New self-clinching fasteners for electric conductive connections

• Published in: Journal of Manufacturing and Materials Processing Vol. 6; no. 6; pp. 1 - 15
• Main Authors: Sampaio, Rui F. V., da Fonseca Matos Pragana, João Pedro, Martins, Paulo, Bragança, Ivo, Silva, Carlos
• Format: Journal Article
• Language: English
• Published: Basel MDPI 01-12-2022; MDPI AG
• Subjects: Alloys; Aluminum; Aluminum alloys; Analysis; Bolted joints; Busbars; Clinching; Contaminants; Cooling; Copper; Deformation; Electric contacts; Electric currents; Electric vehicles; Electrical resistance; Energy distribution; Experimentation; Fasteners; Finite element method; Mechanical joining; Oxide coatings; self-clinching fasteners; Temperature; Portugal
• ISSN: 2504-4494; 2504-4494
• DOI: 10.3390/jmmp6060159

This paper presents new rotational and longitudinal symmetric self-clinching fasteners to fabricate reliable connections in busbars with low electrical resistance for energy distribution systems. Connections consist of form-closed joints that are hidden inside regions where two busbars overlap. The investigation into the fabrication and performance of the new self-clinched joints involved finite element modelling and experimentation to determine the required forces and to evaluate the electric current flow and the electrical resistance at different service temperatures. The original design of the joints that was proposed in a previous work was modified to account for busbar strips of copper and/or aluminum with similar or dissimilar thicknesses, connected by means of self-clinching fasteners made from the same materials of the busbars, instead of steel. The effectiveness of the new self-clinched joints was compared to that of conventional bolted joints that are included in the paper for reference purposes. The results show that rotational symmetric self-clinching fasteners yield lighter fabrication and more compact joints with a similar electrical resistance to that of bolted joints. They also show that longitudinal symmetric self-clinching fasteners aimed at replicating the resistance-seam-welding contact conditions yield a reduction in electrical resistance to values close to that of ideal joints, consisting of two strips in perfect contact and without contaminant or oxide films along their overlapped surfaces.