A bus bar assembly includes a nonconductive terminal cap configured to at least partially surround an electrically conductive terminal. The terminal cap has a perimeter wall configured to circumscribe at least a portion of the terminal to provide a gap configured to expose the terminal. The terminal cap includes a first attachment feature. The bus bar assembly also includes a bus bar having an end configured to mechanically and electrically engage the terminal in an assembled condition and a nonconductive shroud enclosing the bus bar. The shroud includes a second attachment feature configured to removably engage the first attachment feature in the assembled condition to secure the shroud to the terminal cap. A method of electrically connecting cells of a battery is also provided.

A bus bar assembly includes a nonconductive terminal cap configured to at least partially surround an electrically conductive terminal. The terminal cap has a perimeter wall configured to circumscribe at least a portion of the terminal to provide a gap configured to expose the terminal. The terminal cap includes a first attachment feature. The bus bar assembly also includes a bus bar having an end configured to mechanically and electrically engage the terminal in an assembled condition and a nonconductive shroud enclosing the bus bar. The shroud includes a second attachment feature configured to removably engage the first attachment feature in the assembled condition to secure the shroud to the terminal cap. A method of electrically connecting cells of a battery is also provided.

A spacer assembly includes a first clamping body having first and second ends and first and second protrusions extending from the first and second ends, respectively. A second clamping body has third and fourth ends and third and fourth protrusions extending from the third and fourth ends, respectively. A first gripping member disposed between the first and third ends has first and second openings for receiving the first and third protrusions, respectively, such that the first and third protrusions pass completely through the first and second openings to contact a first conductor received by the first gripping member. A second gripping member disposed between the second and fourth ends has third and fourth openings for receiving the second and fourth protrusions, respectively, such that the second and fourth protrusions pass completely through the third and fourth openings to contact a second conductor received by the second gripping member.

A spacer assembly includes a first clamping body having first and second ends and first and second protrusions extending from the first and second ends, respectively. A second clamping body has third and fourth ends and third and fourth protrusions extending from the third and fourth ends, respectively. A first gripping member disposed between the first and third ends has first and second openings for receiving the first and third protrusions, respectively, such that the first and third protrusions pass completely through the first and second openings to contact a first conductor received by the first gripping member. A second gripping member disposed between the second and fourth ends has third and fourth openings for receiving the second and fourth protrusions, respectively, such that the second and fourth protrusions pass completely through the third and fourth openings to contact a second conductor received by the second gripping member.

An insulation system includes a number of mica hard-boards joinable to form a free-standing slot-liner for insulating a conductor when placed therein and accommodating an expansion of the conductor. In another embodiment, an electromagnetic pump includes a stator of the electromagnetic pump including a number of laminations, a slot-liner positioned within a gap formed by the laminations, an annular wound copper conductor coil positioned within the slot-liner. The slot-liner includes a number of mica hard-boards joined to form an annular volume for insulating the conductor coil and accommodating an expansion of the conductor coil.

An insulation system includes a number of mica hard-boards joinable to form a free-standing slot-liner for insulating a conductor when placed therein and accommodating an expansion of the conductor. In another embodiment, an electromagnetic pump includes a stator of the electromagnetic pump including a number of laminations, a slot-liner positioned within a gap formed by the laminations, an annular wound copper conductor coil positioned within the slot-liner. The slot-liner includes a number of mica hard-boards joined to form an annular volume for insulating the conductor coil and accommodating an expansion of the conductor coil.

Disclosed is a method of manufacturing an insulating sheet, comprising: forming at least a groove on a flat sheet; a first cutting step for cutting a side surface of the groove by irradiating a laser beam to a side surface of the sheet; a second cutting step for cutting the insulating sheet to completely separate the groove from the insulating sheet by irradiating a laser beam from above the groove having the side surface cut; a tape attaching step for attaching a tape to an outer surface of the insulating sheet; and a bending step for bending one end portion of the surface of the insulating sheet having the tape attached toward a place where the tape is attached. It is possible to mass-produce the insulating sheets having a three-dimensional shape, regarded as being difficult to manufacture with a mold.

Disclosed is a method of manufacturing an insulating sheet, comprising: forming at least a groove on a flat sheet; a first cutting step for cutting a side surface of the groove by irradiating a laser beam to a side surface of the sheet; a second cutting step for cutting the insulating sheet to completely separate the groove from the insulating sheet by irradiating a laser beam from above the groove having the side surface cut; a tape attaching step for attaching a tape to an outer surface of the insulating sheet; and a bending step for bending one end portion of the surface of the insulating sheet having the tape attached toward a place where the tape is attached. It is possible to mass-produce the insulating sheets having a three-dimensional shape, regarded as being difficult to manufacture with a mold.

A bus bar assembly includes a nonconductive terminal cap that is configured to secure to an electrically conductive terminal via an attachment feature. The terminal cap has a slot that is configured to expose a terminal portion of the terminal when in an assembled condition. A bus bar has an end that is configured to be received in and extend through the slot when in the assembled condition in which the end is in electrical contact with the terminal portion of the terminal. A nonconductive shroud encloses the bus bar.

A bus bar assembly includes a nonconductive terminal cap that is configured to secure to an electrically conductive terminal via an attachment feature. The terminal cap has a slot that is configured to expose a terminal portion of the terminal when in an assembled condition. A bus bar has an end that is configured to be received in and extend through the slot when in the assembled condition in which the end is in electrical contact with the terminal portion of the terminal. A nonconductive shroud encloses the bus bar.