Self-Tapping Threaded Insert for Vibration-Resistant Busbar Assembly
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Solution Overview
Problem
Existing screw connections for busbars in battery modules, particularly in e-mobility, face challenges in providing a contact-protected, durable, and easy-to-assemble connection that withstands fluctuating environmental conditions and vibration.
Innovation Solution
A threaded insert with a self-tapping external thread is used to screw into a busbar, along with a contact assembly that includes a busbar, threaded insert, and a contact screw. This configuration allows for a high-strength, corrosion-resistant connection that is easy to manufacture and assemble.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a screw connection is used to connect busbars, then the connection is reliable and contact-protected, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The threaded insert is pre-installed into the busbar before the final assembly process. This preliminary action creates ready-to-use threaded holes, eliminating the need for on-site threading operations and simplifying the overall assembly process while maintaining reliable screw connections
Solution Approach 2:
The threaded insert acts as an intermediary component between the busbar and the screw connection. It provides a standardized threaded interface that facilitates easy assembly while ensuring reliable and contact-protected electrical connections, resolving the contradiction between connection reliability and assembly simplicity
2Ease of operation
If a thread is cut in advance into the busbar, then the assembly is simplified, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The manufacturing process is segmented into two independent stages: busbar production (without threading) and threaded insert installation. This segmentation allows busbars to be manufactured using standard processes, while threading is added later through the threaded insert, reducing overall manufacturing complexity and time
Solution Approach 2:
The threaded insert serves as a mediator that separates the busbar manufacturing process from the threading operation. This allows each component to be optimized independently - the busbar can be manufactured without complex threading operations, while the threaded insert provides the necessary threaded interface for easy assembly
3Strength
If the threaded insert material is matched optimally to the busbar and screw, then connection strength is maximized, but material selection and manufacturing become more complex
Solution Approach 1:
The material properties of the threaded insert are optimized by selecting appropriate material parameters (such as using aluminum or aluminum-containing materials for corrosion resistance, or steel for high strength). This parameter optimization maximizes connection strength while maintaining manageable material selection through standardized material choices
Data Source
AI summary
A threaded insert to screw into a busbar, particularly a busbar of a battery module, wherein the threaded insert comprises a self-tapping or self-forming external thread. The invention further relates to a contact assembly with a threaded insert, a busbar and a contact screw that can be screwed into the threaded insert. The threaded insert preferably comprises a touch protection and is screwed into the busbar and in particular into a thread in the busbar that has been cut with the external thread of the threaded insert.