CN115206732A

CN115206732A - Electrical assembly

Info

Publication number: CN115206732A
Application number: CN202210145946.1A
Authority: CN
Inventors: 格雷格·迪克尔胡夫; 马修·扎米埃斯基; 阿里克·安格林; 罗伯特·M·施密特; 鲁图恩·雷
Original assignee: Lear Corp
Current assignee: Lear Corp
Priority date: 2021-04-06
Filing date: 2022-02-17
Publication date: 2022-10-18
Anticipated expiration: 2042-02-17
Also published as: DE102021130486A1; CN115206732B

Abstract

An electrical assembly may include a contactor, a bus bar connected to the contactor, a carrier connected to the bus bar, a flexible circuit electrically connected to the contactor, and/or a cooling member connected to the carrier. A method of assembling an electrical assembly may include disposing a flexible circuit at least partially on and/or in a cradle, connecting a bus bar with one or more contacts, connecting the bus bar with the cradle, electrically connecting the flexible circuit with the one or more contacts, disposing a cooling member on or around the cradle, and/or connecting the cooling member with the cradle.

Description

Electrical assembly

Technical Field

The present disclosure relates generally to electrical assemblies, including assemblies that may include electrical contacts and/or flexible circuits, which may be used, for example, in conjunction 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 solutions/options that minimize or eliminate 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 contactor, a bus bar connected to the contactor, a carrier connected to the bus bar, a flexible circuit electrically connected to the contactor, and/or a cooling member connected to the carrier.

In some embodiments, the flexible circuit is disposed substantially between the support and the cooling member.

In some embodiments, the flexible circuit is disposed on and along a surface of the bracket.

In some embodiments, the bracket comprises a recess; the bus bar is at least partially disposed in the recess; and at least a portion of the flexible circuit is disposed in the recess between the bus bar and the surface of the bracket.

In some embodiments, the electrical assembly includes an electronic controller configured to control the contactor to selectively provide power from a power source to one or more electrical loads.

In some embodiments, the contactor includes a first control terminal and a second control terminal.

In some embodiments, the flexible circuit includes one or more conductors.

In some embodiments, the flexible circuit includes a first section electrically connected to the electronic controller and a second section electrically connected to the contactor.

In some embodiments, the first section of the flexible circuit includes an electrical connector having a respective terminal for each of the one or more conductors.

In some embodiments, the second segment of the flexible circuit includes a pair of integral eyelets.

In some embodiments, the pair of integral eyelets includes a first eyelet integral with a first conductor of the one or more conductors and a second eyelet integral with a second conductor of the one or more conductors; the first eyelet is disposed around and connected to the first control terminal of the contactor; and the second aperture is disposed around and connected to the second control terminal of the contactor.

In some embodiments, the flexible circuit comprises a length, a width, and a thickness; the width is at least five times the thickness; and the length is at least five times the width.

In some embodiments, the contactor is directly secured to and in contact with the bus bar; the bus bar is directly fixed to and in contact with the bracket; and the bracket 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.

For an embodiment, a method of assembling an electrical assembly may include disposing a flexible circuit at least partially on and/or in a carrier, connecting a bus bar with one or more contacts, connecting the bus bar with the carrier, electrically connecting the flexible circuit with the one or more contacts, disposing a cooling member on or around the carrier, and/or connecting the cooling member with the carrier.

For an embodiment, a method of assembling the electrical assembly described above may include: disposing the flexible circuit at least partially on and/or in the support; inserting one or more contacts including the contact into the holder; electrically connecting the bus bar with the one or more contactors; connecting the bus bar to the bracket; electrically connecting the flexible circuit to the one or more contactors; disposing the cooling member on or around the support; and connecting the cooling member with the bracket.

In some embodiments, the bus bar is connected with the one or more contactors such that a portion of the flexible circuit is disposed directly between the bus bar and the bracket.

In some embodiments, disposing the cooling member on the cradle includes inserting the cradle, the flexible circuit, the bus bar, and the one or more contactors at least partially into a recess of the cooling member.

In some embodiments, the method includes electrically connecting the flexible circuit to a controller configured to control the one or more contactors to selectively provide power from a power source to one or more electrical loads.

In some embodiments, the method includes controlling operation of the one or more contactors via the controller, the controller providing one or more control signals to the one or more contactors via the flexible circuit.

In some embodiments, the flexible circuit is a single piece and connecting the flexible circuit to the one or more contactors includes connecting a pair of integral eyelets of the flexible circuit to respective control terminals of the one or more contactors.

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 understanding of various aspects may 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 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 perspective view generally illustrating an embodiment of an electrical assembly with the bracket and cooling member concealed.

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

Fig. 6 is a partial perspective view generally illustrating an embodiment of an electrical assembly.

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

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

Fig. 9 is a perspective view generally illustrating an embodiment of a flexible circuit.

Fig. 10A-10C are partial perspective views generally illustrating an embodiment of a flexible circuit.

Fig. 11 is a flow chart generally illustrating an embodiment of a method of assembling an electrical assembly.

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 fourth contactor 22 ₄ Bus bar assembly 24 (see fig. 2), 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 help dissipate 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) to the first terminal 52 of the one or more contactors 22, and may be connected at least indirectly 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 contact 22 that may be connected to the first bus bar ₁ And a second contactor 22 ₂ May include a first portion 60A of the first terminal 52 and/or may include a second portion connectable to the third contactor 22 ₃ And a fourth contactor 22 ₄ And a second portion 60B of the first terminal 52. 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). 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 and

second recesses

76, 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 bracket 26 may be configured such as via a bus bar assembly24 connect the cooling member 28 with 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, but not limiting of, the bracket 26 may comprise plastic and/or one or more electrically insulating materials, and may comprise a generally elongated rectangular frame configuration. The support 26 may include one or more apertures 100 (e.g., aperture 100) ₁ ，100 ₂ ，100 ₃ ，100 ₄ ) The one or more apertures 100 may be configured to at least partially receive the contact 22 (see, e.g., 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 the contact 22 such that the sleeve portions 104 cover some of the outer wall 50 of the contact 22 and the exposed portions 106 of the outer wall 50 are not covered by the sleeve portions 104 (see, e.g., contact 22) ₁ ). 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 the 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 the same length as the contact 22 or longer than the contact 22, such that the sleeve portion 104 and the body 102 may substantially cover a side surface (e.g., an outer radial surface) of the outer wall 50 (e.g., see 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 the entirety 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, and without limitation, one or more contactors 22 may be secured (e.g., bolted/screwed) to 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, the one or more contactors 22 may be, for example, directly secured to 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 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 contact 22, such as until the contact 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 via a flex circuit/ribbon cable 144Coupled to the

control terminals

140, 142, the flex circuit/ribbon cable 144 may include a conductor 146 (e.g., conductor 146) for each control terminal 140, 142 _1-8 ). The flexible circuit 144 may include a first segment 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 and 9).

For an embodiment, the flexible circuit 144 may include one or more second segments 152 (e.g., the second segments 152) ₁ 、152 ₂ 、152 ₃ 、152 ₄ ) One or more second segments 152 may be connected to respective contactors 22 (see, e.g., fig. 5, 8, and 9). The second segment 152 may include a pair of conductors 146 (e.g., conductors 146) connected to the

control terminals

140, 142 ₁ And 146 ₂ ). The pair of conductors 146 may, for example, include eyelets 154 (e.g., eyelets 154A and 154B), and eyelets 154 may be disposed over/around control terminals 140, 142 (e.g.,

control terminals

140, 142 may be inserted into eyelets 154). The eyelets 154 may be integrally formed with the respective conductors 146 (e.g., without a separate connection process, such as crimping or welding) as part of the flexible circuit 144 (see, e.g., fig. 9 and 10A-10C). In some examples, in the assembled configuration, the contactor 22 may include a top cover 162, and the top cover 162 may provide a protective covering for the eyelet 154 and/or the control terminals 140, 142 (see, e.g., fig. 4). The top cover 162 may, for example, comprise an electrically insulating and/or thermally conductive material, such as a polymer and/or plastic.

For an embodiment, the controller 110 may be electrically connected to the flexible circuit 144, for example, via an electrical connector 150. The electrical connector 150 may include each conductor 146 (e.g., conductor 146) for the flexible circuit 144 _1-8 ) Terminal/pin of (a). 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. In some configurations, the first segment 148 of the flexible circuit 144 may include more conductors 146 than the second segment 152 of the flexible circuit 144 (see, e.g., fig. 9 and 10A).

In embodiments, such as generally illustrated in fig. 9, and 10A-10C, the flexible circuit 144 may include one or more of a variety of shapes, sizes, materials, and/or configurations. For example, but not limiting of, the flexible circuit 144 may comprise a single-piece (e.g., unitary, monolithic) structure. Additionally or alternatively, the flexible circuit 144 may include one or more material layers 144A, which may be integrally formed on and/or around each other and/or one or more conductors 146. The one or more layers may include one or a combination of an insulating layer, an adhesive layer, and/or a protective coating layer.

In some example configurations, the flexible circuit 144 may include a thin configuration. For example, the flexible circuit 144 may include less than its width W ₁₄₄ Thickness T of ₁₄₄ (see, e.g., FIG. 7). In some examples, the flexible circuit 144 may include a width W equal to or less than it ₁₄₄ About 1/10 of the thickness T ₁₄₄ . In some other examples, the flexible circuit 144 may include more than its width W ₁₄₄ About 1/10 of the thickness T of ₁₄₄ . In some embodiments, such as the exemplary embodiment of fig. 9, the length L of the flexible circuit 144 ₁₄₄ Can be significantly longer than its width W ₁₄₄ And/or its thickness T ₁₄₄ . Such as, but not limited to, length L ₁₄₄ May be larger than the width W thereof ₁₄₄ At least five or ten times (or more or less) longer and/or may be thicker than its thickness T ₁₄₄ At least fifty times or one hundred times (or more or less) longer.

For embodiments, such as generally illustrated in fig. 8 and 9, the flexible circuit 144 may be substantially planar. For example, some, most, and/or substantially all of the flexible circuit 144 may extend along a single plane. In some example configurations, the flexible circuit 144 may be configured such that at least a portion of the second segment 152 of the flexible circuit 144 is arranged to contact at least a portion of the first surface 50A of the respective contact 22 and/or extend along at least a portion of the first surface 50A of the respective contact 22 (e.g., see fig. 8). For some configurations, the plurality of conductors 146 may be aligned in a common plane and/or may be separated by an electrically insulating material. Adjacent conductors 146 may be separated by the same material/layer 144A (e.g., an electrically insulating material/layer), which material/layer 144A may be formed directly on and/or around some or all of conductors 146.

In some example configurations, the flexible circuit 144 may be disposed, for example, at least partially between the bus bar assembly 24 and the bracket 26 (see, e.g., fig. 7). In an embodiment, such as generally illustrated in fig. 5-7, the flexible circuit 144 may be disposed on the surface S of the support 26 ₂₆ Up and/or along the surface S of the support 26 ₂₆ Extending, such as to some or each of the one or more contacts 22. In some examples, surface S of stent 26 ₂₆ A recess 159 may be included and at least a portion of the flexible circuit 144 may be disposed within the recess 159 (see, e.g., fig. 6). In some examples, at least a portion of the bus bar assembly 24 may be disposed in the recess 159 such that at least a portion of the flexible circuit 144 is disposed between the bus bar assembly 24 and the bracket 26. The recess 159 may, for example, comprise a generally U-shaped configuration that may be upwardly open.

In some example configurations, some, most, and/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 distance S from the surface of the bracket 26 ₂₆ Relatively small distance D ₁ Here (see, e.g., fig. 6). In some examples, distance D ₁ May be sufficient to have the flexible circuit 144 fit therein, but may be insufficient to have a replacement for the flexible circuit 144 (e.g., a separate wire, an electrical connector, and/or other conventional types of cables/wires, etc.) fit therein. At least in some configurations, the distance D ₁ May be determined by the height of a ledge 174 (e.g., a step, lip, etc.) of the bracket 26 that may extend into the recess 159. The ledge 174 may extend into the recess 159 such that the width of the recess 159 is reduced and a bus bar (e.g., bus bar 62) is at least partially disposed on the ledge 174 and disposed from the surface S ₂₆ Distance D of ₁ To (3).

For the examples, theAs generally illustrated in fig. 5 and 10A-10C, the flexible circuit 144 may include one or more vias 156 (e.g., vias 156) ₁ 、156 ₂ 、156 ₃ 、1564、156 ₅ ) And/or one or more voids 158 (e.g., voids 158) ₁ 、158 ₂ 、158 ₃ ) Which may be configured to receive a corresponding portion of the bracket 26. In some example configurations, corresponding fasteners (not depicted) may be disposed in at least some and/or all of the one or more through-holes 156 and may be received by the bracket 26. For example, and without limitation, the one or more through-holes 156 and/or the one or more voids 158 may at least partially assist in securing the flexible circuit 144 with the bracket 26 (e.g., limit and/or prevent movement of the flexible circuit 144 relative to the bracket 26). In some examples, the through-holes 156 and/or voids 158 may be arranged to assist in the process of assembling the flexible circuit 144 with the bracket 26. For example, through-holes 156 and/or voids 158 may serve as error-proofing features (poka-yoke features) that may help, at least in part, ensure proper alignment and/or assembly of flex circuit 144 with bracket 26.

In an embodiment, 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 group) 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 an embodiment, such as generally illustrated in fig. 11, a method 200 of assembling the electrical assembly 20 may include providing a cradle 26 and/or one or more contacts 22 (block 202). One or more contacts 22 may be inserted into the cradle 26 (block 204), such as into the corresponding apertures 100, until the flanges 132 of the one or more contacts 22 contact the lips 130 of the apertures 100. Inserting one or more contacts 22 into the holder 26 may not include securing the one or more contacts 22 directly to the holder 26. The flexible circuit 144 may be disposed on the support 26 and/or in the support 26 (block 206). The flexible circuit 144 may be electrically connected to one or more contactors 22, such as

control terminals

140, 142, and/or to the electrical connector 150 (block 208). Electrically connecting the flexible circuit 144 to one or more of the contacts 22 may, for example, include disposing an eyelet 154 (e.g., an integral eyelet) of the flexible circuit 144 on the

control terminals

140, 142 and/or welding the eyelet 154 and the

control terminals

140, 142 together.

In an embodiment, the method 200 may include connecting the bus bar assembly 24 with one or more contactors 22 (block 210). Connecting the bus bar assembly 24 with the one or more contactors 22 may include disposing the one or more bus bars 60, 62 on and/or in the cradle 26, and/or 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. Disposing one or more bus bars 60, 62 on the bracket 26 and/or in the bracket 26 may include disposing the one or more bus bars 60, 62 over a portion of the flexible circuit 144 such that the portion of the flexible circuit 144 is disposed directly between the bracket 26 and the bus bars 60, 62. One or more bus bars 60, 62 may be disposed in contact with one or more contactors 22.

For 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 the one or more second fasteners 122 (block 212). 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 cradle 26 may connect (e.g., indirectly) the one or more contactors 22 to the cradle 26. Method 200 may include disposing cooling member 28 on holder 26 (block 214), which may include inserting one or more contacts 22, bus bar assembly 24, holder 26, and/or portions of flexible circuit 144 into cooling member 28, such as into second recess 78. Method 200 may include connecting cooling member 28 with bracket 26 (block 216), which may include fastening (e.g., securing) cooling member 28 with 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 upwardly into the cooling member 28.

In an embodiment, the method 200 may include connecting (e.g., electrically connecting) the flexible circuit 144 with the controller 110 (block 218). The method 200 may include controlling operation of one or more contactors 22 via the controller 110 (block 220). For example, the controller 110 may provide one or more control signals to the flexible circuit 144, and the flexible circuit may provide one or more control signals to the

respective control terminals

140, 142 of each of the one or more contactors 22, which control

terminals

140, 142 may open and/or close the contactors to selectively provide power from the power source 40 to the one or more loads 170.

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 appropriate 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 "embodiment," or the like, where appropriate, throughout this 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 a feature, structure, function, and/or characteristic of one or more other embodiments/examples without limitation, so 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 construed broadly and may include intermediate members between connected elements, 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, and/or wireless connections, and the like. The use of "for example" and "such as" in this specification is to be interpreted broadly and to provide non-limiting examples of embodiments of the disclosure, and the disclosure is not limited to such examples or to this type of 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 contactor;

a bus bar electrically connected to the contactor;

a bracket connected to the bus bar;

a flexible circuit electrically connected to the contactor; and

a cooling member connected to the bracket.

2. The electrical assembly of claim 1, wherein the flexible circuit is disposed substantially between the bracket and the cooling member.

3. The electrical assembly of claim 2, wherein the flexible circuit is disposed on and along a surface of the bracket.

4. The electrical assembly of claim 2, wherein the bracket includes a recess;

the bus bar is at least partially disposed in the recess; and is

At least a portion of the flexible circuit is disposed in the recess between the bus bar and a surface of the bracket.

5. The electrical assembly of claim 1, comprising an electronic controller configured to control the contactor to selectively provide power from a power source to one or more electrical loads.

6. The electrical assembly of claim 5, wherein the contactor includes a first control terminal and a second control terminal.

7. The electrical assembly of claim 6, wherein the flexible circuit comprises one or more conductors.

8. The electrical assembly of claim 7, wherein the flexible circuit includes a first section electrically connected to the electronic controller and a second section electrically connected to the contactor.

9. The electrical assembly of claim 8, wherein the first section of the flexible circuit includes an electrical connector having a respective terminal for each of the one or more conductors.

10. The electrical assembly of claim 9, wherein the second section of the flexible circuit includes a pair of integral eyelets.

11. The electrical assembly of claim 10, wherein the pair of integral eyelets comprises a first eyelet integrally formed with a first conductor of the one or more conductors and a second eyelet integrally formed with a second conductor of the one or more conductors;

the first aperture disposed around and connected to the first control terminal of the contactor; and is

The second aperture is disposed around and connected to the second control terminal of the contactor.

12. The electrical assembly of claim 1, wherein the flexible circuit comprises a length, a width, and a thickness;

the width is at least five times the thickness; and is

The length is at least five times the width.

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

the bus bar is directly fixed to and in contact with the bracket; and is provided with

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

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

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

disposing the flexible circuit at least partially on and/or in the support;

inserting one or more contacts including the contact into the holder;

electrically connecting the bus bar with the one or more contactors;

connecting the bus bar to the bracket;

electrically connecting the flexible circuit to the one or more contactors;

disposing the cooling member on or around the support; and

connecting the cooling member with the bracket.

16. The method of claim 15, wherein the bus bar is connected with the one or more contactors such that the portion of the flexible circuit is disposed directly between the bus bar and the bracket.

17. The method of claim 15, wherein disposing the cooling member on the bracket includes inserting the bracket, the flexible circuit, the bus bar, and the one or more contacts at least partially into a recess of the cooling member.

18. The method of claim 15, comprising electrically connecting the flexible circuit to a controller configured to control the one or more contactors to selectively provide power from a power source to one or more electrical loads.

19. The method of claim 18, comprising controlling operation of the one or more contactors via the controller, the controller providing one or more control signals to the one or more contactors via the flexible circuit.

20. The method of claim 15, wherein the flexible circuit is a single piece and connecting the flexible circuit to the one or more contactors comprises connecting a pair of integral eyelets of the flexible circuit to respective control terminals of the one or more contactors.