LOW INDUCTANCE BUS BAR CONNECTION

• US 20140342612A1
• Filed: 10/31/2013
• Published: 11/20/2014
• Est. Priority Date: 10/31/2012
• Status: Active Grant

• Current Assignee: Magna E-Car Systems Of America, Inc. (Magna International Incorporated)
• Original Assignee: Magna E-Car Systems Of America, Inc. (Magna International Incorporated)
• Inventors: Mohr, Bert, Pfeuffer, Viktor, Patwardhan, Ajay V.
• Granted Patent: US 9,083,128 B2
• Time in Patent Office: Days
• US Class Current: 439/626
• CPC Class Codes: B60L 15/007 Physical arrangements or structures of drive train converters specially adapted for the propulsion motors of electric vehicles
• CPC Class Codes: B60L 2200/18 Buses
• CPC Class Codes: B60L 2200/36 Vehicles designed to transport cargo, e.g. trucks
• CPC Class Codes: B60L 2210/40 DC to AC converters
• CPC Class Codes: B60L 2270/145 Structure borne vibrations
• CPC Class Codes: B60L 3/003 relating to inverters
• CPC Class Codes: B60L 3/0069 relating to the isolation, e.g. ground fault or leak current
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: H01R 25/14 Rails or bus-bars constructed so that the counterparts can be connected thereto at any point along their length supporting elements for lighting devices, displaceable along guiding elements and making electrical contact with conductors running along the guiding elements F21V21/35
• CPC Class Codes: H01R 25/145 Details, e.g. end pieces or joints H01R25/147 takes precedence
• CPC Class Codes: H02M 7/003 Constructional details, e.g. physical layout, assembly, wiring or busbar connections
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 10/72 Electric energy management in electromobility

Abstract

In one aspect, a set of male and female bus bars is provided. The male bus bar includes first and second conductors and an insulation layer therebetween. The male bus bar has a male connecting portion with one or more fingers. The female bus bar third and fourth conductors and an insulation layer therebetween. The female bus bar has a female connecting portion with one or more receptacles, each having contact surfaces that are free of insulation and that are positioned to contact contact surfaces on an associated finger which are free of insulation so as to connect the first conductor and the third conductor and to connect the second conductor and the fourth conductor. Each finger has a width. A gap exists between the contact surfaces of an associated receptacle. The width and gap are sized to provide a press fit between the fingers and the receptacles.

Claims

1. A set of bus bars, comprising:

a male bus bar including a first conductor overlying a second conductor and having a first insulation layer positioned between the first and second conductors, wherein a portion of the male bus bar is a male connecting portion that includes at least one finger provided by the first and second conductors and the insulation layer; and

a female bus bar, including a third conductor overlying a fourth conductor and having a second insulation layer positioned between the third and fourth conductors, wherein a portion of the female bus bar is a female connecting portion that includes at least one receptacle provided by a divergence between the third and fourth conductors, wherein the at least one receptacle has contact surfaces that are free of insulation and that are positioned to contact contact surfaces on the at least one finger which are free of insulation so as to connect the first conductor and the third conductor and to connect the second conductor and the fourth conductor,

wherein the at least one finger has a width and wherein a gap exists between the contact surfaces of the at least one receptacle, wherein the width and the gap are sized to provide a press fit between the at least one finger and the at least one receptacle when the at least one finger is inserted into the at least one receptacle.

2. A set of bus bars as claimed in claim 1, wherein the width of the at least one finger and the gap between the contact surfaces of the at least one receptacle are sized to provide an interference fit between the at least one finger and the at least one receptacle when the at least one finger is inserted into the at least one receptacle.

3. A set of bus bars as claimed in claim 2, wherein the at least one finger includes a flowable material that flows to provide substantially complete surface-to-surface contact between mutually overlapping portions of the contact surfaces of the at least one finger and the at least one receptacle.

4. A set of bus bars as claimed in claim 2, wherein the at least one receptacle includes a flowable material that flows to provide substantially complete surface-to-surface contact between mutually overlapping portions of the contact surfaces of the at least one finger and the at least one receptacle.

5. A set of bus bars as claimed in claim 1, wherein the female bus bar includes an opening immediately adjacent each receptacle so as to space each finger from other portions of the female bus bar when the finger is inserted into the receptacle.

6. A set of bus bars as claimed in claim 1, wherein the second bus bar includes a base portion and a plurality of contact portions on which the contact surfaces of the at least one receptacle are provided, and wherein the at least one receptacle includes a plurality of spring portions extending between the base portion and the plurality of contact portions to permit the contact portions to move apart to accommodate insertion of the at least one finger in the at least one receptacle.