A busway system including a first electrical busway section, a second electrical busway section, the first and the second electrical busway sections being offset from each other, a busway joint for coupling the first and the second electrical busway sections. The busway joint including a plurality of busbars, a plurality of splice plates electrically coupled to the plurality of busbars, the plurality of splice plates and the plurality of busbars configured to electrically couple the first and the second electrical busway sections, and a pivot shaft passing through the plurality of busbars and splice plates.

An electrical bus bar assembly includes an elongate flexible electrical conductor formed of a strip of electrically conductive material having a generally rectangular cross section and a width to thickness ratio of at least 20:1 and a dielectric material covering a central portion of the electrical conductor such that the electrical conductor has exposed distal portions at each end of the assembly. Further, a method for forming such as assembly includes the steps of forming a flexible strip from an electrically conductive sheet such that the strip has a generally rectangular cross section with a width to thickness ratio of at least 20:1 and covering a central portion of the strip with a dielectric material and leaving distal portions at each end exposed.

A high voltage distribution system is provided with multiple fuses. The high voltage distribution system includes multiple laminated busbars that are electrically coupled to a battery and to the multiple fuses. Busbars are electrically coupled to the one or more fuses via electrical connections between the busbars and the fuses. The electrical connections can pass through other busbars without having an electrical coupling to the other busbars. An insulating layer may be used between the busbars to prevent overcurrent events. The configuration, size, and position of each busbar is selected based on the electrical requirements of components that are electrically coupled to the busbar and based on the prevention of overcurrent events.

A laminated busbar assembly includes one or more busbars that are configured to be electrically coupled to a plurality of battery cells, one or more insulative layers arranged adjacent to the one or more busbars, and a steel layer arranged between the one or more busbars and the plurality of battery cells. The steel layer is configured to shield the one or more busbars from a thermal event associated with one or more battery cells of the plurality of battery cells. The thermal event may include a debris, hot gas, sparks, embers, or other emanations. Each of the battery cells each include a respective venting end, where electrical terminals are located, that face the steel layer. The laminated busbar is a stack of layers that can include two busbars that form a DC bus, with insulation arranged between the busbars and between the steel layer and the proximal busbar.

Provided is a connector assembly capable of suppressing temperature rise in a bus bar during energization. The connector assembly of the present invention includes a connector portion having an insertion port, and a bus bar portion having a bus bar, and the bus bar includes a first connection part, a second connection part extending in an opposite direction from the first connection part along the first direction, and a joint portion joining the first connection part and the second connection part. The width of the joint portion is larger than that of each of the first connection part and the second connection part in a range from one end to another end of the joint portion, and a distance from the one end to the another end of the joint portion is larger than the width of each of the first connection part and the second connection part.

Provided is a connector assembly capable of suppressing temperature rise in a bus bar during energization. The connector assembly of the present invention includes a connector portion having an insertion port, and a bus bar portion having a bus bar, and the bus bar includes a first connection part, a second connection part extending in an opposite direction from the first connection part along the first direction, and a joint portion joining the first connection part and the second connection part. The width of the joint portion is larger than that of each of the first connection part and the second connection part in a range from one end to another end of the joint portion, and a distance from the one end to the another end of the joint portion is larger than the width of each of the first connection part and the second connection part.

An electrical assembly, such as a multi-layer bus bar, includes an electrical connection pin and a plurality of electrically conductive layers. Each of the electrically conductive layers is formed to define a cutout therein to receive the electrical connection pin and allow access for joining material to join the electrical connection pin with the plurality of electrically conductive layers. Each of the cutouts is formed to include a first through hole arranged around the electrical connection pin and a second through hole located radially outward of the first through hole.

A battery pack includes battery cells arranged in a first direction, and a busbar assembly coupled to upper portions of the battery cells, the busbar assembly having a busbar electrically connected to the battery cells, a flexible substrate configured to measure a state information of the battery cells, and an insulating film surrounding the busbar and the flexible substrate.

An electrical bus bar assembly includes a first bus bar segment, a second bus bar segment separated from the first bus bar segment, and a first plurality of bearings formed of an electrically conductive material and in electrical contact with the first bus bar segment and the second bus bar segment. The first plurality of bearings is configured to allow the first bus bar segment to move relative to the second bus bar segment. A method of manufacturing such an electrical bus bar assembly is also provided.

According to a manufacturing method of the present invention, it is possible to manufacture a busbar assembly in an efficient manner, the busbar assembly including busbars disposed in parallel in a common plane and an insulative resin layer including a gap filling portion filled into a gap between the adjacent busbars and a bottom-surface-side laminated portion extending integrally from the gap filling portion and arranged on bottom surfaces of the busbars, a top surface of the busbar being at least partially exposed to form a top-surface-side connection portion, the bottom surface of the busbar including a first bottom surface region which is located at the same position in a thickness direction as a lower end portion of the gap and on which the bottom-surface-side laminated portion is arranged and a second bottom surface region located farther away from the top surface than the first bottom surface region and exposed to the outside to form a bottom-surface-side connection portion.