may preferably consist of an electrically insulating or dielectric material such as plastic. The touch protection portion may be configured as a protective cap and may be, for example, cylindrical and may have approximately the same diameter as the threaded insert. The touch protection portion may have a square or rectangular shape, may be conical, or may have any other shape.

[0024] The touch protection is preferably provided with one or more openings and / or recesses, and at least one opening in the touch protection may be large enough to allow a contact screw to pass through it in order to be screwed into the threaded insert.

[0025] The at least one recess and / or opening may be used as an alternative to a screw drive for screwing the threaded insert in. For this purpose, the touch protection is preferably pre-connected firmly to the threaded insert.

[0026] The at least one recess may further be used to attach the touch protection to the threaded insert, for example by turning the touch protection, similar to a screw cap or bayonet lock, in which case the threaded insert comprises an additional thread or a complementary protrusion that holds part of the touch protection in the end position where the touch protection is turned.

[0027] The head of the threaded insert may be provided with a form-fit element that holds the touch protection to the threaded insert with a form-fit.

[0028] The form-fitting element of the head may, in one configuration, comprise an axial undercut. The undercut may be formed by a shoulder. The shoulder may be formed, for example, by a recess that extends partially or continuously in the circumferential direction, such as a groove or recess, or by a protrusion that extends partially or continuously in the circumferential direction, such as a latching lug or rib. A touch protection, for example a protective cap, may latch onto the head at the undercut.

[0029] The touch protection part may have a form-fitting element complementary to the form-fitting element of the head part. For example, if the form-fitting element of the head part is a protrusion, the form-fitting element of the touch protection part may be a complementary recess. If the form-fitting element of the touch protection part is a recess, the form-fitting element of the touch protection part may be a complementary protrusion.

[0030] A form-fit element of the touch protection is disposed within the touch protection and is preferably configured to be complementary to the head of the threaded insert. The form-fit element of the touch protection also preferably has an axial undercut configured to engage with the axial undercut of the touch protection.

[0031] The touch protection, in particular the face of the touch protection facing the threaded insert, may abut the end of the threaded insert provided with the screw drive and may be attached to the face of the head facing the touch protection. For example, the touch protection may be connected to the screw drive. The touch protection may at least partially cover the head.

[0032] In a further configuration, the touch protection may be frictionally connected to the threaded insert. To form a press fit, the diameter of the threaded insert at the point where the touch protection is or will be attached must be slightly larger than the inner diameter of the touch protection or the opening of the touch protection. A friction connection provides high load capacity and uniform load distribution and does not require any additional fastening elements. When a friction connection is created, it is preferred that the touch protection is pressed onto the threaded insert, in particular its head.

[0033] In addition, the touch protection can be injection molded onto the threaded insert, which increases the design flexibility of the touch protection and allows for complex shapes. This is advantageous for mass production and therefore reduces costs, especially in the case of large quantities. Furthermore, separate assembly of the touch protection onto the threaded insert can be omitted.

[0034] To mount the threaded insert, the component of the contact assembly for receiving the threaded insert may have an unthreaded hole for receiving the threaded insert. In particular, the busbar of the contact assembly may have an unthreaded hole for receiving the threaded insert. The diameter of the unthreaded hole may be adapted to the size depending on the material and external thread of the threaded insert.

[0035] The threaded insert may be screwed into the busbar, particularly into threads tapped / formed in the busbar by its external threads. The threads tapped from the external threads of the threaded insert may be internal threads complementary to the external threads of the threaded insert. The threading provides high holding and tensile strength as the threaded insert anchors itself firmly to the material, and has a large contact surface for safely transferring and distributing forces.

[0036] Another embodiment of the contact assembly provides for a threaded insert to be pressed into the busbar. This may be pressed in with or without external threads, which can save costs as no special equipment is required for pressing in.

[0037] In one embodiment of the contact assembly, the contact screw passes through the second busbar and threads longitudinally into the threaded insert, particularly into the internal threads of the threaded insert, thereby connecting the two busbars together.

[0038] The invention will now be described by way of an embodiment with reference to the drawings, in which the same reference signs are always used in the drawings for elements that correspond to one another in terms of function and / or structure.

[0039] In accordance with the above description, a feature of an embodiment may be omitted if the technical effect associated with that feature is not important for a particular application. Conversely, a feature not yet present may be added to an embodiment in accordance with the above description if the technical effect of the feature to be added is important for a particular application.

[0040] This is shown by the following: [Brief explanation of the drawings]

[0041] [Figure 1] FIG. 1 is a schematic diagram of a threaded insert. [Figure 2] FIG. 2 is a schematic cross-sectional view of a threaded insert. [Figure 3] 1 is a schematic diagram of a contact assembly having a busbar and a threaded insert with touch protection. FIG. [Figure 4] FIG. 1 is a schematic diagram of a contact assembly having a busbar and a threaded insert. [Figure 5] FIG. 10 is a schematic diagram of a contact assembly having a second bus bar and a contact screw. DETAILED DESCRIPTION OF THE INVENTION

[0042] 1 shows one embodiment of a threaded insert 1. The threaded insert 1 may be configured as a hollow cylinder and may be made from a high strength material such as steel. In some applications, it may be made from stainless steel.

[0043] The threaded insert 1 is provided at least partially on its outer periphery 2 with an external thread 4. This external thread 4 is preferably a self-tapping or, as used synonymously herein, a self-forming external thread 4. Self-tapping or self-forming means that the threaded insert 1 itself, without any further assistance, forms the complementary thread 6 ( FIG. 4 ) it requires in the workpiece into which the threaded insert 1 is to be screwed. By screwing the threaded insert 1 into the workpiece material, the specially adapted external thread 4 of the threaded insert 1 gradually bites into the material, which is then displaced and molded to form the thread 6 against which the threaded insert 1 is held. The resulting thread 6 may be an internal thread.

[0044] The threaded insert 1 may include a head 8, which may also include a flange 10. The diameter 11 of the head 8 is larger than the diameter 12 of the external thread 4. The flange 10 has a diameter 14 that is larger than the diameter 11 of the head 8. The flange 10 includes a lower annular surface 16 that faces the end of the threaded insert 1 opposite the head 8.

[0045] Furthermore, the threaded insert 1 comprises a screw driver 18 at the head 8. Exemplarily, an internal hexagon 20 is shown here. In another configuration, the screw driver 18 may be an external hexagon. It should be noted that the drive geometry, or likewise the connection geometry 22, is optional and the shape can be freely selected. For example, an instrument (not shown) may be inserted into an internal recess 24 of the threaded insert 1 or may grip the outer periphery or outer contour 26 of the threaded insert 1. For example, a hex wrench may be used to screw in the threaded insert 1.

[0046] The screw drive 18 may be chamfered at an upper end 30 opposite a threading direction 28 for easy insertion of an instrument in the recess 24 or upper edge 32 of the internal hexagon 22. The threading direction 28 faces axially from the head 8 to the free end 34 of the threaded insert 1, and preferably coincides with the axial direction of the threaded insert 1. In one configuration, both an internal and external profile may be provided on the threaded insert 1 for engagement with a complementary instrument.

[0047] Furthermore, the threaded insert 1 has a through opening 36 which passes through the entire threaded insert in the screw-in direction or equivalently in the longitudinal direction 28 and is provided with an internal thread 38. This internal thread 38 may preferably be metric for the sake of versatility.

[0048] In order to be able to screw a component to be screwed, such as a contact screw 44 (see FIG. 5 ), into the threaded insert 1 in the screwing direction 28, and in particular into the internal thread 38 of the threaded insert 1, the through opening 36, in particular in the region 40 of the screw drive 18, must be larger than the diameter 42 of the internal thread 38. The threaded insert 1 may be unthreaded in the head 8, in particular in the screw drive 18.

[0049] In FIG. 2, a cross-sectional view of one embodiment of a threaded insert 1 is shown having an internal thread 38, preferably metric, an external self-tapping thread 4, and a head 8.

[0050] The female thread 38 may extend in the longitudinal direction 28 over a longer region 43a than the male thread 4. In this case, the male thread 4 extends over a shorter region 43b in the longitudinal direction. In another configuration, the female thread 38 may extend over a shorter region 43a in the longitudinal direction 28 than the male thread 4.

[0051] Below the flange 10 of the head 8 , the threaded insert 1 may be provided with an undercut 48 , i.e. an unthreaded area below the head 8 .

[0052] The flange 10 of the head 8 preferably defines an annular surface 16 , the plane of which extends perpendicular to the screwing direction 28 and faces the other end 34 of the threaded insert 1 .

[0053] Preferably, the head 8 is configured to be primarily cylindrical. Therefore, the head 8 may be configured as a flat head. In this FIG. 2, the flange 10 has a slightly conical shape. Other possible embodiments include, among others, a hexagonal head, a round head, a round-flat head, or a countersunk head. Exemplarily, the head 8 is shown here as a flat head with a flange 10.

[0054] At the head 8, the threaded insert 1 may comprise a form-fitting element 52. The form-fitting element 52 may comprise an axial undercut 53. For example, the form-fitting element 52 may be a latch protrusion 54. The latch protrusion 54 may preferably extend over the entire outer periphery 2 of the head 8 and may be continuous. In another configuration, the head 8 may have multiple latch protrusions 54, for example, equidistantly spaced apart in the circumferential direction 56. The latch protrusions 54 may be, for example, latch lugs, whose latch surfaces 58 may extend parallel to the annular surface 16 of the flange 10. A touch protection 60 may be latched to the latch protrusion 54 (see FIG. 3). The touch protection 60 may consist of a dielectric material, such as plastic, and may be cylindrical. Other configurations include, for example, a rectangular, conical, or spherical touch protection 60.

[0055] 3, for example, shows one embodiment of a contact assembly 62 comprising a busbar 64 and a threaded insert 1 having touch protection 60. Busbar 64 preferably has a contact surface 66 that may extend parallel to annular surface 16 of flange 10 (FIG. 2).

[0056] 3, the threaded insert 1 is shown threaded onto the busbar 64. The inner diameter 68 of the touch protection 60 or the opening 70 in the touch protection 60 must be larger than the diameter of the contact screw 44 (FIG. 5) so that the contact screw 44 can be threaded onto the threaded insert 1.

[0057] The touch protection 60 may have a recess 72 which may be used for assembly by means of a component or a tool. Likewise, the recess 72 may be used for releasing the latched connection of the touch protection 60 with the threaded insert 1, for example by means of a tool adapted for this purpose.

[0058] 4 shows one embodiment of a contact assembly 62 having a busbar 64 and a housing 74. The housing 74 surrounds both the busbar 64 and the threaded insert 1 having the touch protection 60. The housing 74 may have a shoulder 76 against which the busbar 64 or a protrusion 78 of the busbar 64 may rest.

[0059] The threaded insert 1 can be threaded into the busbar 64 by inserting it into the hole 80 in the busbar 64 and using a tool to rotate the screw driver 18 around the busbar 64 in a threading direction. In doing so, the threaded insert 1 cuts the threads 6 into the busbar 64, where it is retained. The diameter 82 of the hole 80 depends on the diameter 14 of the external thread 4 and / or the selected material of the busbar 64.

[0060] Preferably, the threaded insert 1 may be screwed up to the flange 10. This means that the annular surface 16 facing the end 34 opposite the head 8 may abut against the contact surface 66 of the busbar 64.

[0061] In this configuration, the touch protection 60 is preferably connected to the threaded insert 1 via the latch protrusion 54 by a form fit. Other embodiments may provide a friction fit or a form fit connection by other form fit elements. For example, a clamping ring, a groove and feather key or a wedge may be used to connect the touch protection 60 to the threaded insert 1, in particular to the head 8 of the threaded insert 1. In the case of a friction fit, the diameter, in particular the outer diameter 11, of the head 8 of the threaded insert 1 may be slightly larger than the inner diameter 68 of the touch protection 60, resulting in a press fit.

[0062] Another configuration provides that the touch protection 60 can be injection molded directly onto the head 8 of the threaded insert 1. The touch protection 60 can be fully or partially fitted onto the head 8. On the opposite side of the longitudinal direction 28, the touch protection 60 can be attached to a horizontal surface 84 at the upper end 30 of the threaded insert 1 and can be connected to the screw drive 18, for example.

[0063] FIG. 5 shows one embodiment of a contact assembly 62 having a busbar 64, a threaded insert 1 threaded onto the busbar 64, and a second busbar 64a through which a contact screw 44 passes and whose external threads 86 engage the internal threads 38 of the threaded insert 1.

[0064] The second busbar 64a preferably has a through hole 88 through which the contact screw 44 can pass. The contact screw 44 may have a screw head 90 with a screw flange 92, the support surface 94 of which rests against the contact surface 66a of the busbar 64a. The contact screw 44 may preferably have a touch protection 60a, which may be used to thread the contact screw 44 into the threaded insert 1 and make the assembly touch-safe.

[0065] The busbar 64a through which the contact screw 44 passes may be configured such that at least a portion 96 of the busbar 64a contacts the contact surface 66 of the first busbar 64, thereby allowing this contact to be strengthened and secured by the threaded connection.

[0066] In this Figure 5, the contact screw 44 includes an area 98 in the longitudinal direction 28 that is unthreaded. In other words, the contact screw 44 has threads only partially, rather than along its entire length 100, and in Figure 5 is unthreaded, particularly in the area 98 below the screw flange 92. The unthreaded area 98 can make the contact screw 44 easier to thread, as fewer turns are required to thread the contact screw 44. Other configurations provide a contact screw 44 that is threaded along its entire length 100.

[0067] In another configuration, the threaded insert 1 may be pressed into the busbar 64. This may be done by means of a self-tapping external thread 4. This pressing may preferably be done without an external thread 4 on the threaded insert 1. The busbar 64 may then have a hole 80 into which the threaded insert 1 is pressed, as already shown in the configuration of Figure 4. This hole 80 may be configured to be unthreaded.

[0068] Contact screws 44 engaging threaded insert 1 connect busbar 64 to busbar 64a, establishing electrical contact with, for example, battery module 102 connected to busbar 64. [Explanation of symbols]

[0069] 1 threaded insert 2. Outer circumference 4 male threads 6 threads 8 head 10 flange 11 Head diameter 12 Male thread diameter 14 flange diameter 16 Annular Surfaces 18 Screw drive unit 20 internal hexagons 22 Connection Geometry 24 depression 26 Outer contour 28 Screw-in direction 30 End 32 Edge of recess 34 Free end of threaded insert 36 Through opening 38 Female thread 40 Screw drive area 42 Female thread diameter 43a Female thread area 43b Male thread area 44 Contact screw 48 Undercut 52 Form-fit elements 53 Undercut of form-fit element 54 Latch protrusion 56 Circumferential direction 58 Latch surface 60 Touch protection part 60a Screw touch protection 62 Contact Assembly 64 Busbar 64a Second busbar 66 Contact surface 66a Second busbar contact surface 68 Inner diameter of touch protection part 70 Opening 72 recess 74 Housing 76 Shoulder 78 Protrusion 80 holes 82 Hole diameter 84 Horizontal plane 86 Male thread of screw 88 Through Hole 90 screw head 92 screw flange 94 Support surface 96 parts 98 Threadless Area 100 length 102 Battery Module

Claims

1. A threaded insert (1) for screwing into a busbar (64), in particular a busbar (64) of a battery module (102), comprising: The threaded insert (1) comprises a self-tapping or self-forming external thread (4), Threaded insert (1).

2. 2. The threaded insert (1) of claim 1, wherein the threaded insert (1) has a through opening (36) extending entirely through the threaded insert (1) and having an internal thread (38).

3. 3. The threaded insert (1) according to claim 2, wherein the female thread (38) extends over a region (43a) that is longer in the longitudinal direction (28) of the threaded insert (1) than the male thread (4) of the threaded insert (1).

4. 4. The threaded insert (1) according to any one of claims 1 to 3, wherein the threaded insert (1) comprises a head (8) provided with a threaded drive (18).

5. Threaded insert (1) according to claim 4, wherein the head (8) is configured as a flat head with a flange (10).

6. 6. The threaded insert (1) according to claim 4 or 5, wherein the internal thread (38) of the threaded insert (1) extends to an end (34) opposite the screw drive (18).

7. 7. The threaded insert (1) according to any one of claims 1 to 6, wherein the threaded insert (1) comprises a touch protection (60) made from an electrically insulating material.

8. Threaded insert (1) according to claim 7, characterized in that the head (8) is provided with a form-fitting element (52) which holds the touch protection (60) on the threaded insert (1) by form-fitting.

9. 9. The threaded insert (1) according to claim 7 or 8, wherein the threaded insert (1) is frictionally connected to the touch protection (60).

10. Threaded insert (1) according to claim 7 or 8, wherein the touch protection (60) is injection molded onto the threaded insert (1).

11. A contact assembly (62) comprising a threaded insert (1) according to any one of claims 1 to 10, a busbar (64), and a contact screw (44) that can be screwed into the threaded insert (1).

12. The contact assembly (62) of claim 11, wherein the busbar (64) comprises an unthreaded hole (80) for receiving the threaded insert (1).

13. 13. A contact assembly (62) according to claim 11 or 12, wherein the threaded insert (1) is screwed into the busbar (64), in particular into a thread (6) of the busbar (64) cut by the external thread (4) of the threaded insert (1).

14. 13. A contact assembly (62) according to claim 11 or 12, wherein the threaded insert (1) is pressed into the busbar (64).

15. 15. A contact assembly (62) according to any one of claims 11 to 14, wherein the contact screw (44) extends through a second busbar (64a) and is threaded into the threaded insert (1) in the longitudinal direction (28) of the threaded insert (1).

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