Electronic assembly with a direct current bus connection

1. An electronic assembly comprising:

a direct current (DC) bus terminating in a folded outer tab and a bent inner tab; the folded outer tab comprising a first outer dielectric layer and a second outer dielectric layer contacting or overlying an outer terminal, the outer terminal associated with a first polarity of the DC bus;

the bent inner tab comprising a first inner dielectric layer a second inner dielectric layer contacting or overlying an inner terminal, the inner terminal associated with a second polarity of the DC bus that is opposite the first polarity, wherein the folded outer tab and the bent inner tab have electrically conductive vertical faces, of opposite polarities, formed of exposed portions of the outer terminal and the inner terminal;

a module comprising a module tab projecting generally vertically from an exterior of the module, the module tab comprising a central dielectric substrate that supports a first conductive pad on a first side and a second conductive pad on a second side opposite the first side; the first conductive pad and the second conductive pad engaging the exposed portions; and

a clamp for forming an electrical and mechanical connection between the first conductive pad, the second conductive pad and the exposed portions.

2. The electronic assembly according to claim 1 wherein the folded outer tab forms a first recess for receiving the module tab and a second recess for receiving a portion of a clamp member of the conductive clamp.

3. The electronic assembly according to claim 1 wherein the clamp comprises:

a first clamp member;

a second clamp member spaced apart from the first clamp member;

a plurality of openings in the first clamp member and second clamp member, the openings arranged to receive threaded fasteners to apply compressive forces to the first clamp member and second clamp member.

4. The electronic assembly according to claim 1 wherein the openings comprise:

a first pair of bores in the first clamp member for receiving the threaded fastener; and

a second pair of threaded bores in the second clamp member for engaging the threaded fastener.

5. The electronic assembly according to claim 1 wherein the first clamp member and the second clamp member each a have crowned face or convex face for contacting the folded outer tab and the bent inner tab.

6. The electronic assembly according to claim 5 wherein an outermost outwardly projecting portion of the crowned face or convex face contacts a first outer dielectric layer of the folded outer tab and a second inner dielectric layer of the bent inner tab.

7. The electronic assembly according to claim 1 wherein the second outer dielectric layer is electrically isolated from and spaced apart from the inner terminal by a clearance gap.

8. The electronic assembly according to claim 1 wherein the module comprises a power inverter module that receives direct current power via the electrical connection of the module tab.

9. The electronic assembly according to claim 8 wherein the inner terminal and the outer terminal conduct thermal energy from the module via the module tab.

10. The electronic assembly according to claim 1 wherein the inner terminal and the outer terminal are composed of copper, a copper alloy, aluminum or an aluminum alloy.

11. The electronic bus assembly according to claim 1 wherein the inner terminal and the outer terminal are composed of a metal layer that is approximately a thickness of 2 millimeters or greater.

12. The electronic assembly according to claim 1 wherein the clamp provides an evenly distributed compressive force to the exposed portions (of the outer terminal and the inner terminal), the first conductive pad, and the second conductive pad to reduce an electrical resistance between the outer terminal and the first conductive pad and an electric resistance between the inner terminal and the second conductive pad to approximately three micro-ohms or lower.