Flexible electrical bus bar and method of manufacturing the same
An electrical bus bar assembly includes an elongate flexible electrical conductor formed from a strip of electrically conductive material having a distal portion that defines two parallel tabs extending from the conductor, and an electrical terminal having two different parallel sides received between the tabs. The tabs flex to resiliently retain the terminal, providing a low-resistance electrical interface and accommodating terminals of varying thicknesses. This arrangement enables simplified assembly and reliable electrical connections in compact power distribution systems.
1 . An electrical bus bar assembly, comprising:
an elongate flexible electrical conductor formed of a strip of electrically conductive material having a distal portion defining two parallel tabs extending from the electrical conductor; and
an electrical terminal having two different parallel sides disposed between the two parallel tabs, the two parallel tabs are integrally formed from the same flexible conductor and are configured to engage opposite parallel sides of the electrical terminal.
2 . The electrical bus bar assembly according to claim 1 , wherein the two parallel tabs are welded to the two different parallel sides of the electrical terminal.
3 . The electrical bus bar assembly according to claim 1 , wherein the two parallel tabs are formed of at least two layers of the electrically conductive material.
4 . The electrical bus bar assembly according to claim 1 , wherein leading edges of a free end of the two parallel tabs have a rounded edge.
5 . The electrical bus bar assembly according to claim 1 , wherein a thickness of the two parallel tabs is greater than a thickness of the central portion of the flexible electrical conductor.
6 . The electrical bus bar assembly according to claim 1 , wherein the strip of electrically conductive material has a generally rectangular cross section and a width to thickness ratio of at least 20:1.
7 . A method of manufacturing an electrical bus bar assembly, comprising:
forming a flexible strip from an electrically conductive sheet;
folding a portion of the flexible strip such that it defines two parallel tabs integrally formed from the same flexible strip extending from a distal portion of the flexible strip; and
inserting an electrical terminal having two different parallel sides so that the two parallel tabs respectively engage opposite sides of the electrical terminal.
8 . The method according to claim 7 , wherein the method further comprises welding the two parallel tabs to the two different parallel sides of the electrical terminal.
9 . The method according to claim 7 , wherein the method further comprises applying a dielectric material to the flexible strip, thereby covering a central portion of the flexible strip, wherein the dielectric material does not cover the distal portion.
10 . The method according to claim 9 , wherein a thickness of the two parallel tabs is greater than a thickness of the central portion of the flexible strip.
11 . The method according to claim 9 , wherein the two parallel tabs extend beyond a width of the central portion of the flexible strip.
12 . The method according to claim 7 , wherein the two parallel tabs are formed of at least two layers of the flexible strip.
13 . The method according to claim 7 , wherein the distal portion is folded such that leading edges of free ends of the two parallel tabs define rounded edges.
14 . The method according to claim 7 , wherein a width of the two parallel tabs is less than a width of the flexible strip.
15 . The method according to claim 7 , wherein the strip has a generally rectangular cross section and a width to thickness ratio of at least 20:1.