Electrical assembly
An electrical assembly comprises a body, an electrical terminal connected to the body and a bus bar electrically connected to the electrical terminal. The bus bar includes an aperture in which the electrical terminal is partially disposed. The bus bar includes a slot extending from the aperture. A second electrical terminal can be connected to the body. A second bus bar can be electrically connected to the second electrical terminal.
1 . An electrical assembly, comprising:
a body;
an electrical terminal connected to the body; and
a bus bar electrically connected to the electrical terminal, the bus bar including an aperture in which the electrical terminal is partially disposed and including a slot extending from the aperture to an outer edge of the bus bar, wherein the bus bar includes a recess disposed about a periphery of the aperture and a thickness of the bus bar at the recess is reduced relative to at least some other portions of the bus bar.
2 . The electrical assembly of claim 1 , further comprising:
a second electrical terminal connected to the body; and
a second bus bar electrically connected to the second electrical terminal;
wherein the body is a contactor body including a housing;
an actuator and a contact member are disposed in the housing; and
the actuator moves the contact member into contact with the electrical terminal and the second electrical terminal to selectively electrically connect the bus bar with the second bus bar.
3 . The electrical assembly of claim 1 , wherein the bus bar is laser welded with the electrical terminal about at least a portion of a periphery of the aperture.
4 . The electrical assembly of claim 1 , wherein the bus bar includes a first inner surface and a second inner surface that define the slot; and
the first inner surface and the second inner surface are welded together.
5 . The electrical assembly of claim 1 , wherein the electrical terminal includes a terminal recess; and
the recess of the bus bar and the terminal recess collectively at least partially define a weld channel.
6 . The electrical assembly of claim 5 , wherein a weld bead is disposed in the weld channel such that the weld bead does not extend outward beyond the weld channel.
7 . The electrical assembly of claim 5 , wherein an upper surface of the bus bar and an upper surface of the electrical terminal are disposed at the same height above the body.
8 . The electrical assembly of claim 5 , wherein an upper surface of the bus bar and an upper surface of the electrical terminal are coplanar.
9 . The electrical assembly of claim 5 , wherein the electrical terminal includes a circumferential shoulder;
the bus bar is disposed partially on the circumferential shoulder; and
the circumferential shoulder extends radially beyond the aperture.
10 . The electrical assembly of claim 9 , wherein the bus bar is fixed to the electrical terminal via a circumferential laser weld about a full circumference of the electrical terminal.
11 . The electrical assembly of claim 9 , wherein the circumferential shoulder is spaced from the body such that the bus bar is spaced from the body and a gap is defined between the bus bar and the body.
12 . The electrical assembly of claim 9 , wherein the bus bar is fixed to the electrical terminal via a plurality of separate and circumferentially spaced spot welds.
13 . The electrical assembly of claim 1 , wherein the bus bar is interference fit on the electrical terminal.
14 . A method of assembling an electrical assembly, the method comprising:
disposing a bus bar on an electrical terminal such that the electrical terminal is disposed partially in an aperture of the bus bar, wherein the bus bar includes a recess disposed about a periphery of the aperture and a thickness of the bus bar at the recess is reduced relative to at least some other portions of the bus bar; and
laser welding the bus bar with the electrical terminal.
15 . The method of claim 14 , wherein the laser welding includes laser welding about a full circumference of the electrical terminal.
16 . The method of claim 15 , wherein the bus bar includes a slot extending from the aperture to an outer edge of the bus bar, and wherein the bus bar includes a first inner surface and a second inner surface that define the slot; and
the laser welding includes laser welding the first inner surface with the second inner surface.
17 . The method of claim 14 , wherein disposing the bus bar on the electrical terminal includes increasing a dimension of the slot.
18 . The method of claim 15 , wherein the electrical assembly comprises a body and the electrical terminal is connected to the body, and wherein during the laser welding about a full circumference of the electrical terminal, a circumferential shoulder of the electrical terminal prevents laser light from reaching the body.
19 . The method of claim 14 , further comprising forming the bus bar with the aperture with a tolerance including a clearance fit or an interference fit relative to the electrical terminal.
20 . An electrical assembly, comprising:
a body;
an electrical terminal connected to the body; and
a bus bar electrically connected to the electrical terminal, the bus bar including an aperture in which the electrical terminal is partially disposed, wherein the bus bar includes a recess disposed about a periphery of the aperture, wherein the electrical terminal includes a terminal recess, and wherein the recess of the bus bar and the terminal recess collectively at least partially define a weld channel.