Bus bar assembly and method of manufacturing same

1. A bus bar assembly, comprising:

a first main conductor having first outer edges;

a second main conductor having second outer edges aligned with the first outer edges; and

a plated insulator member (i)provided between the first and second main conductors and (ii) including;

an insulator component formed of a single sheet of dielectric material comprising third outer edges,

a first conductor layer plated on a top surface of the insulator component, and

a second conductor layer plated on a bottom surface of the insulator component, the plated first and second conductor layers preventing a trapping of air with the insulator component,

wherein all outer edges of the first and second conductor layers align with all of the first and second outer edges,

wherein the third outer edges create an overhanging portion of the insulator component extending beyond the first and second outer edges and the outer edges of the first and second conductor layers, and

wherein no air is trapped between the first conductor layer and the top surface of the insulator component, and wherein no air is trapped between the second conductor layer and the bottom surface of the insulator component.

2. The bus bar assembly according to claim 1 ,

wherein the first conductor layer includes a first conductive material onto the top surface of the insulator component and the outer edge of the first conductor layer is at least a certain distance from the third outer edges around the total perimeter of the insulator component, and

wherein the second conductor layer includes a second conductive material onto the bottom surface of the insulator component and the outer edge of the second conductor layer is at least the length of the overhanging portion from the third outer edges around the total perimeter of the insulator component.

3. The bus bar assembly according to claim 2 , wherein the first and second conductive materials are copper.

4. The bus bar assembly according to claim 3 , wherein the insulator component is a sheet of dielectric material selected from the group consisting of fibre-reinforced 4 (FR-4), glass polyester-2 (GPO-2), glass polyester-3 (GPO-3), and a ceramic dielectric material.

5. A bus bar assembly, comprising:

a first main conductor, and a second main conductor, each having outer edges; and

a plated insulator member (i) sandwiched between the first and second main conductors, and (ii) comprising:

an insulator component formed of a single sheet of dielectric material and having outer edges;

a first conductor layer plated on a top surface of the insulator component and a second conductor layer plated on a bottom surface of the insulator component, the plated first and second conductor layers preventing a trapping of air with the insulator component, wherein all outer edge of the first and second conductor layers align with all the outer edges of the first main conductor,

wherein the outer edges of the insulator component create a creepage distance forming an overhanging portion extending beyond the outer edges of the first main conductor and the second main conductor and the outer edges of the first and second conductor layers, and

wherein no air is trapped between the first conductor layer and the top surface of the insulator component, and wherein no air is trapped between the second conductor layer and the bottom surface of the insulator component.

6. The bus bar assembly of claim 5 , wherein a thickness of the plated insulator member is greater than a thickness of the first main conductor and a thickness of the second main conductor.