Bus bar connector

Abstract

A connector for connecting an aluminum bus bar to a printed circuit board. The connector includes a channel-shaped frame having a top wall and spaced apart side walls. A side wall of the frame is fixed to the bus bar. A contact plate is disposed inside the frame and fixed to a top wall of the frame. The contact plate has a flat body abutting the inner surface of the top wall and a plurality of annular spring fingers protruding downward therefrom. An edge portion of the printed circuit board extends through a trench in a sidewall of the frame. Inside the frame, at least one conductive pad of the printed circuit board engages the spring fingers of the contact plate to electrically connect the printed circuit board to the contact plate.

Description

Cross-references to related applications

[0001] This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 539,912, filed September 22, 2023, pursuant to 35 U.S. SC §119(e), which is incorporated herein by reference. Technical Field

[0002] This disclosure generally relates to connectors for connecting two parts together to transmit electrical signals, and more specifically to connectors for connecting busbars to printed circuit boards to transmit electrical signals. Background Technology

[0003] Busbars are commonly used to supply power to electrical and electronic components, such as printed circuit boards (PCBs). Typically, busbars are strips or plates made of conductive metals such as copper or aluminum, and are relatively wide and thick to better conduct current. Due to their composition, thickness, and configuration, busbars are difficult to connect to relatively fragile and flexible substrates, such as PCBs, especially where space is limited. This difficulty is exacerbated when busbars are made of aluminum (e.g., commonly used in electric vehicles). Aluminum oxidizes rapidly when exposed to air, adversely affecting its conductivity. This rapid oxidation of aluminum (especially when electrical connections must be made several times) complicates the electrical connection between the PCB and the aluminum busbar.

[0004] Based on the foregoing, it is desirable to have a simple and compact busbar connector that allows the aluminum busbar and printed circuit board to be connected together multiple times. Summary of the Invention

[0005] According to this disclosure, a connector for connecting an aluminum busbar to a printed circuit board is provided. The connector includes a conductive frame having a top wall with an inner surface extending between a pair of spaced-apart sidewalls, and the sidewalls having grooves formed therein. The grooves in the sidewalls engage to define a lateral channel through the frame, the lateral channel being configured to receive an edge portion of the printed circuit board therein. Each sidewall extends from the top wall and has a free end having at least one mounting structure configured to secure to the busbar to physically and electrically connect the frame to the busbar. A contact plate is disposed within the frame and secured to the top wall of the frame to electrically connect the contact plate to the frame. The contact plate has a flat (planar) body abutting the inner surface of the top wall and at least one spring finger projecting downward to be at least partially disposed in the channel to engage the printed circuit board when the printed circuit board is inserted into the channel. Attached Figure Description

[0006] The features, aspects, and advantages of the invention will become more readily understood with reference to the following description, the appended claims, and the accompanying drawings, wherein: Figure 1 A front perspective view of a connector constructed according to an embodiment of the present disclosure is shown; Figure 2 It shows Figure 1 Side view of the connector; Figure 3 It shows Figure 1 A three-dimensional view of the bottom of the connector; Figure 4 It shows Figure 1 A three-dimensional view of the bottom of the connector frame; Figure 5 It shows Figure 1 A three-dimensional view of the bottom of the connector's contact plate; Figure 6 The connection to the busbar is shown. Figure 1 A side sectional view of the connector; Figure 7 This illustrates connecting a printed circuit board to a busbar. Figure 1 Side view of the connector; Figure 8 The connection to the busbar is shown. Figure 1 A front perspective view of the connector; and Figure 9 This illustrates connecting a printed circuit board to a busbar. Figure 1 A three-dimensional sectional view of the connector. Detailed Implementation

[0007] It should be noted that in the following detailed description, the same components have the same reference numerals, regardless of whether they are shown in different embodiments of this disclosure. It should also be noted that, for the purposes of clarity and brevity, the drawings may not necessarily be drawn to scale, and certain features of this disclosure may be shown in a slightly schematic form.

[0008] Spatial relative terms such as “top,” “bottom,” “lower,” “above,” and “upper” are used herein for ease of description only to describe the relationship of one element or feature to another as shown in the accompanying drawings. It should be understood that spatial relative terms are not intended to be limiting and are intended to cover different orientations of the device in use or operation other than those depicted in the drawings.

[0009] Now for reference Figure 1-3The diagram illustrates a connector 10 constructed according to the present disclosure. The connector 10 is used to connect a busbar 12 to a printed circuit board (PCB) 14 to transmit signals (e.g., voltage signals monitored by a monitoring unit mounted or connected to the PCB 14) to the PCB 14. The connector 10 can be used in a battery pack of an electric vehicle. The connector 10 includes a housing or frame 20 and a contact plate 22.

[0010] Frame 20 can be a single or integral structure formed of aluminum alloy and can be generally channel-shaped. As will be described more fully below, frame 20 can be formed by stamping aluminum alloy strips. Frame 20 includes a top wall 24 extending between a pair of side walls 26. The opposite side of top wall 24 is connected to side walls 26 at bends 25, and side walls 26 extend from top wall 24 at approximately right angles relative to top wall 24. Each side wall 26 has a free end that can include a central tab 28 disposed between a pair of outwardly extending legs 30. The central tab 28 extends below the legs 30 and is configured for insertion into a groove 52 of busbar 12. The bottom surface of each leg 30 may have a hemispherical button 32 projecting therefrom. The button 32 can be used for welding to busbar 12. However, in some embodiments, legs 30 can be eliminated, and alternatively, the central tab 28 can be welded into the groove 52.

[0011] Each sidewall 26 of the frame 20 has a longitudinally extending groove 34 formed therein. The grooves 34 of the two sidewalls 26 cooperate to form a laterally extending channel 35 through the frame 20 for receiving the edge of the PCB 14. Each groove 34 has an enlarged portion at the front of the sidewall 26, which is formed by an inwardly sloping top edge and a bottom edge. The top edge slopes downward and inward, and the bottom edge slopes upward and inward, to provide a funnel-shaped inlet for the groove 34, which facilitates guiding the PCB 14 into the channel 35 formed by the groove 34.

[0012] Special Reference Figure 3 And now we also refer to Figure 4 The top wall 24 may have guide holes 36 for picking up and moving the frame 20. Additionally, a set of bosses or posts 40 may be formed in the top wall 24 and project downwards from the inner surface of the top wall 24. The posts 40 may be forged (form-forged) through openings 42 in the contact plate 22 to secure the contact plate 22 to the frame 20, as described more fully below.

[0013] Now for reference Figure 3 and Figure 5The contact plate 22 can be formed of a conductive metal such as copper or a copper alloy. One such copper alloy that can be used is phosphor bronze. The contact plate 22 can also be plated with another metal, such as tin, silver, gold, or nickel. The contact plate 22 has a flat (planar) body 44 with an inner edge to which a pair of spring fingers 46 are attached. The spring fingers 46 are spaced apart and can be bent to have an almost closed, irregular annular shape. More specifically, each spring arm 46 can be bent downward, then backward, and then upward, terminating at a free end that can be narrowly spaced from the body 44. Due to their annular shape, the spring fingers 46 can be elastically deflected toward the body 44.

[0014] The body 44 of the contact plate 22 may have an opening 42 extending through it. The opening 42 may be arranged in a pattern, such as the square pattern shown. The post 40 of the frame 20 may extend through the opening 42 and its end portion may deform to engage the body 44 of the contact plate 22 between the top wall 24 of the frame 20 and the deformed end portion of the post 40, thereby physically securing the contact plate 22 to the frame 20. However, in some embodiments, the contact plate 22 may alternatively be secured to the frame 20 by welding. For example, the contact plate 22 may be secured to the frame 20 using one or more lap laser welds. In addition to being physically secured to the frame 20, the contact plate 22 is also electrically connected to the frame 20.

[0015] With the contact plate 22 fixed to the frame 20 as described above, the spring finger 46 protrudes downward from the top wall 24 of the frame 20, such that the lowest part of the ring of the spring finger 46 is disposed in the channel 35 of the frame 20, as shown. Figure 2 The side view of connector 10 is shown. In this way, when PCB 14 is inserted into the channel 35 of frame 20, the PCB will engage the rings of spring fingers 46, causing them to deflect and apply a downward force to at least one conductive pad 56 of PCB 14, as shown. Figure 9 As shown.

[0016] Multiple connectors 10 can be formed in an automated manufacturing process using elongated frame strips made of aluminum alloy and elongated contact strips made of copper or copper alloy.

[0017] The frame strip moves through a first stamping station, where it is stamped to form a pair of strips, each strip including multiple nascent frames fixed at the end portions to a narrow head strip. Within each strip, the nascent frames can be fixed to the narrow head via notched connections. The nascent frames include all the features of frame 20, except that they are flat and do not include the pile 40.

[0018] The contact strip moves through a second stamping station, where it is stamped to form a pair of strip pieces, each strip piece including a plurality of nascent contact plates fixed at its end portions to a narrow head strip. In some embodiments, the contact strip may be plated on one or both sides with a tin, silver, gold, or nickel composition. In each strip piece, the nascent contact plates are fixed to the narrow head by a serrated connection. The nascent contact plates include all the features of contact plate 22, except that they are flat.

[0019] Then, the stamped frame strip and the stamped contact strip move through the station, where the stamped contact strip covers the stamped frame strip, such that the portions of the new contact plate corresponding to the main body 44 and the opening 42 forming the pattern in the contact plate 22 respectively cover the portions of the new frame corresponding to the top wall 24 and the grouped piles 40 in the frame 20. The new contact plate is then deformed using a first die to push the aluminum alloy upward through the opening 42 in the new contact plate, thereby forming the piles 40. The piles 40 in the initial frame are then deformed using a second die to fix the initial contact plates to the initial frame, thereby combining the stamped frame strip and the stamped contact strip.

[0020] The combined stamped frame strip / contact strip is then moved through one or more bending or forming stations, where a new frame is formed into frame 20 and a new contact plate is formed into contact plate 22, thereby forming a new connector strip. In a subsequent cutting station, the fully formed connector 10 is separated from the new connector strip.

[0021] It should be understood that the above manufacturing process (in particular the formation and forging of the pile 40 through the opening 42) removes sufficient alumina from the aluminum alloy of the frame strip, thereby establishing a good electrical connection between the frame 20 and the contact plate 22.

[0022] Now for reference Figure 7 The diagram shows a side view of component 50, which includes a PCB 14 physically and electrically connected to busbar 12 via connector 10. Component 50 can be formed by first securing connector 10 to busbar 12 by inserting the center tabs 28 of connector 10 into a pair of grooves 52 formed in busbar 12, as shown. Figure 8 As shown, the support 30 is then resistance-welded to the top surface of the busbar 12. In this way, the frame 20 is physically and electrically connected to the busbar 12. In an embodiment without the support 30, the center tab 28 can be simply welded into the groove 52.

[0023] The edge portion of PCB 14 is inserted into the channel 35 of frame 20, such that at least one conductive pad 56 of PCB 14 is physically and electrically engaged with the spring finger 46 of contact plate 22, thereby electrically and physically connecting PCB 14 to contact plate 22, as shown. Figure 9 As shown. Since the contact plate 22 is electrically connected to the frame 20 and the frame is electrically connected to the busbar 12, the PCB 14 is electrically connected to the busbar 12. The conductive pad 56 can take different forms. The conductive pad 56 can be part of the exposed traces of the PCB 14, which may or may not be coated with additional solder during the assembly of the PCB 14, or the conductive pad 56 can be a thin electroplated stamped part soldered to the PCB 14.

[0024] It should be understood that the foregoing description of exemplary embodiments is intended to be illustrative only and not exhaustive. Those skilled in the art will be able to make certain additions, deletions, and / or modifications to embodiments of the disclosed subject matter without departing from the spirit or scope of this disclosure.

Claims

1. A connector for connecting an aluminum busbar to a printed circuit board, the connector comprising: A conductive frame having a top wall having an inner surface extending between a pair of spaced-apart sidewalls having grooves formed therein, wherein the grooves in the sidewalls engage to define a lateral channel through the frame, the lateral channel being configured to receive an edge portion of the printed circuit board therein, and wherein each sidewall extends from the top wall and has a free end having at least one mounting structure configured for securing to the busbar to physically and electrically connect the frame to the busbar; and A contact plate, disposed inside the frame and fixed to the top wall of the frame, for electrically connecting the contact plate to the frame, the contact plate having a flat body adjacent to an inner surface of the top wall and at least one spring finger projecting downward to be at least partially disposed in the channel to engage the printed circuit board when the printed circuit board is inserted into the channel.

2. The connector according to claim 1, wherein, The frame is formed of aluminum alloy, and the contact plate is formed of a conductive metal other than aluminum or aluminum alloy.

3. The connector according to claim 2, wherein, The contact plate is made of phosphor bronze.

4. The connector according to claim 2, wherein, The body of the contact plate has at least one mounting hole formed therein, wherein the top wall of the frame has at least one post protruding downward from its inner surface, and wherein the at least one post of the frame is forged into the at least one mounting hole of the contact plate to fix the contact plate to the frame.

5. The connector according to claim 4, wherein, The at least one mounting hole includes a plurality of mounting holes, and the at least one pile includes a plurality of piles, wherein the piles are respectively forged into the mounting holes.

6. The connector according to claim 4, wherein, The at least one spring finger includes multiple spring fingers.

7. The connector according to claim 6, wherein, The contact plate is an integral structure.

8. The connector according to claim 7, wherein, The main body of the contact plate has an inner edge, the spring fingers are connected to the inner edge, and the spring fingers are spaced apart and bent into an annular shape.

9. The connector according to claim 8, wherein, Each spring arm bends downward from the inner edge of the body of the contact plate, then backward, then upward, and terminates at a free end spaced apart from the body.

10. The connector according to claim 7, wherein, The framework is an integral structure.

11. The connector according to claim 10, wherein, The at least one mounting structure on each sidewall of the frame includes a pair of outwardly extending legs having a flat bottom surface for welding to the busbar.

12. The connector according to claim 11, wherein, The free end of each sidewall also includes a tab extending downwards beyond the foot.

13. The connector according to claim 10, wherein, The groove in the sidewall has an enlarged inlet portion located at the front of the frame, the inlet portion being configured to guide an edge portion of the printed circuit board into the groove.

14. A component comprising the connector, aluminum busbar, and printed circuit board as claimed in claim 1, wherein, The busbar is electrically connected to the frame of the connector, and the printed circuit board is electrically connected to the contact plate of the connector.

15. The component of claim 14, wherein, The busbar and the printed circuit board are arranged parallel to each other.

16. The component of claim 14, wherein, The at least one mounting structure of each sidewall of the frame includes a pair of outwardly extending legs with a flat bottom surface welded to the surface of the busbar.

17. The component of claim 14, wherein, The at least one mounting structure of each sidewall of the frame includes tabs extending downward from the free end of the sidewall, respectively; The busbar has a pair of grooves formed therein; and The protrusions on the sidewalls are welded into the grooves of the busbar.

18. The component of claim 14, wherein, The printed circuit board includes at least one conductive pad connected to a circuit, the at least one conductive pad being disposed toward an edge portion of the printed circuit board, the edge portion of the printed circuit board being disposed in a channel of the connector, such that at least one spring finger presses against the at least one conductive pad to make an electrical connection thereto.

19. The component of claim 14, wherein, The at least one spring finger includes multiple spring fingers.

20. The component of claim 14, wherein, The frame is made of aluminum alloy, and the contact plate is made of phosphor bronze.

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