Plug-in busbar cable connector and a method for manufacturing a busbar and cable assembly

Abstract

An end connector (34) for a cable (10) includes a first end (40) with a cable receptacle (36) sized to receive an end of a cable (10), a second end (42) opposite to the first end (40), a plug portion (54) and a retaining surface (70). The plug portion (54) is at least partly between the first end (40) and the second end (42) and has an electrical connection surface (52) sized for receipt within an opening (26), and the plug portion (54) includes a void (56) that defines at least part of a contact portion (58) of the electrical connection surface (52) that is radially flexible so that the plug portion (54) has a first state with a first size and a second state with a second size that is less than the first size. The retaining surface (70) is adjacent to the electrical connection surface (52) and extends radially relative to the electrical connection surface (52).

Description

PLUG-IN BUSBAR CABLE CONNECTOR AND A METHOD FOR MANUFACTURING A BUSBAR AND CABLE ASSEMBLYTechnical Field

[0001] The present disclosure relates generally to an end connector for connection with a busbar and a cable, a busbar and cable assembly, and a method of making a busbar and cable assembly.Background

[0002] Electrical connections of cable ends terminated with cable lugs to busbars require mechanical fasteners such as nuts and bolts that must be handled and installed individually and separately. This increases the cost and complexity of the installation and requires more direct contact with metal surfaces on and around the busbar.Summary

[0003] An object of the present invention is the provision of an end connector, a busbar and cable assembly, and a method of manufacturing a busbar and cable assembly, each with the aim of overcoming the shortcomings and limitations of the state of the art.

[0004] A further object of the present invention is the provision of an end connector, a busbar and cable assembly, and a method of making a busbar and cable assembly, each with the aim of reducing the time and effort required to make a reliable electrical connection between a cable and a busbar, particularly in environments with high demands on vibrations.

[0005] A further object of the present invention is the provision of an end connector, a busbar and cable assembly, and a method of making a busbar and cable assembly, each with the aim of making a reliable electrical connection between a cable and a busbar without the use of tools such as a wrench.

[0006] According to the invention, these aims are attained by the object of the attached claims, and especially by the end connector, the busbar and cable assembly, and the method of making the busbar and cable assembly.

[0007] In a first aspect of the invention, an end connector (also electrical end connector) for a cable includes a first end with a cable receptacle sized to receive an end of a cable, a second end opposite to the first end, a plug portion and a retaining surface. The plug portion is at least partly between the first end and the second end and has an electrical connection surface sized for receipt within an opening of a busbar, the busbar is external to the end connector, and the plug portion includes a void that defines at least part of a contact portion of the electrical connection surface that is radially flexible so that the plug portion has a first state with a first size and a second state with a second size that is less than the first size. The retaining surface is adjacent to the electrical connection surface and extends radially relative to the electrical connection surface.

[0008] The radial flexibility of the end connector means that it can deform during the insertion process into the opening of a busbar. At the beginning of the mating process, the plug portion is deformed radially, which reduces the diameter so that the plug portion plunges into the recess. At the end of the mating process, i.e. when the plug portion is fully immersed in the opening, the diameter can increase again so that an electrically conductive connection is made between the inner wall of the opening and the connection surface. Furthermore, the retaining surface ensures that the plug portion remains in the opening if it is subjected to a tensile force, for example on the cable, thus enabling a reliable electrical connection between the cable and the busbar. Advantageously, the electrical connection can be made without the use of tools, simply by pushing the plug portion into or through the opening.

[0009] In an embodiment of the first aspect, a stop surface can be located at an end of the electrical connection surface that can be closer to the first end than the second end, wherein the stop surface can extend outwardly beyond the electricalconnection surface.The stop surface can prevent the end connector from plunging too deeply into the busbar opening, as the diameter of the stop surface can be larger than the diameter of the second end.

[0010] In another embodiment of the first aspect, the retaining surface can be partially defined by at least one void that permits inward flexing of the plug portion and retaining surface. In at least some implementations, the void can extend into at least part of the electrical connection surface. In at least some implementations, the electrical connection surface can be cylindrical and can have a central axis, and multiple voids can be provided, the voids can be circumferentially spaced apart and extend axially from the second end, through the retaining surface and at least partially into the electrical connection surface.

[0011] In a further embodiment of the first aspect, an inner surface can be defined by a cavity open to the second end, extending axially toward the first end, and located radially inwardly of the retainer and at least part of the electrical connection surface. In at least some implementations, a biasing member can be received at least partly within the cavity and can provide onto the inner surface a radially outwardly acting and biasing force. The biasing force, which can be outwardly acting can improve the electrical connection and can reduce the contact resistance between the inner wall of the busbars opening and the connection surface. In at least some implementations, the biasing member can be a torsion spring having an outer surface that can be engaged with at least part of the inner surface. In at least some implementations, the biasing member can be received outboard of or defines an outer surface of at least part of the electrical connection surface. In at least some implementations, the biasing member can include at least one portion that can be radially compressible.

[0012] In another embodiment of the first aspect, the retaining surface can be formed in the electrical connection surface and can be defined by a radially inwardly extending groove. This can allow the retaining surface to be pushed through the busbaropening, which can simplify handling and / or mating. In addition, the mechanical design and manufacturing of the end connector can be simplified.

[0013] In a further embodiment of the first aspect, the retaining surface can be defined by an outwardly extending surface at an end of the electrical connection surface. In at least some implementations, the retaining surface can be defined by, can include, or can be configured as a flexible retainer located within the plug portion. In at least some implementations, the flexible retainer can be carried within a groove formed in the electrical connection surface. The flexible retainer can compensate for mechanical vibrations. It can also increase the retention force, resulting in a more reliable hold.

[0014] In a second aspect of the invention, a busbar and cable assembly includes a busbar having a body with an opening formed through the body, a cable having a conductor and an end conductor. The end connector, that can be configured according to the first aspects (including any embodiment, implementation, or combination thereof), has a first end with a cable receptacle in which part of the conductor is received, a second end opposite to the first end, and a plug portion at least partly between the first end and the second end and having an electrical connection surface sized for receipt within the opening. The plug portion includes a retaining surface adjacent to the electrical connection surface and extending radially relative to the electrical connection surface. A retainer is carried by one of the end connector and the busbar, and the retainer is arranged to engage the retaining surface when the plug portion is within the opening to resist removal of the plug portion from the opening.

[0015] The busbar and cable assembly as a whole inherits the advantages of the end connector of the first aspect, whereby the retention can be improved thanks to the retainer in engagement with the busbar and / or end connector.

[0016] In an embodiment of the second aspect, the retainer can be carried by the busbar and can be within the opening, and the retaining surface can be arranged toengage the retainer when the plug portion is installed in the opening. In at least some implementations, the busbar can include a groove that can be open to the opening and the retainer can be received within the groove, and the retainer can extend radially inwardly into the opening. In at least some implementations, the end connector can include a groove in which the retainer can be partly received when the plug portion is installed in the opening.

[0017] In another embodiment of the second aspect, the retainer can be carried by the end connector and can be partially received in a groove formed in the electrical connection surface, and wherein the retainer can define the retaining surface and the busbar can include a groove that can be open to the opening and in which the retainer can be partly received when the plug portion is installed in the opening.

[0018] In a third aspect of the invention, a method of manufacturing a busbar and cable assembly includes providing the busbar having at least one through opening and said cable assembly having a cable assembled with said end connector, and inserting the end connector with its second end into the at least one through opening and moving the end connector until the retainer is arranged to engage the retaining surface when the plug portion is within the opening to resist removal of the plug portion from the opening.

[0019] The end connector can be electrically connected to the busbar, but not disconnected from it. Therefore, the method preferably establishes a permanent reliable electrical connection between the cable and the busbar through the end connector, so that the electrical or mechanical connection cannot be separated without destroying the end connector (or the busbar).Brief Description of the Drawings

[0020] The following detailed description of preferred implementations and best mode will be set forth with regard to the accompanying drawings, in which:

[0021] FIG. 1 is a perspective view showing multiple cables connected to a busbar;

[0022] FIG. 2 is a side view showing a cable with an end connector coupled to the busbar;

[0023] FIG. 3 is an enlarged fragmentary view showing a retaining surface of the end connector on a back side of the busbar;

[0024] FIG. 4 is an end view of the cable connector showing a biasing member within the end connector;

[0025] FIG. 5 is a sectional view of the end connector and part of the busbar;

[0026] FIG. 6 is an end view of a spring element that may be part of the end connector or busbar;

[0027] FIG. 7 is a partial sectional view showing a retainer carried by the busbar and releasably engageable with the end connector;

[0028] FIG. 8 is a side sectional view showing an end connector and part of the busbar prior to assembly of the end connector to the busbar; and

[0029] FIG. 9 is a side sectional view like FIG. 8 and showing the end connector assembled to the busbar.Detailed Description of the Drawings

[0030] Referring in more detail to the drawings, FIG. 1 illustrates a plurality of cables 10 coupled to one or more busbars 12. The busbars 12 are typically uninsulated, air-cooled conductive members having multiple connection points to which cables 10 may be connected to distribute electrical power. The busbars 12 may be mounted in any suitable way to a support structure, which may be insulated.

[0031] In at least some implementations, such as shown in FIGS. 2-5, the busbar 12 is generally rectangular in cross-section and has opposite first and second ends 14, 16 (FIG. 1), a front side 18, an opposite back side 20, and left and right sides 22, 24 extending between the ends 14, 16 and sides 18, 20, and multiple openings 26 formed through the busbar 12. In at least some implementations eachbusbar opening 26 is located between the busbar sides 22, 24 and extends through the front side 18 and the back side 20, has a circular periphery and a central axis 28, and the central axis 28 may be perpendicular to the front side 18 and the back side 20.

[0032] Each cable 10 may include an insulative outer layer 30 surrounding an inner conductor 32, and an end connector 34 that is fixed to the conductor 32 at a first location and releasably coupled to the busbar 12 at a second location. The end connector 34 is formed from an electrically highly conductive material, such as metals like copper or aluminum, by way of two, non-limiting examples. For connection to the conductor 32 of the cable 10, the end connector 34 may include a cable receptacle 36 that includes an inlet 38 at a first end 40 of the end connector 34, and is defined by a cavity located inboard of the first end 40 (e.g. between the first end 40 and a second end 42 of the end connector 34). The cable receptacle 36 may be defined by an inner surface 44 (FIG. 5) of a tubular portion 46 of the end connector 34, and an outer surface 48 of the tubular portion 46 defines part of an exterior surface of the end connector 34. An end 50 of the conductor 32 may be fixed in the cable receptacle 36, in at least some implementations, such as by crimping or otherwise plastically deforming the tubular portion 46 around or into firm engagement with the conductor 32. If desired, the cable 10 could be fixed in other ways, such as with a fastener, weld or the like.

[0033] To facilitate connecting the end connector 34 to the busbar 12, the end connector 34 includes an electrical connection surface 52, shown in FIG. 5. The electrical connection surface 52 is arranged to be received in the busbar opening 26 when the end connector 34 is coupled to the busbar 12. At least a portion of the electrical connection surface 52 maybe complementary in shape to the opening 26, and sized for direct contact between the surface of the busbar 12 that defines the opening 26 and the electrical connection surface 52. In the illustrated examples, the busbar openings 26 are cylindrical and the electrical connection surface 52 is cylindrical, and defined by part of the exterior surface of the end connector 34. Theelectrical connection surface 52 may be axially arranged between the cable receptacle 36 and the second end 42 of the end connector 34, and may extend to the second end 42 of the end connector 34 in some implementations.

[0034] In at least some implementations, the electrical connection surface 52 is coaxial with the busbar opening 26, and the end connector 34 is constructed so that it may be “plugged into” the busbar opening 26. This may be done by aligning the second end 42 of the connector 34 with the opening 26 at the front side 18 of the busbar 12 and pushing / slidably advancing the second end 42 of the end connector 34 into the busbar opening 26 until at least part of the electrical connection surface 52 is received within the opening 26, and in direct contact with the busbar 12 within the opening 26.

[0035] To facilitate insertion of the end connector 34 into the busbar opening 26, the electrical connection surface 52 may be defined in a plug portion 54 of the end connector 34 that is tubular or hollow, and the end connector 34 includes one or more voids 56 (FIGS. 3-5) extending through the electrical connection surface 52. The voids 56 define edges of flexible contact portions 58 (FIG. 5) of the end connector 34 that are cantilevered at one end and may flex inwardly when pushed into the busbar opening 26, and the contact portions 58 may be resilient and seek to return to their unflexed state where the return / resilient force provides a contact force on the busbar 12 within the opening 26 and improves electrical conduction between the busbar 12 and the electrical connection surface 52 of the end connector 34.

[0036] In at least some implementations, the plug portion 54 of the end connector 34 is the portion that is received in the opening 26 of the busbar 12 during assembly and / or when fully assembled to the busbar 12. The plug portion 54 has a first state with a first size (which may be a peripheral length or diameter) when not received in the busbar opening 26, and a second state having a second size (e.g. peripheral length) when received in the busbar opening 26, where the second size is less than the first size. Here, the size includes the circumferential dimension of thematerial of the end connector 34 and the voids 56 formed therein. So arranged, the plug portion 54 of the end connector 34 is adapted to be compressed, wherein contact portions 58 of the plug portion 54 are flexed inwardly, as the plug portion 54 is inserted into the busbar opening 26. The resilient nature of the material of the plug portion 54 / end connector 34 causes the contact portions 58 to tend to return toward their unflexed state and provides direct metal-to-metal contact between at least some the contact portions 58 and the busbar 12, within the opening 26.

[0037] While the resilient nature of the plug portion 54 material may, in at least some implementations, provide an outward force on the busbar 12 within the opening 26, as noted above, the end connector 34 may also or instead include a biasing member 60 to permit some flexing upon insertion of the plug portion 54 into a busbar opening 26 and some contact force between the busbar 12 and the end connector 34.

[0038] As shown in FIGS. 4 and 5, part of all of the plug portion 54 may be hollow and a biasing member 60 may be received within a cavity 62 of the plug portion 54. The biasing member 60 may engage an inner surface 64 of the contact portion(s) 58 and yieldably outwardly bias the engaged contact portion(s) 58. In the example shown, the biasing member 60 is a torsion spring that is in compression when installed in the cavity 62 and has an outer surface in contact with and providing an outwardly directed force on part of the inner surface 64 of the plug portion 54. Other springs or biasing members may be used, as desired. By way of a non-limiting example, a split or c- shaped spring may be received under compression within the cavity.

[0039] Further, as shown in FIG. 6, a flexible sleeve or ring, or a split or c-shaped ring 66 may be provided on (e.g against) the outside of the plug portion 54 and have a first state or at rest diameter / size / periphery larger than the busbar opening 26 and a second state that is radially compressed or smaller relative to the opening 26 and which fits within the busbar opening 26 with metal-to-metal contact between the busbar 12 and the ring 66, and between the ring 66 and the electrical connection surface 52 / the plug portion 54 of the end connector 34. The ring 66 may be considered anintermediate part between the busbar 12 and the electrical connection surface 52 or the ring 66 may define all or part of the electrical connection surface 52. Instead of a split or c-shaped ring 66, or on such a ring, the biasing member on the outside of the plug portion 54 may include ridges or outward extending regions 67 (shown in dashed lines in FIG. 6) that are flexible and which can be radially compressed upon insertion of the plug portion 54 into the busbar opening 26, and which may resiliently expand upon removal of the plug portion 54 form the busbar opening 26 to permit multiple insertions and removal of the end connector 34 with sufficient electrical connection between the end connector 34 and the busbar 12.

[0040] In at least some implementations, a retainer or retaining surface 70 is provided in one or both of the end connector 34 and the busbar 12 to yieldably, releasably retain the plug portion 54 in the busbar opening 26 until removal efforts are intentionally undertaken, and to thus inhibit or resist unintended disconnection of the end connector 34 from the busbar 12. As shown in FIGS. 2-5, the retaining surface 70 may be defined by an enlarged end portion of the end connector 34. In at least some implementations, the retaining surface is defined by a flange 70 that extends radially outwardly relative to the electrical connection surface 52, axially from the second end 42 of the end connector 34 to or toward the electrical connection surface 52, and circumferentially about a periphery of the end connector 34. The void or voids 56 extend through the retaining surface 70 such that the retaining surface is not circumferentially continuous. At the second end 42, the flange 70 may be tapered so that it is smaller at the second end 42 that at a location axially spaced from the second end 42. This may facilitate aligning and initial insertion of the second end 42 and retaining surface 70 into the busbar opening 26. Spaced from the tapered portion of the flange 70, the flange may include a retaining surface 72 that overlaps and may engage the backside 20 of the busbar 12. That is, when the end connector 34 is fully installed in the busbar 12, the retaining surface 70 may be received fully through the opening 26 and may rest against or be located adjacent to the backside 20 of the busbar 12, and may be directly adjacent to the busbar 12, including arrangementswherein the retaining surface 70 is in contact with the busbar 12. So arranged, the retaining surface 70 engages the busbar 12 and resists a certain magnitude of force tending to withdraw the plug portion 54 form the busbar opening 26, although the resistance can be overcome by a sufficient force to permit intentional removal of the end connector 34 from the busbar 12.

[0041] FIG. 7 illustrates a retainer 74 that is carried by the busbar 12, and which extends radially into the busbar opening 26 to engage a retaining feature or retaining surface 76 of the end connector 34 when the plug portion 54 is installed in the busbar opening 26. The retainer 74 is flexible and resilient and is outwardly flexed or compressed when part of the plug portion 54 passes the retainer 74, and which resiliently returns toward its unflexed position to radially overlap a retaining surface 76 that defines the retaining surface of the plug portion 54 when aligned therewith. In the example shown, the retainer 74 includes an annular spring, such as an annular canted coil spring, received within a groove 78 that is open to the busbar opening 26. The spring 74 may be a coil spring, or other type of spring as desired. The retaining surface 76 is defined by a groove 78 formed in the plug portion 54 of the end connector 34 that, when aligned with the spring 74, allows the spring 74 to expand / unflex into the groove 78 so that the spring radially overlaps the retaining surface 76 of the plug portion 54. Until a sufficient magnitude of force is applied to the end connector 34, the spring 74 resists movement of the end connector 34 and when sufficient force is applied, the spring 74 yields / flexes and permits the end connector 34 to be withdrawn from the busbar opening 26.

[0042] Other constructions and arrangements may be used. For example, a retainer 84 (e.g. spring, an annular canted coil spring, or other flexible member) could instead be carried by and movable with the end connector 34, such as by being retained within a slot 86 formed in the periphery of the plug portion 54, as generally shown in FIGS. 8 and 9. The retainer 84 in an at rest state, as shown in FIG. 8 prior to assembly of the end connector 34 to the busbar 12, extends radially outwardly farther than theelectrical connection surface 52. As the end connector 34 is slid into the opening 26 of the busbar 12, the retainer 84 is compressed to permit passage of the plug portion 54 into the opening 26. In the assembled state or position, shown in FIG. 9, the end connector is received in the opening 26 until the retainer 84 is moved fully through the opening 26 and is received adjacent to the backside 20 of the busbar 12. In this position, the retainer 84 defines a retaining surface 70 that engages the busbar 12 when a force in the direction tending to cause removal of the end connector 34 from the opening 26 is applied to the end connector 34.

[0043] Next, in this embodiment, the electrical connection surface 52 is defined at least in part by a flexible or deformable member 88 or spring which could be formed integrally, in the same piece of material, as the plug portion 54 or as a separate component assembled to the plug portion 54, and which may be defined by one or more than one distinct component, as desired. The deformable member 88 has an outer surface 90 that, in the at rest or pre-assembly state shown in in FIG. 8, has a greater size or diameter than the busbar opening 26. In the assembled state, shown in FIG. 9, the deformable member 88 is radially inwardly deformed or compressed and the outer surface 90 thereof directly contacts the busbar 12 within the opening 26, and defines at least part of the electrical connection surface 52, enabling electrical conduction between the busbar 12 and end connector 34.

[0044] Further, the retaining surface could be formed in or associated with the busbar 12. For example, the retaining surface could be a groove in the busbar opening 26 into which a radially outer portion of the spring is received when aligned with the groove. In this example, the spring would be radially inwardly compressed upon insertion of the plug portion 54 into the busbar opening 26 and would slide within the busbar opening 26 as the plug portion 54 is advanced in the opening. When the spring becomes axially aligned with the groove, the spring outwardly expands and is partially received in the groove to resist unintended withdrawal of the end connector 34 from the busbar opening 26.

[0045] In at least some implementations, to limit the depth of insertion of the end connector 34 into the busbar opening 26, the end connector 34 includes a radially outward extending stop surface 80, which may be defined by an axial end of an annular flange 82, if desired. The stop surface 80 is arranged between the electrical connection surface 52 and the first end 40 of the end connector 34. The stop surface 80 / flange 82 is not received in the busbar opening 26 and instead radially overlaps part of the front side 18 of the busbar 12 when the end connector 34 is coupled to the busbar 12. When the stop surface 80 contacts the front side 18 of the busbar 12, the end connector 34 is fully installed and the electrical connection surface 52 fully within the busbar opening 26. In this position, a retainer, if provided, may also overlap a stop surface to releasably retain and inhibit withdrawal of the end connector 34 from the busbar opening 26, as noted above.

[0046] Accordingly, a cable 10 can be simply and efficiently coupled to a busbar 12 via an end connector 34 that is pushed or plugged into an opening 26 of the busbar 12. The coupling simultaneously provides electrical connection and mechanical connection and retention of the end connector 34 to the busbar 12 with simple linear / axial motion of the end connector 34 relative to the busbar 12. Mechanical fasteners, like nuts and bolts or otherwise, that must be individually and separately actuated are not needed to secure the end connector 34 to the busbar 12 or establish electrical connection. Thus, connection and disconnection of a cable 10 to the busbar 12 can be achieved simply and in less time and at least cost. Further, while the plug portion 54 and busbar opening 26 are shown as being cylindrical and complementary in size and shape, these components need not be complementarily shaped. For example, the plug portion 54 could have a different polygonal shape (e.g. peripheral shape), providing discrete areas, lines or regions of contact with the busbar 12 within the busbar opening 26, if desired.

[0047] Further constructions and arrangements may be employed. For example, the retainer 84 (e.g., spring or other flexible member) generally shown in FIGS. 8and 9 or the flange 70 of FIG. 3 may be combined with the retaining feature shown in FIG. 7 in which the retainer 74 is carried by the busbar 12. The end connector 34 is thereby configured at its second end with the retainer 74 of FIG. 8 or the flange 70 of FIG. 3 and includes the groove 78 shown in FIG. 7 in which the retainer 74 carried by the busbar 12 engages. The combination of these retention features increases the retention force so that a greater pulling force, e.g., on the cable, is required to disconnect the end connector 34 from the busbar.

[0048] All terms used in the claims are intended to be given their broadest reasonable construction and their ordinary meanings as understood by those skilled in the art unless an explicit indication to the contrary is made herein. In particular, use of the singular articles such as “a,” “the,” “said,” etc. should be read to recite one or more of the indicated elements unless a claim recites an explicit limitation to the contrary.Reference symbols in the figures10 Cable12 Busbar14 First end16 Second end18 Front side20 Back side22 Left side24 Right side26 Busbar opening28 Central axis30 Insulative outer layer32 Conductor34 End connector, electrical end connector36 Cable receptacle38 Inlet40 First end (of the end connector)42 Second end (of the end connector)44 Inner surface46 Tubular portion48 Outer surface50 End (of the conductor)52 Electrical connection surface54 Plug portion56 Void or voids58 Contact portion or flexible contact portion60 Biasing member62 Cavity64 Inner surface66 C-shaped ring67 Ridges or outward extending regions70 Retainer, flange, or retaining surfaceFlangeSpring or torsion springRetaining surfaceGrooveStop surfaceAnnular flangeRetainerSlotDeformable memberOuter surface

Claims

Claims1. An end connector (34) for a cable (10), comprising: a first end (40) with a cable receptacle (36) sized to receive an end of a cable (io); a second end (42) opposite to the first end (40); a plug portion (54) arranged at least partly between the first end (40) and the second end (42) and having an electrical connection surface (52) sized for receipt within an opening (26) of a busbar (12), the plug portion (54) including a void (56), the plug portion (54) defines at least part of a contact portion (58) of the electrical connection surface (52), the contact portion (58) being radially flexible so that the plug portion (54) comprises a first state with a first size and a second state with a second size that is less than the first size; and a retaining surface (70) arranged adjacent to the electrical connection surface (52) and configured to extend radially relative to the electrical connection surface (52).

2. The end connector (34) according to claim 1, which includes a stop surface (80) arranged at an end (40, 42) of the electrical connection surface (52) that is closer to the first end (40) than the second end (42), wherein the stop surface (80) is configured to extend outwardly beyond the electrical connection surface (52).

3. The end connector (34) according to claim 1 or 2, wherein the retaining surface (70) being partially defined by at least one void (56) configured to permit inward flexing of the plug portion (54) and retaining surface (70).

4. The end connector (34) according to claim 3, wherein the void (56) is configured to extend into at least part of the electrical connection surface (52).

5. The end connector (34) according to claim 3 or 4, wherein the electrical connection surface (52) is cylindrical and comprises a central axis (28), and multiplevoids (56) are provided, the voids (56) are circumferentially spaced apart and are configured to extend axially from the second end (42), through the retaining surface (70) and at least partially into the electrical connection surface (52).

6. The end connector (34) according to any one of claims 1 to 5, which includes an inner surface (44) defined by a cavity (62) open to the second end (42), configured to extend axially toward the first end (40), and located radially inwardly of the retaining surface (70) and at least part of the electrical connection surface (52).

7. The end connector (34) according to claim 6, which includes a biasing member (60) received at least partly within the cavity (62) and configured to provide onto the inner surface (44) a radially outwardly acting and biasing force.

8. The end connector (34) according to claim 7, wherein the biasing member (60) is configured as a torsion spring, having an outer surface, configured to engage with at least part of the inner surface (44).

9. The end connector (34) according to claim 7 or 8, wherein the biasing member (60) is received outboard of or defines an outer surface (48, 90) of at least part of the electrical connection surface (52).

10. The end connector (34) according to any one of claims 7 to 9, wherein the biasing member (60) includes at least one portion that is radially compressible.

11. The end connector (34) according to any one of claims 1 to 10, wherein the retaining surface (70) is formed in the electrical connection surface (52) and being defined by a radially inwardly extending groove (78).

12. The end connector (34) according to any one of claims 1 to 11, wherein the retaining surface (70) being defined by an outwardly extending surface at an end of the electrical connection surface (52).

13. The end connector (34) according to claim 12, wherein the retaining surface (70) being defined by or is configured as a flexible retainer (84) located within the plug portion (54).

14. The end connector (34) according to claim 13, wherein the flexible retainer (84) is carried within a groove formed in the electrical connection surface (52).

15. A busbar (12) and cable assembly, comprising: a busbar (12) having a body with an opening (26) formed through the body; a cable (10) having a conductor (32); an end connector (34), preferably configured according to any one of claims 1 to 14, having a first end (40) with a cable receptacle (36) in which part of the conductor (32) is received, the end connector (34) having a second end (42) opposite to the first end (40), and the end connector (34) including a plug portion (54) at least partly between the first end (40) and the second end (42) and having an electrical connection surface (52) sized for receipt within the opening (26), the plug portion (54) including a retaining surface (70) arranged adjacent to the electrical connection surface (52) and configured to extend radially relative to the electrical connection surface (52); and a retainer (74, 84) carried by one of the end connector (34) and the busbar (12), wherein the retainer (74, 84) is arranged to engage the retaining surface (70) when the plug portion (54) is within the opening (26) for resisting removal of the plug portion (54) from the opening (26).

16. The busbar (12) and cable assembly according to claim 15, wherein the retainer (74, 84) is carried by the busbar (12) and is within the opening (26), and the retainingsurface (70) is arranged to engage the retainer (74, 84) when the plug portion (54) is installed in the opening (26).

17. The busbar (12) and cable assembly according to claim 15 or 16, wherein the busbar (12) includes a groove open to the opening (26) and the retainer (74, 84) is received within the groove, and the retainer (74, 84) extends radially inwardly into the opening (26).

18. The busbar (12) and cable assembly according to any one of claims 15 to 17, wherein the end connector (34) includes a groove (78) in which the retainer (74, 84) is partly received when the plug portion (54) is installed in the opening (26).

19. The busbar (12) and cable assembly according to any one of claims 15 to 17, wherein the retainer (74, 84) is carried by the end connector (34) and is partially received in a groove (78) formed in the electrical connection surface (52), and wherein the retainer (74, 84) defines the retaining surface (70), and the busbar (12) includes a groove that is open to the opening (26) and in which the retainer (74, 84) is partly received when the plug portion (54) is installed in the opening (26).

20. A method for manufacturing a busbar (12) and cable assembly according to any one of claims 15 to 19, comprising the steps of: providing said busbar (12) having at least one through opening (26) and said cable assembly having a cable (10) assembled with said end connector (34), preferably configured according to any one of claims 1 to 14; inserting the end connector (34) with its second end (42) into the at least one through opening (26) and moving the end connector (34) until the retainer (74, 84) is arranged to engage the retaining surface (70) when the plug portion (54) is within the opening (26) to resist removal of the plug portion (54) from the opening (26).

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