Electrical busbar, electrical connector assembly and power converter
View Patent ↗An electrical connector assembly is provided with an electrical busbar for conducting power. The busbar has a width, a length, and a thickness. The busbar has a first portion with a first length, and a second portion with a second length. The second portion is oriented at a non-zero angle relative to the first portion. A connector is mounted to the busbar. One of the width and the thickness is reduced for receipt of a sensor about the busbar. A power converter assembly is provided with a direct current bus capacitor and a power module oriented in a housing. A plurality of the electrical connector assemblies are each connected to at least one of the direct current bus capacitor and the power module.
1. An electrical connector assembly comprising:
an electrical busbar for conducting power, the busbar having a width, a length, and a thickness, the busbar having a first portion with a first length, and a second portion with a second length, the second portion oriented generally perpendicular to the first portion; and
a connector mounted to the busbar;
wherein the connector is mounted to the first portion;
wherein the electrical connector assembly further comprises a sensor mounted to the second portion;
wherein the second portion is formed with an abutment surface spaced apart from the first portion for locating the sensor; and
wherein the sensor comprises a current sensor.
2. The electrical connector assembly of claim 1 wherein the connector is formed integrally with the busbar.
3. The electrical connector assembly of claim 1 wherein the connector is welded to the busbar.
4. The electrical connector assembly of claim 1 wherein the connector is not fastened to the busbar by a threaded fastener.
5. The electrical connector assembly of claim 1 wherein the connector comprises at least one blade.
6. The electrical connector assembly of claim 1 wherein the connector comprises a female portion formed integrally with the busbar.
7. The electrical connector assembly of claim 1 wherein an aperture is formed into the second portion of the busbar to receive a fastener to electrically connect the busbar to another electrical component.
8. The electrical connector assembly of claim 1 wherein the sensor is not fastened to the busbar by a threaded fastener.
9. A power converter assembly comprising:
a housing;
a power module oriented in the housing; and
a plurality of electrical connector assemblies according to claim 1 each connected to the power module.
10. The electrical connector assembly of claim 1 wherein the second portion is formed with a pair of abutment surfaces spaced apart from the first portion to locate the sensor.
11. The electrical connector assembly of claim 5 wherein the at least one blade extends from the first portion in a direction that is generally parallel with a length of the second portion.
12. A power converter assembly comprising:
a housing;
a power module oriented in the housing;
a plurality of electrical connector assemblies according to claim 7 each connected to the power module;
a collector with a plurality of apertures in engagement with the second portion of each of the plurality of electrical connector assemblies; and
a plurality of fasteners fastening the plurality of electrical connector assemblies to the collector.