Connector for modular busbar

Abstract

A busbar connector assembly (10) includes a first insulator (120) disposed within a first passageway (112) of a first busbar (100), defining a first insulator passage (130), and retaining a washer (140) therein. A second insulator (220) is disposed within a second passageway (212) of a second busbar (200), defines a second insulator passage (230), and retains a connector body (240) therein. The assembly includes a fastener (300) including a head (302), a threaded body (304), and a tip (306), the threaded body (304) extending through the first and second insulator passages (130, 230) to engage with the connector body (240). A locking washer (320) disposed adjacent to the washer (140) engages with the threaded body (304) of the fastener (300). The fastener (300) mechanically and electrically couples the first and second busbars (100, 200) together. The fastener (300) is electrically isolated from the first and second busbars (100, 200).

Description

MCC Docket No. 11694-119WO1Eaton Ref. P24-1832WO01 CONNECTOR FOR MODULAR BUSBARCROSS REFERENCE

[0001] This application claims priority to and the benefit of Italian Patent Application No.102025000000270, filed January 9, 2025, the entire contents of which is hereby incorporated by reference.BACKGROUND

[0002] Electrical connectors, such as busbar connectors, are used to mechanically and electrically connect components of an electrical assembly. For example, two conductive busbars may be coupled to each other via a connector. The two conductive busbars and the connector between them may form a connection between two components in an electrical assembly (e.g., a battery module and / or a current drawing device). Such an electrical assembly may operate at a high voltage and may include insulative elements to protect a user from the high voltage.

[0003] A need exists for a busbar connector providing a consistent and safe connection between adjacent busbars.SUMMARY

[0004] According to one implementation, a busbar connector assembly is disclosed. The busbar connector assembly includes a first insulator, a second insulator, a fastener, and a locking washer. The first insulator defines a first insulator passage. The first insulator retains a washer therein. The second insulator defines a second insulator passage. The second insulator retains a connector body therein. The second insulator is configured to couple to the first insulator to align the first and second insulator passages along a longitudinal axis . The fastener including a head, a threaded body, and a tip. The threaded body extends through the first and second insulator passages to engage with the connector body. The locking washer is disposed adjacent to the washer and engaged with the threaded body of the fastener. The first insulator is configured to be at least partially disposed within a first passageway of a first busbar and the second insulator is configured to be at least partially disposed within a second passageway of a second busbar. The fastener is configured to mechanically and electrically couple the first and second busbars together. The fastener is electrically isolated from the first and second busbars.MCC Docket No. 11694-119WO1Eaton Ref. P24-1832WO01

[0005] In some implementations, the first insulator includes a first collar retaining the washer and abutting a first opening in the first busbar, wherein the first collar is adjacent a first end of the first insulator, and a first neck integrally formed with the first collar and extending into the first passageway of the first busbar, the first neck extending from the first collar to a second end of the first insulator.

[0006] In some implementations, the first neck includes a shoulder defined adjacent the second end of the first insulator, and wherein the second insulator further includes a second neck having an extension couplable with the shoulder of the first insulator.

[0007] In some implementations, the first neck is disposed within the first passageway of the first busbar, wherein the second insulator further includes a second neck extending outside of the second passageway of the second busbar and is configured to extend into the first passageway of the first insulator and engage with the first neck of the first insulator.

[0008] In some implementations, the second insulator include: a second collar abutting a second opening of the second busbar; and a second neck integrally formed with the second collar and extending into the second passageway of the second busbar, wherein the connector body is retained by the second collar and extends along a portion of the second neck.

[0009] In some implementations, wherein the connector body includes a tapered inner surface and a threaded inner surface couplable to the threaded body of the fastener.

[0010] In some implementations, the second collar includes an anti-rotation opening retaining a portion of the connector body to prevent rotation of the connector body relative to the second insulator.

[0011] In some implementations, the anti-rotation opening has a non-circular shape as viewed in a plane that is perpendicular to the longitudinal axis.

[0012] In some implementations, the first busbar includes a first flange defining the first passageway and the second busbar includes a second flange defining the second passageway, wherein the first flange is mechanically and electrically couplable to the second flange.

[0013] In some implementations, the first flange is mechanically and electrically coupled to the second flange.MCC Docket No. 11694-119WO1Eaton Ref. P24-1832WO01

[0014] In some implementations, the first flange and the first passageway are formed via a punching process in a solid busbar.

[0015] In some implementations, the locking washer is configured to maintain connection between the first and second busbars and prevent loosening of the fastener.

[0016] In some implementations, the locking washer engages with the washer to prevent loosening of the fastener.

[0017] In some implementations, the head of the fastener forms a touch proof portion of the busbar connector assembly.

[0018] In some implementations, a diameter of the threaded body of the fastener is smaller than an inner diameter of the washer such that the washer does not contact the fastener.

[0019] In some implementations, during assembly, the first insulator is fit into the first passageway of the first busbar, then the locking washer and the fastener are inserted into first insulator passageway.

[0020] In some implementations, the first insulator is fit into the first busbar by any one of: (i) epoxy filling, (ii) stamping, or (iii) insulation tape.

[0021] In some implementations, the busbar connector assembly further includes a first housing encapsulating at least a portion of the first busbar, the first insulator, and the fastener, the first housing electrically isolating at least a portion of the first busbar from an external environment.

[0022] In some implementations, the first housing includes a protrusion surrounding the head of the fastener, the protrusion defining a fastener opening allowing access to the head of the fastener.

[0023] In some implementations, the first housing includes a first flange covering that surrounds and extends longitudinally past a first flange of the first busbar.

[0024] In some implementations, the first housing includes two portions that are couplable together via one or more snap fit protrusions.

[0025] In some implementations, the first housing defines a busbar opening adjacent to a second end of the first busbar opposite from the first end having the first passageway, wherein the busbarMCC Docket No. 11694-119WO1Eaton Ref. P24-1832WO01 opening is configured to provide electrical connection access to the first busbar by a separate electrically conductive device.

[0026] In some implementations, the busbar connector assembly further includes a second housing encapsulating at least a portion of the second busbar, the second insulator, and the fastener, the second housing electrically isolating a portion of the second busbar from the external environment.

[0027] In some implementations, the first housing and the second housing engage with each other to insulate the connection between the first and second busbars from the external environment.

[0028] This summary is illustrative only and is not intended to be in any way limiting. Other aspects, features, and advantages of the devices or processes described herein will become apparent in the detailed description set forth herein, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements.BRIEF DESCRIPTION OF DRAWINGS

[0029] Devices, assemblies, and systems are explained in even greater detail in the following drawings. The drawings are merely exemplary, and certain features may be used singularly or in combination with other features. The drawings are not necessarily drawn to scale.

[0030] FIG. 1 is an isometric view of a busbar connector assembly, according to one implementation.

[0031] FIG. 2 is another isometric view of the busbar connector assembly of FIG. 1.

[0032] FIG. 3 is a side view of the busbar connector assembly of FIG. 1.

[0033] FIG. 4 is a top view of the busbar connector assembly of FIG. 1.

[0034] FIG. 5 is a cross-sectional view of the busbar connector assembly of FIG. 1 taken along line 5-5 in FIG. 4.

[0035] FIG. 6 is an isometric view of the cross-section of FIG. 5.

[0036] FIG. 7 is a cross-sectional view of the busbar connector assembly of FIG. 1 taken along line 7-7 in FIG. 4.MCC Docket No. 11694-119WO1Eaton Ref. P24-1832WO01

[0037] FIG. 8 is an isometric view of the cross-section of FIG. 7.

[0038] FIG. 9A and FIG. 9B show isometric views of a first insulator, according to one implementation.

[0039] FIG. 10A and FIG. 10B show isometric views of a second insulator, according to one implementation.

[0040] FIG. 11 shows a cross-sectional view of a second insulator and a connector body coupled together, according to one implementation.

[0041] FIG. 12 is an isometric view of a first half of the busbar connector assembly of FIG. 1, including the second housing, according to one implementation.

[0042] FIG. 13 is an isometric view of a second half of the busbar connector assembly of FIG. 1, including the first housing, according to one implementation.DETAILED DESCRIPTION

[0043] Following below are more detailed descriptions of concepts related to, and implementations of, methods, apparatuses, and systems for a busbar connector assembly. The figures illustrate exemplary implementations in detail, and the present disclosure is not limited to the details or methodology set forth in the description or illustrated in the figures. The terminology used herein is for the purpose of description only and should not be regarded as limiting.

[0044] In general, conductive members, such as busbars, may be used in electrical assemblies to provide a connection between electrical components. For example, busbars may be used in electric vehicles to couple battery modules between each other or between adjacent electrical devices in the vehicle (e.g., a motor, a charging unit, or an interior current-drawing device). Busbars may be used in high voltage applications to quickly and efficiently transfer electrical potential where desired (e.g., from a charging unit to a battery module).

[0045] As shown in FIGS. 1-13, a busbar connector assembly 10 is shown, according to one implementation. In particular, FIGS. 5-8 show cross-sectional views of the busbar connector assembly 10, which show the internal elements of the assembly and the connection formed therein. The busbar connector assembly 10 is configured to mechanically and electrically couple a first conductive member to a second conductive member. As shown in FIGS. 5-8, the busbar connectorMCC Docket No. 11694-119WO1Eaton Ref. P24-1832WO01 assembly 10 is configured mechanically and electrically couple a first busbar 100 to a second busbar 200. The busbars 100, 200 provide a flow path for current and / or voltage between electrical connections and / or devices. The busbars 100, 200 may also be insulated to allow transfer of current and voltage in a safe manner, as further described herein.

[0046] As shown in FIGS. 5-8, the first busbar 100 includes a first side 102 and a second side 104 opposite and spaced apart from the first side 102. The first busbar 100 further includes a first end 108 and a second end (not shown) spaced apart from the first end 108 in a longitudinal direction. The first busbar 100 includes an eyelet or a first flange 110 punched out from the body on the first end 108 of the first busbar 100. A first opening 106 is defined on the first side 102 of the first busbar 100, axially aligned with the first flange 110. The first flange 110 extends from the second side 104 of the first busbar 100 away from the first side 102 along a longitudinal axis. The first flange 110 defines a first passageway 112 that extends through the first busbar 100. Specifically, an inner surface 114 of the first flange 110 defines the first passageway 112. The first passageway 112 extends from the first opening 106 on the first side 102 of the first busbar 100 to a first flange opening on the end of the first flange 110.

[0047] The second busbar 200 is substantially similar to the first busbar 100. The second busbar 200 includes a first side 202 and a second side 204 opposite and spaced apart from the first side 202. The second busbar 200 further includes a first end 208 and a second end (not shown) spaced apart from the first end 108 in a longitudinal direction. The second busbar 200 includes an eyelet or a second flange 210 punched out from the body on the first end 208 of the second busbar 200.A second opening 206 is defined on the first side 202 of the second busbar 200, axially aligned with the second flange 210. The second flange 210 extends from the second side 204 of the second busbar 200 away from the first side 202 along a longitudinal axis. The second flange 210 defines a second passageway 212 that extends through the second busbar 200. Specifically, an inner surface 214 of the second busbar 200 defines the second passageway 212. The second passageway 212 extends from the second opening 206 on the first side 202 of the second busbar 200 to a second flange opening.

[0048] Each of the first and second busbar 100, 200 includes a conductive material (e.g., copper) configured to transfer high voltage electricity therethrough. When assembled and / or coupled together, the first ends 108, 208 of the first and second busbars 100, 200 are mechanically and electrically connected on the ends of their respective flanges 110, 210, as shown in FIGS. 5-8. The second ends (not shown) of the first and second busbars 100, 200 opposite from the connected firstMCC Docket No. 11694-119WO1Eaton Ref. P24-1832WO01 ends 108, 208 are configured to couple to a separate electrically conductive component or device (e.g., a battery module). As shown in FIGS. 5-6, the first and second busbars 100, 200 are partially shown, wherein the second end extending out of the respective housings is not shown. However, it is understood that the busbars 100, 200 may extend further to connect to a separate electrically conductive component or device (e.g., a battery module).

[0049] To connect the first and second busbars 100, 200 together in a safe and efficient manner, the busbar connector assembly 10 includes a first insulator 120, a second insulator 220, a first housing 160, a second housing 260, a fastener 300, and a locking washer 320. In general, the first and second insulators 120, 220 electrically isolate the fastener 300 from the first and second busbars 100, 200 as further described herein. The first and second insulators 120, 220 include a rigid, insulative material (e.g., a rigid plastic material).

[0050] The first insulator 120 is at least partially disposed within the first passageway 112 of the first flange 110 of the first busbar 100. As shown in more detail in FIGS. 9A and 9B, the first insulator 120 includes an inner surface 122 that defines a first insulator passage 130. The first insulator 120 includes a first collar 124 on a first end that is integrally formed with a first neck 126. The first neck 126 extends axially from the first collar 124 to a second end of the first insulator 120 opposite and spaced apart from the first end. As shown in FIGS. 5-8, the first insulator passage 130 axially aligns with the first passageway 112 of the first flange 110 of the first busbar 100.

[0051] As shown in FIG. 9B, the first neck 126 includes a shoulder 128 defined adjacent to the second end of the first insulator 120. In particular, the shoulder 128 of the first neck 126 is a circumferential surface extending between two portions of an outer surface 132 of the first insulator 120, wherein the two portions of the outer surface 132 are radially spaced apart from one another. Thus, the circumferential surface of the shoulder 128 is substantially perpendicular to the outer surface 132 of the first insulator 120, providing a landing surface for a portion of the second insulator 220, as further described herein. In other implementations, the shoulder on the second end of the first insulator has a different orientation or geometry (e.g., a shoulder defined along the inner surface of the first insulator, along the first insulator passage).

[0052] The first collar 124 of the first insulator 120 retains a washer 140 therein. The washer 140 may be formed of a conductive and / or rigid material (e.g., a metal material). As shown in FIGS.5-8, the washer 140 includes an outer diametric edge 142 entirely embedded within the first collar 124 of the first insulator 120 (e.g., formed by a molding operation). The washer 140 includes anMCC Docket No. 11694-119WO1Eaton Ref. P24-1832WO01 inner diametric edge 144 defining a washer opening that is axially aligned with the first insulator passage 130. As shown, the inner diametric edge 144 of the washer 140 coincides with, or has the same diameter as, a portion of the inner surface 122 that defines the first insulator passage 130. However, in other implementations, the inner diametric edge of the washer may have a different diameter.

[0053] When assembled, the first insulator 120 fits into the first passageway 112 of the first busbar 100 such that the first collar 124 abuts the first side 102 of the first busbar 100 adjacent to the first opening 106. The first neck 126 of the first insulator 120 extends into the first passageway 112 of the first busbar 100 along the inner surface 114 of the first flange 110. In particular, at least a portion of the outer surface 132 of the first insulator 120 abuts and / or aligns parallel to the inner surface 114 of the first flange 110. In some implementations, the first insulator 120 is coupled and / or fitted into the first busbar 100 by (i) epoxy filling, (ii) stamping, or (iii) insulation tape.

[0054] As shown in FIGS. 5-8, the second insulator 220 is at least partially disposed within the second passageway 212 of the second flange 210 of the second busbar 200. As shown in more detail in FIGS. 10A and 10B, the second insulator 220 includes an inner surface 222 that defines a second insulator passage 230. The second insulator passage 230 axially aligns with the second passageway 212 of the second busbar 200. The second insulator 220 includes a second collar 224 on a first end that is integrally formed with a second neck 226. The second neck 226 extends axially from the second collar 224 to a second end of the second insulator 220 opposite and spaced apart from the first end of the second insulator 220.

[0055] As shown in FIG. 10A, the second neck 226 includes an extension 228. As shown in FIGS. 5-8, the extension 228 of the second insulator 220 is couplable to the shoulder 128 of the first insulator 120. For example, the shoulder 128 of the first insulator 120 and the extension 228 of the second insulator 220 have corresponding or complementary diameters such that the extension 228 of the second insulator 220 abuts the shoulder 128 of the first insulator 120. Furthermore, a portion of the first neck 126 is inserted into the second insulator passage 230 to abut a shoulder or a radial extension formed along the inner surface 222 of the second insulator passage 230 of the second insulator 220. The interaction between the second ends of the first and second insulators 120, 220 effectively couples the first and second insulators 120, 220 together. In other implementations, a portion of the second neck 226 may be inserted into the first insulator passage 130 to couple the first and second insulators 120, 220 together. In other implementations,MCC Docket No. 11694-119WO1Eaton Ref. P24-1832WO01 the second ends of the first and second insulators 120, 220 have a different corresponding geometry to facilitate coupling therebetween.

[0056] As shown in FIG. 11, the second insulator 220 retains a connector body 240 therein. The connector body 240 includes a rigid and / or conductive material (e.g., metal or rigid plastic). The connector body 240 includes a connector head 242 and a connector neck 244 extending axially from the connector head 242. The connector body 240 is retained by the second collar 224 of the second insulator 220. The second collar 224 of the second insulator 220 defines an anti-rotation opening that receives and retains a portion of the connector body 240 (e.g., the connector head 242) to prevent rotation of the connector body 240 within or relative to the second insulator 220. For example, the anti-rotation opening has a non-circular shape (e.g., polygonal, hexagonal, or oval) as viewed in a plane that is perpendicular to the longitudinal axis of the second insulator 220 and / or the connector body 240.

[0057] As shown in FIG. 11, at least a portion of the connector neck 244 extends along a portion of the second neck 226 within the second insulator passage 230 of the second insulator 220. Thus, an outer surface 246 of the connector body 240 contacts the inner surface 222 of the second insulator 220. The connector body 240 includes an inner surface 248 defining a connector passage 250 extending between a first opening and a second opening axially spaced apart from each other. The inner surface 248 of the connector body 240 further includes a tapered surface 252 adjacent one end of the connector body 240 (e.g., adjacent to the second end of the second insulator 220). For example, the tapered surface 252 facilitates entry and alignment of a fastener entering the connector passage 250. The inner surface 248 of the connector body 240 also includes a threaded surface 254 extending along at least a portion of the inner surface 248 (e.g., adjacent to the first end of the second insulator 220). In FIG. 11, the threads along the threaded surface 254 are not explicitly or individually shown, but it is understood that standard screw threads may be included along the threaded surface 254 of the connector body 240.

[0058] The fastener 300 of the busbar connector assembly 10 is configured to mechanically couple the first and second busbars 100, 200 together. As shown in FIGS. 5-8, , the fastener 300 (e.g., a screw) includes a head 302, a threaded body 304, and a tip 306. The threaded body 304 of the fastener 300 extends at least partially through both the first insulator passage 130 of the first insulator 120 and second insulator passage 230 of the second insulator 220. The head 302 of the fastener 300 is adjacent to the first collar 124 of the first insulator 120. The head 302 defines a drive 308 configured to receive a screwdriver or other similar tool.MCC Docket No. 11694-119WO1Eaton Ref. P24-1832WO01

[0059] The threaded body 304 has a diameter smaller than that of the inner diametric edge 144 of the washer 140 such that the washer 140 does not touch or interfere with the fastener 300. The threaded body 304 of the fastener 300 is inserted into and engaged with the connector body 240 retained in the second insulator 220. Thus, the fastener 300 engages with and couples to the connector body 240. For example, the tip 306 of the fastener 300 may be aligned via the tapered surface 252 of the connector body 240. The threaded body 304 engages with the threaded surface 254 of the connector body 240 to couple the connector body 240 to the fastener 300.

[0060] Connection of the threaded body 304 of the fastener 300 to the threaded surface 254 of the connector body 240 draws the first and second busbars 100, 200 together, along with their surrounding elements / features. For example, the fastener 300 may be rotated to engage with the connector body 240 until the first and second busbars 100, 200 and / or the first and second insulators 120, 220 mechanically engage with each other. For example, the fastener 300 may be rotated to engage with the connector body 240 until the first flange 110 of the first busbar 100 contacts the second flange 210 of the second busbar 200, as shown in FIG. 5. In some implementations, the force of the connection between the first and second busbars 100, 200 is controlled based on rotation of the fastener 300.

[0061] The fastener 300 is electrically isolated from the first and second busbars 100, 200 via the first and second insulators 120, 220. The connector body 240 is also electrically isolated from the first and second busbars 100, 200. Thus, the fastener 300 can be used to force the first and second flanges 110, 210 of the first and second busbars 100, 200 together without the danger of the fastener 300 being electrically active and / or charged. Thus, a user connecting the first and second busbars 100, 200 together can avoid any danger associated with contacting the fastener 300 (since it is electrically isolated).

[0062] The locking washer 320 is configured to maintain the connection between the first and second busbars 100, 200, and prevent loosening of the fastener 300. For example, the fastener 300 and the threaded body 304 thereof engage with the locking washer 320 to maintain the coupling force between the fastener 300 and the connector body 240. In some implementations, the locking washer 320 is an elastic component that provides compliance for thermal expansion of the assembly and maintains pressure between the first and second busbars 100, 200.

[0063] As shown in FIGS. 5-8, the locking washer 320 is disposed within a space defined by the inner surface 122 of the first insulator 120 adjacent to the first collar 124. However, in otherMCC Docket No. 11694-119WO1Eaton Ref. P24-1832WO01 implementations, the locking washer 320 is disposed in a different position relative to the first insulator 120. The locking washer 320 extends around the threaded body 304 of the fastener 300. The locking washer 320 is disposed between the washer 140 in the first insulator 120 and the head 302 of the fastener 300. During assembly, after the first insulator 120 is inserted into the first passageway 112 of the first busbar 100, the locking washer 320 is inserted into the first insulator passage 130, followed by the tip 306 of the fastener 300.

[0064] The locking washer 320 may include a ratcheting surface (or other locking mechanism) adjacent to the washer 140 to prevent loosening of the fastener. The pressure and / or force from the fastener 300 that is transferred to the locking washer 320 is then transferred through the washer 140 in the first insulator 120, rather than to the first insulator 120 directly. The washer 140 in the first insulator 120 thus provides a rigid surface for force transfer between (i) the fastener 300 and / or locking washer 320 and (ii) the first insulator 120. This arrangement avoids any metal components (e.g., the fastener and / or locking washer) from damaging the relatively softer material (e.g., plastic insulative material) of the first insulator 120.

[0065] In other implementations, the locking washer is a grower washer (or pressure washer), which acts as an elastic component. The grower washer is configured to maintain the load between the first and second busbars while avoiding loosening of the electrical contact therebetween.

[0066] The first housing 160 of the busbar connector assembly 10 encapsulates at least a portion of the first busbar 100, the first insulator 120, and the fastener 300. The first housing 160 electrically isolates at least a portion of the first busbar 100 from an external environment. As shown in FIGS. 1-6, the first housing 160 defines a busbar opening 162 adjacent to a second end of the first busbar 100 opposite from the first end 108 having the first flange 110. The busbar opening 162 is configured to provide electrical connection access to the first busbar 100 by a separate electrically conductive device or component (not shown).

[0067] As best shown in FIGS. 1-2 and FIG. 13, the first housing 160 includes at least two portions that are couplable to each other. For example, the first housing 160 includes a first portion 164 (e.g., an upper portion) and a second portion 166 (e.g., a lower portion) coupled to the first portion 164. The first portion 164 includes at least one sidewall defining one or more openings 168. The second portion 166 of the first housing 160 includes at least one sidewall including one or more protrusions 170 (e.g., snap-fit protrusions with a shoulder and a ramp). As shown in FIGS.1-2, the sidewall of the first portion 164 extends over the sidewall of the second portion 166. TheMCC Docket No. 11694-119WO1Eaton Ref. P24-1832WO01 one or more protrusions 170 of the second portion 166 extend through the one or more openings 168 of the first portion 164, coupling the first portion 164 to the second portion 166. The arrangement, number, and orientation of the snap fit protrusions and corresponding openings may be reconfigured, reorganized, or otherwise changed from the embodiment shown in the drawings. Thus, other configurations of coupling features for the first housing are contemplated by this disclosure.

[0068] The first portion 164 of the first housing 160 further includes a fastener covering portion 172. As shown in FIG. 5, the fastener covering portion 172 surrounds and covers the head 302 of the fastener 300. The fastener covering portion 172 defines a fastener opening 174 allowing access to the head 302 and the drive 308 of the fastener 300 (e.g., for a screwdriver or other tool to engage the fastener).

[0069] As shown in FIG. 13, the first housing 160 further includes a first flange covering 180. The first flange covering 180 extends outwardly from a surface of the second portion 166 around the first flange 110 and the first insulator 120. In general, the first flange covering 180 includes a cylindrical body 182 defining a cylindrical opening 186 within which the fastener 300 is disposed. The cylindrical body 182 provides touch-proof protection and isolation for the first busbar 100. For example, a user is unable to accidentally contact the first busbar 100 or other internal components within the first housing 160 due to the shape and location of the first flange covering 180.

[0070] The first flange covering 180 further includes alignment ridges 184 extending radially outwardly from the cylindrical body 182. The alignment ridges 184 are configured to be inserted into a portion of the second housing 260 for proper alignment of the first housing 160 with the second housing 260, as further described herein.

[0071] As shown in FIG. 13, the first housing 160 further includes a block protrusion 176 that extends towards the second housing 260 and a receptacle 274 defined therein. As shown in FIG.6, the block protrusion 176 of the first housing 160 can couple to the receptacle 274 of the second housing 260. This connection can increase rigidity, alignment, and / or consistency of the connection between the first and second housings 160, 260.

[0072] The second housing 260 of the busbar connector assembly 10 encapsulates at least a portion of the second busbar 200, the second insulator 220, and the fastener 300. The second housing 260 electrically isolates at least a portion of the second busbar 200 from the externalMCC Docket No. 11694-119WO1Eaton Ref. P24-1832WO01 environment. As shown in FIG. 1 and FIG. 12, the second housing 260 defines a busbar opening 262 adjacent to a second end of the second busbar 200 opposite from the first end 208 having the second flange 210. As shown, the busbar 200 includes a curved portion that is out of plane from the first end 208 of the second busbar 200, extending upward in FIGS. 1 and 12 to exit through the busbar opening 262. The busbar opening 262 is configured to provide electrical connection access to the second busbar 200 by a separate electrically conductive device or component (not shown).

[0073] As shown in FIG. 1 and FIG. 12, the second housing 260 includes at least two portions that are couplable to each other. For example, the second housing 260 includes a first portion 264 (e.g., an upper portion) and a second portion 266 (e.g., a lower portion) coupled to the first portion 264. The first portion 264 includes at least one sidewall defining one or more openings 268. The second portion 266 of the second housing 260 includes at least one sidewall including one or more protrusions 270 (e.g., snap-fit protrusions with a shoulder and a ramp). As shown in FIG. 1, the sidewall of the first portion 264 extends over the sidewall of the second portion 266. The one or more protrusions 270 of the second portion 266 extend through the one or more openings 268 of the first portion 264, coupling the first portion 264 to the second portion 266. The arrangement, number, and orientation of the snap fit protrusions and corresponding openings may be reconfigured, reorganized, or otherwise changed from the embodiment shown in the drawings. Thus, other configurations of coupling features for the first housing are contemplated by this disclosure.

[0074] As shown in FIG. 12, the second housing 260 further includes a second flange covering 280. The second flange covering 280 extends outwardly from a surface of the second portion 266 around the second flange 210 and the second insulator 220. In general, the second flange covering 280 includes a body 282 defining a cylindrical opening 284. The body 282 provides touch-proof protection and isolation for the second busbar 200. For example, a user is unable to accidentally contact the second busbar 200 or other internal components within the second housing 260 due to the shape and location of the second flange covering 280.

[0075] The second flange covering 280 further includes alignment channels 286 extending radially outwardly from the body 282. The alignment channels 286 are configured to receive the alignment ridges 184 of the first flange covering 180. In particular, each of the alignment ridges 184 on the first flange covering 180 of the first housing 160 are aligned with and inserted into theMCC Docket No. 11694-119WO1Eaton Ref. P24-1832WO01 alignment channels 286 of the second flange covering 280 of the second housing 260. Thus, the first and second housings 160, 260 are properly aligned and coupled together.

[0076] As shown in FIG. 12, the second housing 260 further includes the receptacle 274 that receives the block protrusion 176 of the first housing 160. This connection can increase rigidity, alignment, and / or consistency of the connection between the first and second housings 160, 260. Proper alignment and coupling of the first and second housings 160, 260 further ensures proper alignment and coupling of the first flange 110 of the first busbar 100 with the second flange 210 of the second busbar 200.

[0077] The resulting busbar connector assembly 10 forms a touch-proof connection between the first and second busbars 100, 200. During assembly, each side of the busbar connector assembly 10 (e.g., the first busbar side and the second busbar side) is configured such that a user cannot accidentally contact the conductive busbar. For example, as shown in FIGS. 12 and 13, the first flange covering 180 and the second flange covering 280 provide an axial offset between the corresponding first flange 110 or second flange 210. Any space between the conductor (e.g., the first flange 110 or the second flange 210 of the respective busbar) and a portion of the respective insulative housing is still smaller than a user’s finger. Thus, accidental contact with the conductive material of the busbar connector assembly 10 is prevented.Conclusion

[0078] For purposes of this description, certain advantages and novel features of the aspects and configurations of this disclosure are described herein. The described methods, systems, and apparatus should not be construed as limiting in any way. Instead, the present disclosure is directed toward all novel and nonobvious features and aspects of the various disclosed aspects, alone and in various combinations and sub-combinations with one another. The disclosed methods, systems, and apparatus are not limited to any specific aspect, feature, or combination thereof, nor do the disclosed methods, systems, and apparatus require that any one or more specific advantages be present or problems be solved.

[0079] Although the figures and description may illustrate a specific order of method steps, the order of such steps may differ from what is depicted and described, unless specified differently above. Also, two or more steps may be performed concurrently or with partial concurrence, unless specified differently above. All such variations are within the scope of the disclosure.MCC Docket No. 11694-119WO1Eaton Ref. P24-1832WO01

[0080] Features disclosed in this specification (including any accompanying claims, abstract, and drawings), and / or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and / or steps are mutually exclusive. The claimed features extend to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract, and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

[0081] As used in the specification and the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise. The terms “coupled”, “connected”, and the like as used herein mean the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another. If “coupled” or variations thereof are modified by an additional term (e.g., directly coupled), the generic definition of “coupled” provided above is modified by the plain language meaning of the additional term (e.g., “directly coupled” means the joining of two members without any separate intervening member), resulting in a narrower definition than the generic definition of “coupled” provided above. Such coupling may be mechanical, electrical, or fluidic.

[0082] Certain terminology is used in the following description for convenience only and is not limiting. The words “inner” and “outer” refer to directions toward and away from, respectively, the geometric center of the described feature or device. The terminology includes the above-listed words, derivatives thereof, and words of similar import.

[0083] Throughout the description and claims of this specification, the word “comprise” and variations of the word, such as “comprising” and “comprises”, means “including but not limited to”, and is not intended to exclude, for example, other additives, components, integers or steps. “Exemplary” means “an example of’ and is not intended to convey an indication of a preferred or ideal aspect. “Such as” is not used in a restrictive sense, but for explanatory purposes.

[0084] The corresponding structures, materials, acts, and equivalents of all means or step plus function elements in the claims below are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed. TheMCC Docket No. 11694-119WO1Eaton Ref. P24-1832WO01 description of the present disclosure has been presented for purposes of illustration and description but is not intended to be exhaustive or limited to the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the present disclosure.

Claims

MCC Docket No. 11694-119WO1Eaton Ref. P24-1832WO01 What is claimed is:

1. A busbar connector assembly, comprising:a first insulator defining a first insulator passage, the first insulator retaining a washer therein;a second insulator defining a second insulator passage, the second insulator retaining a connector body therein, wherein the second insulator is configured to couple to the first insulator to align the first and second insulator passages along a longitudinal axis;a fastener comprising a head, a threaded body, and a tip, the threaded body extending through the first and second insulator passages to engage with the connector body; anda locking washer disposed adjacent to the washer and engaged with the threaded body of the fastener;wherein the first insulator is configured to be at least partially disposed within a first passageway of a first busbar and the second insulator is configured to be at least partially disposed within a second passageway of a second busbar,wherein the fastener is configured to mechanically and electrically couple the first and second busbars together, andwherein the fastener is electrically isolated from the first and second busbars.

2. The busbar connector assembly of claim 1, wherein the first insulator comprises:a first collar retaining the washer and abutting a first opening in the first busbar, wherein the first collar is adjacent a first end of the first insulator; anda first neck integrally formed with the first collar and extending into the first passageway of the first busbar, the first neck extending from the first collar to a second end of the first insulator.

3. The busbar connector assembly of claim 2, wherein the first neck includes a shoulder defined adjacent the second end of the first insulator, and wherein the second insulator further includes a second neck having an extension couplable with the shoulder of the first insulator.

4. The busbar connector assembly of claim 2, wherein the first neck is disposed within the first passageway of the first busbar, wherein the second insulator further includes a second neck extending outside of the second passageway of the second busbar and is configured to extend into the first passageway of the first insulator and engage with the first neck of the first insulator.MCC Docket No. 11694-119WO1Eaton Ref. P24-1832WO015. The busbar connector assembly of claim 1, wherein the second insulator comprises: a second collar abutting a second opening of the second busbar; anda second neck integrally formed with the second collar and extending into the second passageway of the second busbar, wherein the connector body is retained by the second collar and extends along a portion of the second neck.

6. The busbar connector assembly of claim 5, wherein the connector body includes a tapered inner surface and a threaded inner surface couplable to the threaded body of the fastener.

7. The busbar connector assembly of claim 5, wherein the second collar includes an antirotation opening retaining a portion of the connector body to prevent rotation of the connector body relative to the second insulator.

8. The busbar connector assembly of claim 7, wherein the anti -rotation opening has a noncircular shape as viewed in a plane that is perpendicular to the longitudinal axis.

9. The busbar connector assembly of claim 1, wherein the first busbar includes a first flange defining the first passageway and the second busbar includes a second flange defining the second passageway, wherein the first flange is mechanically and electrically couplable to the second flange.

10. The busbar connector assembly of claim 9, wherein the first flange and the first passageway are formed via a punching process in a solid busbar.

11. The busbar connector assembly of claim 1, wherein the head of the fastener forms a touch proof portion of the busbar connector assembly.

12. The busbar connector assembly of claim 1, wherein, during assembly, the first insulator is fit into the first passageway of the first busbar, then the locking washer and the fastener are inserted into first insulator passageway.MCC Docket No. 11694-119WO1Eaton Ref. P24-1832WO01 13. The busbar connector assembly of claim 1, wherein the first insulator is fit into the first busbar by any one of: (i) epoxy filling, (ii) stamping, or (iii) insulation tape.

14. The busbar connector assembly of claim 1, further comprising a first housing encapsulating at least a portion of the first busbar, the first insulator, and the fastener, the first housing electrically isolating at least a portion of the first busbar from an external environment.

15. The busbar connector assembly of claim 14, wherein the first housing includes a protrusion surrounding the head of the fastener, the protrusion defining a fastener opening allowing access to the head of the fastener.

16. The busbar connector assembly of claim 14, wherein the first housing comprises a first flange covering that surrounds and extends longitudinally past a first flange of the first busbar.

17. The busbar connector assembly of claim 14, wherein the first housing comprises two portions that are couplable together via one or more snap fit protrusions.

18. The busbar connector assembly of claim 14, the first housing defining a busbar opening adjacent to a second end of the first busbar opposite from the first end having the first passageway, wherein the busbar opening is configured to provide electrical connection access to the first busbar by a separate electrically conductive device.

19. The busbar connector assembly of claim 14, further comprising a second housing encapsulating at least a portion of the second busbar, the second insulator, and the fastener, the second housing electrically isolating a portion of the second busbar from the external environment.

20. The busbar connector assembly of claim 19, wherein the first housing and the second housing engage with each other to insulate the connection between the first and second busbars from the external environment.

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