Busbar system featuring externally crimped connections for electrical contacts
First Claim
1. A busbar system, comprising:
- an electrically conductive busbar having multiple ridges that project from a first side of the busbar, each ridge defining a channel having an opening on a second side of the busbar, wherein interior facing surfaces of each ridge that define the channel are substantially smooth and/or free of protrusions or teeth prior to the ridge being externally crimped; and
multiple electrically conductive electrical contacts having a substantially broad and thin configuration, wherein at least one electrical contact is secured within each channel of the busbar by the ridge being externally crimped by a tool having surfaces that include one or more protrusions.
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Accused Products
Abstract
A busbar system comprises an electrically conductive busbar having multiple ridges that project from a first side of the busbar. Each ridge defines a channel having an opening on a second side of the busbar. Interior facing surfaces of each ridge that define the channel are substantially smooth and/or free of protrusions or teeth prior to the ridge being externally crimped. The busbar system further comprises multiple electrically conductive electrical contacts having a substantially broad and thin configuration, wherein one or more of the electrical contacts are secured within each channel of the busbar by the ridge being externally crimped by a tool having surfaces that include one or more protrusions.
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Citations
20 Claims
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1. A busbar system, comprising:
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an electrically conductive busbar having multiple ridges that project from a first side of the busbar, each ridge defining a channel having an opening on a second side of the busbar, wherein interior facing surfaces of each ridge that define the channel are substantially smooth and/or free of protrusions or teeth prior to the ridge being externally crimped; and multiple electrically conductive electrical contacts having a substantially broad and thin configuration, wherein at least one electrical contact is secured within each channel of the busbar by the ridge being externally crimped by a tool having surfaces that include one or more protrusions. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A busbar system, comprising:
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an electrically conductive busbar having multiple electrically conductive contacts each externally crimped within a respective channel of multiple channels defined by multiple ridges of the electrically conductive busbar to retain the multiple electrically conductive contacts within the multiple channels; wherein a thinnest dimension of each electrically conductive contact is located between two interior facing surfaces of a respective channel of the multiple channels; wherein a first dimension of each electrically conductive contact that is larger than the thinnest dimension of that electrically conductive contact extends along a respective channel of the multiple channels; and wherein a second dimension of each electrically conductive contact that is larger than the thinnest dimension of that electrically conductive contact projects outward from a respective channel of the multiple channels in a direction that opposes the multiple ridges. - View Dependent Claims (10, 11, 12, 13, 14, 15, 16)
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17. A method of manufacturing a busbar system, comprising:
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inserting a plurality of electrically conductive contacts into each channel of an electrically conductive busbar having multiple channels; and externally crimping opposing sides of each ridge that projects from a first side of the busbar to secure the plurality of electrical conductive contacts within each channel, each ridge defining a respective channel of the multiple channels having an opening on a second side of the busbar. - View Dependent Claims (18, 19, 20)
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Specification