Abstract: An electrical assembly includes an electrical conductor having a planar portion and defining a bore hole extending through the planar portion and an electrical contact having a tubular portion disposed within the bore hole and a plurality of contact petals extending radially from the tubular portion. The plurality of contact petals are in electrical contact with the electrical conductor. A method of producing such an electrical assembly is also provided.

Abstract: A busbar connection system comprises a plate member formed of a first material having a higher tensile strength than second and third materials of first and second busbars, respectively, and defining first and second apertures and first and second stud members securely inserted through the first and second apertures of the plate member, respectively, the first and second stud members being configured to be securely inserted through first and second apertures, respectively, in each of the first and second busbars, wherein the first and second stud members mitigate rotational movement between the first and second busbars when connected.

Abstract: A bus bar assembly includes, among other things, a nonconductive terminal cap that is configured to at least partially surround an electrically conductive terminal. The terminal cap has a perimeter wall that is configured to circumscribe at least a portion of the terminal to provide a gap that is configured to expose the terminal. The terminal cap includes a first attachment feature. The terminal cap also includes a bus bar that has an end that is configured to mechanically and electrically engage the terminal in an assembled condition. The terminal cap further includes a nonconductive shroud that encloses the bus bar. The shroud includes a second attachment feature that is configured to removably engage the first attachment feature in the assembled condition to secure the shroud to the terminal cap.

Abstract: A backing plate, a corresponding electrical connector for mating with the backing plate, an electrical header, and an assembly thereof are described herein. The backing plate has an inner portion having a first thickness and an outer portion having a second thickness that is greater than the first thickness. The outer portion surrounds a perimeter of the inner portion and forms a cavity within the backing plate for acceptance of the electrical header. The backing plate also contains a connector attachment portion configured to attach the backing plate to the electrical connector and an intermediate surface attachment portion configured to attach the backing plate to the intermediate surface.

Abstract: An electrical bus bar assembly includes an elongate flexible electrical conductor formed of a strip of electrically conductive material having a distal portions defining two parallel tabs extending from the electrical conductor and an electrical terminal having two different parallel sides disposed between the two parallel tabs. Several methods of manufacturing an electrical bus bar assembly are also presented.

Abstract: An electrical conductor assembly includes a planar first conductor, a planar second conductor overlaying the first conductor, and a first electrically insulative layer between the first and second conductors. The first electrically insulative layer and the first conductor define a first aperture though which a portion of the second conductor is exposed. A process of forming the electrical conductor assembly is also contained herein.

Abstract: A bus bar assembly includes a nonconductive terminal cap configured to at least partially surround an electrically conductive terminal. The terminal cap has a perimeter wall configured to circumscribe at least a portion of the terminal to provide a gap configured to expose the terminal. The terminal cap includes a first attachment feature. The bus bar assembly also includes a bus bar having an end configured to mechanically and electrically engage the terminal in an assembled condition and a nonconductive shroud enclosing the bus bar. The shroud includes a second attachment feature configured to removably engage the first attachment feature in the assembled condition to secure the shroud to the terminal cap. A method of electrically connecting cells of a battery is also provided.

Abstract: An electrical bus bar assembly includes an elongate flexible electrical conductor formed of a strip of electrically conductive material having a generally rectangular cross section and a width to thickness ratio of at least 20:1 and a dielectric material covering a central portion of the electrical conductor such that the electrical conductor has exposed distal portions at each end of the assembly. Further, a method for forming such as assembly includes the steps of forming a flexible strip from an electrically conductive sheet such that the strip has a generally rectangular cross section with a width to thickness ratio of at least 20:1 and covering a central portion of the strip with a dielectric material and leaving distal portions at each end exposed.

Abstract: An connector assembly includes a connector header configured to be attached to a mounting substrate by a first mounting stud extending through a first aperture defined by the connector header, a connector configured to mate and unmate with the connector header and having a mating assist lever configured to attach and detach the connector to and from the connector header, and a mounting tab defined by the connector and configured to attach the connector to the first mounting stud extending through a second aperture defined by the mounting tab. Methods of assembling such a connector assembly are also provided.

Abstract: An electrical bus bar assembly includes an elongate flexible electrical conductor formed of a strip of electrically conductive material having a generally rectangular cross section and a width to thickness ratio of at least 20:1 and a dielectric material covering a central portion of the electrical conductor such that the electrical conductor has exposed distal portions at each end of the assembly. Further, a method for forming such as assembly includes the steps of forming a flexible strip from an electrically conductive sheet such that the strip has a generally rectangular cross section with a width to thickness ratio of at least 20:1 and covering a central portion of the strip with a dielectric material and leaving distal portions at each end exposed. No new matter is added. A substitute abstract reflecting these amendments is submitted concurrently with the filing of this paper.

Abstract: A power terminal includes a contact portion, a connection portion, and an intermediate portion. The contact and intermediate portions include conductive layers stacked along a direction corresponding to their respective thicknesses. The contact portion includes a main top surface and at least one contact area protruding from the main top surface. Each layer in the contact portion includes at least one first embossed region, the at least one first embossed region of each layer being registered with the at least one first embossed region of an adjacent layer, and the at least one first embossed region of a top layer forming the at least one contact area. A set of power terminals including a plurality of such a power terminal and a connector including such a power terminal are also disclosed.

Abstract: An electrical connector includes a contact button having a first layer formed of a first electrically conductive material that is attached to a first electrical bus bar and having a second layer formed of a second electrically conductive material clad to the first layer. The electrical connector includes a clamp assembly including a retaining band surrounding the contact button and the first electrical bus bar and having a spring configured to provide a contact force between the contact button and a second electrical bus bar when the second electrical bus bar is disposed between the contact button and the spring.

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: The shielded electrical conductor assembly described herein includes an electrical conductor having a rectangular cross-section, a first insulative layer surrounding the electrical conductor, a conductive layer surrounding the first insulative layer, and a second insulative layer encasing the conductive layer.

Abstract: An electrical connector assembly includes a connector housing defining a cavity in which an electrical busbar is disposed. The connector housing defines an opening to the cavity. The electrical connector assembly also includes a cover configured to enclose the cavity. The cover has an inlet port, an outlet port, and a coolant channel that is in fluidic communication with the inlet port and the outlet port. A portion of the cover is in intimate thermal contact with the electrical busbar.

Abstract: An electrical connector assembly includes a connector housing, a planar busbar having a rectangular cross section defining two opposed major surfaces and four minor surfaces, a cooling plate that is sized, shaped, and arranged to be in conductive thermal contact with a first major surface of the planar busbar, and an L-shaped busbar partially disposed within the connector housing having a first end connected to an electrical terminal and having a second end attached to, and in conductive thermal contact with, a second major surface of the planar busbar. The cooling plate is configured to reduce a temperature of the planar busbar and the attached L-shaped busbar. A method of assembling such an electrical connector is also presented.

Abstract: A two-piece high voltage (HV) terminal frame having a terminal frame and a contact spring. The terminal frame includes at least a top portion, a bottom portion, and a middle portion forming an opening for receiving a first bus bar and a second bus bar. The contact spring is configured to engage the top portion of the terminal frame, wherein the contact spring includes a spring portion that extends into the opening of the terminal frame.

Abstract: An electrical connector assembly includes a connector housing and a busbar having a rectangular cross section defining two opposed major surfaces and two opposed minor surfaces disposed within the connector housing. A planar surface is defined by one of the two opposed major surfaces of the busbar. The electrical connector assembly further includes a cooling plate that is sized, shaped, and arranged to be in conductive thermal contact with the planar surface of the busbar. The cooling plate is configured to reduce a temperature of the busbar.

Abstract: A bus bar assembly includes a nonconductive terminal cap that is configured to secure to an electrically conductive terminal via an attachment feature. The terminal cap has a slot that is configured to expose a terminal portion of the terminal when in an assembled condition. A bus bar has an end that is configured to be received in and extend through the slot when in the assembled condition in which the end is in electrical contact with the terminal portion of the terminal. A nonconductive shroud encloses the bus bar.

Abstract: An electrical connector assembly includes a connector housing defining a cavity in which a pair of electrical terminals is disposed. The assembly also includes a cover that is configured to enclose the cavity, thereby protecting the pair of electrical terminals and thermally manage heat within the cavity. The cover has a thermal management mechanism including one or more liquid ports configured to receive a liquid coolant flow.