Busbar connection tolerance compensation, shielding and sealing

Abstract

A conductor assembly (100) includes a first electrically conductive busbar (10), a second electrically conductive busbar (10), and a flexible conductor (40) electrically connected to exposed ends of the first and second busbars (10) for establishing electrical communication therebetween.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 759,656, filed February 18, 2025, and U.S. Provisional Patent Application No. 63 / 803,147, filed May 9, 2025, the entire disclosure of which is incorporated herein by reference. Technical Field

[0003] This subject matter relates to an electrical conductor assembly, and more specifically, to an electrical conductor assembly comprising a pair of rigid conductive busbars connected via flexible conductors for improving tolerance compensation, and shielding and sealing methods used therewith. Background Technology

[0004] Within the electric vehicle (EV) space, manufacturers need systems and methods that improve performance while reducing cost and weight. One important approach to achieving this is to abandon relatively heavy stranded copper cables in favor of lightweight aluminum busbars. However, due to the rigid nature of busbars, many automakers hesitate to move towards all-busbar solutions. More specifically, using busbars as the sole or primary source of conductors within the electrical system increases tolerance requirements during manufacturing and assembly. Furthermore, solutions utilizing busbars can present additional challenges, such as ensuring adequate shielding and sealing of joints or interfaces in these systems. Summary of the Invention

[0005] A conductor assembly suitable for use with electric vehicles includes a first conductive busbar, a second conductive busbar, and a flexible conductor electrically connecting the first and second busbars. The first and second busbars include exposed ends to which the flexible conductor is electrically connected (e.g., welded). The assembly also includes an insulating component, such as a flexible polymer sleeve mounted on the flexible conductor and at least covering the exposed ends of each of the first and second busbars. Attached Figure Description

[0006] The invention will now be described by way of example with reference to the accompanying drawings, in which:

[0007] Figure 1 This is a side perspective view of a conductor assembly or charging cable according to an embodiment of the present disclosure, which is attached to an electronic component, such as a charging port of an electric vehicle.

[0008] Figure 2 This is a side perspective view illustrating a first step in a method for preparing a conductor assembly according to an embodiment of the present disclosure;

[0009] Figure 3This is a side perspective view illustrating a second step in a method for preparing a conductor assembly according to an embodiment of the present disclosure;

[0010] Figure 4 This is a side perspective view illustrating a third step in a method for preparing a conductor assembly according to an embodiment of the present disclosure;

[0011] Figure 5 This is a side perspective view illustrating the fourth step in a method for preparing a conductor assembly according to an embodiment of the present disclosure;

[0012] Figure 6 This is a side perspective view showing a partially assembled conductor assembly according to another embodiment of the present disclosure, the conductor assembly including a pair of rigid busbars joined by flexible conductive segments;

[0013] Figure 7 It shows the basis Figure 6 A side perspective view of the conductor assembly after the flexible cap or sleeve has been applied to it;

[0014] Figure 8 This shows that the flexible cap or sleeve has been secured to the wall by a pair of fasteners. Figure 6 and Figure 7 A side perspective view of the conductor assembly following the conductor assembly;

[0015] Figure 9 This is a perspective view showing a conductor assembly according to another embodiment of the present disclosure;

[0016] Figure 10 This is a perspective view of a layered copper component according to an embodiment of the present disclosure, which can be used as a flexible conductor connected to at least one busbar;

[0017] Figure 11 This is a perspective view of a multi-strand copper wire according to an embodiment of the present disclosure, which can also be used as a flexible conductor for connection to at least one busbar.

[0018] Figure 12 This is a perspective view of a completed conductor assembly according to another embodiment of the present disclosure, the conductor assembly including a shielded busbar connected to a stranded conductor;

[0019] Figure 13 yes Figure 12 Cross-sectional view of the conductor assembly;

[0020] Figure 14 yes Figure 12 and 13 stranded cables in preparation for use Figure 12 A cross-sectional view of the component in its current state;

[0021] Figure 15 yes Figure 14 A perspective view of the prepared cable;

[0022] Figure 16 yes Figure 12 and Figure 13 Rigid busbars in preparation for use Figure 12 A cross-sectional view of the component in its current state;

[0023] Figure 17 yes Figure 16 A perspective view of the prepared busbar;

[0024] Figure 18 It is a perspective view of the prepared cables and busbars arranged during the bonding or welding operation.

[0025] Figure 19 This is a description of the assembly steps, which include steps performed by... Figure 18 Apply an insulating cap or sleeve to the weld joint produced by the welding steps shown.

[0026] Figure 20 yes Figure 19 Cross-sectional view of the component;

[0027] Figure 21 It shows the assembly in Figure 19 and 20 A perspective view of the metal shielding sleeve or shell on the component;

[0028] Figure 22 yes Figure 21 Cross-sectional view of the component;

[0029] Figure 23 This is another cross-sectional view of the component in the aforementioned figure, wherein the shielding shell has been secured to the rest of the component by fasteners;

[0030] Figure 24 This is a perspective view showing the final assembly step, which includes applying heat shrinkage to the joints of the components in the aforementioned figure;

[0031] Figure 25 This is an exploded view of a conductor assembly including a shielded busbar connected to a stranded conductor, according to another embodiment of the present disclosure;

[0032] Figure 26 yes Figure 25 Cross-sectional view of the conductor assembly; and

[0033] Figure 27 This is a cross-sectional view of a conductor assembly including a shielded busbar connected to a stranded conductor, according to another embodiment of the present disclosure. Detailed Implementation

[0034] Exemplary embodiments of the present disclosure will be described in detail below with reference to the accompanying drawings, wherein like reference numerals denote like elements. However, the present disclosure may be implemented in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that the concepts of the disclosure will be conveyed to those skilled in the art. Furthermore, in the following detailed description, numerous specific details are set forth for purposes of explanation in order to provide a thorough understanding of the disclosed embodiments. However, it will be apparent, however, that one or more embodiments may also be implemented without these specific details.

[0035] Embodiments of this disclosure include systems and methods for bridging the gap between fully rigid busbar solutions and current stranded cable wiring solutions, particularly those used in automotive manufacturing. The design provides tolerance compensation that allows movement along all three axes while retaining the advantages of busbars. More specifically, the tolerance compensation solution described herein provides flexibility for a small segment of the charging harness, allowing manufacturers to assemble the harness into a vehicle without maintaining tight tolerances. Based on the length of the braided or flexible section of the harness segment, the solution has the added benefit of controlling how much tolerance is achieved along each axis.

[0036] General reference Figure 1-5 This disclosure provides an exemplary portion of a conductor assembly 100 according to embodiments of the present disclosure. Embodiments include electrical components, such as a charging port 50 of an EV. For example, the conductor assembly 100 includes a charging harness adapted to mate with the charging port 50.

[0037] Provide a pair of busbars 10, 10' (e.g., lightweight aluminum or copper busbars, see [link]). Figure 2-5 Busbar 10 is used to carry most of the current through the system or vehicle. Busbar 10 may be insulated via a sheath or insulating cover 12. Busbar 10' may be adapted to be inserted into and mate with charging port 50 (e.g., its terminals).

[0038] To improve tolerance compensation and achieve multiaxial flexibility of the originally rigid busbars 10, 10', the flexible section of assembly 100 includes a section arranged in the flexible conductor (e.g., a braided copper or aluminum cable or wire 40, such as...) Figure 2 A flexible cover 20 (shown) is provided on the assembly 100, with the flexible conductor disposed between the first and second rigid busbars 10, 10'. Attached to the end of the terminating busbar 10' near the charging port 50 is an adapter 24 configured to interface (e.g., form a snap-fit) with the housing of the charging port 50, thereby securing the assembly 100 to the charging port. A shrink wrap 22 may be provided on either end of the flexible cover 20 to seal the assembly and maintain the cover's position.

[0039] Now for specific reference Figure 2-5An exemplary process for constructing the charging plug side of the conductor assembly 100 is shown. (Reference) Figure 2 The braided flexible cable 40 can be butt-welded or ultrasonically welded to the terminating busbar 10' or busbar connector. A similar welding operation can also be performed between the flexible cable 40 and the busbar 10, such as... Figure 1 As shown (see also) Figure 6 The busbar 10' may include features (e.g., recess 11) for achieving a snap-fit ​​connection with the adapter 24.

[0040] like Figure 3 As shown, once the terminating busbar 10' is secured to the flexible cable 40, a protective flexible cover 20 is disposed thereon. Next, an adapter or plug 24 is fitted onto the busbar 10', and can be connected via the aforementioned complementary features (e.g., as...). Figure 2 The recess 11 shown, and the corresponding protrusion formed inside the plug 24, are mechanically fixed to the busbar 10'.

[0041] refer to Figure 4 A heat shrinkable element or heat shrinkable tube 22 may be applied to the ends of the flexible cover 20 and the adapter 24. This seals the arrangement, preventing moisture and debris from reaching the flexible cable 40. The use of the heat shrinkable tube 22 further helps to maintain the position of the flexible cover 20 during use, including when it is manipulated during installation into the system. In one embodiment, the heat shrinkable element or heat shrinkable tube 22 may have a conductive ink that forms a layer integrated with the heat shrinkable element 22, for example, on the surface of the heat shrinkable element 22, to provide additional shielding. While the use of the heat shrinkable element 22 is shown, it should be understood that, by way of non-limiting example only, other fastening devices, such as cable ties or clamps, may also be used depending on the sealing requirements.

[0042] Finally, as Figure 5 As shown, seal 27 can be disposed on or above adapter 24. Seal 27 is configured to form a seal with the mating plug on charging port 50 (or other electrical component). The completed assembly 100 can then be snapped into charging port 50, and busbar 10' can be bolted to internal conductive terminals (e.g., through through hole 13 shown).

[0043] Now for reference Figure 6-8 In another embodiment of this disclosure, a similar tolerance compensation component can be used anywhere along the length of the busbar 10. More specifically, these embodiments are not limited to areas immediately adjacent to electrical component formations, such as... Figure 1-5As illustrated in the embodiments. As a non-limiting example, a rigid copper or aluminum busbar according to embodiments of this disclosure can be directly attached to or connected to an electrical component (e.g., a charging port), wherein a flexible segment is attached to the end of the busbar away from the electrical component. Furthermore, it should be understood that embodiments of this disclosure are not limited to a single flexible segment or connector along a given connection or harness. Rather, any number of flexible segments can be used depending on application requirements. For example, a flexible segment can be used along the middle or center of the harness, wherein a second flexible segment is used closer to the electrical component.

[0044] For details, please refer to the following: Figure 6 A pair of busbars 10 are provided and connected together by a braided cable 40. As described above, butt welding or ultrasonic welding can be used to attach the exposed end of each busbar 10 to the braided cable 40. Similar to the foregoing embodiment, a flexible cover 20 is then fitted onto the braided cable 40, as... Figure 7 As shown. Reference Figure 8 Cable ties, wire harnesses, or other fasteners 21 can be used to secure the end of the cover 20 to each busbar 10. In other embodiments, for example, without departing from the scope of this disclosure, heat shrinkable, sealing elements, or sealing caps may be implemented to improve sealing and isolation performance.

[0045] Figure 9 Another component 150 according to an embodiment of this disclosure is shown, which utilizes a circular busbar or a solid circular cable 60. The circular busbar 60 can be butt-welded or ultrasonically welded to, for example, a braided cable 40 as described above. An insulating sleeve or protective boot 62 can then be fitted onto the resulting welded joint. Once the protective boot 62 is installed, two-piece housings 64, 65 can snap-fit ​​onto the ends of the protective boot 62, securing it in place. This arrangement is suitable for dry environments where sealing is less of a concern. Figure 9 In an exemplary embodiment, the terminated busbar 10' is shown having a fastener 66. The fastener 66 can be used to secure the busbar 10' to, for example... Figure 1 The charging port 50 shown, or more specifically, is fixed to its conductive terminals.

[0046] like Figure 10 and Figure 11 As shown, the embodiments of this disclosure are not limited to flexible braided cables. Instead, other forms of flexible conductors may be used without departing from the scope of the invention. For example, a flexible layered copper structure 44 ( Figure 10 ) or standard round cable 46 ( Figure 11 It can also be used to achieve multiaxial flexibility of conductor assemblies between rigid busbars.

[0047] While the above embodiments provide flexibility and tolerance compensation to the originally rigid busbar conductor assembly, challenges remain. In particular, the combination of these flexible and rigid conductors presents challenges in terms of electrical isolation and sealing from environmental conditions. Figure 12-27 An improved method for sealing the aforementioned busbar to the flexible conductor portion is shown.

[0048] like Figure 12 and Figure 13 As shown, an exemplary conductor assembly 200 according to an embodiment of the present disclosure includes a rigid shielded aluminum busbar 202 attached to a flexible stranded copper cable 204, wherein a heat-shrinkable member 22 surrounds the resulting joint between them. In one embodiment, as described above, the heat-shrinkable member 22 may have conductive ink, which is formed, for example, on the surface of the heat-shrinkable member 22 as an integral layer with the heat-shrinkable member 22 to provide additional shielding.

[0049] Figure 13 The cross-sectional view shows the combined busbar 202 and copper cable 204 welded together at joint 209. The resulting joint insulation assembly 201 is formed from several different components. For example, a two-piece snap-fit ​​plastic cap assembly includes a first cap half 206 and a second cap half 208, and is fitted onto the welded joint 209 to provide electrical isolation. Joint assembly 201 also includes a metal shielding sleeve 210 fitted onto the cap assemblies 206, 208. The sleeve 210 electrically contacts the shielding layer 205 of the copper cable 204 and the shielding layer 203 of the busbar 202 for electrical isolation of the joint.

[0050] Figure 14-17 The preparation steps for the busbar 202 and cable 204 before brazing the joint 209 and forming the remaining joint assembly 201 are shown. Specifically, as Figure 14 and 15 As shown, the shielding layer 205 and inner ferrule 240 of cable 204 are exposed to contact the shielding sleeve 210. The inner insulator 230 of cable 204 extends beyond the exposed shielding in a direction toward the exposed conductor end 215. Busbar 202 is prepared in a similar manner, wherein the shielding layer 203 is exposed therefrom, and its insulator 250 extends beyond it in a direction toward its exposed end 223.

[0051] refer to Figure 18-24 On the above about Figure 14-17 Having described the preparation of the busbar 202 and cable 203, the production of component 200 will now be described.

[0052] like Figure 18As shown, the exposed ends 215, 223 of the cable 204 and the busbar 202 are welded together, as described above with respect to the previous embodiments of this disclosure. Next, a connector assembly 201 is formed. Specifically, two-piece insulating covers 206, 208 snap together on the welded connector 209, as shown. Figure 19 and Figure 20 As shown. Once covers 206 and 208 are in place, the metal shielding sleeve 210 is slidable or fitted onto the assembly and positioned to contact the exposed shielding layers 205 and 203 of the cable 204 and busbar 202, as shown. Figure 21 and 22 As shown in the image. Reference Figure 23 Metal cable ties 240 can be used to secure the shielding cover or sleeve 210 into firm contact with the exposed shielding layers 203, 205. Finally, as Figure 24 As shown, the heat shrinkable element 22 can be applied to the assembly to provide further sealing and insulation benefits. Similar to other embodiments described herein, the heat shrinkable element or heat shrink tube 22 may have a conductive ink that forms a layer integrated with the heat shrinkable element 22, for example, on the surface of the heat shrinkable element 22, to provide additional shielding.

[0053] exist Figure 13 , Figure 22 and Figure 23 In one embodiment, the connector assembly 201, including the shielding sleeve 210, is shown positioned inside the heat shrinkable member 22. In another embodiment, the connector assembly 201, including the shielding sleeve 210, may be positioned outside the heat shrinkable member 22, for example, formed as a bundle shield spanning the connector.

[0054] refer to Figure 25 and 26 This illustrates another conductor assembly 300 according to an embodiment of the present disclosure. An exemplary conductor assembly 300 according to an embodiment of the present disclosure includes a rigid shielded busbar 304 (e.g., a circular busbar) attached to a flexible stranded cable 302, wherein heat-shrinkable elements 22 surround the resulting joint between them (see [link to documentation]). Figure 26 Cable 302 includes an exposed shielding layer 303 and a collar 320 adapted to be mounted on the exposed shielding layer. Similarly, busbar 304 includes an exposed shielding layer 305 and also has a collar 322 mounted thereon and adapted to be arranged on the exposed shielding layer.

[0055] Figure 25An exploded or disassembled view shows the combined busbar 304 and cable 302 welded together at joint 309. The resulting joint insulation assembly 301 is formed from several different components. For example, a two-piece snap-fit ​​plastic housing assembly includes a first isolation housing half 306 and a second isolation housing half 308, and is fitted onto the welded joint 309 to provide electrical isolation. The isolation housing halves 306, 308 are selectively joined together via complementary latches and catches 307, 309 formed thereon.

[0056] The connector assembly 301 also includes a two-part metal shielding sleeve, each comprising a pair of shielding halves 310, 312 adapted to be fitted onto cover assemblies 306, 308. Each shielding half 310, 312 includes a locking feature 330 for engaging a complementary locking feature 340 formed on the first isolation housing half 306 and the second isolation housing half 308. Crimping ends 311, 313 are formed on each end of the shielding halves 310, 312 and are adapted to... Figure 26 In the assembled state, the component 300 shown is pressed onto or onto the shielding layers 303 and 305 via the corresponding rings in rings 320 and 322.

[0057] Still referencing Figure 25 and Figure 26 This document provides a brief description of the process for manufacturing component 300. As shown, with cable 302 and busbar 304 welded together, insulating halves 306 and 308 are fitted onto them to define an isolation housing surrounding connector 309. Notably, the isolation housings 306 and 308 are arranged over the insulation layer 302' of cable 302 and the insulation layer 304' of cable 302 and busbar 304, respectively. Next, shielding halves 310 and 312 are fitted (e.g., snap-fit) onto the isolation housings 306 and 308. The crimped ends 311 and 312 of each half 301 and 312 are arranged to contact the exposed shielding layers 303 and 305. Then, ferrules 320 and 322 move over the crimped ends 311 and 312, after which they are mechanically crimped radially inward to ensure a reliable electrical connection between the shielding layers 303 and 305 of cable 302 and busbar 304 and the shielding housings 306 and 308. Finally, the heat shrinkable element 22 can be positioned on the connector 309 and secured in place by selectively applying heat to it. As with other embodiments described herein, the heat shrinkable element or heat shrink tube 22 can have conductive ink that forms a layer integrated with the heat shrinkable element 22, for example, on the surface of the heat shrinkable element 22, to provide additional shielding.

[0058] Now for reference Figure 27This illustration shows another conductor assembly 400 according to an embodiment of the present disclosure. As in the previous embodiments, a flexible conductor 402 (e.g., a cable) is coupled to a busbar 404 at a connector 409. Isolation housings 406, 408 (e.g., two-part polymer housings) are arranged over the connector 409. Shielding elements 410, 412 (e.g., two-part metal housings) are fitted onto the isolation housings, their ends positioned to contact or be disposed thereon with respect to the exposed portions of the shielding layers of each of the cables 302 and the busbar 304, as detailed above with respect to the previous embodiments of the present disclosure. Loops 420, 422 may be arranged on the ends of the shielding elements 410, 412 for securing the shielding elements in electrical contact with the shielding layers.

[0059] Unlike other embodiments of this disclosure, Figure 27 The embodiment includes an external sealing assembly 500, which includes a body 502, a pair of end caps 504, 506, a pair of seals 508, 510, and a spacer element 512. Specifically, the body 502 (e.g., a polymer body) can be mounted on the aforementioned connector assembly, and specifically on the shields 410, 412. The body 502 can consist of two parts snap-fitted onto the shield, or it can be a single hollow element that slides on the shield. With the body 502 in place over the connector 409, the seal 508 can be inserted into or slid into one end thereto. As shown, the seal 508 is mounted on the inner insulation layer of the cable 402 to form a seal thereto. The outer surface of the seal 508 sealably contacts the inner surface of the body 502. The seal 508 is axially held or positioned via inwardly projecting stops or walls of the body 502, as shown. Once positioned as shown, the end cap 504 is assembled (e.g., snap-fit) onto the body 502. This secures the seal 508, ensuring a reliable seal and isolation of the joint from the external environment.

[0060] Similarly, on the busbar side of the assembly, with the body 502 in place, a spacer element 512 can be inserted into the body 502. The spacer element can define an annular hollow space adapted to receive the collar 422 when it is axially positioned over the busbar 404. Once the spacer element 512 is in place, a seal 510 can be inserted or slid into the other end of the body 502. The seal 510 is fitted onto the insulation layer of the busbar 404 to form a seal therewith. The outer surface of the seal 510 sealably contacts the inner surface of the body 502. The seal 510 is axially held or positioned via the spacer element 512, as shown. It should be understood that the use of the spacer element 512 (unlike integrally inwardly extending stops on cable ends) allows the body 502 to be formed from a single piece that can slide onto the connector. Once positioned as shown, the end cap 506 is fitted (e.g., snap-fit) onto the body 502. This fixes the position of seal 510, ensuring a reliable seal and isolation between the joint and the external environment.

[0061] The foregoing description illustrates some possibilities for practicing the invention. Many other embodiments are possible within the scope and spirit of the invention. Therefore, the foregoing description is intended to be illustrative rather than restrictive, and the scope of the invention is given by the appended claims and their full scope.

Claims

1. A conductor assembly (100), comprising: First conductive busbar (10); Second conductive busbar (10); and A flexible conductor (40) is electrically connected to the exposed ends of the first busbar (10) and the second busbar (10) for establishing an electrical connection between them.

2. The conductor assembly (100) according to claim 1 further includes an electrically insulating flexible sleeve (20) mounted on the flexible conductor (40) and covering the exposed end portions of each of the first busbar and the second busbar.

3. The conductor assembly (100) of claim 2, wherein each of the busbars (10) includes an insulating material (12) covering the busbar between exposed end portions of the busbar, wherein the flexible sleeve (20) overlaps the insulating material at the end of each of the busbars.

4. The conductor assembly (100) according to claim 3 further includes a plurality of fasteners (21), each fastener (21) securing the insulating flexible sleeve (20) near one of the covered end portions of each of the first busbar (10) and the second busbar (10).

5. The conductor assembly (100) according to claim 2 further includes a heat shrinkable element (22) arranged around each end of the flexible sleeve (20) and covering at least a portion of the insulating material (12) arranged around the first busbar (10).

6. The conductor assembly (100) according to claim 5 further includes a charging port (50) for an electric vehicle, wherein the second busbar (10) is adapted to selectively engage with a terminal of the charging port (50).

7. The conductor assembly (100) according to claim 6, further comprising: A plug (24) is fitted onto a portion of the second busbar (10) and a portion of the flexible conductor (40), and the plug (24) is adapted to be fitted onto the charging port (50). and A seal (27) is mounted on the plug (24) and adapted to form a seal with the charging port (50) of the electric vehicle, wherein the heat shrinkable element (22) is fitted on the end of the flexible sleeve (20) adjacent to the second busbar (10) and is at least partially fitted on the plug (24).

8. The conductor assembly (100) of claim 1, wherein the flexible conductor (40) comprises a braided cable, a layered copper element, or a multi-strand wire.

9. The conductor assembly (100) according to claim 1, wherein the first busbar (10) and the second busbar (10) are electrically connected to the flexible conductor (40) via one of ultrasonic welding or butt welding.

10. The conductor assembly (100) according to claim 1, wherein each of the first busbar (10) and the second busbar (10) is formed of aluminum, and the flexible conductor (40) is formed of copper.

11. A conductor assembly (200, 300, 400), comprising: A flexible conductor (204, 302, 402), the flexible conductor comprising a conductive core and a metal shielding layer (205, 303), the metal shielding layer being at least partially exposed on the exterior of the flexible conductor; A first rigid busbar (202, 304, 404) includes a conductive aluminum core and a metal shielding layer (203, 305) at least partially exposed on the outside of the busbar. The exposed ends of the flexible conductors (204, 302, 402) and the exposed ends of the busbars (202, 304, 404) are electrically connected at connectors (209, 309, 409). The first insulating assembly (201, 301, 500) is assembled on the connector (209, 309, 409).

12. The conductor assembly (200, 300, 400) according to claim 11, wherein the first insulating assembly (201, 301, 500) includes an electrically insulating housing (206, 208, 306, 308, 406, 408) disposed on the connector (209, 309, 409).

13. The conductor assembly (200, 300, 400) according to claim 12, wherein the electrical isolation housing (206, 208, 306, 308, 406, 408) comprises a two-piece housing adapted to snap onto the connector (209, 309, 409).

14. The conductor assembly (200, 300, 400) of claim 13, wherein the first insulating assembly (201, 301, 500) further comprises a metal shielding sleeve (210, 310, 312) disposed on the housing and electrically contacting the exposed metal shielding layer of each of the first busbar (202, 304, 404) and the flexible conductor (204, 302, 402).

15. The conductor assembly (200, 300, 400) according to claim 14, wherein the first insulation assembly further comprises a plurality of fasteners (21), each fastener securing the shielding sleeve (210, 310, 312) to a corresponding one of the metal shielding layers of the first busbar (202, 304, 404) and the flexible conductor (204, 302, 402).

16. The conductor assembly (200, 300, 400) of claim 15, wherein the first insulation assembly further comprises a heat-shrinkable element (22) applied to the shielding sleeve (210, 310, 312), the heat-shrinkable element (22) extending to and disposed on the insulation material of each of the first busbar (202, 304, 404) and the flexible conductor (204, 302, 402).

17. The conductor assembly (200, 300, 400) of claim 11 further includes a second rigid busbar (202, 304, 404) electrically connected to the other end of the flexible conductor (204, 302, 402) via a second insulating component in the insulating assembly (201, 301, 500).

18. The conductor assembly (200, 300, 400) according to claim 11, wherein the flexible conductor (204, 302, 402) comprises stranded copper cable.

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