A bus bar assembly includes a bus bar formed of a first electrically conductive material having a planar contact portion. The bus bar defines a first bore extending through the contact portion. The bus bar assembly further includes a contact insert formed of a second electrically conductive material that has a greater hardness than the first electrically conductive material. The contact insert defines a first surface that is mechanically and electrically connected to the contact portion of the bus bar. The contact insert defines a second surface this is plated with a third electrically conductive material which is different than the second electrically conductive material. The contact insert defines a smooth second bore coaxial with the first bore and extending from the first surface to the second surface.

A connector for a flexible busbar is provided. The connector includes a jaw and a relief. The jaw has a first member and a second member both depending from a support member and spaced from one another by a distance. The distance is larger than a thickness of the flexible busbar. The relief is defined on first member and/or second member. The jaw is deformably compressible onto the flexible busbar upon application of a deformation force on the first and second members so that the flexible busbar conforms to the at least one relief to form an electrical and mechanical connection.

A busbar for an aircraft with at least two conductive layers and at least three insulating layers. The conductive layers and the insulating layers are stacked together alternatingly and extend in a longitudinal direction. The conductive layers and the insulating layers include different coefficients of thermal expansion. Each of the conductive layers includes spatial structures. Each spatial structure is connected to an adjacent one by an interconnecting segment. Each conductive layer is embedded between two insulating layers, resulting in a deforming of the side walls of the spatial structures under heat, thereby compensating a longitudinal expansion of the conductive layers. Further, an aircraft with a disclosed busbar and a method of producing such busbar is provided.

A bus assembly includes a planar first bus, a second bus including a first planar bus section on the first bus and a second planar bus section connected to the first planar bus section and offset from the first planar bus section, and a third bus comprising a third planar bus section disposed between the first bus and the second planar bus section, and a fourth planar bus section connected to the third planar bus section, offset from third planar bus section, and disposed on the first planar bus section.

A conductive structure includes: a single-layer busbar that is formed in a plate shape and constitutes a conductive path; and a multi-layer busbar that is configured by laminating a plurality of busbars which are formed as plates thinner than the single-layer busbar and that is joined to an end of the single-layer busbar and constitutes the conductive path. The multi-layer busbar includes a main body portion in which at least some of the laminated plurality of busbars are capable of mutual displacement relative to the busbars adjacent thereto, and a joining end located at a end of the main body portion on the single-layer busbar side and in which the laminated plurality of busbars are incapable of mutual displacement relative to each other, the joining end being joined to the end of the single-layer busbar.

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.

A busbar structure with a metal body, which ensures better discharge of the internal heat generated by the busbars during normal operation, prevents combustion and stops the progression of combustion, in environments that require the power line to be IP68 against the environmental water threat and where IP68 busbar structures are used.

An exemplary busbar assembly includes a first layer, and a second layer having a portion that contacts the first layer and a portion that is spaced from the first layer to provide an opening between the first layer and the second layer. An exemplary method of managing thermal energy includes contacting a first layer and a second layer in a first area of a busbar, and separating, in a second area of the busbar, the first layer from the second layer to provide an opening between the first layer and the second layer.

A current shaping phase leg bus bar for power electronics systems includes a first terminal connector, a second terminal connector, insulated from the first terminal connector, and a third terminal connector, insulated from the first and second terminal connectors. At least one of the terminal connectors is a current shaping terminal connector that includes one or more layers having a plurality of pre-defined locations for electrical connections, said plurality of pre-defined locations including one or more first locations and a plurality of second locations, and includes one or more gaps within or among its one or more layers, to provide substantially balanced conductive pathways among its one or more first locations and its plurality of second locations.

A method for manufacturing an insert-molded bus bar includes the steps of: preparing a first bus bar having a through hole and a second bus bar having a protrusion corresponding to the through hole; preparing a mold having therein a swaging member capable of swaging the protrusion; placing the first and second bus bars in the mold with the protrusion being inserted into the through hole; swaging the first and second bus bars using the swaging member of the mold to obtain connected bus bars that are the bus bars connected to each other; and injecting a molding material around the connected bus bars that are the bus bars connected to each other by swaging to perform insert molding using the mold and obtain the insert-molded bus bar.