Abstract: An electrical device having an electrical component, which has an electric terminal, and a busbar assembly having a busbar and a frame. The busbar is formed of a strip of conductive material and has first and second busbar sides that are opposite from one another. The frame has a busbar seat and a cover member. The busbar seat extends through a first frame side of the frame. The busbar is received into the busbar seat and seated to the frame such that the first busbar side is spaced apart from the first frame side so that the busbar is contained wholly within the frame. The cover member abuts the second busbar side and defines an irradiation aperture that is configured to receive a laser beam from a laser welder therethrough. A laser weld fuses the busbar to the electric terminal.

Abstract: An electrical device according to the principles of the present disclosure includes a frame, a conductor having a conductive element and an electrically insulating cover disposed about at least a portion of the conductive element, and a busbar mounted to the frame. The busbar includes a busbar body and a weld crimp. The weld crimp has a base, which extends from the busbar body, and a cross-member that is coupled to the base on a side of the base that is opposite the busbar body. The cross-member has a weld portion and a crimp portion. The weld portion intersects the base. The crimp portion intersects the weld portion and has a crimp member that receives the conductor. The crimp member is permanently deformed about the conductor so as to apply a clamping force to the conductor. The conductive element is welded to the weld portion.

Abstract: An electrical device having an electrical component, which has an electric terminal, and a busbar assembly having a busbar and a frame. The busbar is formed of a strip of conductive material and has first and second busbar sides that are opposite from one another. The frame has a busbar seat and a cover member. The busbar seat extends through a first frame side of the frame. The busbar is received into the busbar seat and seated to the frame such that the first busbar side is spaced apart from the first frame side so that the busbar is contained wholly within the frame. The cover member abuts the second busbar side and defines an irradiation aperture that is configured to receive a laser beam from a laser welder therethrough. A laser weld fuses the busbar to the electric terminal.

Abstract: An electrical device according to the principles of the present disclosure includes a frame, a conductor having a conductive element and an electrically insulating cover disposed about at least a portion of the conductive element, and a busbar mounted to the frame. The busbar includes a busbar body and a weld crimp. The weld crimp has a base, which extends from the busbar body, and a cross-member that is coupled to the base on a side of the base that is opposite the busbar body. The cross-member has a weld portion and a crimp portion. The weld portion intersects the base. The crimp portion intersects the weld portion and has a crimp member that receives the conductor. The crimp member is permanently deformed about the conductor so as to apply a clamping force to the conductor. The conductive element is welded to the weld portion.