Bus bar with connector shroud

• US 9,166,309 B1
• Filed: 06/27/2014
• Issued: 10/20/2015
• Est. Priority Date: 06/27/2014
• Status: Active Grant

• Current Assignee: TE Connectivity Solutions GmbH (TE Connectivity Limited)
• Original Assignee: Tyco Electronics Corporation (TE Connectivity Limited)
• Inventors: Costello, Brian Patrick, Sechrist, Joshua Tyler
• Primary Examiner(s): HARVEY, JAMES R
• Application Number:
  US14/317,867
• Time in Patent Office: 480 Days
• US Class Current: 1/1
• CPC Class Codes: H01R 12/7088 Arrangements for power supply
• CPC Class Codes: H01R 25/161 Details
• CPC Class Codes: H01R 25/162 Electrical connections between or with rails or bus-bars rails having primarily a non electrical function H01R4/64
• CPC Class Codes: H01R 9/2466 using a planar conductive structure, e.g. printed circuit board
• CPC Class Codes: H01R 9/2675 Electrical interconnections between two blocks, e.g. by means of busbars
• CPC Class Codes: Y10S 439/949 Junction box with busbar for plug-socket type interconnection with receptacle

Abstract

An electrical system includes a bus bar having a plurality of layers including a conductive power layer and a conductive ground layer. The bus bar has a front edge with a plurality of tabs extending therefrom at spaced-apart locations. Each tab includes a power finger extending from the power layer and a ground finger extending from the ground layer. The bus bar also includes a connector shroud coupled to the front edge of the bus bar. The connector shroud has a base, a mating end, and a cavity defined therebetween. The cavity receives one of the tabs through the base. The mating end is configured to mate with an electrical connector. The cavity is configured to receive power and ground contacts of the electrical connector therein for electrical connection to the respective power and ground fingers of the tab.

Claims

1. An electrical system comprising:

a bus bar having a first side and a second side, the bus bar including a plurality of layers between the first and second sides including a conductive power layer and a conductive ground layer, the bus bar having a front edge defining a plurality of tabs extending therefrom at spaced-apart locations along the front edge, each tab including a power finger extending from the power layer and a ground finger extending from the ground layer; and

a connector shroud coupled to the front edge of the bus bar, the connector shroud having a base and a mating end and defining a cavity therebetween, the cavity receiving at least one of the tabs through an opening at the base, the mating end defining a mating interface configured to mate with an electrical connector, wherein the cavity is configured to receive power and ground contacts of the electrical connector therein for electrical connection to the respective power and ground fingers of the at least one tab.

2. The electrical system of claim 1, wherein at least one of the power finger or the ground finger of each tab is stepped at the front edge of the bus bar such that a distance between the power finger and the ground finger at a distal end of each tab is different than a distance between the corresponding power and ground layers from which the fingers extend.

3. The electrical system of claim 1, wherein the connector shroud includes a middle wall within the cavity that extends from the base to the mating end, the middle wall dividing the cavity into first and second channels, wherein the power finger of the at least one tab is received in the first channel and the ground finger of the at least one tab is received in the second channel.

4. The electrical system of claim 1, wherein the connector shroud is composed of a dielectric material.

5. The electrical system of claim 1, wherein the bus bar is planar, the connector shroud coupled to the front edge of the bus bar such that the cavity of the connector shroud extends co-planar to the plane of the bus bar, the electrical connector configured to mate to the mating interface of the connector shroud along a mating axis that is co-planar to the plane of the bus bar.

6. The electrical system of claim 1, wherein the at least one tab is retained in the connector shroud by at least one of an interference fit, an adhesive, or a retention latch between the power and ground fingers of the at least one tab and corresponding interior walls of the connector shroud that engage the power and ground fingers.

7. The electrical system of claim 1, wherein the power layer and the ground layer are formed of copper, the power and ground layers separated by an electrical insulator layer such that the power and ground layers are electrically independent and capable of having different voltages.

8. An electrical system comprising:

a bus bar assembly including first and second bus bars, each bus bar including a conductive power layer and a conductive ground layer, each bus bar having a front edge defining a plurality of tabs extending therefrom, each tab including a power finger extending from the power layer and a ground finger extending from the ground layer, the bus bar assembly having a first side and a second side, the conductive power layer of the first bus bar defining the first side and the conductive power layer of the second bus bar defining the second side such that the conductive ground layers of the first and second bus bars are disposed between the conductive power layers; and

a connector shroud coupled to a front edge of the bus bar assembly defined by the front edges of the first and second bus bars, the connector shroud having a base and a mating end and defining a cavity therebetween, the cavity receiving at least one of the tabs of the bus bar assembly through an opening at the base, the mating end defining a mating interface configured to mate with an electrical connector, wherein the cavity is configured to receive power and ground contacts of the electrical connector therein for electrical connection to the respective power and ground fingers of the at least one tab within the cavity.

9. The electrical system of claim 8, wherein the tabs of the first bus bar and the tabs of the second bus bar are arranged in an alternating pattern along a length of the front edge of the bus bar assembly.

10. The electrical system of claim 8, wherein the cavity and the mating interface of the connector shroud are a first cavity and a first mating interface, respectively, the connector shroud further including a second cavity and a second mating interface spaced apart from the respective first cavity and first mating interface, wherein the at least one tab of the bus bar assembly received in the first cavity is one of the plurality of tabs extending from the first bus bar, and one of the plurality of tabs extending from the second bus bar is received in the second cavity of the connector shroud, the first and second mating interfaces configured to mate to different electrical connectors.

11. The electrical system of claim 10, wherein the connector shroud includes a middle wall within each of the first and second cavities that extends at least partially from the base to the mating end, the middle walls dividing each of the first and second cavities into first and second channels, the first channels proximate to the first side of the bus bar assembly, the second channels proximate to the second side of the bus bar assembly, wherein the tab extending from the first bus bar is received in the first cavity such that the power finger is received in the first channel and the ground finger is received in the second channel, and wherein the tab extending from the second bus bar is received in the second cavity such that the power finger is received in the second channel and the ground finger is received in the first channel.

12. The electrical system of claim 10, wherein the first bus bar is separated from the second bus bar by a gap, the tab extending from the first bus bar is secured in the first cavity of the connector shroud and the tab extending from the second bus bar is secured in the second cavity of the connector shroud to retain the width of the gap.

13. The electrical system of claim 8, wherein the cavity of the connector shroud is configured to receive one tab from the first bus bar and one tab from the second bus bar therein.

14. The electrical system of claim 13, wherein the connector shroud includes a middle wall within the cavity that extends from the base to the mating end, the middle wall dividing the cavity into first and second channels, wherein the power fingers of both tabs are received in the first channel and the ground fingers of both tabs are received in the second channel.

15. The electrical system of claim 8, wherein at least one of the power finger or the ground finger of each tab of the bus bar assembly is stepped at the front edge of the corresponding first or second bus bar such that a distance between the power finger and the ground finger at a distal end of each tab is different than a distance between the corresponding power and ground layers of the bus bar from which each tab extends.

16. The electrical system of claim 8, wherein the bus bar assembly is planar, the connector shroud coupled to the front edge of the bus bar assembly such that the cavity of the connector shroud extends co-planar to the plane of the bus bar assembly, the electrical connector configured to mate to the mating interface of the connector shroud along a mating axis that is co-planar to the plane of the bus bar assembly.

17. The electrical system of claim 8, wherein the at least one tab is retained in the cavity of the connector shroud by at least one of an interference fit, an adhesive, or a retention latch between the power and ground fingers of the at least one tab and corresponding interior walls of the connector shroud that engage the power and ground fingers.

18. The electrical system of claim 8, wherein the power layer and the ground layer of each of the first and second bus bars are formed of copper, the power and ground layers separated by an electrical insulator layer such that the power and ground layers are electrically independent and capable of having different voltages.

19. The electrical system of claim 8, wherein the connector shroud is composed of a dielectric material.

20. The electrical system of claim 8, wherein the connector shroud is a first connector shroud, the bus bar assembly including a rear edge opposite to the front edge, the rear edge including plural tabs extending therefrom, the electrical system further comprising a second connector shroud coupled to the rear edge of the bus bar assembly, at least one of the tabs extending from the rear edge received in a cavity of the second connector shroud for electrical connection to another electrical connector.