Press-fit bus bar distributing power

• US 20030096520A1
• Filed: 09/11/2002
• Published: 05/22/2003
• Est. Priority Date: 11/20/2001
• Status: Active Grant

• Current Assignee: FCI Americas Technology Incorporated (FCI)
• Original Assignee: FCI Americas Technology Incorporated (FCI)
• Inventors: Swain, Wilfred J., Mills, James, Kolivoski, Christopher J., Minich, Steven E., Dodds, John D., Volstorf, James R., Wolford, Gerald, Staron, James S.
• Granted Patent: US 6,840,783 B2
• Time in Patent Office: Days
• US Class Current: 439/110
• CPC Class Codes: H01R 12/585 Terminals having a press fit or a compliant portion and a shank passing through a hole in the printed circuit board
• CPC Class Codes: H01R 25/16 Rails or bus-bars provided with a plurality of discrete connecting locations for counterparts
• CPC Class Codes: H05K 1/0263 High current adaptations, e.g. printed high current conductors or using auxiliary non-printed means; Fine and coarse circuit patterns on one circuit board H05K1/0293 takes precedence
• CPC Class Codes: H05K 3/308 Adaptations of leads connectors to printed circuits H01R12/00

Abstract

A press-fit bus-bar for distributing power along a backplane or a printed circuit board comprises a number of flat bus bar conductors fabricated from an electrically conductive material. Each bus bar conductor is separated from adjacent bus bar conductors by layers of an insulating material. A number of electrically conductive press-fit tails protrude from one edge of each bus bar conductor. When the laminated bus bar conductors and insulating material layers are placed in a housing which is then filled with a hardened epoxy resin, the press-fit tails protrude from the surface of that epoxy resin. These protruding tails can be press-fit in a backplane(s) or printed circuit board(s) for the purpose of supplying these backplane(s) or printed circuit board(s) with electric power.

Claims

1. An elongated press-fit conductor assembly comprising:

at least two elongated, generally flat laminated conductors having respective, adjacent longitudinal edges;

a layer of electrically insulating material interposed between said two laminated conductors; and

a plurality of press-fit contact members extending from the adjacent longitudinal edges of the laminated conductors and distributed along said longitudinal edges for press-fit insertion in respective contact-receiving areas.

2. The elongated press-fit conductor assembly of claim 1, wherein said contact members comprise press-fit tails.

3. The elongated press-fit conductor assembly of claim 2, wherein said press-fit tails comprise eye-of-needle press-fit tails.

4. The elongated press-fit conductor assembly of claim 2, wherein the press-fit tails are integral with the conductors.

5. An elongated press-fit conductor assembly comprising:

at least two elongated, generally flat laminated conductors having respective, adjacent longitudinal edges;

a layer of electrically insulating material interposed between said two laminated conductors;

a plurality of contact members extending from the adjacent longitudinal edges of the laminated conductors;

a housing enclosing a sandwich structure formed of the laminated conductors and layer of electrically insulating material, said housing defining opening means through which the contact members extend; and

a body of electrically insulating material which fills a cavity between the inner surface of the housing and said sandwich structure.

6. The elongated press-fit conductor assembly of claim 5, wherein said housing has a U-shaped cross section and said opening means comprise a longitudinal opening along said adjacent longitudinal edges.

7. The elongated press-fit conductor assembly of claim 5, wherein the electrically insulating material of said body comprises epoxy resin.

8. The elongated press-fit conductor assembly of claim 5, wherein the sandwich structure formed of the laminated conductors and layer of electrically insulating material is completely embedded in said body of electrically insulating material, said body forming a wall across said opening means from which the contact members protrude.

9. The elongated press-fit conductor assembly of claim 5, wherein said housing is made of an electromagnetic interference shielding material.

10. The elongated press-fit conductor assembly of claim 5, further comprising a power connector mounted on said housing and comprising a plurality of contacts respectively connected to the laminated conductors.

11. The elongated press-fit conductor assembly of claim 5, further comprising a power cable comprising a plurality of electric wires respectively connected to the laminated conductors.

12. An elongated press-fit conductor assembly comprising:

a plurality of elongated, generally flat laminated conductors having respective, mutually adjacent longitudinal edges;

a layer of electrically insulating material interposed between each pair of adjacent, laminated conductors; and

a plurality of press-fit contact members extending from the longitudinal edges of the laminated conductors and distributed along said longitudinal edges for press-fit insertion in respective contact-receiving areas.

13. The elongated press-fit conductor assembly of claim 12 wherein said contact members comprise press-fit tails integral with the laminated conductors.

14. The elongated press-fit conductor assembly of claim 13, wherein said press-fit tails comprise eye-of-needle press-fit tails.

15. The elongated press-fit conductor assembly of claim 12, further comprising a housing enclosing a sandwich structure formed of the laminated conductors and layers of electrically insulating material, said housing defining opening means through which the contact members extend.

16. The elongated press-fit conductor assembly of claim 15, wherein said housing has a U-shaped cross section and said opening means comprise a longitudinal opening along said adjacent longitudinal edges.

17. The elongated press-fit conductor assembly of claim 15, comprising a body of electrically conducting material which fills a cavity between an inner surface of the housing and the sandwich structure formed of the laminated conductors and layers of electrically insulating material.

18. The elongated press-fit conductor assembly of claim 17, wherein the sandwich structure formed of laminated conductors and layers of electrically insulating material is completely embedded in said body of electrically insulation material, said body forming a wall across said opening means from which the contact members protrude.

19. The elongated press-fit conductor assembly of claim 12, wherein said housing is made of an electromagnetic interference shielding material.

20. An electrical bus bar assembly comprising:

a plurality of electrical bus bar conductors, each conductor comprising at least two through-hole press-fit contact sections on first sides and at least two protrusions on opposite second sides;

electrical insulating material located between the bus bars conductors; and

a cap connected to the bus bar conductors and the electrical insulating material, wherein the cap comprises deformable electrical insulating material and is located against ends of the protrusions such that the protrusions can extend into the cap by deformation of the material of the cap as the cap is pressed against the protrusions.

21. An electrical bus bar assembly as in claim 20 wherein the deformable electrical insulating material of the cap comprises extruded plastic or polymer material.

22. An electrical bus bar assembly as in claim 21 wherein the electrical insulating material located between the bus bar conductors comprises epoxy material.

23. An electrical bus bar assembly as in claim 20 wherein the cap comprises a general cross sectional inverted U shape with outer legs tapered inward towards each other.

24. An electrical bus bar assembly as in claim 23 wherein the cap clamps portions of the electrical bus bar conductors and electrical insulating material located between the bus bar conductors against each other by the outer legs of the cap.

25. An electrical bus bar assembly as in claim 20 wherein the electrical bus bar conductors comprise generally flat elongate members, and wherein the protrusions are longitudinally offset relative to each other among different ones of the electrical bus bar conductors.

26. An electrical bus bar assembly as in claim 20 wherein the cap comprises means for clamping the electrical bus bar conductors and electrical insulating material located between the bus bar conductors together.

27. An electrical bus bar assembly comprising:

a housing comprising layers of electrical insulating material and a cap connected to outer ones of the layers; and

a plurality of generally flat electrical bus bars separated by the layers of electrical insulating material, each bus bar comprising a first edge with a plurality of through-hole, press-fit connection sections, wherein the electrical bus bar assembly can be through-hole mounted to a printed circuit board by the press-fit connection sections.

28. An electrical bus bar assembly as in claim 27 wherein the cap is comprised of deformable plastic material.

29. An electrical bus bar assembly as in claim 28 wherein the bus bars each comprise a second opposite edge with a plurality of projections, at least one of the projections projecting into the cap with the plastic material of the cap deforming thereat.

30. An electrical bus bar assembly as in claim 27 wherein the cap comprises means for clamping the layers of electrical insulating material and the bus bars together.

31. An electrical bus bar assembly as in claim 27 wherein the cap comprises an extruded plastic or polymer member.

32. A method of assembling an electrical bus bar assembly comprising steps of:

providing a plurality of elongate electrical bus bars with through-hole, press-fit connection sections extending from a first elongate edge;

providing electrically insulating layers between the bus bars; and

connecting an elongate cap to the bus bars and the layers, the cap contacting projections on a second opposite elongate the edge of the bus bars,

wherein, when the cap is pressed against the projections, the cap can deform such that at least one of the projections extends into the cap, wherein the cap can deform to compensate for manufacturing tolerances between heights of the projections relative to each other.

33. A method as in claim 32 further comprising providing the cap as an extruded plastic or polymer member.

34. A method as in claim 32 further comprising the cap clamping the bus bars and the insulating layers together between opposite deflectable legs of the cap.