Self-Tapping Threaded Insert Assembly for Busbar Vibration Resistance
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Solution Overview
Problem
Existing screw connections for busbars in battery modules face challenges in providing a contact-protected, vibration-resistant, and easy-to-assemble connection that withstands fluctuating environmental conditions.
Innovation Solution
A threaded insert with a self-tapping external thread is used to screw into a busbar, accompanied by a contact assembly with a threaded insert and a contact screw, allowing for secure and reliable connections without pre-cut threads, and optionally featuring materials like stainless steel for high strength and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a screw connection is used to connect busbars, then reliable electrical connection and contact protection are achieved, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The connection system is divided into separate functional components: a threaded insert with internal thread that is pre-installed in the busbar, and a separate screw that is inserted later. This segmentation allows the busbar to maintain its structural integrity while providing a reliable threaded connection interface, solving both the reliability and ease of assembly requirements
2Object-affected harmful factors
If a screw connection is used to connect busbars, then contact protection is achieved, but the connection becomes vulnerable to vibration and environmental fluctuations
Solution Approach 1:
The threaded insert is designed with a specific geometry that includes a bearing surface and engagement features that distribute mechanical stresses. This pre-engineered structure cushions against vibration and thermal expansion forces before they can compromise the electrical connection, maintaining reliability under environmental fluctuations
3Ease of manufacture
If a threaded insert is used instead of pre-cut threads, then manufacturing flexibility and material selection are improved, but the structure becomes more complex
Solution Approach 1:
The threaded insert acts as an intermediary component between the busbar material and the screw. It provides a standardized threaded interface that works with various busbar materials (aluminum, copper, steel) without requiring complex material-specific threading processes. The insert's simple cylindrical structure with internal thread minimizes added complexity while maximizing manufacturing flexibility
4Strength
If high-strength materials are used for the threaded insert, then connection strength and wear resistance are improved, but material cost and processing difficulty increase
Solution Approach 1:
The threaded insert is designed with optimized geometric parameters including thread pitch, depth, and bearing surface area that are specifically tailored to the busbar material. These parameter changes allow the use of appropriately graded materials (not necessarily the highest strength possible) while achieving the required connection strength through proper mechanical engagement design rather than material alone
Data Source
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AI summary
The invention relates to a threaded insert (1) to screw into a busbar (64), particularly a busbar (64) of a battery module (102), wherein the threaded insert (1) comprises a self-tapping or self-forming external thread (4). The invention further relates to a contact assembly (2) with a threaded insert (1), a busbar (64) and a contact screw (44) that can be screwed into the threaded insert (1). The threaded insert (1) preferably comprises a touch protection (60) and is screwed into the busbar (64) and in particular into a thread (6) in the busbar (64) that has been cut with the external thread (4) of the threaded insert (1).