Abstract: A bus bar assembly is provided that includes an electrical conductor with a rectangular cross-section. A first insulation layer surrounds the electrical conductor. A shielding layer surrounds the first insulation layer. The shielding layer is formed from an embossed conductive foil wrapped around the first insulation layer with overlapping sections. A method of making the bus bar assembly is provided that includes an electrical conductor being surrounded with a first insulating layer. The first insulating layer is then wrapped with a shielding layer formed from a conductive foil wrapped around the first insulation layer.

Abstract: A bus bar assembly is provided that includes an electrical conductor with a rectangular cross-section. A first insulation layer surrounds the electrical conductor. A shielding layer surrounds the first insulation layer. The shielding layer is formed from an embossed conductive foil wrapped around the first insulation layer with overlapping sections. A method of making the bus bar assembly is provided that includes an electrical conductor being surrounded with a first insulating layer. The first insulating layer is then wrapped with a shielding layer formed from a conductive foil wrapped around the first insulation layer.

Abstract: An electrical cable is provided with a rounded insulated electrical conductor that transitions to a flattened section to fit into areas where the rounded portion does not fit. A round electrical conductor transitions to a flattened section for electrical conduction routing via the undercarriage of a vehicle, for routing under the carpeting of the passenger compartment, or other confined spaces. The electrical cable may illustratively be used in an electric car application where distribution of electrical current from the battery compartment to the motor requires additional wiring in the vehicle not found in combustion based engines. The reduced vertical profile of the flattened section provides for additional clearance between the vehicle undercarriage and the road, or between the undercarriage frame and the interior passenger compartment carpet.

Abstract: An electrical conductor is provided that includes at least one strip of conductive material defining a length and having a first end with a first cutout and a second end having a second cutout. The cutouts engage electrical terminals. The at least two deflections are orthogonal to the length of the strip. The deflections are located between the first cutout and the second cutout and are in plane or out of plane of the cutouts. The electrical conductor is particularly well suited for interconnection of batteries associated with a vehicle power system.

Abstract: An electrical cable is provided with a rounded insulated electrical conductor that transitions to a flattened section to fit into areas where the rounded portion does not fit. A round electrical conductor transitions to a flattened section for electrical conduction routing via the undercarriage of a vehicle, for routing under the carpeting of the passenger compartment, or other confined spaces. The electrical cable may illustratively be used in an electric car application where distribution of electrical current from the battery compartment to the motor requires additional wiring in the vehicle not found in combustion based engines. The reduced vertical profile of the flattened section provides for additional clearance between the vehicle undercarriage and the road, or between the undercarriage frame and the interior passenger compartment carpet.

Abstract: An electrical conductor is provided that includes at least one strip of conductive material defining a length and having a first end with a first cutout and a second end having a second cutout. The cutouts engage electrical terminals. The at least two deflections are orthogonal to the length of the strip. The deflections are located between the first cutout and the second cutout and are in plane or out of plane of the cutouts. The electrical conductor is particularly well suited for interconnection of batteries associated with a vehicle power system.

Abstract: An electrical conductor is provided that includes at least one strip of conductive material defining a length and having a first end with a first cutout and a second end having a second cutout. The cutouts engage electrical terminals. The at least two deflections are orthogonal to the length of the strip. The deflections are located between the first cutout and the second cutout and are in plane or out of plane of the cutouts. The electrical conductor is particularly well suited for interconnection of batteries associated with a vehicle power system.

Abstract: An electrical transmission cable is provided with low inductance properties capable of carrying high current loads with a more uniform heating or loss profile. The low inductance properties of the cable lead to lower current losses resulting in a cooler and more efficient operation of the cable even at higher alternating current (AC) frequencies. Higher current loads are accommodated by a plurality of conductor bundles configured as braided wire strands that are separated and joined into like conductors prior to termination. Equal lengths of the insulated wire strands within the conductor bundles contribute to uniform heating along the length of the inventive cable embodiments. Uniform operating temperature is manifest as more uniform current transmission across the various strands of an inventive cable. In addition, the more equal weave position for all the wire strands making up each braided wire bundle tends to induce cancellation of inductive effects.

Abstract: An electrical conductor is provided that includes at least one strip of conductive material defining a length and having a first end with a first cutout and a second end having a second cutout. The cutouts engage electrical terminals. The at least two deflections are orthogonal to the length of the strip. The deflections are located between the first cutout and the second cutout and are in plane or out of plane of the cutouts. The electrical conductor is particularly well suited for interconnection of batteries associated with a vehicle power system.

Abstract: An electrical transmission cable is provided with low inductance properties capable of carrying high current loads with a more uniform heating or loss profile. The low inductance properties of the cable lead to lower current losses resulting in a cooler and more efficient operation of the cable even at higher alternating current (AC) frequencies. Higher current loads are accommodated by a plurality of conductor bundles configured as braided wire strands that are separated and joined into like conductors prior to termination. Equal lengths of the insulated wire strands within the conductor bundles contribute to uniform heating along the length of the inventive cable embodiments. Uniform operating temperature is manifest as more uniform current transmission across the various strands of an inventive cable. In addition, the more equal weave position for all the wire strands making up each braided wire bundle tends to induce cancellation of inductive effects.

Abstract: An electrical conductor is provided that includes at least one strip of conductive material defining a length and having a first end with a first cutout and a second end having a second cutout. The cutouts engage electrical terminals. The at least two deflections are orthogonal to the length of the strip. The deflections are located between the first cutout and the second cutout and are in plane or out of plane of the cutouts. The electrical conductor is particularly well suited for interconnection of batteries associated with a vehicle power system.

Abstract: A laminar electrical connector is provided that is formed from multiple superimposed strips of conductive material that form a stack having at least two ends. A second conductive material is used to join adjacent superimposed strips. The resultant connector has ends that are adapted to engage electrical terminals and provide an electrical communication therebetween. The resultant connector lacks a sheath on the ends or a grommet extending through the stack. Such a sheath or grommet limits the operative lifetime of the resulting connector and also creates current focusing that diminishes overall connector efficiency. A connector having a continuous layer of the second conductive material joining adjacent strips along the entire interface between the adjacent strips is also provided and improves connector performance in ways that are especially beneficial to applications associated with an electric vehicle or a hybrid vehicle.

Abstract: A laminar electrical connector is provided that is formed from multiple superimposed strips of conductive material that form a stack having at least two ends. A second conductive material is used to join adjacent superimposed strips. The resultant connector has ends that are adapted to engage electrical terminals and provide an electrical communication therebetween. The resultant connector lacks a sheath on the ends or a grommet extending through the stack. Such a sheath or grommet limits the operative lifetime of the resulting connector and also creates current focusing that diminishes overall connector efficiency. A connector having a continuous layer of the second conductive material joining adjacent strips along the entire interface between the adjacent strips is also provided and improves connector performance in ways that are especially beneficial to applications associated with an electric vehicle or a hybrid vehicle.

Abstract: The invention is directed to a fluid cooled electrical conductor assembly. The fluid cooled electrical conductor assembly includes a terminal having an open end and a fluid passage in communication with the open end. A sleeve is at least partially received within the open end of the terminal. The sleeve is metallurgically bonded to the terminal, such as by solder. The sleeve has a flared end disposed around an electrical conductor and a distal end disposed adjacent to an end of the conductor. The sleeve has a longitudinally extending groove which is in communication with the fluid passage in the terminal. A casing is connected to the terminal and surrounds the conductor to thereby define a fluid passageway at a periphery of the conductor. During manufacture, a single sleeve is swedged onto an electrical conductor and subsequently cut in half to define two substantially identical sleeves which may be inserted into respective terminals.