Abstract: This disclosure presents an electrical assembly including an electrical conductor with a planar connection surface and an electrical contact made of an electrically conductive foil with distinct electrical and mechanical characteristics compared to the electrical conductor. The electrical contact is positioned on a specific area of the connection surface and is metallurgically bonded to it. This innovative electrical assembly allows for efficient electrical connections with improved performance and reliability due to the unique properties of the electrically conductive foil and the metallurgical bonding process.

Abstract: The present invention discloses a charging connector assembly designed for an electrical energy transfer system. The assembly includes an electrical conductor with a threaded attachment feature and an electrical terminal with a base having a corresponding threaded attachment feature to engage and disengage the conductor's threaded feature directly. The terminal also features a torque feature that can be operated by a tool to rotate the terminal, enhancing installation and removal. The torque feature is conveniently accessible from a user-facing surface of the charging connector assembly when installed, providing ease of removal and replacement of the terminal when needed.

Abstract: A bus bar assembly includes a bus bar formed of a first electrically conductive material having a planar contact portion. The bus bar defines a first bore extending through the contact portion. The bus bar assembly further includes a contact insert formed of a second electrically conductive material that has a greater hardness than the first electrically conductive material. The contact insert defines a first surface that is mechanically and electrically connected to the contact portion of the bus bar. The contact insert defines a second surface this is plated with a third electrically conductive material which is different than the second electrically conductive material. The contact insert defines a smooth second bore coaxial with the first bore and extending from the first surface to the second surface.

Abstract: A bus bar assembly includes a bus bar formed of a first electrically conductive material having a planar contact portion. The bus bar defines a first bore extending through the contact portion. The bus bar assembly further includes a contact insert formed of a second electrically conductive material that has a greater hardness than the first electrically conductive material. The contact insert defines a first surface that is mechanically and electrically connected to the contact portion of the bus bar. The contact insert defines a second surface this is plated with a third electrically conductive material which is different than the second electrically conductive material. The contact insert defines a smooth second bore coaxial with the first bore and extending from the first surface to the second surface.