Electrical busbar, electrical connector assembly and power converter

• US 9,666,968 B2
• Filed: 01/17/2013
• Issued: 05/30/2017
• Est. Priority Date: 01/17/2013
• Status: Active Grant

• Current Assignee: Lear Corporation
• Original Assignee: Lear Corporation
• Inventors: Hampo, Richard J., Menzies, David, Qin, Yu
• Primary Examiner(s): Hoffberg, Robert J
• Assistant Examiner(s): DANG, HUNG Q
• Application Number:
  US13/743,662
• Publication Number:
  US 20140198475A1
• Time in Patent Office: 1,594 Days
• CPC Class Codes: H01R 13/08 Resiliently-mounted rigid pins or blades
• CPC Class Codes: H05K 5/0091 Housing specially adapted for small components for resistors H01C; for capacitors H01G; for integrated circuits H01L23/00
• CPC Class Codes: H05K 7/1432 specially adapted for power drive units or power converters
• CPC Class Codes: H05K 7/14329 specially adapted for the configuration of power bus bars

Abstract

An electrical connector assembly is provided with an electrical busbar for conducting power. The busbar has a width, a length, and a thickness. The busbar has a first portion with a first length, and a second portion with a second length. The second portion is oriented at a non-zero angle relative to the first portion. A connector is mounted to the busbar. One of the width and the thickness is reduced for receipt of a sensor about the busbar. A power converter assembly is provided with a direct current bus capacitor and a power module oriented in a housing. A plurality of the electrical connector assemblies are each connected to at least one of the direct current bus capacitor and the power module.

Claims

1. An electrical connector assembly comprising:

an electrical busbar for conducting power, the busbar having a width, a length, and a thickness, the busbar having a first portion with a first length, and a second portion with a second length, the second portion oriented generally perpendicular to the first portion; and

a connector mounted to the busbar;

wherein the connector is mounted to the first portion;

wherein the electrical connector assembly further comprises a sensor mounted to the second portion;

wherein the second portion is formed with an abutment surface spaced apart from the first portion for locating the sensor; and

wherein the sensor comprises a current sensor.

2. The electrical connector assembly of claim 1 wherein the connector is formed integrally with the busbar.

3. The electrical connector assembly of claim 1 wherein the connector is welded to the busbar.

4. The electrical connector assembly of claim 1 wherein the connector is not fastened to the busbar by a threaded fastener.

5. The electrical connector assembly of claim 1 wherein the connector comprises at least one blade.

6. The electrical connector assembly of claim 1 wherein the connector comprises a female portion formed integrally with the busbar.

7. The electrical connector assembly of claim 1 wherein an aperture is formed into the second portion of the busbar to receive a fastener to electrically connect the busbar to another electrical component.

8. The electrical connector assembly of claim 1 wherein the sensor is not fastened to the busbar by a threaded fastener.

9. A power converter assembly comprising:

a housing;

a power module oriented in the housing; and

a plurality of electrical connector assemblies according to claim 1 each connected to the power module.

10. The electrical connector assembly of claim 1 wherein the second portion is formed with a pair of abutment surfaces spaced apart from the first portion to locate the sensor.

11. The electrical connector assembly of claim 5 wherein the at least one blade extends from the first portion in a direction that is generally parallel with a length of the second portion.

12. A power converter assembly comprising:

a housing;

a power module oriented in the housing;

a plurality of electrical connector assemblies according to claim 7 each connected to the power module;

a collector with a plurality of apertures in engagement with the second portion of each of the plurality of electrical connector assemblies; and

a plurality of fasteners fastening the plurality of electrical connector assemblies to the collector.