Abstract: Disclosed is a busbar for mechanically and electrically connecting components in a device. The busbar includes a plurality of conductors arranged to provide two opposed end portions and an intermediate portion, wherein each of the conductors has a plurality of intermediate extents that traverse the intermediate portion. The intermediate portion including: (A) an un-fused sector where no intermediate extents of the conductors are fused together, and (B) a fused sector that includes (i) a limited solidification zone where a majority of the intermediate extents of the conductors are fused together to form a laterally solidified region that provides a single consolidated conductor, (ii) a partial solidification zone where a majority of the intermediate extents of the conductors are fused together to form a vertical solidified region that provides a single consolidated conductor, and (iii) an unsolidified region where all of the intermediate extents of the conductors are not fused together.

Abstract: The invention generally provides a busbar for use in mechanically and electrically connecting components in a device. The busbar includes a plurality of conductors arranged to provide two opposed end portions and an intermediate portion, wherein each of the conductors has a plurality of intermediate extents that traverse the intermediate portion.

Abstract: A busbar for electrically connecting components in a power distribution system. The busbar includes a plurality of conductors formed from a first material and having a first end, a second end, and an intermediate portion. The first end, the second end, and the intermediate portion can be integrally formed with one another and stacked to provide the busbar with a first geometry. The intermediate portion includes a handling section with a rigidity that is less than a rigidity of a corresponding section of a reference busbar that has (a) a geometry that substantially matches the first geometry and (b) has a single conductor formed from a material substantially similar to the first material. The handling section is formed using an edge-based fusion process that fuses a portion of the conductors together to form a single consolidated conductor in that section of the busbar.

Abstract: The invention generally provides a busbar for use in mechanically and electrically connecting components in a device. The busbar includes a plurality of conductors arranged to provide two opposed end portions and an intermediate portion, wherein each of the conductors has a plurality of intermediate extents that traverse the intermediate portion.