Electronic shunt resistor assembly

• US 7,385,828 B2
• Filed: 01/27/2006
• Issued: 06/10/2008
• Est. Priority Date: 01/27/2006
• Status: Expired due to Fees

• Current Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Original Assignee: Delphi Technologies, Inc. (BorgWarner Incorporated)
• Inventors: Caputo, John V, Oman, Todd P.
• Primary Examiner(s): Dinh; Tuan T.
• Assistant Examiner(s): Semenenko; Yuriy
• Application Number:
  US11/341,356
• Publication Number:
  US 20070177318A1
• Time in Patent Office: 865 Days
• Field of Search: 361/763, 361/58, 174/522
• US Class Current: 361/763
• CPC Class Codes: G01R 1/203 Resistors used for electric measuring, e.g. decade resistors standards, resistors for comparators, series resistors, shunts resistors in general H01C; microwave or radiowave terminations H01P1/26; coupling devices H01R
• CPC Class Codes: H05K 3/4092 Integral conductive tabs, i.e. conductive parts partly detached from the substrate
• CPC Class Codes: H05K 3/429 Plated through-holes specially for multilayer circuits, e.g. having connections to inner circuit layers

Abstract

An electronic shunt resistor assembly comprises a planar shunt resistor and an electronic monitoring unit. The planar shunt resistor has a resistance element and first and second terminal bars at opposite ends of the resistance element. The electronic measuring unit has a circuit board that is supported on the planar shunt resistor and that includes input contacts for electronic components carried by the circuit board arranged along one edge of the circuit board and input/output contacts for the electronic components arranged along a opposite edge of the circuit board. A first plurality of electrical connectors connect the first terminal bar to the input contacts and a second plurality of electrical connectors connect the second terminal bar to the output contacts of the circuit board. The electrical connectors are attached to the terminal bars and the contacts solderlessly.

Claims

1. An electronic shunt resistor assembly comprising:

a planar shunt resistor and an electronic unit monitoring;

the planar shunt resistor having a resistance element and first and second terminal bars at opposite ends of the resistance element,

the electronic measuring unit having a circuit board that is supported on the terminal bars of the planar shunt resistor and that includes contacts for electronic components carried by the circuit board arranged along each of two opposite edges of the circuit board, and

a first plurality of electrical connectors connecting the first terminal bar to the contacts along one of the two opposite edges of the circuit board and a second plurality of electrical connectors connecting the second terminal bar to the contacts along another of the two opposite edges of the circuit board wherein the electrical connectors are attached to the terminal bars and the contacts solderlessly.

2. The electronic shunt resistor assembly of claim 1 wherein the first and second plurality of electrical connectors are wires that are bonded to the terminal bars of the planar resistor shunt and the contacts of the circuit board.

3. The electronic shunt resistor assembly of claim 1 wherein the first and second plurality of electrical connectors are foil leaves that are bonded to the terminal bars and the contacts of the circuit board.

4. The electronic shunt resistor assembly of claim 3 wherein the first and second plurality of electrical connectors are bonded to the terminal bars by spot welds, resistance welds or ultrasonic welds.

5. The electronic shunt resistor assembly of claim 4 wherein the foil leaves are shaped like gull wings.

6. The electronic shunt resistor assembly of claim 4 wherein the foil leaves are C-shaped.

7. The electronic shunt resistor assembly of claim 1 wherein the wherein the first and second plurality of electrical connectors are foil leaves that are integral extensions of electrical traces or vias of the circuit board and that are bonded to the terminal bars.

8. The electronic shunt resistor assembly of claim 1 wherein the circuit board is supported on the terminal bars by a preformed plastic frame.

9. The electronic shunt resistor assembly of claim 8 wherein the preformed plastic frame has lock arms that engage the resistance element to attach the preformed plastic frame to the planar shunt resistor.

10. The electronic shunt resistor assembly of claim 8 wherein the preformed plastic frame has lock arms that engage the resistance element to attach the preformed plastic frame to the planar shunt resistor.

11. An electronic shunt resistor assembly comprising:

a planar monitoring shunt resistor and an electronic measurement unit;

the planar shunt resistor having a resistance element for its mid section and terminal bars at each end,

the resistance element be of a material selected from the group consisting of manganin, zeranin and isaohm,

the terminal bar being of a material selected from the group consisting of copper and copper alloys,

the electronic monitoring unit having a circuit board that is supported on the terminal bars of the planar shunt resistor and that includes input contacts for electronic components carried by the circuit board, the input contacts being arranged along one edge of the circuit board,

the circuit board being of a resinous or ceramic material and having input/output contacts for the electronic components arranged along a opposite edge of the circuit board,

the contacts being of a material selected from the group consisting of copper and copper alloys,

a first plurality of electrical connectors connecting the terminal bar at one end of the resistance element to the input contacts of the circuit board, and

a second plurality of electrical connectors connecting the terminal bar at an opposite end of the resistance element to the input/output contacts of the circuit board wherein the electrical connectors are a material selected from the group consisting of copper and copper alloys and are bonded to the terminal bars and the contacts solderlessly.

12. The electronic shunt resistor assembly of claim 11 wherein the first and second plurality of electrical connectors are wires that are bonded to the terminal bars of the shunt resistance and the contacts of the circuit board.

13. The electronic shunt resistor assembly of claim 11 wherein the first and second plurality of electrical connectors are foil leaves that are bonded to the terminal bars of the shunt resistance and the contacts of the circuit board.

14. The electronic shunt resistor assembly of claim 13 wherein the first and second plurality of electrical connectors are bonded to the resistance connections by spot welds, friction stir welds, resistance welds or ultrasonic welds.

15. The electronic shunt resistor assembly of claim 14 wherein the foil leaves are shaped like gull wings.

16. The electronic shunt resistor assembly of claim 14 wherein the foil leaves are C-shaped.

17. The electronic shunt resistor assembly of claim 11 wherein the circuit board is supported on the terminal bars by a preformed plastic frame.