CN115206732B

CN115206732B - Electrical component

Info

Publication number: CN115206732B
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: 2024-03-15
Anticipated expiration: 2042-02-17
Also published as: DE102021130486A1; DE102021130486B4; CN115206732A

Abstract

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

Description

Electrical component

Technical Field

The present disclosure relates generally to electrical components, including components that may include electrical contacts and/or flexible circuits, 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 not admitted to be prior art to the present disclosure by definition or implicitly to the extent that it is not otherwise demonstrated to be prior art.

Some electrical components 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 preceding discussion is intended to be merely illustrative of the prior art and not a disclaimer of scope.

SUMMARY

In an embodiment, an electrical assembly may include a contactor, a bus bar connected to the contactor, a bracket connected to the bus bar, a flexible circuit electrically connected to the contactor, and/or a cooling member connected to the bracket.

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 support.

In some embodiments, the bracket includes 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 a 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 segment electrically connected to the electronic controller and a second segment 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 section of the flexible circuit includes a pair of integral eyelets.

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

In some embodiments, the flexible circuit includes 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 includes an at least partially hollow body configured to receive a cooling fluid.

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

For an embodiment, a method of assembling the electrical assembly described above may comprise: disposing the flexible circuit at least partially on and/or in the support; inserting one or more contactors including the contactor into the bracket; electrically connecting the bus bar with the one or more contactors; connecting the bus bar with the bracket; electrically connecting the flexible circuit to the one or more contactors; disposing the cooling member on or around the bracket; 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 bracket includes at least partially inserting the bracket, the flexible circuit, the bus bar, and the one or more contactors 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 present 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 particular illustrations, an appreciation of various aspects can be gained through a discussion of various examples. The figures 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 referring 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, wherein the bracket and cooling member are hidden.

Fig. 5 is a perspective view of an embodiment of a cradle, contactor, and flex 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 in which the bracket, bus bar assembly, and cooling member are hidden.

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 present disclosure will be described in connection with embodiments and/or examples, they are not intended to limit the present 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 Second contactor 22 ₂ Third contactor 22 ₃ And/or fourth contactor 22 ₄ A bus bar assembly 24 (see fig. 2), a bracket 26, and/or a cooling member 28. The current flowing through the busbar assembly 24 and/or the one or more contactors 22 may generate or cause a significant amount of heat. For example, and without limitation, electrical component 20 and/or contactor 22 may be configured to be used with a current of at least 500 amps (e.g., for several 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, a 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. The actuator 58 may include, for example and without limitation, an electromagnet, a coil, and/or a solenoid configured to move the contact member 56 into and out of electrical contact with the terminals 52, 54.

For example, such as generally illustrated in fig. 1, the bus bar assembly 24 may be electrically connected to one or more contactors 22, power sources 40 (e.g., batteries, sockets, etc.), and/or one or more electrical loads 170. The bus bar assembly 24 may include a first bus bar 60 and/or one or more second bus bars 62 (e.g., second bus bar 62) ₁ 、62 ₂ 、62 ₃ 、62 ₄ ) (see, e.g., fig. 1 and 3). The primary bus bar 60 may be electrically connected to some or all of the contacts 22 and/or the power source 40. For example, the first bus bar 60 may be connected (e.g., directly) 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 primary bus bar 60 may includeCan be connected to the first contactor 22 ₁ And a second contactor 22 ₂ And/or may include a first portion 60A that may be connected to the third contact 22 of the first terminal 52 ₃ And a fourth contactor 22 ₄ A second portion 60B of the first terminal 52. The first portion 60A and the second portion 60B may be separate or integrally formed. Respective second bus bars 62 may be connected to the second terminals 54 of one or more contactors 22. The second bus bar 62 may electrically connect the contacts 22 to respective loads 170 (e.g., the loads 170 ₁ 、170 ₂ 、170 ₃ 、170 ₄ ). The load 170 may include, for example, but is not limited to, a single load or multiple loads, such as one or more vehicle systems or components (e.g., air conditioner, heater, motor, etc.).

In an embodiment, such as generally illustrated in fig. 2-4, the busbar assembly 24 may be disposed, for example, at least partially directly on one or more of the contactors 22. For example, but not limited to, the primary bus bar 60 may be disposed directly on the outer wall 50 and/or the primary 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., 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/independent (e.g., separate, single piece components) and may be configured to be connected together. The first portion 72 may be configured as a body and the second portion 74 may be configured as a cover. For example, and without limitation, 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 function as and/or provide a fluid channel 80 (see, e.g., fig. 2). The first recess 76 may extend, for example, 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., pipe, tube, 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 be open in opposite directions). The second recess 78 may be configured to at least partially receive one or more of the contacts 22, the busbar assembly 24, the carrier 26, and/or the flexible circuit 144. The second recess 78 may extend, for example, along substantially the entire length of the cooling member 28. The first recess 76 and/or the second recess 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 to connect the cooling member 28 with one or more contactors 22, such as via the bus bar assembly 24. The bracket 26 may include one or more of a variety of shapes, sizes, materials, and/or configurations. For example, and without limitation, the bracket 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 (e.g., apertures 100) ₁ ，100 ₂ ，100 ₃ ，100 ₄ ) The one or more apertures 100 may be configured to at least partially receive the contacts 22 (see, e.g., fig. 5). For example, and without limitation, the support 26 may include a support for the contactor 22 ₁ 、22 ₂ 、22 ₃ 、22 ₄ Is provided with a hole 100 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 bracket 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 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 contactors 22. For example, and without limitation, if the contactor 22 comprises a generally cylindrical configuration, the sleeve portion 104 may comprise a generally cylindrical configuration, and/or if the contactor 22 comprises a generally rectangular configuration, the sleeve portion 104 may comprise a generally rectangular configuration. Some of the sleeve portions 104 may be shorter (e.g., in the axial/Z direction) than the contacts 22 such that the sleeve portions 104 cover some of the outer wall 50 of the contacts 22 and the exposed portions 106 of the outer wall 50 are not covered by the sleeve portions 104 (e.g., see the contacts 22 ₁ ). The exposed portion 106 may, for example, comprise a side (e.g., a radially outer surface) of the outer wall 50, be disposed near a second (e.g., bottom) end of the contactor 22, comprise a second/bottom surface 50B of the contactor 22, and/or extend around some or all of the perimeter/circumference of the contactor 22.

In embodiments, the other sleeve portions 104 may be about the same length as the contactor 22 or longer than the contactor 22 such that the sleeve portions 104 and the body 102 may substantially cover side surfaces (e.g., outer radial surfaces) of the outer wall 50 (e.g., see the contactor 22 ₂ 、22 ₃ 、22 ₄ ). The body 102 and sleeve portion 104 may not cover the first surface 50A (e.g., top axial surface) of the contactor 22 and/or may not cover the second surface 50B (e.g., 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 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., an insulated 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 of the 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 a 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 (e.g., see fig. 2 and 4). The connection between the bus bar assembly 24 (e.g., bus bars 60, 62) and the contacts 22 may provide and/or facilitate an electrical connection between the bus bars 60, 62 and the contacts 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/screwed) 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 an embodiment, such as generally illustrated in fig. 7, the bracket 26 may be connected to a cooling member 28. For example, and without limitation, the bracket 26 may be secured (e.g., bolted/screwed) to the cooling member 28 via one or more third fasteners 124, and the third fasteners 124 may 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, but not limited to, screws, bolts and/or rivets, among others.

In some embodiments, one or more contactors 22 may be secured, for example, directly to bus bar assembly 24, may be secured indirectly to bracket 26 via bus bar assembly 24, and/or may be secured indirectly to cooling member 28 via bus bar assembly 24 and bracket 26. For example, and without limitation, one or more contactors 22 may not be directly secured to the bracket 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 aperture 100 of the bracket 26 may include a lip 130 (e.g., an axial surface), and the lip 130 may be configured to contact the contactor 22. For example, the outer wall 50 of the contactor 22 may include a flange 132 that may extend outwardly (e.g., radially outward), and the contactor 22 may be inserted into the hole 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 busbar 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 (e.g., see fig. 1 and 3). For example, but not limited to, 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, 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 limited to, 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 include a conductor 146 (e.g., conductor 146 _1-8 ). The flexible circuit 144 may include a first section 148 that may be connected to an electrical connector 150, and the electrical connector 150 may be connected to the bracket 26 (see, e.g., fig. 5 and 9).

For embodiments, the flexible circuit 144 may include one or more second segments 152 (e.g., 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 the eyelets 154 may be disposed over/around the control terminals 140, 142 (e.g., control ends)The sub 140, 142 may be inserted into the eyelet 154). The eyelet 154 may be integrally formed with the corresponding conductor 146 (e.g., without a separate connection process, such as crimping or soldering) as part of the flexible circuit 144 (see, e.g., fig. 9 and 10A-10C). In some examples, in an 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 flex circuit 144 _1-8 ) Terminals/pins of (a). For example, and without limitation, a single electrical connector 150 (e.g., an external electrical connector) may provide/facilitate electrical connection with a plurality of contacts 22. In some configurations, the first section 148 of the flexible circuit 144 may include more conductors 146 than the second section 152 of the flexible circuit 144 (e.g., see 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 limited to, 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 layers of material 144A, and the one or more layers of material 144A may be integrally formed with 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.

In some example configurations, the flexible circuit 144 may include a thin configuration. For example, the flexible circuit 144 may include a width W that is less than its width ₁₄₄ Thickness T of (2) ₁₄₄ (see, e.g., fig. 7). In some examples, flexible circuit 144 may include a width W equal to or less than its width ₁₄₄ About 1/10 of the thickness ofDegree T ₁₄₄ . In some other examples, flexible circuit 144 may include a width W that is greater than its width W ₁₄₄ Is about 1/10 of the thickness T ₁₄₄ . In some embodiments, such as the example 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 . For example, but not limited to, length L ₁₄₄ Can be smaller than the width W ₁₄₄ At least five times or ten times longer (or more or less), and/or may be greater than its thickness T ₁₄₄ At least fifty or one hundred times longer (or more or less).

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 section 152 of the flexible circuit 144 is disposed in contact with at least a portion of the first surface 50A of the respective contactor 22 and/or extends along at least a portion of the first surface 50A of the respective contactor 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 some or all of the conductors 146 and/or formed directly around some or all of the conductors 146.

In some example configurations, the flexible circuit 144 may be disposed at least partially between the busbar assembly 24 and the bracket 26, for example (see 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 On, and/or along surface S of support 26 ₂₆ Such as to some or each of the one or more contactors 22. In some examples, surface S of bracket 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 busbar assembly 24 may be disposed in the recess 159 such thatAt least a portion of the flexible circuit 144 is disposed between the busbar assembly 24 and the bracket 26. 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 surface S from the bracket 26 ₂₆ Relatively small distance D ₁ At (see, e.g., fig. 6). In some examples, distance D ₁ It may be sufficient to have the flexible circuit 144 fit therein, but may not be sufficient to have alternatives to the flexible circuit 144 fit therein (e.g., separate wires, electrical connectors, and/or other conventional types of cables/wires, etc.). At least in some configurations, distance D ₁ May be determined by the height of the ledge 174 (e.g., 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 (2) ₁ Where it is located.

For embodiments, such as generally illustrated in fig. 5 and 10A-10C, the flexible circuit 144 may include one or more vias 156 (e.g., via 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, respective 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, one or more through holes 156 and/or one or more voids 158 may at least partially help secure flex circuit 144 with carrier 26 (e.g., limit and/or prevent movement of flex circuit 144 relative to carrier 26). In some examples, through-holes 156 and/or voids 158 may be arranged to assist in the process of assembling flex circuit 144 with carrier 26. For example, the through holes 156 and/or voids 158 may be used as error proofingA feature (poka-y feature) that may at least partially help ensure proper alignment and/or assembly of the flexible circuit 144 with the 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 the exterior of the contactor 22. For example, but not limiting of, 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, the vent 160 may allow air to flow into the 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. The top cover 162 may at least partially cover the first control terminal 140, the second control terminal 142, and/or the vent 160. For example, but not limited to, the top cover 162 may include a first recess 164, which first recess 164 may at least partially cover and/or receive the first control terminal 140 and/or the second control terminal 142. Additionally or alternatively, the top cover 162 may include a second recess 166, and the second recess 166 may at least partially cover and/or receive the vent 160. The top cover 162 may include an insulating wall 168, and the insulating wall 168 may extend at least partially between the first and second terminals 52, 54 and/or between the first and second recesses 164, 166. For example, but not limited to, the top cover 162 may be substantially planar and may extend from the first recess 164 to the second recess 166 such that the top cover 162 separates the first and second terminals 52, 54 and electrically insulates the first and second terminals 52, 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 group) is expected to be actuated/operated 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 may be included (e.g., such as in a vehicle, providing warm air).

For an embodiment, such as generally illustrated in fig. 11, a method 200 of assembling an electrical assembly 20 may include providing a bracket 26 and/or one or more contactors 22 (block 202). One or more contactors 22 may be inserted into the brackets 26 (block 204), such as into the corresponding apertures 100, until the flange 132 of the one or more contactors 22 contacts the lip 130 of the aperture 100. Inserting one or more contactors 22 into the bracket 26 may not include directly securing one or more contactors 22 to the bracket 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 contacts 22, such as control terminals 140, 142, and/or to the electrical connector 150 (block 208). Electrically connecting the flexible circuit 144 to the one or more 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 soldering the eyelet 154 and the control terminals 140, 142 together.

In an embodiment, the method 200 may include connecting the busbar 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 one or more bus bars 60, 62 on the bracket 26 and/or in the bracket 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 one or more first fasteners 120. Disposing one or more bus bars 60, 62 on the support 26 and/or in the support 26 may include disposing one or more bus bars 60, 62 over portions of the flexible circuit 144 such that portions of the flexible circuit 144 are disposed directly between the support 26 and the bus bars 60, 62. One or more bus bars 60, 62 may be provided 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 one or more second fasteners 122 (block 212). The second fastener 122 may be, for example, but not limited to, inserted/screwed into the busbar assembly 24 and then down into the bracket 26. Connecting the busbar assembly 24 with the bracket 26 may connect (e.g., indirectly) one or more of the contactors 22 with the bracket 26. The method 200 may include disposing the cooling member 28 on the bracket 26 (block 214), which may include inserting one or more of the contacts 22, the busbar assembly 24, the bracket 26, and/or portions of the flexible circuit 144 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 216), 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 limited to, 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 to 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 the control terminals 140, 142 may open and/or close to selectively provide power from the power source 40 to the one or more loads 170.

For embodiments, 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, integral) component. For example, and without limitation, the bracket 26 may be formed as a single piece of plastic component, and/or the first portion 72 may be formed as a single piece of metal (e.g., aluminum) component.

In an example, the 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), 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 more detail herein, using suitable programming instructions and/or code embodied in software, hardware, and/or other media. In an embodiment, the controller may include a plurality of controllers. In an embodiment, the controller may be connected to a display, such as a touch screen display.

Various examples/embodiments for various devices, systems, and/or methods are described herein. 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 description. It will be appreciated by persons of ordinary skill in the art that the examples/embodiments described and illustrated herein are non-limiting examples, and thus it may 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 this 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 "exemplary," "in an example," "according to an example," "in various embodiments," "according to an embodiment," "in an embodiment," or "an embodiment," or the like, in various places 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 described or illustrated 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, provided that such combination is not inconsistent or nonfunctional. 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, but may include one or more of 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 engaging (e.g., attached, coupled, connected, etc.) are to be construed 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 joining does not necessarily mean that the two elements are directly connected/coupled and in a fixed relationship relative to each other. The connection of electrical components (if any) may include mechanical, electrical, wired, and/or wireless connections, etc. The use of "e.g." and "such as" in this specification should be interpreted broadly and used to provide non-limiting examples of embodiments of the present disclosure, and the present disclosure is not limited to such examples or examples of this type. The use of "and" or "is to be interpreted broadly (e.g., as" and/or "). For example and without limitation, the use of "and" does not necessarily require all elements or features listed, and the use of "or" is inclusive unless such structure is not logical.

Although 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 certain steps performed concurrently, with additional steps, and/or with the omission of certain described steps.

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 in detail or structure may be made without departing from this 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;

a cooling member connected to the support, the flexible circuit being disposed substantially between the support and the cooling member, and wherein the support includes 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 a surface of the bracket.

2. The electrical assembly of claim 1, wherein the flexible circuit is disposed on and along a surface of the bracket.

3. 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.

4. The electrical assembly of claim 3, wherein the contactor comprises a first control terminal and a second control terminal.

5. The electrical assembly of claim 4, wherein the flexible circuit comprises one or more conductors.

6. The electrical assembly of claim 5, wherein the flexible circuit comprises a first segment electrically connected to the electronic controller and a second segment electrically connected to the contactor.

7. The electrical assembly of claim 6, wherein the first section of the flexible circuit comprises an electrical connector having a respective terminal for each of the one or more conductors.

8. The electrical assembly of claim 7, wherein the second section of the flexible circuit includes a pair of one-to-one eyelets.

9. The electrical assembly of claim 8, wherein the pair of apertures includes a first aperture integrally formed with a first conductor of the one or more conductors and a second aperture integrally formed 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 is also provided with

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

10. 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 also provided with

The length is at least five times the width.

11. 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 also provided with

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

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

13. 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 contactors including the contactor into the bracket;

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

connecting the bus bar with the bracket;

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

disposing the cooling member on or around the bracket; and

the cooling member is connected to the bracket.

14. The method of claim 13, wherein 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.

15. The method of claim 13, wherein disposing the cooling member on the bracket comprises at least partially inserting the bracket, the flexible circuit, the bus bar, and the one or more contactors into a recess of the cooling member.

16. The method of claim 13, 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.

17. The method of claim 16, 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.

18. The method of claim 13, wherein the flexible circuit is a single piece and connecting the flexible circuit to the one or more contactors comprises connecting a pair of apertures of the flexible circuit to respective control terminals of the one or more contactors.