busbar assembly

Abstract

A busbar assembly includes first and second rigid and elongated electrically conductive busbars, an insulator sandwiched between first portions of the busbars, and a signal connector sandwiched between second portions of the busbars. The signal connector has an insulative housing and an electrically conductive signal terminal mounted within the insulative housing.

Description

[0001] Related applications

[0002] This application claims priority to U.S. Provisional Application US63 / 223,088, filed July 19, 2021, which is incorporated herein by reference. Technical Field

[0003] This disclosure relates to a busbar assembly and a combination of a busbar assembly and an electrical connector. Background Technology

[0004] Busbar assemblies are commonly used in electrical power distribution systems to distribute electrical power from a power source to numerous electrical devices such as servers and switches. In a power distribution system, a busbar is a metal strip or bar, typically housed within switchgear, panel boards, and busway enclosures, for localized high-current power distribution. Busbars are also used to connect high-voltage installations in electrical switchyards to low-voltage installations in battery banks.

[0005] Typically, power distribution using busbars is limited to power supply and lacks a method for integrating signals. Therefore, in addition to the busbar itself, separate cable assemblies are required. Some users may appreciate an alternative construction that incorporates signal transmission within the busbar assembly, thereby saving space. Summary of the Invention

[0006] Therefore, this disclosure provides an improved busbar assembly.

[0007] In one embodiment, a busbar assembly includes: first and second rigid and elongated conductive busbars; an insulator sandwiched between first portions of the two busbars; and a signal connector sandwiched between second portions of the two busbars. The signal connector has an insulating housing and a conductive signal terminal mounted within the insulating housing.

[0008] In one embodiment, a busbar assembly includes: first and second rigid and elongated conductive busbars; an insulator sandwiched between first portions of the two busbars; and a signal connector sandwiched between second portions of the two busbars. Each busbar has a first portion and a second portion extending from the first portion. Each second portion has a first segment extending from the first portion and a second segment extending from the first segment. The two first portions are parallel to each other. The two second segments are parallel to each other and parallel to the two first segments. In each busbar, the first segment is angled relative to the first portion and relative to the second segment. The signal connector includes an insulating housing, a plurality of conductive signal terminals mounted within the insulating housing, and a plurality of cables connected to the plurality of signal terminals. The insulating housing is attached to the two busbars by a locking member. Attached Figure Description

[0009] This disclosure is illustrated by way of example, but not limited to, the accompanying drawings, in which similar reference numerals denote similar parts, and in the accompanying drawings:

[0010] Figure 1 A perspective view of a busbar assembly and a mating connector according to a first embodiment is shown;

[0011] Figure 2 Show Figure 1 A three-dimensional cross-sectional view of the busbar assembly and docking connectors is given.

[0012] Figure 3 A front view showing a perspective view of the busbar assembly;

[0013] Figure 4 Show along Figure 3 A cross-sectional view of the busbar assembly of line 4-4;

[0014] Figure 5 Show along Figure 3 A cross-sectional view of the busbar assembly of line 5-5;

[0015] Figure 6 A cross-sectional view of a busbar assembly according to a second embodiment is shown; and

[0016] Figure 7 A cross-sectional view of a busbar assembly according to a third embodiment is shown. Detailed Implementation

[0017] While this disclosure can be readily implemented in various forms, the embodiments shown in the accompanying drawings and described in detail herein are specific examples. It is understood that this disclosure should be considered as an example of the principles of this disclosure and is not intended to limit it to what is shown and illustrated herein. Thus, unless otherwise stated, the features disclosed herein may be combined to form other combinations not given for purposes of simplicity. It will be further appreciated that in some embodiments, one or more components illustrated by way of example in the drawings may be removed and / or replaced with alternative components within the scope of this disclosure.

[0018] Directional terms such as front, back, horizontal, and vertical are used for ease of explanation, but do not indicate the direction required when using them.

[0019] A busbar assembly 20 includes: a first rigid and elongated conductive busbar 22; a second rigid and elongated conductive busbar 22a; an insulator 24 sandwiched between first portions 26, 26a of the buses 22, 22a; and a signal connector 28 sandwiched between second portions 30, 30a of the buses 22, 22a, the second portions 30, 30a extending from and integrally formed with the first portions 26, 26a. Each busbar 22, 22a has a first surface 34, 34a and an opposite second surface 36, 36a. One busbar provides a feed, while the other busbar provides a return.

[0020] The first portions 26, 26a are flat, and the opposing surfaces 34, 34a, 36, 36a of each of the first portions 26, 26a are parallel to each other. A longitudinal plane 38, 38a is defined between the opposing surfaces 34, 34a, 36, 36a of each of the first portions 26, 26a. The first portion 26 of busbar 22 is parallel to the first portion 26a of busbar 22a, while surfaces 34, 34a face insulator 24. Insulator 24 prevents electrical conduction between the first portion 26 of busbar 22 and the first portion 26a of busbar 22a. Busbars 22, 22a and insulator 24 are permanently attached together in a sandwich configuration. The first portions 26, 26a are configured to be clamped on surfaces 36, 36a by a busbar connector (not shown).

[0021] The second portions 30, 30a of buses 22, 22a are offset from each other, thereby forming a signal connector receiving space 40 between the second portions 30, 30a of buses 22, 22a. Each second portion 30, 30a includes a first segment 42, 42a extending from the first portions 26, 26a and a flat second segment 44, 44a extending from the first segment 42, 42a. Figure 4 and Figure 6As shown, each of the first segments 42, 42a is at an angle relative to the first parts 26, 26a and extends outward from each other, for example as... Figure 4 The ground is shown at a forty-five (45) degree angle or approximately forty-five (45) degree angle relative to planes 38, 38a, such that an included angle of ninety (90) degrees is provided between the first portions 26, 26a, or for example as Figure 6 The first segments 42 and 42a are arranged at a 90-degree angle or approximately 90-degree angle relative to planes 38 and 38a, such that an included angle of 180 degrees is provided between the first segments 26 and 26a. Alternatively, the first segments 42 and 42a can be arranged at different angles relative to planes 38 and 38a, for example, the first segment 42 at a 45-degree angle and the first segment 42a at a 90-degree angle. Any desired angle of the first segments 42 and 42a can be set, provided that the signal connector receiving space 40 is formed. The second segments 44 and 44a are parallel to each other and parallel to the first segments 26 and 26a. Figure 7 In one embodiment shown, one of the second portions 30 and 30a, such as the second portion 30, is coplanar with the first portion 26, and the second portion 30a includes a first segment 42a and a second segment 44a.

[0022] Signal connector 28 is disposed within signal connector receiving space 40 between the second segments 44 and 44a, with surfaces 34 and 34a of buses 22 and 22a facing signal connector 28. A portion of signal connector receiving space 40 is disposed between a rear end face 46 of signal connector 28 and the first segments 42 and 42a of buses 22 and 22a. Signal connector 28 prevents electrical conduction between the second portions 30 and 30a of buses 22 and 22a. Buses 22 and 22a and signal connector 28 are permanently attached together in a sandwich structure.

[0023] like Figure 2As shown, the signal connector 28 includes: an insulating housing 48; a plurality of conductive electrical signal terminals 50 mounted within the housing 48; and a plurality of cables 52, each cable 52 mating with one of the signal terminals 50. In one embodiment, the signal connector 28 includes a single electrical signal terminal 50 mounted within the housing 48 and a single cable 52 mating with the electrical signal terminal 50. The housing 48 has opposing rear end faces 46 and a front end face 54, and a top face 56, a bottom face 58, and two side faces 60, 62 extending between the front end face 54 and the rear end face 46, forming a plurality of spaced-apart channels 64. Each channel 64 extends longitudinally from an opening at the front end face 54 to an opening at the rear end face 46. The plurality of channels 64 may be aligned in a row. The plurality of signal terminals 50 distributes a plurality of signals from the plurality of cables 52 to an electrical device (not shown). Each signal terminal 50 may be formed by a body, a pair of wings extending from a rear end of the body, and a pair of flexible contact beams extending from a front end of the body. Each signal terminal 50 is disposed within a front portion of the channel 64, and a flexible contact beam faces the opening at the front of the housing 48. Suitable couplings are provided to secure the signal terminals 50 within the channel 64.

[0024] The top surface 56 abuts against the first surface 34 of the second portion 30 of bus 22, while the bottom surface 58 abuts against the first surface 34a of the second portion 30a of bus 22a. Buses 22, 22a and signal connector 28 are locked together by locking member 66 to prevent signal connector 28 from separating from buses 22, 22a. In one embodiment, locking member 66 is formed by a protrusion 68 extending from the top surface 56 of housing 48 and disposed within a similarly shaped opening 70 formed on the second portion 30 of bus 22, and protrusion 72 extending from the bottom surface 58 of housing 48 and disposed within a similarly shaped opening 74 formed on the second portion 30a of bus 22a. In one embodiment, locking member 66 is formed by a single protrusion and opening. Signal connector 28 can be easily snapped between buses 22, 22a. Other locking members 66 are also within the scope of this disclosure.

[0025] In use, each cable 52 is routed through the signal connector receiving space 40, thereby partially passing between the two busbars 22, 22a. The cable 52 passes through an opening at the rear of the housing 48 and is inserted into one of the channels 64. Before insertion, a portion of the insulation of the cable 52 is removed, and the two wings of the signal terminal 50 are crimped to an exposed conductor of the cable 52. The cable 52 exits via both sides of the busbar assembly 20.

[0026] An electrical connector 76 mating with bus assembly 20 includes: an insulating housing 78; a row of electrical signal contacts 80 mounted within the housing 78; a row of power contacts 82 mounted within the housing 78 on one side of the signal contacts 80; and a row of power contacts 82a mounted within the housing 78 on the other side of the signal contacts 80. The housing 78 has a rear wall 84 and a top wall 86, a bottom wall 88, and side walls 90, 92 extending from the rear wall 84 to a front end 94. The walls 84, 86, 88, 90, 92 define a central cavity 96 extending from the front end 94 to a plurality of channels through the rear wall 84 for the plurality of signal contacts 80 to extend through, a plurality of channels on the rear wall 84 for the plurality of power contacts 82 to extend through, and a plurality of channels on the rear wall 84 for the plurality of power contacts 82a to extend through. Contacts 80, 82, and 82a extend into cavity 96, with power contact 82 positioned near top wall 86 and power contact 82a positioned near bottom wall 88, thereby positioning signal contact 80 between power contacts 82 and 82a. Alternatively, signal contact 80 can be configured as a separate connector, inserted / assembled into a corresponding opening within housing 78.

[0027] Bus assembly 20 passes through front end 94 and is housed in cavity 96. Signal contact 80 enters channel 64 and mates with signal terminal 50. Power contact 82 mates with bus 22, while power contact 82a mates with bus 22a. This allows bus assembly 20 to be inserted into / removed from connector 76 in a single step without the need for additional cable assemblies.

[0028] While specific embodiments are shown and illustrated in the accompanying drawings, it is contemplated that various modifications can be devised by those skilled in the art without departing from the spirit and scope of the appended claims. Therefore, it will be appreciated that the scope of this disclosure and the appended claims is not limited to the specific embodiments shown and illustrated in the drawings, and that modifications and other embodiments will be included within the scope of this disclosure and the appended drawings. Furthermore, although the foregoing description and associated drawings illustrate exemplary embodiments in the context of certain exemplary combinations of components and / or functions, it should be recognized that different combinations of components and / or functions may be provided by alternative embodiments without departing from the scope of this disclosure and the appended claims. Moreover, the foregoing description describes a method of performing multiple steps. Unless stated to the contrary, one or more steps in a method may be optional, one or more steps may be performed in a different order than described, and one or more steps may be performed substantially simultaneously. Finally, the drawings are not necessarily drawn to scale.

Claims

1. A busbar assembly for one-time insertion / removal from a central cavity of a mating connector, the busbar assembly comprising: A rigid and slender conductive first busbar; A rigid and slender conductive second busbar; An insulator, sandwiched between the first portions of the two busbars; and A signal connector, sandwiched between the second portions of the two busbars, includes an insulating housing and a conductive signal terminal mounted within the insulating housing. The signal terminals of the busbar assembly are connected to the signal contacts of the docking connector, the first busbar is connected to the power contacts of the docking connector, and the second busbar is connected to another power contact of the docking connector.

2. The busbar assembly as claimed in claim 1, wherein, Each second portion has a first segment extending from the first portion and a second segment extending from the first segment, wherein at least one of the two first segments is at an angle relative to its respective first portion and relative to its respective second segment.

3. The busbar assembly as described in claim 2, wherein, The first part and the second segment are parallel to each other.

4. The busbar assembly as described in claim 2, wherein, The at least one first segment is at an angle of about forty-five (45) degrees to about ninety (90) degrees relative to the first portion.

5. The busbar assembly as claimed in claim 4, wherein, The first part and the second segment are parallel to each other.

6. The busbar assembly as claimed in claim 1, wherein, The signal connector also includes a cable connected to the signal terminal.

7. The busbar assembly as claimed in claim 1, wherein, The signal connector includes multiple signal terminals installed within the insulating housing and cables connected to each signal terminal, the cables extending outward from the busbar.

8. The busbar assembly as claimed in claim 1, wherein, Each second part has a first segment extending from the first part and a second segment extending from the first segment, wherein, in each busbar, the first segment is at an angle relative to the first part and relative to the second segment.

9. The busbar assembly as claimed in claim 8, wherein, In each busbar, the first section and the second section are parallel to each other.

10. The busbar assembly as claimed in claim 8, wherein, In each busbar, the first segment is at an angle of about forty-five (45) degrees to about ninety (90) degrees relative to the first portion.

11. The busbar assembly of claim 10, wherein, In each busbar, the first section and the second section are parallel to each other.

12. The busbar assembly as claimed in claim 8, wherein, The signal connector also includes a cable connected to the signal terminal.

13. The busbar assembly as claimed in claim 8, wherein, The signal connector includes multiple signal terminals installed inside the insulating housing and cables connected to each signal terminal, the cables extending outward from the two busbars.

14. The busbar assembly as claimed in claim 1, wherein, The insulating housing is attached to at least one of the two busbars by a locking element.

15. The busbar assembly of claim 14, wherein, The locking element includes a protrusion that extends from the insulating housing into an opening in the first busbar.

16. The busbar assembly of claim 14, wherein, The locking member includes: a first protrusion extending from the insulating housing into a first opening in the first busbar; and a second protrusion extending from the insulating housing into a second opening in the second busbar.

17. The combination of the bus assembly as claimed in claim 1 and a mating electrical connector configured to mate with the bus assembly.

18. The combination of claim 17, wherein, The electrical connector includes: an insulating housing; an electrical signal contact mounted within the housing; a first power contact mounted within the housing on one side of the signal contact; and a second power contact mounted within the housing on the other side of the signal contact.

19. A busbar assembly for one-time insertion / extraction into a central cavity of a mating connector, the busbar assembly comprising: Rigid and elongated conductive first and second busbars, each busbar having a first portion and a second portion extending from the first portion, each second portion having a first segment extending from the first portion and a second segment extending from the first segment, the two first portions being parallel to each other, the two second segments being parallel to each other and parallel to the two first portions, in each busbar the first segment being at an angle relative to the first portion and also at an angle relative to the second segment. An insulator, sandwiched between the first portions of the two busbars; and A signal connector, sandwiched between the second portions of the two busbars, includes an insulating housing, a plurality of conductive signal terminals mounted within the insulating housing, and a plurality of cables connected to the signal terminals. The insulating housing is attached to the two busbars by a locking element. The signal terminals of the bus assembly are connected to the signal contacts of the docking connector, the first bus is connected to the first power contact of the docking connector, and the second bus is connected to the second power contact of the docking connector.

20. The combination of the bus assembly of claim 19 and a mating electrical connector configured to mate with the bus assembly, the electrical connector comprising an insulating housing; the signal contact being mounted within the insulating housing; the first power contact being mounted within the insulating housing on one side of the signal contact; and the second power contact being mounted within the insulating housing on the other side of the signal contact.

Images