CN115206706A

CN115206706A - Electrical assembly

Info

Publication number: CN115206706A
Application number: CN202210234094.3A
Authority: CN
Inventors: 鲁图恩·雷; 罗伯特·M·施密特; 阿里克·安格林
Original assignee: Lear Corp
Current assignee: Lear Corp
Priority date: 2021-04-06
Filing date: 2022-03-10
Publication date: 2022-10-18
Also published as: DE102022103028A1

Abstract

An electrical assembly may include a bus bar assembly, a fuse connected to the bus bar assembly, a contactor connected to the bus bar assembly, a bracket connected to the bus bar assembly, and/or a cooling member connected to the bracket such that the fuse is indirectly connected to the cooling member via the bus bar assembly and the bracket. A method of operating an electrical assembly may include controlling a contactor to provide current from a power source to a load, generating heat via the current flowing through a fuse, conducting heat from the fuse to a bus bar assembly, conducting heat from the bus bar assembly to a cooling member, and/or dissipating heat via the cooling member.

Description

Electrical assembly

Technical Field

The present disclosure relates generally to electrical assemblies, including assemblies that may include electrical contacts and/or fuses, which may be used, for example, in connection with vehicles.

Background

This background description is set forth below for the purpose of providing context only. Thus, any aspect described in this background is neither expressly nor implicitly admitted as prior art to the present disclosure to the extent that it is not otherwise proven prior art.

Some electrical assemblies do not provide adequate functionality, are not configured for use with high currents, do not provide adequate cooling (e.g., cooling that may be associated with high currents), and/or require complex assembly processes.

Accordingly, there is a need for a solution/option that minimizes or eliminates one or more challenges or drawbacks of electrical components. The foregoing discussion is intended to be merely illustrative of the art and not a disavowal of scope.

SUMMARY

In an embodiment, an electrical assembly may include a bus bar assembly, a fuse connected to the bus bar assembly, a contactor connected to the bus bar assembly, a bracket connected to the bus bar assembly, and/or a cooling member connected to the bracket, such that the fuse is indirectly connected to the cooling member via the bus bar assembly and the bracket.

In some embodiments, the first terminal of the fuse is directly secured to and in contact with a bus bar of the bus bar assembly; and the second terminal of the fuse is directly fixed to and in contact with another bus bar of the bus bar assembly.

In some embodiments, the contactor is directly secured to and in contact with a bus bar of the bus bar assembly; the bus bar of the bus bar assembly and another bus bar of the bus bar assembly are directly fixed to and in contact with the bracket; and the holder is directly fixed to and in contact with the cooling member.

In some embodiments, the cooling member comprises an at least partially hollow body configured to receive a cooling fluid.

In some embodiments, a potting material is at least partially disposed between the bus bar assembly and the cooling member to facilitate heat transfer from the bus bar assembly to the cooling member.

In some embodiments, the bus bar assembly includes a first bus bar and a second bus bar connected to the contactor; the second bus bar is connected to the fuse; the bus bar assembly includes a third bus bar connected to the fuse; and the second bus bar is configured to facilitate heat transfer from the contactor and the fuse to the cooling member.

In some embodiments, the electrical assembly includes an additional fuse; wherein the fuse comprises a first length; and the additional fuse includes a second length different from the first length.

In some embodiments, the fuse is configured for a current of at least 500 amps and at least 1000 volts.

In some embodiments, at least first, second, and third sides of the fuse are exposed.

In some embodiments, the bus bar of the bus bar assembly includes a protrusion configured to facilitate heat transfer from the fuse to the cooling member.

In some embodiments, the protrusion is disposed directly between the bracket and the fuse.

In some embodiments, the second bus bar of the bus bar assembly includes a second protrusion configured to facilitate heat transfer from the fuse to the cooling member.

In some embodiments, the electrical assembly includes one or more additional contacts; wherein the holder comprises a sleeve for each of the contacts and the one or more additional contacts; and the contact is at least partially disposed in the sleeve.

In some embodiments, the cooling member is configured to dissipate heat generated via current flowing through the fuse, the bus bar assembly, and the contactor.

For an embodiment, a method of assembling an electrical assembly may include inserting a contactor into a rack, connecting a fuse to a bus bar assembly, connecting the bus bar assembly to the contactor, connecting the bus bar assembly to the rack, disposing a cooling member on or around the rack, and/or connecting the cooling member to the rack.

In some embodiments, the cooling member is connected with the cradle such that the fuse and the contactor are indirectly connected to the cooling member via the bus bar assembly and the cradle; and the bus bar assembly is indirectly connected to the cooling member via the bracket.

In some embodiments, disposing the cooling member on the cradle includes inserting the cradle, the bus bar assembly, and the contactor at least partially into a recess of the cooling member.

In some embodiments, the fuse is connected to the bus bar assembly such that at least first, second, and third sides of the fuse are exposed to ambient air for passive cooling.

In an embodiment, a method of operating an electrical assembly may include controlling a contactor to provide current from a power source to a load, generating heat via the current flowing through a fuse, conducting heat from the fuse to a bus bar assembly, conducting heat from the bus bar assembly to a cooling member, and/or dissipating heat via the cooling member.

In some embodiments, conducting heat from the fuse to the bus bar assembly includes conducting heat from the fuse to a protrusion of a bus bar of the bus bar assembly; the projection is at least partially disposed between the fuse and the bracket; and the bus bar is electrically connected to the fuse.

The foregoing and other possible aspects, features, details, utilities, and/or advantages of the examples/embodiments of the disclosure will be apparent from reading the following description and from reviewing the accompanying drawings.

Brief Description of Drawings

While the claims are not limited to the specific illustrations, an appreciation of various aspects can be gained through a discussion of various examples. The drawings are not necessarily to scale and certain features may be exaggerated or hidden to better illustrate and explain an innovative aspect of an example. Furthermore, the exemplary illustrations described herein are not intended to be exhaustive or otherwise limiting, and the embodiments are not limited to the precise forms and configurations shown in the drawings or disclosed in the following detailed description. The exemplary illustrations are described in detail by reference to the following drawings:

fig. 1 is a perspective view generally illustrating an embodiment of an electrical assembly.

Fig. 2 is a cross-sectional perspective view generally illustrating a portion of an embodiment of an electrical assembly.

Fig. 3 is a cross-sectional perspective view generally illustrating an embodiment of an electrical assembly.

Fig. 4 is a partial sectional perspective view generally illustrating a portion of an embodiment of an electrical assembly with the bracket and cooling member concealed.

Fig. 5 is a perspective view of a portion of an embodiment of a cradle, contacts and flexible circuit generally illustrating an embodiment of an electrical assembly.

Fig. 6 is a partial cross-sectional perspective view generally illustrating a portion of an embodiment of an electrical assembly.

Fig. 7 is a cross-sectional perspective view generally illustrating a portion of an embodiment of an electrical assembly.

Fig. 8 is a partial perspective view generally illustrating a portion of an embodiment of an electrical assembly with a bracket, a bus bar assembly, and a cooling member concealed.

Figure 9 is a perspective view generally illustrating an embodiment of a cradle, a bus bar assembly, a fuse, and a contactor of an embodiment of an electrical assembly.

Fig. 10 is a cross-sectional perspective view generally illustrating a portion of an embodiment of an electrical assembly.

Fig. 11 is a partial perspective view generally illustrating an embodiment of an electrical assembly with the bracket and cooling member concealed.

Figure 12 is a flow chart generally illustrating an embodiment of assembling an electrical assembly.

FIG. 13 is a flow chart generally illustrating an embodiment of operating an electrical component.

Detailed Description

Reference will now be made in detail to embodiments of the present disclosure, examples of which are described herein and illustrated in the accompanying drawings. While the disclosure will be described in conjunction with the embodiments and/or examples, they are not intended to limit the disclosure to these embodiments and/or examples. On the contrary, the present disclosure covers alternatives, modifications, and equivalents.

In embodiments, such as generally illustrated in fig. 1 and 2, the electrical assembly 20 may include one or more contactors 22 (or relays, electrical switches, etc.), such as a first contactor 22 ₁ A second contactor 22 ₂ A third contactor 22 ₃ And/or a fourth contactor 22 ₄ Bus bar assembly 24, bracket 26, and/or cooling member 28. The current flowing through the bus bar assembly 24 and/or one or more contactors 22 may generate or cause a significant amount of heat. For example, and without limitation, the electrical component 20 and/or the contactor 22 may be configured for use with currents of at least 500 amps (e.g., for minutes or more), at least 1000 amps, and/or at least 2500 amps (e.g., for at least 10-15 seconds). The cooling member 28 may be configured to facilitate dissipation of at least some of the generated heat.

In an embodiment, such as generally illustrated in fig. 2, the contactor 22 may include an outer wall 50, a first contactor terminal 52, a second contactor terminal 54, an electrically conductive contact member 56 configured to selectively electrically connect the first terminal 52 and the second terminal 54, and/or an actuator 58. The actuator 58 may be configured to change the contactor 22 between an inactive/open state in which the contact member 56 does not electrically connect the first and

second terminals

52, 54 and an active/closed state in which the contact member 56 electrically connects the first and

second terminals

52, 54. Actuator 58 may include, for example and without limitation, an electromagnet, a coil, and/or a solenoid configured to move contact member 56 into and out of electrical contact with

terminals

52, 54.

For an example, such as generally illustrated in fig. 1, the bus bar assembly 24 may be electrically connected to one or more contactors 22, a power source 40 (e.g., a battery, a receptacle, etc.), and/or one or more electrical loads 170. The bus bar assembly 24 may include a primary bus bar 60 and/or one or more secondary bus bars 62 (e.g., secondary bus bars 62) ₁ 、62 ₂ 、62 ₃ 、62 ₄ ) (see, e.g., FIGS. 1 and 3). The first bus bar 60 may be electrically connected to some or all of the contactors 22 and/or the power sources 40. For example, the first bus bar 60 may be connected (e.g., directly connected) to the first terminals 52 of the one or more contactors 22, and may be at least indirectly connected to the power source 40 to provide current from the power source 40 to the one or more contactors 22. In some configurations, the first bus bar 60 may include a first portion 60A that may be connected to the first terminals 52 of the first and

second contactors

221, 222 and/or may include a second portion 60B that may be connected to the first terminals 52 of the third and

fourth contactors

223, 224. The first portion 60A and the second portion 60B may be separate or integrally formed. The respective second bus bars 62 may be connected to the second terminals 54 of the one or more contactors 22. The second bus bar 62 may electrically connect the contactor 22 to a corresponding load 170 (e.g., load 170) ₁ 、170 ₂ 、170 ₃ 、170 ₄ ). The load 170 may include, for example, without limitation, a single load or multiple loads, such as one or more vehicle systems or components (e.g., air conditioners, heaters, motors, etc.).

In an embodiment, such as generally illustrated in fig. 2-4, the bus bar assembly 24 may be disposed, for example, at least partially directly on one or more contactors 22. For example, but not limiting of, the first bus bar 60 may be disposed directly on the outer wall 50 and/or the first terminal 52 of the contactor 22. The second bus bar 62 may be disposed directly on the outer wall 50 and/or the second terminal 54 of the contactor 22.

In an example, such as generally illustrated in fig. 1 and 2, the cooling member 28 may be configured for active cooling (e.g., as an active cooling member). The cooling member 28 may include a body 70 (e.g., a cold plate) having a first portion/member 72 and a second portion/member 74. The first portion 72 and the second portion 74 may be separate (e.g., separate, single-piece components) and may be configured to be coupled together. The first portion 72 may be configured as a body and the second portion 74 may be configured as a cover. For example, but not limiting of, the first portion 72 may include a first recess 76 disposed in a first (e.g., top) surface, and the second portion 74 may be configured to cover the first recess 76, such that the first recess 76 and the second portion 74 may serve as and/or provide a fluid channel 80 (e.g., see fig. 2). The first recess 76 may, for example, extend along substantially the entire length of the cooling member 28. The fluid channel 80 may be configured to receive a cooling fluid 82 (e.g., water, glycol, air, etc.) and/or a fluid conduit 84 (e.g., tubing, pipe, etc.) for the cooling fluid 82. The fluid channels 80 and/or the fluid conduits 84 may be connected to a fluid reservoir/tank 86 of the cooling fluid 82 and/or a pump 88, which pump 88 may pump the cooling fluid 82, such as from the fluid reservoir 86 through the cold plate 70, to dissipate heat from the electrical assembly 20 (see, e.g., fig. 1).

In an embodiment, such as generally illustrated in fig. 2, 6, and 7, the cooling member 28 may include a second recess 78, which second recess 78 may be disposed opposite the first recess 76 (e.g., the first recess 76 and the second recess 78 may open in opposite directions). The second recess 78 may be configured to at least partially receive one or more of the contacts 22, the bus bar assembly 24, the bracket 26, and/or the flexible circuit 144. The second recess 78 may, for example, extend along substantially the entire length of the cooling member 28. The first and/or

second recesses

76, 78 of the cooling member 28 may provide the cooling member 28 and/or the body 70 with an at least partially hollow configuration and/or a generally H-shaped cross-sectional shape.

For embodiments, such as generally illustrated in fig. 1 and 5, the support 26 may be configured such as viaThe bus bar assembly 24 connects the cooling member 28 with the one or more contactors 22. The support 26 may include one or more of a variety of shapes, sizes, materials, and/or configurations. For example, and without limitation, the support 26 may comprise plastic and/or one or more electrically insulating materials, and may comprise a generally elongated rectangular frame configuration. The bracket 26 may include one or more apertures 100, and the one or more apertures 100 may be configured to at least partially receive the contact 22 (e.g., see fig. 5). For example, but not limiting of, the bracket 26 may include a contact for the contact 22 ₁ 、22 ₂ 、22 ₃ 、22 ₄ Hole 100 (a) ₁ 、100 ₂ 、100 ₃ 、100 ₄ . The aperture 100 may be configured as a through-hole that may extend through the bracket 26. The support 26 may include one or more sleeve portions 104 (e.g., sleeve portions 104) ₁ 、104 ₂ 、104 ₃ 、104 ₄ ) One or more sleeve portions 104 may extend from the body 102 of the bracket 26 and may at least partially define the one or more apertures 100. The sleeve portion 104 may be configured to limit movement (e.g., tilt, X-direction movement, Y-direction movement, etc.) of the contactor 22. For example, the shape of at least some of the sleeve portions 104 may generally correspond to the shape of at least some of the contacts 22. For example, and without limitation, sleeve portion 104 may include a generally cylindrical configuration if contactor 22 includes a generally cylindrical configuration, and/or sleeve portion 104 may include a generally rectangular configuration if contactor 22 includes a generally rectangular configuration. Some sleeve portions 104 may be shorter (e.g., in the axial/Z direction) than contacts 22, such that sleeve portions 104 cover some of outer wall 50 of contacts 22, and exposed portions 106 of outer wall 50 are not covered by sleeve portions 104 (see, e.g., contacts 221). The exposed portion 106 may, for example, include a side (e.g., a radially outer surface) of the outer wall 50, be disposed near a second (e.g., bottom) end of the contact 22, include a second/bottom surface 50B of the contact 22, and/or extend around some or all of a perimeter/circumference of the contact 22.

In embodiments, the other sleeve portion 104 may be about long with the contact 22Is the same degree or longer than the contact 22 such that the sleeve portion 104 and the body 102 can substantially cover a side surface (e.g., an outer radial surface) of the outer wall 50 (see, e.g., contact 22) ₂ 、22 ₃ 、22 ₄ ). The body 102 and the sleeve portion 104 may not cover the first surface 50A (e.g., the top axial surface) of the contactor 22 and/or may not cover the second surface 50B (e.g., the bottom axial surface) of the contactor 22, which may facilitate cooling. For example, and without limitation, the outer wall 50, the second surface 50B, and/or the exposed portion 106 of the contactor 22 may comprise a metal (e.g., steel), and ambient air may flow over the second surface 50B and/or the exposed portion 106, which may provide cooling/heat dissipation, at least to some extent. In contrast, some other contactor designs include a plastic housing (e.g., a thermally insulating housing) that covers all of the contactor, limiting cooling/heat dissipation.

For embodiments, such as illustrated in fig. 2, 4, 6, and 7, one or more contactors 22, bus bar assemblies 24, brackets 26, and/or cooling members 28 may be connected together (e.g., mechanically connected). One or more contactors 22 may be connected to the bus bar assembly 24. For example, but not limiting of, the one or more contactors 22 may be secured (e.g., bolted/screwed) to the first and second bus bars 60, 62 via one or more first fasteners 120 (see, e.g., fig. 2 and 4). The connection between the bus bar assembly 24 (e.g., bus bars 60, 62) and the contactor 22 may provide and/or facilitate an electrical connection between the bus bars 60, 62 and the contactor 22. In an embodiment, such as generally illustrated in fig. 6, the bus bar assembly 24 may be connected to a bracket 26. For example, and without limitation, the bus bars 60, 62 may be secured (e.g., bolted/threaded) to the bracket 26 via one or more second fasteners 122, and the second fasteners 122 may be inserted into the bus bars 60, 62 and then down into the top of the bracket 26. For embodiments, such as that generally illustrated in fig. 7, the bracket 26 may be connected to a cooling member 28. For example, and without limitation, the bracket 26 can be secured (e.g., bolted/threaded) to the cooling member 28 via one or more third fasteners 124, and the third fasteners 124 can be inserted into the bracket 26 and then up into the bottom of the cooling member 28. The

fasteners

120, 122, 124 may include, for example and without limitation, screws, bolts, and/or rivets, among others.

In some embodiments, one or more contactors 22 may be secured, for example, directly to a bus bar assembly 24, may be secured indirectly to a rack 26 via the bus bar assembly 24, and/or may be secured indirectly to a cooling member 28 via the bus bar assembly 24 and the rack 26. For example, but not limiting of, one or more of the contactors 22 may not be directly secured to the support 26 and/or the cooling member 28. The bus bar assembly 24 may be directly secured to the bracket 26 and/or may be indirectly secured to the cooling member 28 via the bracket 26. For example, but not limiting of, the bus bar assembly 24 may not be directly secured to the cooling member 28.

For embodiments, such as generally illustrated in fig. 2, the bore 100 of the carrier 26 may include a lip 130 (e.g., an axial surface), and the lip 130 may be configured to contact the contact 22. For example, the outer wall 50 of the contact 22 may include a flange 132 that may extend outward (e.g., radially outward), and the contact 22 may be inserted into the aperture 100 until the flange 132 contacts the lip 130. The lip 130 may at least temporarily support the contactor 22, such as until the contactor 22 is connected with the bus bar assembly 24.

In an embodiment, the controller 110 may be configured to control the contactor 22 to selectively provide power from the power source 40 to one or more electrical loads 170 (see, e.g., fig. 1 and 3). For example, and without limitation, the controller 110 may be configured to generate one or more control signals to control operation of the actuator 58 of the contactor 22 to selectively open and close the contactor 22, and the contactor 22 may selectively provide power from the power source 40 to one or more electrical loads 170.

In some example configurations, the controller 110 may be electrically connected to the first control terminal 140 and/or the second control terminal 142 of the contactor 22, and the contactor 22 may be connected (e.g., electrically connected) to the actuator 58 of the contactor 22 (e.g., see fig. 7-8). For example, but not limiting of, the controller 110 may be connected to the

control terminals

140, 142 via a flex circuit/ribbon cable 144, the flex circuit/ribbon cable 144 may includeConductor 146 (e.g., conductor 146) for each control terminal 140, 142 _1-8 ). The flexible circuit 144 may include a first end 148 that may be connected to an electrical connector 150, which electrical connector 150 may be connected to the bracket 26 (see, e.g., fig. 5). The controller 110 may be electrically connected to the flexible circuit 144 via an electrical connector 150. The electrical connector 150 may include a terminal/pin for each conductor 146 of the flexible circuit 144. For example, and without limitation, a single electrical connector 150 (e.g., an external electrical connector) may provide/facilitate electrical connection with multiple contacts 22.

For an embodiment, the flexible circuit 144 may include one or more second ends 152 (e.g., second ends 152) ₁ 、152 ₂ 、152 ₃ 、152 ₄ ) One or more second ends 152 may be connected to respective contacts 22 (see, e.g., fig. 5 and 8). The second end 152 may include a pair of conductors 146 connected to the

control terminals

140, 142. The pair of conductors 146 may, for example, include eyelets 154, and the eyelets 154 may be disposed over/around the control terminals 140, 142 (e.g., the

control terminals

140, 142 may be inserted into the eyelets 154). The eyelet 154 may be integrally formed as part of the flexible circuit 144.

In an embodiment, such as generally illustrated in fig. 3, 6, and 7, the flexible circuit 144 may be disposed on and/or extend along a top surface of the cradle 26, such as to some or each of the one or more contacts 22. For example, the flexible circuit 144 may be disposed at least partially under the bus bar assembly 24. For example, but not limiting of, most or substantially all of the flexible circuit 144 may be disposed between one or more of the bus bars 60, 62 and the bracket 26. The bus bars 60, 62 may be disposed at a relatively small distance from the bracket 26, which may be sufficient for the flex circuit 144, but may not be sufficient space for individual wires or other types of cables/wires.

For embodiments, such as generally illustrated in fig. 8, the contactor 22 may include a vent 160 (e.g., a fluid vent). The vent 160 may be configured to limit a fluid pressure differential between the interior and exterior of the contactor 22. For example, and without limitation, if the temperature inside the contactor 22 increases, the air pressure inside the contactor may increase. The vent 160 may allow air to flow out of the contactor 22 to reduce the internal air pressure, such as if the pressure exceeds a pressure threshold. Additionally or alternatively, vent 160 may allow air to flow into contactor 22 to increase the internal air pressure, such as if the pressure is below a second pressure threshold.

For embodiments, such as illustrated in fig. 4, the contactor 22 may include a top cover 162. Top cover 162 may at least partially cover first control terminal 140, second control terminal 142, and/or vent 160. For example, and without limitation, top cover 162 may include a first recess 164, where first recess 164 may at least partially cover and/or receive first control terminal 140 and/or second control terminal 142. Additionally or alternatively, top cover 162 may include a second recess 166, and second recess 166 may at least partially cover and/or receive vent 160. Top cap 162 may include an insulating wall 168, and insulating wall 168 may extend at least partially between first terminal 52 and second terminal 54 and/or between first recess 164 and second recess 166. For example, but not limiting of, top cap 162 may be substantially planar and may extend from first recess 164 to second recess 166 such that top cap 162 separates first terminal 52 and second terminal 54 and electrically insulates first terminal 52 and second terminal 54. The top cover 162 may include an electrically insulating material that may or may not be thermally conductive.

In an embodiment, the electrical load 170 may include one or more complementary loads, which may include loads configured such that only one (e.g., one of a pair or a set) is expected to actuate/operate at any given time. For example, but not limited to, a first electrical load 170 ₁ May include an air conditioner (e.g., such as in a vehicle, providing cooled air) and/or a second electrical load 170 ₂ A heater (e.g., such as in a vehicle, providing warm air) may be included.

For embodiments, such as generally illustrated in fig. 9-11, an electrical assembly20 may include one or more fuses 180, such as a first fuse 180 ₁ A second fuse 180 ₂ And/or third fuse 180 ₃ . One or more fuses 180 may include a first terminal 182 ₁ And a second terminal 182 ₂ . In some examples, the first terminal 182 ₁ May be disposed at the first end 184 of the fuse 180 ₁ Second terminal 182 ₂ May be disposed at the second end 184 of the fuse 180 ₂ . First end 184 ₁ May be coupled to the second end 184 ₂ Spaced apart from and spaced from the second end 184 ₂ And (4) oppositely. In some examples, the first terminal 182 ₁ And a second terminal 182 ₂ May be provided on the same end, side, and/or surface of fuse 180.

In some example configurations, one or more fuses 180 may be secured directly to the bus bar assembly 24. For example, and without limitation, one or more fuses 180 may be secured (e.g., bolted/threaded) to the bus bar assembly 24 via one or more fasteners 186. The fasteners 186 may include, for example and without limitation, screws, bolts, and/or rivets, among others. In some cases, the first fuse 180 ₁ First terminal 182 ₁ Can be connected to the second bus bar 62 ₁ First fuse 180 ₁ Second terminal 182 ₂ Can be connected to the third bus bar 64 ₁ . In some configurations, an additional fuse (e.g., second fuse 180) ₂ And a third fuse 180 ₃ ) Can be connected to an additional secondary bus bar 62 _2-3 And a third bus bar 64 _2-3 (see, e.g., FIG. 9).

In some embodiments, the one or more fuses 180 may be indirectly secured to the one or more contactors 22, for example, via the bus bar assembly 24, may be indirectly secured to the rack 26 via the bus bar assembly 24, and/or may be indirectly secured to the cooling member 28 via the bus bar assembly 24. The one or more fuses 180 may be, for example, but not limited to, not directly secured to the one or more contactors 22, racks 26, and/or cooling members 28. The bus bar assembly 24 may be directly secured to the bracket 26 and/or may be indirectly secured to the cooling member 28 via the bracket 26. For example, but not limiting of, the bus bar assembly 24 may not be directly secured to the cooling member 28. A thermally conductive and electrically insulating material 68 (e.g., potting material) may be at least partially disposed between the bus bar assembly 24 and the cooling member 28. For example, the material 68 may be in contact with the bus bar assembly 24 and the cooling member 28 to facilitate heat transfer from the bus bar assembly 24 (which may include heat from components connected to the bus bar assembly 24, such as the one or more contacts 22 and/or the fuse 180) to the cooling member 28.

In an embodiment, one or more fuses 180 may include one or more of a variety of shapes, sizes, materials, and/or configurations, such as generally illustrated in fig. 9-11. For example, but not limiting of, the body 188 of the fuse 180 may include a polygonal shape (e.g., square, rectangular, etc.) (see, e.g., fig. 10 and 11). In some examples, one or more fuses 180 may include substantially similar physical dimensions (e.g., length, width, thickness, etc.). In some examples, one or more fuses 180 may include at least one different physical dimension. For example, the first fuse 180 ₁ May include more than the second fuse 180 ₂ Second length L ₂ First length L of ₁ (see, e.g., FIG. 9). In some cases, one or more fuses 180 may include a component (e.g., first terminal 182) comprising a conductive material (e.g., a metal) ₁ And a second terminal 182 ₂ Etc.).

In some example configurations, the one or more fuses 180 may include high speed and/or high power fuses capable of withstanding a large amount of temperature, current, and/or voltage. In some examples, one or more fuses 180 may include a predetermined current threshold and/or voltage rating. For example, the fuse 180 may allow a flow of current to flow up to a predetermined current threshold. The fuses 180 may be configured to prevent current from continuing to flow if the flow of current exceeds a predetermined current threshold (e.g., one or more of the fuses 180 may open a closed circuit). In some examples, one or more fuses 180 may include a pre-fuse that may be substantially similarConstant current threshold/capacity and/or rated voltage. In some examples, one or more fuses 180 may include different predetermined current thresholds and/or voltage ratings. For example, but not limited to, first fuse 180 ₁ Which may include a current threshold of about 900 amps and a voltage rating of about 1250 volts, a second fuse 180 ₂ A predetermined current threshold of about 900 amps and a voltage rating of about 690 volts may be included (see, e.g., fig. 9). In some examples, the one or more fuses 180 may include a predetermined current threshold of less than or greater than 900 amps and a voltage rating of less than or greater than 1250 volts.

In some examples, the one or more fuses 180 may be configured to protect the one or more electrical loads 170 from large currents that may result from the occurrence of a fault condition (e.g., a short circuit, etc.). For example, the one or more fuses 180 may prevent a large current from reaching the one or more electrical loads 170 if the current flowing through the bus bar assembly 24 and the one or more fuses 180 exceeds a predetermined current threshold of the one or more fuses 180. For example, one or more fuses 180 may be connected between the power source 40 and one or more electrical loads 170. In some configurations, one or more fuses 180 may be electrically connected between the contactor 22 and the load 170. For example, the second bus bar 62 _1-3 The contact 22 may be at least partially secured _1-3 And fuse 180 _1-3 Is electrically connected, and the third bus bar 64 _1-3 Fuse 180 may be at least partially attached _1-3 And a load 170 _1-3 Electrically connected (e.g., fuse 180 may be disposed between contact 22 and load 170). In other configurations, the contactor 22 may be disposed between the fuse 180 and the load 170.

In some cases, the current flowing through one or more fuses 180 may cause the temperature of one or more fuses 180 to increase. Generally, the elevated temperature may result in reduced performance of one or more fuses 180. In some examples, the cooling member 28 indirectly connected to the one or more fuses 180 may help, at least in part, to cool/dissipate heat from the one or more fuses 180, which may help maintain the performance of the one or more fuses 180 and/or increase the effective current threshold of the one or more fuses 180. For example, but not limiting of, the fuse 180 may be configured to operate at high currents for longer periods of time and/or at greater currents.

In some example configurations, one or more fuses 180 may include at least a first side 190 that is exposed to air (e.g., ambient air) and/or not directly covered ₁ A second side 190 ₂ And/or third side 190 ₃ (see, e.g., fig. 10 and 11). In this regard, at least the first side 190 is oriented ₁ A second side 190 ₂ And/or third side 190 ₃ Exposure to air may help cool the one or more fuses 180 at least partially (e.g., via passive cooling).

Additionally or alternatively, in embodiments, portions of one or more bus bars (e.g., bus bars 62, 64) of the bus bar assembly 24 may be disposed adjacent to and/or in contact with the body 188 of the fuse 180, and may be configured to facilitate transfer and/or dissipation of heat from the fuse 180. For example, but not limiting of, a third bus bar 64 ₁ Portion 64A of ₁ And/or secondary bus bar 62 ₁ Part 62A of ₁ May be disposed adjacent to and/or in contact with the fuse 180 ₁ Fourth side 190 of ₄ And may be configured to transfer heat from the fuse 180 ₁ To the cooling member 28. Portion 64A ₁ 、62A ₁ May include a bus bar 64 ₁ 、62 ₁ The protrusion/enlargement section of (a), the protrusion/enlargement section and the fuse 180 ₁ E.g., fourth side 190 ₄ And/or other sides) are aligned and/or parallel to add bus bars 64 ₁ 、62 ₁ And a fuse 180 ₁ Contact (or near contact) area therebetween, thereby facilitating cooling. For example, portion/projection 64A ₁ 、62A ₁ The bus bar 64 may not be substantially affected ₁ 、62 ₁ And may be included to facilitate heat dissipation/transfer (e.g., from the fuse 180) ₁ To the cooling member). In some configurations, portion/protrusion 64A ₁ 、62A ₁ May be at least partially disposed in fuse 180 ₁ And the bracket 26 (e.g., directly between the fuse 180 ₁ And bracket 26).

For an embodiment, such as generally illustrated in fig. 12, a method 200 of assembling the electrical assembly 20 may include inserting one or more contacts 22 into the cradle 26 (block 202), such as into a respective hole 100, until the flange 132 of the one or more contacts 22 contacts the lip 130 of the hole 100. Inserting one or more contacts 22 into the cradle 26 may not include securing the one or more contacts 22 directly to the cradle 26.

In an embodiment, the method 200 may include connecting the bus bar assembly 24 with one or more fuses 180 (block 204). Connecting the bus bar assembly with the one or more fuses 180 may include disposing the one or more bus bars 60, 62 on and/or in the bracket 26, and/or connecting the one or more bus bars 60, 62 with the terminals 182 of the fuses 180, such as via one or more fasteners 186 ₁ 、182 ₂ Fastening (e.g., securing).

For an embodiment, the method 200 may include connecting the bus bar assembly 24 with one or more contactors 22 (block 206). One or more bus bars 60, 62 may be in contact with one or more contactors 22. Connecting the bus bar assembly 24 with the one or more contactors 22 may include fastening (e.g., securing) the one or more bus bars 60, 62 with the

terminals

52, 54 of the contactors 22, such as via the one or more first fasteners 120.

In an embodiment, the method 200 may include connecting the bus bar assembly 24 with the bracket 26, which may include fastening (e.g., securing) the bus bar assembly 24 with the bracket 26 via one or more second fasteners 122 (block 208). The second fastener 122 may be inserted/screwed into the bus bar assembly 24, for example and without limitation, and then down into the bracket 26. Connecting the bus bar assembly 24 to the bracket may (e.g., indirectly) connect one or more fuses 180 to the bracket 26.

For an embodiment, the method 200 may include disposing the cooling member 28 on the cradle 26 (block 210), which may include inserting portions of the one or more contacts 22, the bus bar assembly 24, the cradle 26, and/or the one or more fuses 180 into the cooling member 28, such as into the second recess 78. The method 200 may include connecting the cooling member 28 with the bracket 26 (block 212), which may include fastening (e.g., securing) the cooling member 28 with the bracket 26 via one or more third fasteners 124. For example, but not limiting of, one or more third fasteners 124 may be inserted into the bracket 26 and then inserted upwardly into the cooling member 28.

In an embodiment, such as generally illustrated in fig. 13, a method 300 of operating the electrical assembly 20 may include connecting one or more portions of the electrical assembly 20 to the power source 40 (block 302). In some configurations, the power source 40 may be included with the electrical assembly 20. Connecting one or more portions of the electrical assembly 20 with the power source 40 may include electrically connecting the bus bar assembly 24 with the power source 40 and/or electrically connecting the bus bar assembly 24 with one or more contactors 22 and/or one or more fuses 180.

For an embodiment, the method 300 may include operating one or more contactors 22 (block 304), such as selectively providing power to one or more loads 170. For example, the controller 110 may provide control signals to one or more contactors 22. Operating the one or more contactors 22 may cause/allow current to flow through the one or more fuses 180, which may cause the fuses 180 to generate heat (block 306). The method 300 may include dissipating heat from the one or more fuses 180, such as via conducting heat from the one or more fuses 180 to the bus bar assembly 24 (block 308), conducting heat from the bus bar assembly 24 to the cooling member 28 (block 310), and/or dissipating heat from the one or more fuses 180 and/or the bus bar assembly 24 via the cooling member 28 (block 312). Conducting heat from the one or more fuses 180 to the bus bar assembly 24 may include conducting heat from the first terminal 182 ₁ Conducts/transfers to a first portion of the bus bar assembly 24 (e.g., the third bus bar 64) ₁ Portion 64A of ₁ ) To transfer heat from the second terminal 182 ₂ Conducting/transmitting to the bus bar assembly 24Two parts (e.g. second bus bar 62 ₁ Part 62A of ₁ ) And/or conduct/transfer heat from the body 188 of the fuse 180 to the first and/or second portions of the bus bar assembly 24.

For an embodiment, the bracket 26, the first portion 72 of the cooling member 28, and/or the second portion 74 of the cooling member 28 may be formed, for example, as a single-piece (e.g., unitary, monolithic) component. For example, but not limiting of, the bracket 26 may be formed as a one-piece plastic component, and/or the first portion 72 may be formed as a one-piece metal (e.g., aluminum) component.

In an example, a controller (e.g., controller 110) may include an electronic controller and/or include an electronic processor, such as a programmable microprocessor and/or microcontroller. In an embodiment, the controller may comprise, for example, an Application Specific Integrated Circuit (ASIC). The controller may include a Central Processing Unit (CPU), a memory (e.g., a non-transitory computer-readable storage medium), and/or an input/output (I/O) interface. The controller may be configured to perform various functions, including those described in greater detail herein, using suitable programming instructions and/or code embodied in software, hardware, and/or other media. In an embodiment, the controller may comprise a plurality of controllers. In an embodiment, the controller may be connected to a display, such as a touch screen display.

Various examples/embodiments are described herein for various devices, systems, and/or methods. Numerous specific details are set forth in order to provide a thorough understanding of the overall structure, function, manufacture, and use of the examples/embodiments described in the specification and illustrated in the accompanying drawings. However, it will be understood by those skilled in the art that the examples/embodiments may be practiced without such specific details. In other instances, well-known operations, components, and elements have not been described in detail so as not to obscure the examples/embodiments described in this specification. It will be appreciated by those of ordinary skill in the art that the examples/embodiments described and illustrated herein are non-limiting examples, and thus, it can be appreciated that the specific structural and functional details disclosed herein may be representative and do not necessarily limit the scope of the embodiments.

Reference throughout the specification to "an example," "in an example," "according to an example," "various embodiments," "according to an embodiment," "in an embodiment," or "an embodiment," or the like, means that a particular feature, structure, or characteristic described in connection with the example/embodiment is included in at least one embodiment. Thus, appearances of the phrases "example," "in an example," "according to an example," "in various embodiments," "according to an embodiment," "in an embodiment," or "an embodiment," or the like, in places throughout the specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more examples/embodiments. Thus, a particular feature, structure, or characteristic illustrated or described in connection with one embodiment/example may be combined, in whole or in part, with features, structures, functions, and/or characteristics of one or more other embodiments/examples without limitation, as long as such combination is not illogical or functional. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the disclosure without departing from the scope thereof.

It should be understood that reference to a single element is not necessarily so limited, and may include one or more such elements. Any directional references (e.g., positive, negative, upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are only used for identification purposes to aid the reader's understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of the examples/embodiments.

References to engagement (e.g., attached, coupled, connected, etc.) are to be interpreted broadly and may include intermediate members between a connected element, relative movement between elements, direct connection, indirect connection, fixed connection, movable connection, operational connection, indirect contact, and/or direct contact. Thus, reference to engagement does not necessarily mean that the two elements are directly connected/coupled and in a fixed relationship to each other. The connections of the electrical components, if any, may include mechanical connections, electrical connections, wired connections, wireless connections, and/or the like. The use of "for example" and "such as" in this specification is to be construed broadly and to provide non-limiting examples of embodiments of the disclosure, and the disclosure is not limited to such examples. The use of "and" or "should be interpreted broadly (e.g., as" and/or "). For example and not by way of limitation, the use of "and" does not necessarily require all of the elements or features listed, and the use of "or" is inclusive unless such structure is illogical.

Although the processes, systems, and methods may be described herein in connection with one or more steps in a particular sequence, it should be understood that the methods may be practiced with steps in a different order, with some steps being performed simultaneously, with additional steps, and/or with some described steps being omitted.

It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes may be made in detail or structure without departing from the disclosure.

Claims

1. An electrical assembly, comprising:

a bus bar assembly;

a fuse connected to the bus bar assembly;

a contactor connected to the bus bar assembly;

a bracket connected to the bus bar assembly; and

a cooling member connected to the bracket such that the fuse is indirectly connected to the cooling member via the bus bar assembly and the bracket.

2. The electrical assembly of claim 1, wherein the first terminal of the fuse is directly secured to and in contact with a bus bar of the bus bar assembly; and is

The second terminal of the fuse is directly fixed to and in contact with another bus bar of the bus bar assembly.

3. The electrical assembly of claim 1, wherein the contactor is directly secured to and in contact with a bus bar of the bus bar assembly;

the bus bar of the bus bar assembly and another bus bar of the bus bar assembly are directly fixed to and in contact with the bracket; and is

The bracket is directly fixed to and in contact with the cooling member.

4. The electrical assembly of claim 1, wherein the cooling member comprises an at least partially hollow body configured to receive a cooling fluid.

5. The electrical assembly of claim 1, wherein a potting material is at least partially disposed between the bus bar assembly and the cooling member to facilitate heat transfer from the bus bar assembly to the cooling member.

6. The electrical assembly of claim 1, wherein the bus bar assembly includes a first bus bar and a second bus bar connected to the contactor;

the second bus bar is connected to the fuse;

the bus bar assembly includes a third bus bar connected to the fuse; and is

The second bus bar is configured to facilitate heat transfer from the contactor and the fuse to the cooling member.

7. The electrical assembly of claim 1, comprising an additional fuse;

wherein the fuse comprises a first length; and is

The additional fuse includes a second length different from the first length.

8. The electrical assembly of claim 1, wherein the fuse is configured for a current of at least 500 amps and at least 1000 volts.

9. The electrical assembly of claim 1, wherein at least first, second, and third sides of the fuse are exposed.

10. The electrical assembly of claim 1, wherein the bus bar of the bus bar assembly includes a protrusion configured to facilitate heat transfer from the fuse to the cooling member.

11. The electrical assembly of claim 10, wherein the protrusion is disposed directly between the bracket and the fuse.

12. The electrical assembly of claim 11, wherein the second bus bar of the bus bar assembly includes a second protrusion configured to facilitate heat transfer from the fuse to the cooling member.

13. The electrical assembly of claim 1, comprising one or more additional contacts;

wherein the holder comprises a sleeve for each of the contacts and the one or more additional contacts; and is

The contact is at least partially disposed in the sleeve.

14. The electrical assembly of claim 1, wherein the cooling member is configured to dissipate heat generated via electrical current flowing through the fuse, the bus bar assembly, and the contactor.

15. A method of assembling the electrical assembly of claim 1, the method comprising:

inserting the contactor into the holder;

connecting the fuse with the bus bar assembly;

connecting the bus bar assembly with the contactor;

connecting the bus bar assembly to the bracket;

disposing the cooling member on or around the support; and

connecting the cooling member to the bracket.

16. The method of claim 15, wherein the cooling member is connected with the bracket such that the fuse and the contactor are indirectly connected to the cooling member via the bus bar assembly and the bracket; and is provided with

The bus bar assembly is indirectly connected to the cooling member via the bracket.

17. The method of claim 15, wherein disposing the cooling member on the cradle includes inserting the cradle, the bus bar assembly, and the contactor at least partially into a recess of the cooling member.

18. The method of claim 15, wherein the fuse is connected to the bus bar assembly such that at least first, second, and third sides of the fuse are exposed to ambient air for passive cooling.

19. A method of operating the electrical assembly of claim 1, the method comprising:

controlling the contactor to supply current from a power source to a load;

generating heat via current flowing through the fuse;

conducting the heat from the fuse to the bus bar assembly;

conducting the heat from the bus bar assembly to the cooling member; and

dissipating the heat via the cooling member.

20. The method of claim 19, wherein conducting heat from the fuse to the bus bar assembly comprises conducting heat from the fuse to a protrusion of a bus bar of the bus bar assembly;

the projection is at least partially disposed between the fuse and the bracket; and is

The bus bar is electrically connected to the fuse.