Electrical assembly

Abstract

An electrical assembly includes a body, an electrical terminal connected to the body, and a bus bar electrically connected to the electrical terminal. The bus bar includes a hole in which the electrical terminal is partially disposed. The bus bar includes a slot extending from the aperture. A second electrical terminal may be connected to the body. The second bus bar may be electrically connected to the second electrical terminal.

Description

Technical Field

[0001] The present disclosure relates generally to electrical assemblies, including electrical assemblies including contactors, bus bars, and / or electrical terminals. BRIEF DESCRIPTION OF THE DRAWINGS

[0002] Although the claims are not limited to specific illustrations, an understanding of various aspects may be gained through a discussion of various examples. The drawings are not necessarily to scale, and certain features may be exaggerated or hidden to better illustrate and explain the innovative aspects of the examples. In addition, the exemplary illustrations described herein are not exhaustive or otherwise limiting, and the embodiments are not limited to the precise forms and configurations shown in the drawings or disclosed in the following detailed description. The exemplary illustrations are described in detail with reference to the drawings as follows:

[0003] Figure 1 is a perspective view generally illustrating an embodiment of an electrical assembly according to example teachings of the present disclosure.

[0004] Figure 2 is a partial cross-sectional view generally illustrating an embodiment of an electrical assembly according to example teachings of the present disclosure.

[0005] Figure 3 is a perspective view generally illustrating an embodiment of an electrical assembly according to example teachings of the present disclosure.

[0006] Figure 4 is a top view generally illustrating an embodiment of an electrical assembly according to example teachings of the present disclosure.

[0007] Figure 5 is a partial cross-sectional view generally illustrating an embodiment of an electrical assembly according to example teachings of the present disclosure.

[0008] Figure 6 is an enlarged partial cross-sectional view generally illustrating an embodiment of an electrical assembly according to example teachings of the present disclosure.

[0009] Figure 7 is a schematic top view generally illustrating an embodiment of an electrical assembly and a welding machine according to example teachings of the present disclosure.

[0010] Figure 8 is a schematic partial cross-sectional view generally illustrating an embodiment of an electrical assembly and a welding machine according to example teachings of the present disclosure.

[0011] Figure 9A-9C is a partial cross-sectional view generally illustrating an embodiment of an electrical assembly according to example teachings of the present disclosure.

[0012] Fig.10 is an enlarged partial cross-sectional view generally illustrating an embodiment of an electrical assembly according to example teachings of the present disclosure.

[0013] Figures 11A-11C is a partial top view generally illustrating an embodiment of an electrical assembly according to example teachings of the present disclosure.

[0014] Fig.12 is a flow chart generally illustrating an embodiment of a method of assembling an electrical assembly according to example teachings of the present disclosure. Detailed Description

[0015] Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings. In the detailed description that follows, many specific details are set forth in order to provide a thorough understanding of the various embodiments described. However, it is apparent to one of ordinary skill in the art that the various embodiments described may be practiced without these specific details. In other instances, well-known methods, processes, components, circuits, and networks are not described in detail to avoid unnecessarily obscuring aspects of the embodiments.

[0016] refer to Figure 1 The electrical assembly 20 includes a body 30, a first bus bar 32, a second bus bar 34, a first terminal 36 (e.g., a first electrical terminal), and a second terminal 38 (e.g., a second electrical terminal). The first terminal 36 and the second terminal 38 are connected to the body 30 (e.g., mechanically). The first bus bar 32 is electrically connected to the first terminal 36. The second bus bar is electrically connected to the second terminal 38. Optionally, the first terminal 36 and the second terminal 38 extend from the same side of the outer surface 40 of the body 30, such as from the upper surface 42. The upper surface 42 may include an electrically insulating material, such as a ceramic material, etc., to electrically insulate the terminals 36 and 38 from each other.

[0017] refer to Figure 2, the body 30 may be a contactor body and include a housing 50. Optionally, the housing 50 includes an electrically insulating material (such as plastic), an electrically conductive material (such as metal), or a combination thereof. An actuator 52 (e.g., an electromagnet) coupled to a conductive contact member 54 is disposed in the housing 50. The actuator 52 moves the contact member 54 to contact and disengage with the terminals 36, 38 to selectively electrically connect the terminals 36, 38 to the first bus bar 32 and the second bus bar 34. For example, the electrical component 20 may be configured as a contactor. Optionally, the electrical component 20 includes a cooling member 60 disposed adjacent to the first bus bar 32 and / or the second bus bar 34. A coupling layer 62 may be disposed between the cooling member 60 and the bus bars 32, 34. The coupling layer 62 may include an electrically insulating material and a thermally conductive material, so that the coupling layer 62 electrically insulates the bus bars 32, 34 from the cooling member 60 and thermally couples the bus bars 32, 34 to the cooling member 60. The cooling member 60 may include one or more of a variety of configurations. For example, the cooling member 60 may include a heat sink, a cooling plate, cooling fins, a heat pipe, a cooling fluid channel, or a combination thereof, among other configurations. Optionally, the electrical assembly 20 does not include the cooling member 60 and / or the coupling layer 62 .

[0018] refer to Figure 3 and Figure 4 , the body 30 includes control terminals 70, 72 extending from an outer surface 40 (such as an upper surface 42) of the body 30. The control terminals 70, 72 are electrically connected to the actuator for controlling the actuator 52. The body includes a vent 74, which is configured to at least temporarily connect the interior of the body 30 with the exterior of the body 30, such as to create a vacuum in the body 30 and / or to at least partially fill the body with a gas (e.g., hydrogen, nitrogen, helium, or a combination thereof). Optionally, the terminals 70, 72 and the vent 74 are disposed at opposite sides of the upper surface 42 of the outer surface 40 of the body 30 and at opposite sides of the terminals 36, 38, but the terminals 70, 72 and the vent 74 may also be disposed at other portions of the outer surface 40.

[0019] The first bus bar 32 includes a hole 80 and a slot 82. The hole 80 is a through hole that extends through the first bus bar 32 and partially receives the first terminal 36. The slot 82 extends from the hole 80 through the outer edge / outer surface 84 of the first bus bar 32. The slot 82 is shown as extending in the longitudinal direction X toward the second terminal 38, but the slot 82 can also extend in other directions, such as in the transverse direction Y or at an angle between the longitudinal direction X and the transverse direction Y. The slot 82 extends through the thickness of the first bus bar 32 in the vertical direction Z. The first bus bar 32 includes a first inner surface 90 and a second inner surface 92 spaced a distance D from the first inner surface 90, so that the inner surfaces 90, 92 define the slot 82. Optionally, the inner surfaces 90, 92 are planar, parallel to each other and / or perpendicular to the transverse direction Y. The groove 82 is configured to increase the flexibility and / or compliance of the first bus bar 32 near the hole 80 and allow the size of the hole 80 (e.g., the diameter of the circular configuration) to change, such as during the insertion of the first terminal 36 into the hole 80. For example, prior to inserting the first terminal 36, the diameter 80D of the hole 80 may include a first dimension and the distance D may have a first dimension (e.g., in the lateral direction Y), and during the insertion, the first bus bar 32 may flex such that the diameter 80D of the hole 80 includes a second dimension greater than the first dimension and / or the distance D has a second dimension greater than the first dimension. After the insertion is completed, the first bus bar 32 may remain in the flexed configuration with the diameter 80D and the distance D having the second dimension. Although described in conjunction with the first bus bar 32, the second bus bar 34 ( Figure 1 ) may also include holes 86 and slots 88. Optionally, the first bus bar 32 and / or the second bus bar 34 do not include slots 82, 88, for example if the gaps and / or tolerances between the bus bars 32, 34 and the terminals 36, 38 are small (e.g., about 0.05 mm or less).

[0020] The hole 80 includes a cylindrical configuration, but may include other configurations. For example, the hole 80 may include one or more tapered portions, such as to provide the hole 80 with a tapered configuration. For a tapered hole 80, the first terminal 36 may include a corresponding tapered configuration, which may increase the surface area of ​​contact between the first bus bar 32 and the first terminal 36 and / or may reduce the effects of radial tolerances of the hole 80 and the terminal 36.

[0021] refer to Figure 5, the first terminal 36 and the second terminal 38 include shoulders 100, 102 extending radially outward from the terminals 36, 38 (e.g., relative to the central axis of the terminals 36, 38 extending in the vertical direction Z) to define first axial surfaces 104, 106 and second axial surfaces 108, 110, the first axial surfaces 104, 106 being away from the body 30, and the second axial surfaces 108, 110 facing the outer surface 40 (e.g., the upper surface 42) of the body 30 and contacting the outer surface 40 of the body 30. The bus bars 32, 34 are partially disposed on the shoulders 100, 102, such as on the axial surfaces 104, 106, and the shoulders 100, 102 extend beyond (e.g., in the XY plane) the hole 80. For example, in the case of a circular configuration of the terminals 36, 38, the outer diameter 100D, 102D of the shoulders 100, 102 (e.g., circumferential shoulders) is greater than the maximum inner diameter 80D, 86D of the holes 80, 86, such that the shoulders 100, 102 are not disposed in the holes 80. The shoulders 100, 102 space the bus bars 32, 34 from the upper surface 42 of the body 30 (e.g., in the vertical direction Z), such that a gap 120 exists between the upper surface 42 and at least some portions of the bus bars 32, 34. The diameter 100D, 102D may be, for example, 5% greater, 20% greater, or be equal to or between 5% and 20% greater than the diameter 80D, 86D of the bus bar holes 80, 86.

[0022] Reference Figure 6 , the thickness 32T of the first bus bar 32 is thicker than the thickness 100T of the shoulder 100. For example, but not limited to, the thickness 100T may be equal to 20%, 60%, or between 20% and 60%, such as about 30%, of the thickness 32T. Optionally, the thickness 100T is equal to or greater than the thickness 32T. The thickness 100T may correspond to a minimum thickness for brazing the terminal 36 with the body 30 (e.g., with the upper surface 42) and / or a minimum thickness for blocking the laser during welding. The thickness 32T may correspond to a desired current capacity. A portion of the shoulder 100 that may include the axial surface 108 is disposed in the body 30, for example, in the housing hole 130 of the housing 50. According to this configuration, the size 120T of the gap 120 (e.g., in the vertical direction Z) is less than the thickness 100T of the shoulder 100. In other configurations, the shoulder 100 is not disposed in the body 30 , and the dimension 120T of the gap 120 is equal to or greater than the thickness 100T of the shoulder 100 .

[0023] The upper surface 150 of the first bus bar 32 and the upper surface 152 of the first terminal 36 are parallel and offset in the vertical direction Z by 10% or less of the thickness 32T of the bus bar 32 or not offset at all (e.g., coplanar). For example, the upper surface 150 of the first bus bar 32 and the upper surface 152 of the first terminal 36 can be disposed at the same height above the upper surface 42 of the body 30. This configuration can reduce and / or minimize the thickness 62T of the coupling layer 62, which can reduce and / or minimize (i) the amount of coupling layer material 62 and / or (ii) the distance between the cooling member 60 and the first bus bar 32 and the first terminal 36. In some examples, the cooling member 60 can be disposed at the same distance from the upper surfaces 150, 152 of the first bus bar 32 and the first terminal 36. The second bus bar 34 can be connected to the second terminal 38 in the same or different manner as the first bus bar 32 is connected to the first terminal 36. For example, the second bus bar 34 may include the aperture 86 and include a slot 88 defined by the inner surfaces 94, 96 (see Figure 7 ).

[0024] Reference Figure 7 , the bus bars 32, 34 are fixed to the terminals 36, 38, respectively, by welding (such as via laser welding). The welding may include welding via spot welds 140 (e.g., separate and circumferentially spaced spot welds), such as shown with the hole 80 of the first bus bar 32 and the first terminal 36, and / or welding via one or more peripheral welds 142, such as shown with the hole 86 of the second bus bar 34 and the second terminal 38. The peripheral welds (e.g., circumferential welds for a circular configuration) may extend along some or all of the perimeters of the hole 80 of the bus bar (e.g., bus bars 32, 34) and / or some or all of the perimeters of the perimeters of the terminals (e.g., terminals 36, 38). According to some examples, one or both of the bus bars 32, 34 are fixed to the terminals 36, 38 via circumferential laser welding around the entire circumference of the terminals 36, 38. The slots 82, 88 may be closed via spot welds and / or elongated welds. For example, the inner surfaces 90 , 92 of the slot 82 of the first bus bar 32 may be welded together, and / or the inner surfaces 94 , 96 of the slot 88 of the second bus bar 34 may be welded together.

[0025] Both bus bars 32, 34 may be spot welded to the terminals 36, 38, both bus bars 32, 34 may be circumferentially welded to the terminals 36, 38, or the bus bars 32, 34 may be welded differently to each other. In some configurations, the bus bars 32, 34 may be welded to the terminals 36, 38 via spot welds at some portions of the circumference of the terminals 36, 38 and via circumferential welds along other portions of the circumference of the terminals 36, 38.

[0026] refer to Figure 8 , the interface 160 between the first bus bar 32 and the first terminal 36 includes a first interface portion 162 and a second interface portion 164. The first interface portion 162 includes an interface between a surface of the hole 80 of the first bus bar 32 and a radial surface 170 of the first terminal 36. The first interface portion 162 is parallel to the vertical direction Z, but may also include other configurations. The first interface portion 162 may include an interference fit, a sliding fit, or a clearance fit of the first bus bar 32 and the first terminal 36. The second interface portion 164 includes an interface between a lower surface 172 of the first bus bar 32 and an axial surface 104 of the shoulder 100 of the first terminal 36. The first interface portion 162 is welded to secure the first bus bar 32 to the first terminal 36, such as via circumferential welding, spot welding, or a combination thereof. The welding may include laser welding, and the alignment relationship of the shoulder 100 with the first interface portion 162 in the vertical direction Z causes the shoulder 100 to limit or prevent the laser light of the laser 202 of the welding machine 200 from reaching the body 30, such as preventing the laser light from reaching the housing 50 and / or components disposed therein. For example, the shoulder 100 may protect one or more portions of the body 30 during welding. The laser 202 may penetrate into the shoulder 100, such as to a depth of 5%, 10%, or between 5% and 10% of the thickness 32T of the bus bar 32. The thickness 100T may be selected to be at least 10% of the thickness 32T of the bus bar 32. Additionally or alternatively, the shoulder 100 may help maintain proper alignment of the first bus bar 32 with the first terminal 36, such as during welding.

[0027] The upper surface 150 of the first bus bar 32 includes a recess 180 disposed around the periphery of the hole 80. The thickness 32T of the first bus bar 32 is reduced at the recess 180 relative to at least some other portions of the first bus bar 32. The upper surface 152 of the first terminal 36 includes a terminal recess 182 disposed around the periphery of the first terminal 36. In the assembled configuration, the recess 180 and the terminal recess 182 together at least partially define a welding channel 184. One or more weld beads 186 are disposed in the welding channel 184. The one or more weld beads 186 are formed during welding of the first bus bar 32 and the first terminal 36. The one or more weld beads 186 can be disposed in the welding channel 184 so that the one or more weld beads 186 do not extend beyond the welding channel 184, such as in the vertical direction Z. The welding channel 184 can be annular, for example having a circular configuration of the first terminal 36. The weld beads 186 are disposed in the welding channel 184. Figure 8 The weld bead 186 is shown as an oval shape for illustration purposes only. The weld bead 186 can have various shapes, including round, rounded, polygonal, non-polygonal, and / or combinations thereof.

[0028] The recess 180 includes a width 180W that can be defined in the XY plane and a depth 180D in the vertical direction Z. The terminal recess 182 includes a width 182W that can be defined in the XY plane and a depth 182D in the vertical direction Z. The weld channel 184 includes a width 184W and a depth 184D, the width 184W can be equal to the sum of the widths 180W, 182W plus the gap (if any) between the first bus bar 32 and the first terminal 36, and the depth 184D can be equal to the depths 180D, 182D. The depths 180D, 182D and the widths 180W, 182W can be configured so that the depth 184D and the width 184W are at least as large as the expected size of one or more weld beads 186. In some examples, the depths 180D, 182D can be equal to each other and / or can be equal to 5%, 10%, or between 5% and 10% of the thickness 32T of the first bus bar 32. Additionally or alternatively, in some examples, the widths 180W, 182W may be equal to each other, may be equal to the depths 180D, 182D, and / or may be equal to 5%, 10%, or between 5% and 10% of the thickness 32T of the first bus bar 32. In some examples, the width 184W may be equal to 10%, 15%, or between 10% and 15% of the thickness 32T of the first bus bar 32.

[0029] refer to Figure 9A-9C , the recesses 180, 182 may include one or more of a variety of configurations. For example, the recesses 180, 182 may be chamfered so that the depths 180D, 182D increase toward the first interface portion 162 ( Fig.9A ), the recesses 180, 182 may have a rectangular cross section ( Fig. 9B ), or the recesses 180, 182 may have a combination of chamfered and rectangular configurations ( Fig. 9C ), and other possible configurations.

[0030] refer to Fig.10 , the first bus bar 32 may include a chamfer / radius 190 at the intersection of the surface of the hole 80 and the lower surface 172. The chamfer / radius 190 may help the first bus bar 32 partially rest on the shoulder 100 so that the lower surface 172 is flush with the axial surface 104 of the shoulder 100 and / or so that the upper surfaces 150, 152 are coplanar. Additionally or alternatively, the chamfer / radius 190 may help assemble the bus bar 32 with the terminal 36 prior to welding, for example, by providing a guide surface and centering the bus bar hole 80 on the terminal 36.

[0031] refer to Figures 11A-11C , the first bus bar 32 can be designed to have a clearance fit 192 ( Fig.11A )、Sliding fit 194( Fig. 11B ) or interference fit 196( Fig. 11C ). Additionally or alternatively, the tolerance of the hole 80 may include a clearance fit, a sliding fit, and an interference fit. For example, but not limited to, with the circular configuration of the first terminal 36, the tolerance of the radius of the hole 80 may be in a range of 0.1 mm greater than the radius of the first terminal 36 (e.g., a clearance fit) to 0.1 mm less than the radius of the first terminal 36 (e.g., an interference fit), the range including a sliding fit (e.g., 0.02 mm greater than the radius of the first terminal 36). This tolerance range may be achieved by the groove 82, which allows for changes in size (e.g., a radius for circular applications) after forming the first bus bar 32 and during insertion of the first terminal 36 into the hole 80. Without the groove 82, the interference fit and / or large negative tolerance of the hole 80 may not be feasible for the first terminal 36 and / or laser welding. For example, the forces associated with an interference fit without the groove 82 may damage the body 30, such as the upper surface 42.

[0032] According to some configurations, the shoulders 100, 102 can (i) provide a support surface for the bus bars 32, 34, (ii) serve as a positioning feature for vertical Z positioning of the bus bars 32, 34, (iii) facilitate holding the bus bars 32, 34 in the appropriate position (e.g., parallel to the XY plane) during welding, and (iv) prevent the laser 202 from impacting and damaging the upper surface 42.

[0033] Although various example features are described in conjunction with the first bus bar 32 or the second bus bar 34, such example features may be applied to either, both, or neither of the bus bars 32, 34, and the bus bars 32, 34 may or may not have the same configuration. Although various example features are described in conjunction with the first terminal 36 or the second terminal 38, such example features may be applied to either, both, or neither of the terminals 36, 38, and the terminals 36, 38 may or may not have the same configuration.

[0034] According to some examples, the bus bars 32 , 34 may be unthreaded and / or at least some portions of the terminals 36 , 38 disposed outside of the body 30 may be unthreaded.

[0035] refer to Fig.12, generally showing a method 300 of assembling an electrical assembly 20. The method 300 includes forming a first bus bar 32 (block 302). Forming the first bus bar (block 302) may include forming the first bus bar 32 with a hole 80, the hole 80 having a tolerance including a clearance fit, a slip fit, and an interference fit. The method 300 includes disposing the first bus bar 32 on the first terminal 36 so that the first terminal 36 is partially disposed in the hole 80 (e.g., inserting the first terminal 36 into the hole 80) (block 304). Disposing the first bus bar 32 on the first terminal 36 may include at least temporarily increasing the size of the slot 82. For example, if the size of the hole 80 is smaller than the size of the inserted portion of the first terminal 36, the first bus bar 32 may flex so that the inner surfaces 90, 92 move away from each other and increase at least one dimension of the hole 80. The method 300 includes welding (e.g., laser welding) the first bus bar 32 to the first terminal 36 (block 306). For example, the welding machine 200 can direct one or more lasers 202 to the first interface portion 162 and / or the groove 82 (see Figure 7 ). The welding (block 306) can include laser welding around the entire circumference of the first terminal 36. Additionally or alternatively, the welding (block 306) can include laser welding the first inner surface 90 to the second inner surface 92. During welding (block 306), the shoulder 100 can limit or prevent one or more lasers / laser rays from reaching the body 30, for example to limit or prevent damage to the body 30.

[0036] The method 300 may be repeated for the second bus bar 34 and the second terminal 38 , and at least some portions may be performed in parallel with the actions associated with the first bus bar 32 and the first terminal 36 .

[0037] Embodiments of the electrical assembly 20 may have lower resistance between the bus bars 32, 34 and the terminals 36, 38 than other designs, such as designs that bolt the bus bars to the terminals. Additionally or alternatively, embodiments of the electrical assembly 20 may be less complex to assemble because separate fasteners (e.g., bolts) may not be used when connecting the bus bars 32, 34 to the terminals 36, 38.

[0038] The present disclosure includes the following non-limiting examples:

[0039] 1. An electrical component, comprising: a body; an electrical terminal connected to the body; and a bus bar electrically connected to the electrical terminal, the bus bar comprising a hole and a slot, the electrical terminal being partially disposed in the hole, the slot extending from the hole to an outer edge of the bus bar.

[0040] 2. The electrical component according to any of the preceding embodiments further includes: a second electrical terminal, which is connected to the main body; and a second bus bar, which is electrically connected to the second electrical terminal; wherein the main body is a contactor body including a shell; an actuator and a contact member are arranged in the shell; and the actuator moves the contact member to contact the electrical terminal and the second electrical terminal to selectively electrically connect the bus bar to the second bus bar.

[0041] 3. The electrical assembly of any preceding embodiment, wherein the bus bar is laser welded to the electrical terminal around at least a portion of a perimeter of the aperture.

[0042] 4. The electrical assembly of any preceding embodiment, wherein the bus bar comprises a first inner surface and a second inner surface defining the slot; and the first inner surface and the second inner surface are welded together.

[0043] 5. The electrical assembly of any preceding embodiment, wherein the bus bar includes a recessed portion disposed around a perimeter of the hole; and wherein a thickness of the bus bar at the recessed portion is reduced relative to at least some other portion of the bus bar.

[0044] 6. The electrical assembly of any preceding embodiment, wherein the electrical terminal comprises a terminal recess; and the recess of the bus bar and the terminal recess together at least partially define a weld channel.

[0045] 7. The electrical assembly of any preceding embodiment, wherein a weld bead is disposed in the weld channel such that the weld bead does not extend outwardly beyond the weld channel.

[0046] 8. The electrical assembly of any preceding embodiment, wherein an upper surface of the bus bar and an upper surface of the electrical terminal are disposed at a same height above the body.

[0047] 9. The electrical assembly of any preceding embodiment, wherein an upper surface of the bus bar and an upper surface of the electrical terminal are coplanar.

[0048] 10. The electrical assembly of any preceding embodiment, wherein the electrical terminal includes a circumferential shoulder; the bus bar is partially disposed on the circumferential shoulder; and the circumferential shoulder extends radially beyond the aperture.

[0049] 11. The electrical assembly of any preceding embodiment, wherein the bus bar is secured to the electrical terminal via circumferential laser welding around the entire circumference of the electrical terminal.

[0050] 12. The electrical assembly of any preceding embodiment, wherein the circumferential shoulder is spaced apart from the body such that the bus bar is spaced apart from the body and defines a gap therebetween.

[0051] 13. The electrical assembly of any preceding embodiment, wherein the bus bar is secured to the electrical terminal via a plurality of individual and circumferentially spaced spot welds.

[0052] 14. The electrical assembly of any preceding embodiment, wherein the bus bar is interference fit on the electrical terminal.

[0053] 15. A method of assembling an electrical assembly according to any preceding embodiment, the method comprising: disposing the bus bar on the electrical terminal such that the electrical terminal is partially disposed in the hole; and laser welding the bus bar to the electrical terminal.

[0054] 16. The method of any preceding embodiment, wherein the laser welding comprises laser welding around the entire circumference of the electrical terminal.

[0055] 17. The method of any preceding embodiment, wherein the bus bar includes a first inner surface and a second inner surface defining the slot; and the laser welding includes laser welding the first inner surface to the second inner surface.

[0056] 18. The method of any preceding embodiment, wherein a circumferential shoulder of the electrical terminal prevents laser light from reaching the body during laser welding around the entire circumference of the electrical terminal.

[0057] 19. The method of any preceding embodiment, wherein positioning the bus bar on the electrical terminal includes increasing the size of the slot.

[0058] 20. The method of any preceding embodiment, further comprising forming the bus bar with the hole having a tolerance including a clearance fit and an interference fit relative to the electrical terminal.

[0059] 21. The electrical assembly of any preceding embodiment, wherein an upper surface of the bus bar and an upper surface of the electrical terminal are coplanar.

[0060] 22. The electrical assembly of any preceding embodiment, comprising a cooling member disposed adjacent the bus bar and the electrical terminals.

[0061] 23. The electrical assembly of any preceding embodiment, wherein the cooling member is disposed at the same distance from an upper surface of the bus bar and from an upper surface of the electrical terminal.

[0062] 24. An electrical component according to any of the preceding embodiments, comprising a second electrical terminal connected to the body and a second bus bar electrically connected to the second electrical terminal; wherein the second bus bar comprises a hole and a groove, the second electrical terminal is partially disposed in the hole of the second bus bar, and the groove extends from the hole to an outer edge of the second bus bar.

[0063] 25. The electrical component of any preceding embodiment, wherein the electrical component is configured as a contactor and selectively electrically connects the bus bar with the second bus bar.

[0064] 26. The electrical assembly of any preceding embodiment, wherein the aperture is circular, cylindrical, conical, or a combination thereof.

[0065] Various examples / embodiments for various devices, systems, and / or methods are described herein. Many specific details are set forth to provide a thorough understanding of the overall structure, function, manufacture, and use of the examples / embodiments described in the specification and illustrated in the accompanying drawings. However, it should be understood by those skilled in the art that the examples / embodiments can be practiced without such specific details. In other examples, well-known operations, parts, and elements are not described in detail so as not to obscure the examples / embodiments described in this specification. It should be understood by those of ordinary skill in the art that the examples / embodiments described and illustrated herein are non-limiting examples, and therefore it can be appreciated that the specific structural and functional details disclosed herein can be representative and do not necessarily limit the scope of the embodiments.

[0066] References to "examples", "in examples", "according to examples", "various embodiments", "according to embodiments", "in embodiments", "embodiments", "according to some configurations", "in some configurations", etc. throughout the specification mean that a particular feature, structure, or characteristic described in conjunction with the example / embodiment is included in at least one embodiment. Therefore, the appearance of the phrases "examples", "in examples", "according to examples", "in various embodiments", "according to embodiments", "in embodiments", "embodiments", "according to some configurations", "in some configurations", etc. throughout the specification do not necessarily refer to the same embodiment. In addition, particular features, structures, and / or characteristics may be combined in any suitable manner in one or more examples / embodiments. Therefore, the particular features, structures, or characteristics shown or described in conjunction with one embodiment / example may be combined in whole or in part with the features, structures, functions, and / or characteristics of one or more other embodiments / examples without restriction, as long as such combination is not illogical or non-functional. In addition, many modifications may be made to adapt particular situations or materials to the teachings of the present disclosure without departing from the scope of the present disclosure.

[0067] It should be understood that references to a single element are not necessarily so limited, and may include one or more of such elements unless the context clearly indicates otherwise. Any directional references (e.g., positive, negative, upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are used only for identification purposes to help the reader understand the present disclosure and do not create limitations, particularly with respect to the position, orientation, or use of the examples / embodiments.

[0068] “One or more” includes a function performed by one element, a function performed by more than one element (eg, in a distributed fashion), several functions performed by one element, several functions performed by several elements, or any combination of the foregoing.

[0069] It should also be understood that, although in some instances, the terms first, second, etc. are used to describe various elements in this article, these elements should not be limited by these terms. These terms are only used to distinguish one element from another element. For example, a first element can be called a second element, and similarly, a second element can be called a first element without departing from the scope of the various embodiments described. Both the first element and the second element are elements, but they are not the same element.

[0070] The terms used in the description of the various embodiments described herein are only used for the purpose of describing specific embodiments and are not intended to be limited. As used in the description of the various described embodiments and the appended claims, the singular forms "a", "an" and "the" are intended to also include plural forms unless the context clearly indicates otherwise. It should also be understood that the term "and / or" as used herein relates to and covers any and all possible combinations of one or more items in the associated listed items. The use of "and" and "or" should be interpreted broadly (e.g., regarded as "and / or"). For example and without limitation, the use of "and" does not necessarily require all listed elements or features, and the use of "or" is inclusive, unless such a construction is originally illogical. It should be further understood that when used in this specification, the terms "includes", "including", "comprises" and / or "comprising" specify the presence of the features, wholes, steps, operations, elements and / or parts, but do not exclude the presence or addition of one or more other features, wholes, steps, operations, elements, parts and / or groups thereof.

[0071] References to engagement (e.g., attachment, connection, connection, etc.) should be interpreted broadly and may include intermediate members between the connection of elements, relative movement between elements, direct connection, indirect connection, fixed connection, removable connection, operational connection, indirect contact and / or direct contact. Therefore, reference to engagement does not necessarily mean that two elements are directly connected / coupled and are in a fixed relationship with each other. The connection of electrical components (if any) may include mechanical connections, electrical connections, wired connections and / or wireless connections, etc. The use of "for example" and "such as" in this specification should be interpreted broadly and used to provide non-limiting examples of embodiments of the present disclosure, and the present disclosure is not limited to such examples.

[0072] Although processes, systems, and methods may be described herein in conjunction with one or more steps in a particular sequence, it should be understood that these methods may be practiced with steps in a different order, by performing certain steps simultaneously, with additional steps, and / or by omitting certain described steps.

[0073] As used herein, the term "if" is optionally interpreted to mean "when..." or "upon..." or "in response to determining..." or "in response to detecting...", as the context requires. Similarly, the phrases "if it is determined" or "if [the condition or event] is detected" are optionally interpreted to mean "upon determining..." or "in response to determining..." or "upon detecting [the condition or event]" or "in response to detecting [the condition or event]", as the context requires.

[0074] It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes may be made in detail or structure without departing from the disclosure.

Claims

1. An electrical component comprising: main body; an electrical terminal connected to the body; as well as A bus bar is electrically connected to the electrical terminal, the bus bar comprising a hole and a slot, the electrical terminal is partially disposed in the hole, and the slot extends from the hole to an outer edge 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 main body is a contactor body including a shell; 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 according to claim 1, wherein: The bus bar is laser welded to the electrical terminal around at least a portion of a perimeter of the aperture.

4. The electrical assembly according to claim 1, wherein: The bus bar includes a first inner surface and a second inner surface defining the slot; and The first inner surface and the second inner surface are welded together.

5. The electrical assembly of claim 1, wherein: The bus bar includes a recess disposed around a perimeter of the hole; and The bus bar has a reduced thickness at the recess relative to at least some other portions of the bus bar.

6. The electrical assembly according to claim 5, wherein: The electrical terminal includes a terminal recess; and The recess of the bus bar and the terminal recess together at least partially define a weld channel.

7. The electrical assembly of claim 6, wherein: A weld bead is disposed in the weld channel such that the weld bead does not extend outwardly beyond the weld channel.

8. The electrical assembly of claim 6, 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.

9. The electrical assembly of claim 6, wherein: An upper surface of the bus bar and an upper surface of the electrical terminal are coplanar.

10. The electrical assembly of claim 6, wherein: The electrical terminal includes a circumferential shoulder; The bus bar is partially disposed on the circumferential shoulder; and The circumferential shoulder extends radially beyond the bore.

11. The electrical assembly of claim 10, wherein: The bus bar is secured to the electrical terminal via circumferential laser welding around the entire circumference of the electrical terminal.

12. The electrical assembly of claim 10, wherein: The circumferential shoulder is spaced apart from the body such that the bus bar is spaced apart from the body and a gap is defined between the bus bar and the body.

13. The electrical assembly of claim 10, wherein: The bus bar is secured to the electrical terminal via a plurality of individual and circumferentially spaced spot welds.

14. The electrical assembly of claim 1, wherein: The bus bar is interference fit over the electrical terminal.

15. A method of assembling the electrical assembly of claim 1, the method comprising: disposing the bus bar on the electrical terminal such that the electrical terminal is partially disposed in the hole; as well as The bus bar is laser welded to the electrical terminal.

16. The method according to claim 15, wherein: The laser welding includes laser welding around the entire circumference of the electrical terminal.

17. The method according to claim 16, wherein: The bus bar includes a first inner surface and a second inner surface defining the slot; and The laser welding includes laser welding the first inner surface to the second inner surface.

18. The method according to claim 16, wherein: During laser welding around the entire circumference of the electrical terminal, a circumferential shoulder of the electrical terminal prevents laser light from reaching the body.

19. The method according to claim 15, wherein: Positioning the bus bar on the electrical terminal includes increasing the size of the slot.

20. The method of claim 15, further comprising forming the bus bar with the aperture having a tolerance including a clearance fit and an interference fit relative to the electrical terminal.

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