Multi-core rigid busbars for power distribution

Abstract

Aspects of the present disclosure relate to a multi-core rigid busbar (100) including a plurality of rigid conductors (206) and an insulator (202) surrounding the plurality of rigid conductors. Each conductor of the plurality of rigid conductors can carry electrical current between electrical components, such as between a load end and a source end. In certain embodiments, each end of the multi-core rigid busbar can be plugged directly into an electrical terminal of an electrical component without the use of a connector.

Description

[Technical field]

[0001] [CROSS REFERENCE TO RELATED APPLICATIONS] This application claims the benefit of priority to U.S. Provisional Application No. 63 / 311,778, entitled "Connectorless Multicore Rigid Busbar For Electric Power Distribution," filed February 18, 2022, the disclosure of which is incorporated by reference herein in its entirety and for all purposes.

[0002] The techniques of this disclosure relate to power distribution. [Background technology]

[0003] Vehicle power distribution systems may utilize harnesses that include flexible braided cables, with or without connectors, to carry electrical current. The connectors typically include a housing that positions electrical terminals connected to the ends of the cables. The connections between the terminals and the cables are electrical joints, typically formed by bolts, welds, crimps, or any suitable electrical connection. These cables may distribute power between electrical components of the vehicle. These cable assemblies (harnesses) are typically flexible and typically require components such as brackets, fasteners, or housing units for in-vehicle routing and mounting. As the need for vehicle power distribution paths increases, using flexible braided cables with connectors may present technical challenges. Summary of the Invention

[0004] Each of the innovations recited in the claims has several aspects, no single aspect of which is solely responsible for its desirable attributes. Without limiting the scope of the claims, some prominent features of the disclosure will now be discussed briefly.

[0005] One aspect of the present disclosure is a multi-core rigid busbar that includes a plurality of rigid conductors configured to carry electrical current between components and an insulator surrounding the plurality of rigid conductors.

[0006] In a multi-conductor rigid busbar, an end of at least one of the rigid conductors may be configured for direct connection to an electrical terminal.

[0007] In a multi-core rigid busbar, the rigid conductors may include at least one of aluminum or copper.

[0008] In a multi-core rigid busbar, the insulation may include at least one of Cross-Linked PolyEthylene (XLPE), PolyVinyl Chloride (PVC), nylon, silicone, a thermoplastic, or a thermoset plastic.

[0009] In a multi-conductor rigid busbar, the rigid conductors at the source end can be directly connectable to a battery pack, and at least one of the rigid conductors can also be directly connectable to an electrical terminal on a printed circuit board assembly.

[0010] In a multi-core rigid busbar, the multi-core rigid busbar may include a shielding layer surrounding the insulation. The shielding layer may be electrically conductive.

[0011] In a multi-core rigid busbar, the multi-core rigid busbar can be bent to fit within the vehicle's interior packaging and extend between the vehicle battery pack and one or more electrical components.

[0012] In a multi-core rigid busbar, the multi-core rigid busbar can be shaped to fit within the vehicle interior packaging and extend between multiple electrical components.

[0013] In a multi-core rigid busbar, the multi-core rigid busbar may include grooves located between the rigid conductors of the plurality of rigid conductors.

[0014] In the multi-core rigid busbar, the multi-core rigid busbar may include a locking hole in a body of the multi-core rigid busbar. The locking hole may be configured to receive a locking piece.

[0015] In a multi-core rigid busbar, the multi-core rigid busbar may be bent symmetrically, and the ends of the conductors may have substantially the same length from the cut.

[0016] The vehicle may include a multi-core rigid busbar.

[0017] Another aspect of the present disclosure is an electrical connection system including a plurality of rigid conductors within a single outer sheath and an insulating layer surrounding the plurality of rigid conductors. The plurality of rigid conductors are configured to carry electrical current from at least a source to a load. At least one of the plurality of rigid conductors is configured to connect directly to an electrical terminal.

[0018] In an electrical connection system, the system may also include a shielding layer around the insulating layer.

[0019] In the electrical connection system, at least one of the plurality of rigid conductors is configured for direct connection to an electrical terminal.

[0020] For purposes of summarizing the disclosure, certain aspects, advantages, and novel features of the innovation are described herein. It is to be understood that not all such advantages may necessarily be achieved in accordance with any particular embodiment. Thus, the innovation may be embodied or implemented to achieve or optimize one advantage or group of advantages as taught herein, without necessarily achieving other advantages as may be taught or suggested herein. [Brief description of the drawings]

[0021] Embodiments of the present disclosure will now be described, by way of non-limiting examples, with reference to the accompanying drawings, in which:

[0022] [Figure 1A] FIG. 1 depicts a connectorless multi-core rigid busbar.

[0023] [Figure 1B] 1A-1C depict examples of braided harness assemblies including various connectors.

[0024] [Figure 2A] FIG. 2 depicts one end of a connectorless multi-core rigid busbar.

[0025] [Figure 2B] 1A-1D depict cross-sectional views of various embodiments of a connectorless multi-core rigid busbar. [Figure 2C] 1A-1D depict cross-sectional views of various embodiments of a connectorless multi-core rigid busbar. [Figure 2D] 1A-1D depict cross-sectional views of various embodiments of a connectorless multi-core rigid busbar.

[0026] [Figure 2E] FIG. 1 depicts an embodiment of a connectorless multi-core rigid busbar having a rectangular shape. [Figure 2F] FIG. 1 depicts an embodiment of a connectorless multi-core rigid busbar having a rectangular shape.

[0027] [Figure 3A] FIG. 1 depicts one end of a connectorless multi-core rigid busbar having grooves and additional components that interface with the grooves to provide creepage and gap insulation from high voltage. [Figure 3B] FIG. 1 depicts one end of a connectorless multi-core rigid busbar having grooves and additional components that interface with the grooves to provide creepage and gap insulation from high voltage.

[0028] [Figure 4A]FIG. 1 depicts one end of a connectorless, multi-core, rigid busbar that is plugged into a Printed Circuit Board Assembly (PCBA).

[0029] [Figure 4B] FIG. 4B is a diagram depicting one side of the PCBA of FIG. 4A.

[0030] [Figure 4C] FIG. 4C depicts the other side of the PCBA of FIG. 4B.

[0031] [Figure 4D] FIG. 1 depicts one end of a connectorless multi-core rigid busbar after it has been inserted into a PCBA.

[0032] [Figure 4E] FIG. 1 depicts an exemplary assembly of a connectorless multi-core rigid busbar and PCBA.

[0033] [Figure 4F] FIG. 4F depicts the connectorless multi-core rigid busbar and PCBA of FIG. 4E after assembly.

[0034] [Figure 4G] FIG. 1 depicts an example assembly of a connectorless multi-core rigid busbar and header assembly.

[0035] [Figure 4H] FIG. 4F depicts the connectorless multi-core rigid bus bar and header assembly of FIG. 4E after assembly.

[0036] [Figure 5A] FIG. 1 illustrates a rectangular shaped connectorless multi-core rigid busbar with grooves on the ends to provide electrical insulation, the connectorless multi-core rigid busbar being bent to meet vehicle packaging specifications.

[0037] [Figure 5B] FIG. 5B depicts one end of the rectangular connectorless multi-conductor rigid busbar of FIG. 5A with grooves added for mating with additional components to increase the electrical insulation distance between the conductors.

[0038] [Figure 6A] 1 illustrates a rectangular connectorless multi-core rigid busbar with locking holes to position the busbar and prevent fretting of the electrical contacts.

[0039] [Figure 6B] 1 illustrates a rectangular connectorless multi-core rigid busbar with locking holes to position the busbar and prevent fretting of electrical contacts, an enclosure assembly, and a vehicle assembly.

[0040] [Figure 6C] 1 illustrates a rectangular connectorless multi-core rigid busbar with locking holes to position the busbar and prevent fretting of the electrical contacts, and an enclosure assembly.

[0041] [Figure 6D] 1 illustrates a rectangular connectorless multi-core rigid busbar assembled with an enclosure assembly and a printed circuit board assembly (PCBA).

[0042] [Figure 6E] 1 illustrates an exemplary embodiment of a connectorless multi-core rigid busbar assembled with a printed circuit board assembly (PCBA).

[0043] [Figure 7A] FIG. 1 depicts a bent rectangular connectorless multi-core rigid busbar with non-uniform rigid conductors at the load end, the connectorless multi-core rigid busbar being bent to meet vehicle packaging specifications. [Figure 7B]FIG. 1 depicts a bent rectangular connectorless multi-core rigid busbar with non-uniform rigid conductors at the load end, the connectorless multi-core rigid busbar being bent to meet vehicle packaging specifications.

[0044] [Figure 7C] FIG. 1 depicts a symmetrically bent rectangular connectorless multi-core rigid busbar.

[0045] 8-15 illustrate exemplary cross-sectional schematics of connectorless multi-core rigid busbar embodiments including various conductor sizes, cross-sectional shapes, patterns, and materials.

[0046] [Figure 8] FIG. 1 illustrates a cross-sectional view of a connectorless multi-core rigid busbar with hollow portions within the conductors according to one embodiment.

[0047] [Figure 9] FIG. 1 illustrates a cross-sectional view of a connectorless multi-core rigid busbar with conductors and grooves between the conductors at the end portions according to one embodiment.

[0048] [Figure 10] FIG. 1 illustrates a cross-sectional view of a connectorless multi-core rigid busbar with conductors but no grooves for one embodiment.

[0049] [Figure 11] FIG. 1 illustrates a cross-sectional view of a connectorless multi-core rigid busbar with hollow portions but no grooves in the conductors according to one embodiment.

[0050] [Figure 12] FIG. 1 illustrates a cross-sectional view of a connectorless multi-core rigid busbar including two conductors according to one embodiment.

[0051] [Figure 13] FIG. 1 illustrates a cross-sectional view of a connectorless multi-core rigid busbar including conductors having different sizes, according to one embodiment.

[0052] [Figure 14] FIG. 1 illustrates a cross-sectional view of a connectorless multi-core rigid busbar with hollow portions in two conductors according to one embodiment.

[0053] [Figure 15] FIG. 1 illustrates a cross-sectional view of a connectorless multi-core rigid busbar with another conductor arrangement according to one embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0054] The following detailed description of certain embodiments presents various descriptions of specific embodiments. However, the innovations described herein can be embodied in many different ways, for example, as defined and covered by the claims. This description is made with reference to the drawings, where reference numbers may indicate identical or functionally similar elements. It should be understood that the elements illustrated in the figures are not necessarily drawn to scale. Furthermore, it should be understood that certain embodiments can include more elements and / or a subset of the illustrated elements than are illustrated in the drawings. Furthermore, some embodiments can incorporate any suitable combination of two or more features.

[0055] As previously discussed, flexible braided cables for distributing electricity between electrical components can face technical challenges. More specifically, as the demand for the number and power specifications of electrical components in an electrical component package having the same or smaller form factor increases, an effective power distribution system capable of distributing power to electrical components at various power specifications is desired. For example, in a vehicle power distribution system responsible for distributing power between electrical components within a vehicle, the distribution of electricity can face technical challenges as the demand for vehicle electrical components and power specifications increases.

[0056] As vehicle technology advances, more electrical components and electrical paths are included in the vehicle. These electrical paths are typically power distribution paths from a battery pack to each electrical component. For example, one or more electrical components can be connected to a battery pack through a flexible harness including multiple cables, and the battery pack distributes power through the cables. Therefore, a more flexible braided cable is desirable to connect each electrical component. However, the assembly process of the flexible braided cable may involve relatively high assembly costs and vehicle packaging constraints. Typically, assembling a flexible harness involves assembling components such as multiple brackets, fastening materials, cables, connectors, clips, tapes, connector seals, and housings. The manufacture of the cable may also be process intensive and expensive. Therefore, assembling the harness into the vehicle power distribution system may not be cost-effective. Furthermore, since a relatively large number of flexible braided cables may be installed in the vehicle to interconnect electrical components, it may be difficult to package the flexible braided cable in the vehicle. Therefore, assembling the flexible braided cable may cause electric vehicle packaging constraints.

[0057] The disclosed embodiments relate to connectorless multi-core rigid busbars for power distribution systems. The connectorless multi-core rigid busbars can distribute power between a power source and one or more electrical components without the use of connectors. The connectorless multi-core rigid busbars disclosed herein can be plugged directly into an electrical socket or electrical joint without the use of connectors. The conductor cores of such busbars can function as both a path for carrying electrical current and an end electrical terminal of the busbar. For example, the conductor cores can be connected between components to carry electrical current, with each end of the conductor core being directly connected to an electrical terminal of an individual component. The connectorless multi-core rigid busbars can include multiple rigid conductors within a single outer sheath or part. Such an outer sheath or part can provide a protective cover or casing for the multiple rigid conductors.

[0058] The connectorless multi-core rigid busbar can distribute power within a vehicle, such as an electric vehicle. In some embodiments, for example, the connectorless multi-core rigid busbar can electrically connect a battery pack of a vehicle to an electrical component within the vehicle. The connectorless multi-core rigid busbar can carry relatively low or relatively high power in certain applications. The connectorless multi-core rigid busbar can include shielding. The connectorless multi-core rigid busbar can transmit relatively high or relatively low power from a source to a load. The source can include any suitable power source that provides power to one or more electrical components within the vehicle, such as a battery pack or an Alternating Current (AC) generator. In some embodiments, the connectorless multi-core rigid busbar distributes power from a battery pack to one or more electrical components within the vehicle. For example, the connectorless multi-core rigid busbar can distribute power from a battery pack to one or more of a vehicle's Power Conversion System (PCS), drive units, Heating Ventilation and Air Conditions (HVAC) system, battery management system, on-board computer, etc. In some such applications, the connectorless multi-core rigid busbar may extend from the battery pack to the front and / or rear drive units. In one embodiment, the battery pack, PCS, and drive units are connected through the connectorless multi-core rigid busbar. In some embodiments, the connectorless multi-core rigid busbar distributes AC power, Direct Current (DC) power, and / or a combination of AC and DC power. In such embodiments, the connectorless multi-core rigid busbar can replace a conventional wire harness assembly in one or more of the battery pack and / or harness assemblies in a DC heat pump compressor, AC charging, or AC outlet harness. The connectorless multi-core rigid busbar can support low voltage, high voltage, low current, high current, or any suitable combination thereof.

[0059] Compared to a conventional flexible braided harness, the connectorless multi-core rigid busbar disclosed herein can increase system capacity by at least an order of magnitude within the same package volume. For example, the connectorless multi-core rigid busbar utilizes solid conductors as the electrical path. However, the conventional flexible braided harness utilizes a stranded cable (e.g., formed by braided stranded wires) as the electrical path. The overall diameter of the conductors in the connectorless multi-core rigid busbar can be smaller than the overall diameter of the stranded cable distributing the power. Thus, when distributing the same amount of power, the connectorless multi-core rigid busbar can provide a smaller form factor than the flexible braided harness. For example, the connectorless multi-core rigid busbar has a solid cross-sectional area of ​​the conductors, which corresponds to the overall diameter of the connectorless multi-core rigid busbar. However, the overall diameter of the conventional flexible braided harness includes the overall diameter of each wire in the stranded cable. In a stranded cable, the braided wires have air gaps between each other. In addition, the conductors of the connectorless multi-core rigid busbar include a single layer of insulation covering the outer area of ​​the conductor, while each cable of the conventional flexible braided harness includes a layer of insulation covering the outer area of ​​each cable. Thus, a stranded cable may include multiple layers of insulation between adjacent cables. Thus, the cross-sectional area of ​​the conductors in the connectorless multi-core rigid busbar (e.g., the overall diameter of the connectorless multi-core rigid busbar) can be larger than the cross-sectional area of ​​the conductors (e.g., the conductors included in each cable) in the conventional flexible braided harness of the same volume. Thus, the connectorless multi-core rigid busbar can transmit higher power than the conventional flexible braided harness of the same overall diameter.

[0060] The rigid conductors in the connectorless multi-core rigid busbar can provide multiple electrical paths to replace multiple conventional flexible braided cables. The rigid conductors in the connectorless multi-core rigid busbar can provide electrical connections between components without using connectors at both ends of the connectorless multi-core rigid busbar. For example, the connectorless multi-core rigid busbar may connect a battery pack to an electrical component. One end of the conductors of the connectorless multi-core rigid busbar can be directly connected to the terminals of the battery, and the other end of the conductors can be directly connected to the electrical component. Thus, the number of electrical joints with the connectorless multi-core rigid busbar can be reduced compared to a conventional flexible braided cable with connectors at both ends of the cable.

[0061] The rigid conductors in a connectorless multi-core rigid busbar can be a solid conductor cross-section, whereas a conventional braided cable is made up of many stranded wires. The rigid conductors in a connectorless multi-core rigid busbar are the electrical pathway. For example, a connectorless multi-core rigid busbar may distribute power from a battery pack to two or more electrical components in a vehicle, such as an electric vehicle.

[0062] The connectorless multi-core rigid busbar disclosed herein can reduce the number of electrical joints and electrical connection components, such as terminals, typically found in flexible braided cable systems. The conductors of the connectorless multi-core rigid busbar can advantageously form an end-to-end connection with a current distribution path and a mating electrical joint, whereas conventional cables typically require additional terminals to be spliced ​​to the ends to form the mating connection. In certain applications, one or more end conductors of the connectorless multi-core rigid busbar can be plated based on the electrical joint specifications. According to some other applications, one or more end conductors of the connectorless multi-core rigid busbar are not plated based on the electrical joint specifications. In addition, because the conductors in the connectorless multi-core rigid busbar are rigid (e.g., solid conductors), they are geometrically similar to pins that can be crimped onto a stranded flexible cable to form a rigid surface for electrical connection. Thus, this crimp connection can be eliminated in the connectorless multi-core rigid busbar. Thus, the number of electrical joints can be reduced by using the rigid busbar as the electrical interface itself.

[0063] The connectorless multi-core rigid busbar disclosed herein may reduce the number of seals. If sealing is desired, a single seal may be bonded to the outside of the insulation or shielding layer of the connectorless multi-core rigid busbar. Advantageously, reducing the number of seals may make the connectorless multi-core rigid busbar more cost-effective and / or more reliable. In conventional connectors, each individual cable has a wire seal that terminates or passes through the connector interface. Thus, such conventional connectors seal the connector housing and also include a seal for the interface between the plug and the header. Conventional connectors also typically include a seal for the interface between the connector plug and the header.

[0064] Assembling a connectorless multi-core rigid busbar can be cost-effective. This can be due to the elimination of end connector assemblies often used in conventional connectors, including electrical terminals, locking elements, seals, and housings. The connectorless multi-core rigid busbar can be directly connected to an electrical interface. For example, the rigid conductors at the ends of the connectorless multi-core rigid busbar can be directly connected to a printed circuit board assembly (PCBA) of an electrical component. Thus, the connectorless multi-core rigid busbar can be implemented without any connector assembly. Thus, a power distribution system including the connectorless multi-core rigid busbar can be assembled without processing steps for assembling a connector unit.

[0065] Traditional cable manufacturing is labor intensive, adding high processing costs and low tolerances compared to typical machine operations. Cable processing, electrical terminal connections, and connector assemblies also have many parts, processing steps, and expensive equipment. Furthermore, additional brackets and fastening materials are added to flexible cable assemblies to bundle cables together or provide rigidity and mounting points to fit in-vehicle packaging.

[0066] The connectorless multi-core rigid busbar can provide rigidity to fit into vehicle packaging. The connectorless multi-core rigid busbar can include a solid conductive metal such as aluminum or copper. Additionally, the connectorless multi-core rigid busbar can be shaped by bending the busbar and assembling it over or near an opening in the vehicle.

[0067] In some embodiments, the connectorless multi-core rigid busbar comprises a plurality of rigid conductors and electrical insulators. In these embodiments, the electrical insulators surround each of the rigid conductors. The material for the rigid conductors can include any suitable conductive material, such as aluminum, copper, bronze, brass, gold, silver, or the like, or any suitable combinations or alloys thereof. The material of the electrical insulators can include any suitable insulating material, such as cross-linked polyethylene (XLPE), polyvinyl chloride (PVC), silicone, or plastic.

[0068] In embodiments disclosed herein, power is distributed through a connectorless multi-core rigid busbar. Rigid conductors in the connectorless multi-core rigid busbar distribute the power. During power distribution, one end of the rigid conductor can be connected to a power source, such as a battery pack. The other end of the rigid conductor can be connected to a load, such as an electrical component of a vehicle.

[0069] In some embodiments, a connectorless multi-core rigid busbar distributes power from a source, such as a battery pack, to multiple loads, such as electrical components in a vehicle. The connectorless multi-core rigid busbar can extend from the source to one or more loads. In these embodiments, pairs of rigid conductors at one end of the connectorless multi-core rigid busbar are connected to corresponding terminals, such as mating electrical joints in a battery pack. Each pair of rigid conductors at the other end of the connectorless multi-core rigid busbar can be connected to an electrical component. For example, the connectorless multi-core rigid busbar can include three pairs of rigid conductors (six rigid conductors). One end of the three pairs of rigid conductors can be connected to a battery pack with three electrical plugs. Each pair of rigid conductors at the other end of the rigid conductors can be connected to one of a drive unit, a heat pump, and a PCS unit. Thus, a connectorless multi-core rigid busbar with six rigid conductors can distribute power to three electrical components.

[0070] In some embodiments, the connectorless multi-core rigid busbar can electrically connect multiple electrical components. In these embodiments, the connectorless multi-core rigid busbar includes multiple pairs of rigid conductors. A pair of rigid conductors at one end of the connectorless multi-core rigid busbar can be connected to an electrical component. The other end of the pair of rigid conductors can be connected to another electrical component. For example, the connectorless multi-core rigid busbar has two pairs of rigid conductors. A first pair of rigid conductors can connect an ECU and a drive unit. A second pair of rigid conductors can connect a brake system and a battery. Thus, a single connectorless multi-core rigid busbar can electrically connect four electrical components.

[0071] The rigid conductors of the connectorless multi-core rigid busbar may be surrounded by a shielding layer. The shielding layer provides ElectroMagnetic Interference (EMI) shielding and protection from damage. The shielding layer may be flexible or rigid. The shielding layer may be made of any suitable EMI shielding material, such as aluminum, conductive plastic, carbon fiber, stainless steel fiber, etc. In some embodiments, the shielding layer may be grounded to the vehicle's Body In White (BIW). This may provide detection of insulation loss in the case of a high voltage short circuit. The connectorless multi-core rigid busbar may include a shielding layer. Some connectorless multi-core rigid busbars, such as those internal to a battery pack, may be implemented without a shielding layer.

[0072] In some embodiments, the ends of the connectorless multi-core rigid busbar include a groove. Any suitable insulating material can mate with the groove to provide creepage and gap insulation from high voltage between the rigid conductors in the rigid multi-core busbar. For example, an insulating plastic can be used to make a groove cover. The groove cover can mate with (or fit into) the groove. The groove can contribute to insulation from high voltage. The groove cover can provide an opening that mates with the groove cover to provide creepage and gap insulation from high voltage.

[0073] In some embodiments, the connectorless multi-core rigid busbar includes an enclosing assembly. The enclosing assembly may include a locking mechanism. For example, the connectorless multi-core rigid busbar may include one or more locking holes on the enclosing assembly (e.g., a body of the connectorless multi-core rigid busbar). The one or more locking holes on the enclosing assembly may mate with the locking mechanism. For example, a locking piece may be inserted into the locking hole to hold the connectorless multi-core rigid busbar in the vehicle. The locking piece may prevent movement and fretting of the electrical contacts. The electrical contacts may be exposed ends of the connectorless multi-core rigid busbar. In some embodiments, other methods may be utilized to prevent movement and fretting of the electrical contacts, such as using a larger (e.g., oversized) bracket to hold the connectorless multi-core rigid busbar.

[0074] The body of the connectorless multi-core rigid busbar can be bent symmetrically. Symmetric bending techniques can stretch and shift the rigid conductors by a uniform amount. Thus, the bent connectorless multi-core rigid busbar can have rigid conductors of uniform length. In some embodiments, the rigid conductors can be cut at the ends of the connectorless multi-core rigid busbar after bending to create rigid conductors of uniform length. In some embodiments, after bending the connectorless multi-core rigid busbar, non-uniform conductors at the ends of the connectorless multi-core rigid busbar can be stretched to have a uniform length with the other rigid conductors. For example, after bending the connectorless multi-core rigid busbar, non-uniform conductors at the ends of the connectorless multi-core rigid busbar can be pulled to create conductors of uniform length.

[0075] The various cross-sectional shapes of the connectorless multi-core rigid busbars can enhance and / or optimize electrical connections and power distribution within a power distribution system, such as a vehicle power distribution system. In one embodiment, the rigid conductors have a circular cross-section, and the rigid conductors are surrounded by insulation. In some embodiments, the rigid conductors have a rectangular cross-section, and the rigid conductors are surrounded by insulation. Any suitable combination of features of the various cross-sectional shapes of the connectorless multi-core rigid busbars disclosed herein can be implemented together with each other.

[0076] Various numbers of rigid conductors can enhance and / or optimize electrical connectivity packaging, such as electrical connectivity packaging for a vehicle. The number of rigid conductors can be uniform, with each pair of rigid conductors connected to an electrical component. Alternatively, some of the rigid conductors can be an odd number. In one example, with an odd number of rigid conductors, one of the rigid conductors can be connected to a negative terminal (e.g., a ground terminal) of the vehicle, and the other rigid conductor can be connected to a corresponding positive terminal of the electrical component. The negative terminal of the electrical component can be connected to the rigid conductor that is connected to the negative terminal of the vehicle. Although embodiments may be described with a connectorless multi-core rigid busbar having four or five rigid conductors, any suitable principles and advantages disclosed herein may be applied to a multi-core busbar with any other suitable number of rigid conductors.

[0077] The electrical insulation of the multi-core busbar may be made from any electrically insulating material such as cross-linked polyethylene (XLPE), PVC, silicone, or plastic.

[0078] A connectorless multi-core rigid busbar can include a variety of different cross-sectional areas of the rigid conductors for a particular application. For example, one of the rigid conductors can have a larger cross-sectional area than the other rigid conductors in the connectorless multi-core rigid busbar. Although embodiments may be described using connectorless multi-core rigid busbars having circular or rectangular cross-sectional areas for illustrative purposes, any suitable principles and advantages disclosed herein may be applied to applications using any other suitable cross-sectional areas.

[0079] The technology disclosed herein can be applied to a variety of applications. For example, in addition to using the connectorless multi-core rigid busbar to distribute power or connect electrical components, the connectorless multi-core rigid busbar can transfer power from a charging inlet in a vehicle to a battery pack to charge the battery pack. The busbars disclosed herein can be used in a vehicle or in any other suitable system involving power distribution.

[0080] In certain embodiments, the connectorless multi-core rigid busbar can be used in an electric vehicle. The electric vehicle can be a car, a sport utility vehicle, a truck, or any other electric vehicle. When implementing the connectorless multi-core rigid busbar, each end of the connectorless multi-core rigid busbar can be directly connected to one or more electrical joints. Thus, implementing the connectorless multi-core rigid busbar may not involve electrical connector assembly parts such as electrical terminals, seals, insulating plastics, shields, or housing units that connect or are connected to the electrical joints, because each end of the connectorless multi-core rigid busbar can be directly connected (e.g., directly mated) to the electrical joints. Assembly of a power distribution system can be easier with the connectorless multi-core rigid busbar in a factory assembly environment compared to a flexible harness assembly. The connectorless multi-core rigid busbar can carry direct current (DC), alternating current (AC), or AC and DC. The raw materials of the connectorless multi-core rigid busbar can be densely packed and shipped directly from the supplier to the installation site and bent to fit the in-vehicle packaging. Therefore, there is no need to deal with cables and connectors.

[0081] In some applications, a battery pack of an electric vehicle includes one or more electrical joints. One end of the connectorless multi-core rigid busbar can be connected to the battery pack through the electrical joint. The other end of the connectorless multi-core rigid busbar can be connected to one or more other electrical components of the electric vehicle. Power can be distributed to the other electrical components through the connectorless multi-core rigid busbar. The length and route of the connectorless multi-core rigid busbar can be determined based on vehicle packaging constraints and the location of the power source, such as the battery pack, and loads, such as any electrical components, in the electric vehicle.

[0082] To simplify the discussion and not to limit the present disclosure, the figures disclosed herein include certain shapes of connectorless multi-core rigid busbars and certain numbers of rigid conductors. However, these certain shapes of connectorless multi-core rigid busbars and the number of rigid conductors implemented in the connectorless multi-core rigid busbars are provided as examples only. Thus, the present disclosure does not limit the shapes and numbers of connectorless multi-core rigid busbars.

[0083] FIG. 1A is a diagram depicting a connectorless multi-core rigid busbar 100. The connectorless multi-core rigid busbar 100 is rigid and retains its shape. As shown, the connectorless multi-core rigid busbar 100 includes an end 110 and a body 130. In some embodiments, one end 110 of the rigid busbar 100 can be a source end 150 and the other end 110 of the rigid busbar 100 can be a load end 160. The end 110 of the rigid busbar 100 can be directly connected to an electrical terminal of a component without the use of a connector. For example, the end of the rigid busbar 100 can be directly connected to an electrical terminal without additional blades or pins. In some embodiments, when the connectorless multi-core rigid busbar 100 is used to distribute power from a battery pack, the source end 150 can be connected to a battery pack and the load end 160 can be connected to an electrical component. For example, the source end 150 can be positioned in one direction toward the power source. The load ends 160 can be positioned in opposite directions toward a load or electrical component, respectively. In some embodiments, when the connectorless multi-core rigid busbar 100 is used to electrically connect two or more electrical components, the source end 150 is connected to an electrical component and the load end 160 is connected to another electrical component, thereby electrically coupling the two electrical components. As shown in FIG. 1A, the connectorless multi-core rigid busbar 100 can include a body 130. The body 130 can include one or more bend points 131. The bend points 131 and bend shapes can be selected based on vehicle packaging constraints and the location of the power source and / or electrical components.

[0084] 1B is a diagram depicting a braided harness assembly. As shown, the flexible braided harness assembly utilizes one or more stranded cables as electrical pathways, which are tied together using ties 190 and tape to assemble the cable. Additionally, the flexible braided harness assembly includes end connectors 170, 180. The end connectors 170 and 180 may include electrical terminals connected to the ends of the cables that may mate with other electrical components. The assembly process of flexible braided cables may involve relatively high assembly costs and vehicle packaging constraints.

[0085] FIG. 2A is a depiction of one of the two ends 110 of the connectorless multi-core rigid busbar 100. As shown, the end 110 of the connectorless multi-core rigid busbar 100 can include one or more rigid conductors 206. The rigid conductors (shown in FIGS. 2B-2D) inside the electrical insulator 202 extend to both ends 110 to form the rigid conductors 206. The rigid conductors 206 can form a rigid surface for electrical connection and therefore can function as electrical joint terminals. The rigid conductors 206 at both ends 110 of the connectorless multi-core rigid busbar 100 can be coupled with appropriate positive and negative terminals of an electrical component or battery pack in a vehicle. Any suitable end connection unit for transmitting electrical power can be used in various applications.

[0086] In some embodiments, for example, as shown in FIGS. 2A-2F, the connectorless multi-core rigid busbar 100 can include a plurality of rigid conductors 206 surrounded by electrical insulators 202. The rigid multi-core busbar 100 further includes electrical insulators 202, while the electrical insulators 202 include hollow portions 207. As shown in FIGS. 2A-2D, each of the rigid conductors 206 is fitted inside a respective hollow portion 207 of the electrical insulator 202. The rigid conductors 206 may be made of any suitable conductive material, such as aluminum, copper, bronze, brass, gold, silver, or the like, or any suitable combination thereof, or alloy thereof. The electrical insulators 202 may be made of any suitable electrically insulating material, such as XLPE, PVC, nylon, silicone, or plastic. The electrical insulators 202 can be molded by injection molding or extrusion processes.

[0087] 2A and 2C, each end 110 of the connectorless multi-core rigid busbar 100 can include a groove 205. The groove 205 can be mated with a groove cover (or other insulating material covering the groove) to provide appropriate distance for creepage and gap insulation from high voltage. The groove 205 can be molded or machined into the end 110 of the connectorless multi-core rigid busbar 100.

[0088] In some embodiments, the electrical insulator 202 is surrounded by a shielding layer 203, for example as shown in FIG. 2A. The shielding layer 203 provides a shield against electromagnetic interference. Such shielding can protect against damage. The shielding layer 203 can be flexible or solid. The shielding layer 203 can be made of any EMI shielding material, such as aluminum. In some embodiments, the shielding layer 203 can physically protect the insulating layer from external conditions and / or damage during manufacturing processes, such as three-dimensional bending processes. In some embodiments, the shielding layer 203 can be grounded to the vehicle's Body In White (BIW). This can provide detection of insulation loss in case of high voltage short circuits. In some embodiments, the shielding layer 203 is surrounded by a colored layer 204. The colored layer 204 can be made with any suitable color coating.

[0089] 2B-2D depict cross-sectional views of various embodiments of the connectorless multi-core rigid busbar 100. As shown in FIG. 2B, the connectorless multi-core rigid busbar 100 can include four rigid conductors 206. As shown in FIG. 2C, the connectorless multi-core rigid busbar 100 can include four rigid conductors 206 and a groove 205 in the electrical insulator 202. The groove 205 can be located at an end of the connectorless multi-core rigid busbar. As shown in FIG. 2D, the connectorless multi-core rigid busbar 100 includes an odd number of rigid conductors 206 and 208. In such an embodiment, a particular rigid conductor 208 can function as a ground terminal, and the rigid conductor 208 can be connected to a ground terminal of the vehicle. The other rigid conductors 206 can be connected to the positive terminal of each corresponding electrical component in the vehicle. A connectorless multi-core rigid busbar according to any suitable principles and advantages disclosed herein can have any suitable number of rigid conductors.

[0090] 2E and 2F depict an embodiment of a connectorless multi-core rigid busbar 100 having a rectangular shape. For example, the connectorless multi-core rigid busbar 100 can be packaged in a rectangular shape with the rigid conductors 206 mounted in an array. As depicted in FIG. 2E and 2F, four rigid conductors 206 can be mounted in a row. The cross-sectional shape of the connectorless multi-core rigid busbar 100 can be rectangular. FIG. 2E depicts four rigid conductors 206 mounted in the connectorless multi-core rigid busbar 100. As depicted in FIG. 2E, the connectorless multi-core rigid busbar 100 can include four rigid conductors 206 arranged in a row. The connectorless multi-core rigid busbar 100 can also include grooves 205 at its ends. In some examples, for example, as depicted in FIG. 2F, the connectorless multi-core rigid busbar 100 may not include grooves between the ends of the rigid conductors 206.

[0091] The connectorless multi-core rigid busbars disclosed herein can be connected to a variety of connection units. The connectorless multi-core rigid busbars disclosed herein can be compatible with connection units for other busbars in certain applications. Thus, the connectorless multi-core rigid busbars disclosed herein can be compatible with a variety of connection units and electrical components in a vehicle.

[0092] FIG. 3A depicts one end 110 of the connectorless multi-core rigid busbar 100, including a groove cover 310 that interfaces with the groove 205 to provide creepage and gap insulation from high voltage. The groove cover 310 may be inserted into the groove 205. The groove cover 310 may provide creepage and gap insulation from high voltage. The groove cover 310 may be made from any suitable electrically insulating material, such as XLPE, PVC, nylon, silicone, or plastic. The groove and corresponding groove cover may have any suitable structure for a particular application. In some embodiments, the groove cover 310 may include a groove cover top portion 312 and a groove cover extension portion 314. The groove cover top portion 312 may be inserted into the groove 205 to provide creepage and gap insulation from high voltage to the end 110 of the connectorless multi-core rigid busbar 100. The groove cover extension 314 can be used to provide creepage and gap insulation from high voltage when the end 110 of the connectorless multi-core rigid busbar 100 mates with an electrical joint of an electrical component. For example, each rigid conductor 206 and groove cover extension 314 can be plugged into a corresponding electrical joint of an electrical component, and the groove cover extension 314 can provide creepage and gap insulation from high voltage between the electrical joints.

[0093] FIG. 3B is a depiction of one end 110 of the connectorless multi-core rigid busbar 100, including a groove cover 310 that interfaces with the groove 205 to provide creepage and clearance insulation from high voltage. In FIG. 3B, a seal 308 can seal the outer diameter of the connectorless multi-core rigid busbar 100. In some embodiments, the end 110 of the connectorless multi-core rigid busbar 100 can be assembled as shown in FIG. 3B. For example, the end 110 of the connectorless multi-core rigid busbar 100 can be assembled with an enclosure 304 into which the end 110 of the connectorless multi-core rigid busbar 100 is inserted. In some examples, the enclosure 304 can be a battery pack enclosure. The end 110 of the connectorless multi-core rigid busbar 100 can be assembled with a header assembly plastic 306, a header assembly seal 308 that interfaces against the outer diameter of the connectorless multi-core rigid busbar 100, a groove cover (e.g., a header assembly groove cover) 310 that holds the seal and provides creepage and gap insulation from high voltage, and a seal 312 between the header and the enclosure.

[0094] 4A-4H depict various terminals that may be connected to the ends 110 of the connectorless multi-core rigid busbar 100. FIG.

[0095] 4A is a diagram depicting electrical terminals 420 mounted on a printed circuit board assembly (PCBA) 410 that can be connected to the end 110 of the connectorless multi-core rigid busbar 100. The electrical terminals 420 can be inserted into the PCBA 410. The electrical terminals 420 can be implemented by sockets. In some embodiments, the rigid conductors 206 at the end 110 of the connectorless multi-core rigid busbar 100 can be plugged into the electrical terminals 420. For example, the rigid conductors 206 can be plugged into corresponding electrical terminals 420.

[0096] 4B is a diagram depicting a top view of the PCBA 410. In some embodiments, each rigid conductor 206 is inserted into a corresponding electrical terminal 420. The PCBA 410 can also include a groove cover portion 432. For example, the groove cover extension portion 314 of the groove cover 310 can be inserted into the groove cover portion 432 to provide insulation between each electrical terminal 420.

[0097] FIG. 4C depicts a bottom view of the PCBA 410. The electrical terminals 420 can be inserted into the hollow portions 415 of the rigid conductors of the PCBA 410. In some embodiments, the rigid conductors 206 can be plugged into the electrical terminals 420. In some embodiments, the electrical terminals 420 can mate with corresponding terminals of another electrical component via the electrical terminals 420 at the bottom of the PCBA 410. For example, the connectorless multi-core rigid busbar 100 may distribute power to electrical components integrated into the PCBA 410. Furthermore, in this example, the connectorless multi-core rigid busbar 100 may further distribute power to one or more other electrical components via the electrical terminals of the one or more electrical components. In some other embodiments, the bottom of the electrical terminals 420 (e.g., the electrical terminals at the bottom of the PCBA 410) can be electrically insulated by using an electrical terminal cover. For example, the connectorless multi-core rigid busbar 100 may distribute power to electrical components integrated into the PCBA 410.

[0098] The other end of the connectorless multi-core rigid busbar 100 can be connected to another PCBA 410, similar to that shown for end 110. In certain applications, both ends of the multi-core rigid busbar 100 can be similarly connected to separate PCBA 410. One of the ends of the multi-core rigid busbar 100 can be connected to a PCBA 410, and the other end can be connected to a different type of connection unit in some other applications.

[0099] 4D is a diagram depicting an example embodiment of a PCBA 410 connected to an end 110 of a connectorless multi-core rigid busbar 100. In some embodiments, a groove cover top portion 312 of a groove cover 310 is inserted into the groove 205. The groove cover 310 can provide creepage and gap insulation from high voltage between the rigid conductors 206. After the groove cover top portion 312 is inserted into the groove 205, the PCBA 410 can be inserted into a groove cover extension portion 314 of the groove cover 310. For example, the groove cover extension portion 314 can pass through a groove cover portion 432 of the PCBA 410. The rigid conductors 206 can also pass through the PCBA electrical terminals 420 of the PCBA 410. The groove cover extension portion 314 can provide creepage and gap insulation from high voltage between the electrical terminals 420 of the PCBA 410.

[0100] FIG. 4E depicts an exemplary assembly of the connectorless multi-core rigid busbar 100 and the PCBA 410. As shown in FIG. 4E, the end 110 of the connectorless multi-core rigid busbar 100 can be assembled with the PCBA 410 by using a groove cover 310, an electrical terminal 420, and an electrical terminal holder 422. In some embodiments, the electrical terminal holder 422 can hold a corresponding electrical terminal 420. In other embodiments, the electrical terminal 420 can be attached to the PCBA 410 by soldering, gluing using epoxy, or the like. In some embodiments, the groove cover top portion 312 of the groove cover 310 can be inserted into the groove 205. The groove cover top portion 312 can provide creepage and gap insulation from high voltage to the end 110 of the connectorless multi-core rigid busbar 100. In some embodiments, the electrical terminal 420 can be inserted into the PCBA 410 through the hollow portion 415 of the rigid conductor of the PCBA 410. After the electrical terminal 420 is inserted into the hollow portion 415 of the corresponding rigid conductor, the top of the electrical terminal 420 can be located at the top of the PCBA 410, and the bottom of the electrical terminal 420 can be located at the bottom of the PCBA 410. In some embodiments, the rigid conductor 206 at the end 110 of the connectorless multi-core rigid busbar 100 can be inserted into the electrical terminal 420. For example, the rigid conductor 206 can be inserted into the corresponding electrical terminal 420. The rigid conductor 206 can be inserted into the electrical terminal 420. The terminal holder 422. The electrical terminal 420 can be connected to the rigid conductor 206. The rigid conductor 206 can be directly connected to the PCBA 410 by utilizing the electrical terminal 420. In some embodiments, the electrical terminal 420 can be mounted inside the electrical terminal holder 422, and the electrical terminal holder 422 is inserted into the hollow portion 415 of the rigid conductor.

[0101] 4F is a depiction of the connectorless multi-core rigid busbar 100 assembled with a PCBA 410. In some embodiments, the PCBA 410 may include integrated electrical components. Since the PCBA 410 is assembled with the connectorless multi-core rigid busbar 100, it may receive power from a power source via the rigid conductors 206.

[0102] 4G and 4H depict a header assembly 470 into which the end 110 of the connectorless multi-core rigid busbar can be plugged. In some embodiments, for example, as shown in FIG. 4E, the header assembly 470 may include a PCBA 410, a groove cover 310, and a header assembly in an enclosure 440. In such embodiments, the rigid conductors 206 at the end 110 of the connectorless multi-core rigid busbar 100 can be plugged into electrical terminals in the PCBA 410 (electrical terminals not shown in FIG. 4C). In some embodiments, for example, as shown in FIG. 4F, the groove cover 310 fits into the groove 205. The groove cover 310 can provide creepage and gap insulation from high voltage. In such embodiments, the header assembly includes an enclosure 440. The enclosure 440 can be a stamped metal enclosure. In some embodiments, the seal 434 can seal the outer diameter of the end 110 of the connectorless multi-core rigid busbar 100.

[0103] FIG. 5A illustrates a connectorless multi-core rigid busbar 500, according to one embodiment, where the busbar 500 is bent to fit vehicle packaging requirements. The connectorless multi-core rigid busbar 500 has a generally rectangular shape. As illustrated, the connectorless multi-core rigid busbar 500 includes two ends 510 and a body 530. FIG. 5A illustrates rigid conductors 506 at one end 510 of the connectorless multi-core rigid busbar. In some embodiments, when the connectorless multi-core rigid busbar 500 is used to distribute power from a battery pack, one end 510 can be connected to a battery pack and the other end 510 can be connected to an electrical component. In some embodiments, as illustrated in FIG. 5A, when the connectorless multi-core rigid busbar 500 is used to electrically connect two or more electrical components, one end 510 is connected to an electrical component and the other end 510 is connected to another electrical component, thereby electrically coupling the two electrical components. 5A, the body 530 includes a bend point 531. The bend point 531 and the bend shape may be selected based on vehicle packaging constraints and the location of the power source and / or electrical components.

[0104] 5B depicts one end 510 of a connectorless multi-core rigid busbar 500. The other end 520 of the connectorless multi-core rigid busbar 500 may be implemented according to any suitable principles and advantages discussed with reference to the end 510. The end 510 of the connectorless multi-core rigid busbar 500 includes rigid conductors 506. The rigid conductors 506 function as electrical joint terminals. The rigid conductors 506 may be coupled with appropriate positive and negative terminals in an electrical component of a vehicle or a battery pack. Any suitable end connection unit for transmitting electrical power may be implemented for various applications.

[0105] 6A-6C are diagrams illustrating a connectorless multi-core rigid busbar 500 including a locking mechanism for setting the busbar position and preventing fretting of electrical contacts. In the connectorless multi-core rigid busbar 500 of FIG. 6A, the body 530 includes a locking hole 606. FIGS. 6B and 6C show that an enclosing assembly including a locking piece 607 may be inserted into the locking hole 606. The connectorless multi-core rigid busbar 500 may be fixed in a vehicle by using the locking piece 607 and the locking hole 606. For example, as shown in FIG. 6B, one end of the locking piece 607 is inserted into the locking hole 606, and the other end of the locking piece 607 is attached into the enclosing assembly 608. This locking mechanism may fix the position of the connectorless multi-core rigid busbar 500 relative to the enclosing assembly 608. The locking mechanism allows the connectorless multi-core rigid busbar 500 to be securely fixed in place, reducing or preventing fretting or movement of the electrical contacts even with vehicle vibration and / or movement.

[0106] Figures 6D and 6E depict an exemplary embodiment of a connectorless multi-core rigid busbar 100. Figure 6D depicts the connectorless multi-core rigid busbar 100 assembled with locking pieces (not shown in Figure 6D), PCBA 410, channel cover 310, terminal holder 422, and enclosure assembly 608. Figure 6E depicts the connectorless multi-core rigid busbar 100 assembled with channel cover 310, electrical terminals 420, electrical terminal holder 422, and PCBA 410.

[0107] 7A and 7B depict a connectorless multi-core rigid busbar 500 with non-uniform rigid conductors 501 at one end 510, where the busbar is bent to meet vehicle packaging requirements. The non-uniform rigid conductors 506 may be due to bend points 531 in the connectorless multi-core rigid busbar 500. The inner rigid conductors of the connectorless multi-core rigid busbar 500 may stretch and shift at different rates based on the distance to the bend axis centerline of the connectorless multi-core rigid busbar 600. Thus, the rigid conductors 506 at one end 510 of the connectorless multi-core rigid busbar 500 may have non-uniform lengths.

[0108] 7C depicts an embodiment of a connectorless multi-core rigid busbar 500 for mitigating or preventing the connectorless multi-core rigid busbar 500 from having non-uniform rigid conductor lengths at one end 510. As shown in FIG. 7C, the connectorless multi-core rigid busbar 500 is bent symmetrically at bend points 531. Thus, the rigid conductors on the interior of the connectorless multi-core rigid busbar 500 can be stretched and offset approximately evenly. Thus, the rigid conductors have roughly the same length at the ends of the connectorless multi-core rigid busbar 500.

[0109] 8-15 illustrate cross-sectional views of connectorless multi-core rigid busbars. Any of the preferred principles and advantages of these connectorless multi-core rigid busbars may be implemented together with one another. Any of the preferred principles and advantages of these connectorless multi-core rigid busbars may be implemented with any of the other preferred principles and advantages disclosed herein.

[0110] FIG. 8 illustrates a cross-sectional view of a connectorless multi-core rigid busbar 800, according to one embodiment. The connectorless multi-core rigid busbar 800 has a generally rectangular cross-section and includes three grooves 802 and four circular rigid conductors 804, with a hollow portion 812 within each rigid conductor 804. The grooves 802 can be located at end portions of the connectorless multi-core rigid busbar 800. The connectorless multi-core rigid busbar 800 has rounded sides. In some embodiments, the hollow portion 812 can be used for cooling. For example, air can flow through the hollow portion 812 to cool heat generated from the rigid conductors 804 during power distribution. In some embodiments, a liquid coolant can flow through the hollow portion 812.

[0111] 9 illustrates a cross-sectional view of a connectorless multi-core rigid busbar 900, according to one embodiment. The connectorless multi-core rigid busbar 900 has a generally rectangular shaped cross-section and includes three grooves 802 and four circular rigid conductors 206 surrounded by electrical insulators 202.

[0112] 10 illustrates a cross-sectional view of a connectorless multi-core rigid busbar 1000, according to one embodiment. The connectorless multi-core rigid busbar 1000 is similar to the connectorless multi-core rigid busbar 900 of FIG. 9, except that it does not have grooves.

[0113] 11 is a diagram illustrating a cross-sectional view of a connectorless multi-core rigid busbar 1100, according to one embodiment. The connectorless multi-core rigid busbar 1100 is similar to the connectorless multi-core rigid busbar 800 of FIG. 8, except that it does not have grooves.

[0114] 12 illustrates a cross-sectional view of a connectorless multi-core rigid busbar 1200, according to one embodiment. The connectorless multi-core rigid busbar 1200 has a generally rectangular shaped cross-section and includes two circular rigid conductors 206.

[0115] 13 illustrates a cross-sectional view of a connectorless multi-core rigid busbar 1300, according to one embodiment. The connectorless multi-core rigid busbar has a generally rectangular shaped cross-section and includes three circular rigid conductors 206 and 208, with the central rigid conductor 208 having a larger cross-sectional area than the other rigid conductors 206. The central rigid conductor 208 can be grounded.

[0116] 14 illustrates a cross-sectional view of a connectorless multi-core rigid busbar 1400, according to one embodiment. The connectorless multi-core rigid busbar 1400 has a generally rectangular shaped cross-section and includes two circular rigid conductors 804, with a hollow portion 812 within each rigid conductor 804.

[0117] 15 is a diagram illustrating a connectorless multi-core rigid busbar 1500, according to one embodiment. The connectorless multi-core rigid busbar 1500 is a rectangular shaped busbar that includes five circular rigid conductors 206 and 208, with the central rigid conductor 208 having a larger cross-sectional area than the other rigid conductors 206.

[0118] Unless the context clearly dictates otherwise, throughout the specification and claims, the terms "comprise," "comprising," "include," "including," and the like, are to be construed in an inclusive sense, i.e., "including, but not limited to," as opposed to an exclusive or exhaustive sense. As generally used herein, the term "coupled" refers to two or more elements that may be directly connected or connected by one or more intermediate elements. Similarly, as generally used herein, the term "connected" refers to two or more elements that may be directly connected or connected by one or more intermediate elements. Where the context permits, terms in the above detailed description using the singular or plural may also include the plural or singular, respectively. The term "or" in connection with a list of two or more items covers the following interpretations of that term: any of the listed items, all of the listed items, and all of any combination of the listed items.

[0119] Additionally, it should be understood that conditional language used herein, particularly "can," "could," "may," "for example," "such as," and the like, is generally intended to convey that certain embodiments include certain features, elements, and / or conditions, while other embodiments do not, unless specifically stated otherwise or understood otherwise within the context in which it is used. Thus, such conditional language is generally not intended to imply that features, elements, and / or conditions are in any way required for one or more embodiments.

[0120] The foregoing description has been described with reference to specific embodiments. However, the above illustrative discussion is not intended to be exhaustive or to limit the invention to the precise form described. Many modifications and variations are possible in light of the above teachings. Those skilled in the art will thereby be able to best utilize the technology and various embodiments with various modifications suitable for various applications.

[0121] Although the present disclosure and examples have been described with reference to the accompanying drawings, various changes and modifications will become apparent to those skilled in the art. Such changes and modifications should be understood as falling within the scope of the present disclosure.

Claims

1. A multi-core rigid busbar, a plurality of rigid conductors configured to carry electrical current between the components; an insulator surrounding the plurality of rigid conductors; A multi-conductor rigid busbar, wherein each end of at least one of the plurality of rigid conductors functions as an individual electrical coupling terminal and is configured to connect directly to an electrical terminal without a connector assembly.

2. The multi-core rigid busbar of claim 1 , wherein the rigid conductor comprises at least one of aluminum or copper.

3. 10. The multi-core rigid busbar of claim 1, wherein the insulator comprises at least one of cross-linked polyethylene (XLPE), polyvinyl chloride (PVC), nylon, silicone, a thermoplastic, or a thermoset plastic.

4. The multi-core rigid busbar of claim 1 further comprising a load end and a source end, each end having a rigid conductor.

5. The multi-core rigid busbar of claim 4 , wherein the rigid conductors at the source end are directly connectable to a battery pack.

6. The multi-conductor rigid busbar of claim 4 , wherein at least one of the rigid conductors is directly connectable to an electrical terminal on a printed circuit board assembly.

7. The multi-core rigid busbar of claim 1 , further comprising a shielding layer surrounding the insulator.

8. The multi-core rigid busbar of claim 7 , wherein the shielding layer is electrically conductive.

9. 10. The multi-core rigid busbar of claim 1, wherein the multi-core rigid busbar is bent to fit into interior vehicle packaging and extend between a vehicle battery pack and one or more electrical components.

10. The multi-core rigid busbar of claim 1 , wherein the multi-core rigid busbar is shaped to fit within vehicle interior packaging and extend between a plurality of electrical components.

11. The multi-core rigid busbar of claim 1 , further comprising grooves located between rigid conductors of the plurality of rigid conductors.

12. The multi-core rigid busbar according to claim 1 , further comprising a locking hole in the body of the multi-core rigid busbar, the locking hole configured to receive a locking piece.

13. The multi-core rigid busbar of claim 1 , wherein the multi-core rigid busbar is symmetrically bent.

14. The multi-core rigid busbar of claim 13 , wherein the ends of the conductors have substantially the same length from the cut.

15. A vehicle comprising the multi-core rigid busbar according to claim 1.

16. 16. The vehicle of claim 15, further comprising a battery pack connected to the multi-core rigid busbar.

17. The vehicle of claim 15 , wherein the vehicle is an electric vehicle.

18. 1. An electrical connection system comprising: a plurality of rigid conductors within a single outer sheath; an insulating layer around the plurality of rigid conductors, the plurality of rigid conductors being configured to carry electrical current from at least a source to a load, and at least one of the plurality of rigid conductors being configured to connect directly to an electrical terminal; An electrical connection system wherein each end of at least one of the plurality of rigid conductors functions as an individual electrical coupling terminal and is configured to connect directly to an electrical terminal without a connector assembly.

19. 20. The electrical connection system of claim 18, further comprising a shielding layer around the insulating layer.

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