High voltage (HV) terminal frame and method of manufacturing the same
AssigneeAptiv Technologies AG
InventorsNicholas A. Durse, Joseph Sudik, Jr., William C. Lovitz, Jeffrey A. Janis
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Abstract
A single-piece high voltage (HV) terminal frame includes a top wall, a bottom wall, and a side wall extending between the top wall and the bottom wall. The top wall includes a first top wall layer and an adjacently located second top wall layer. The side wall includes a first side wall layer and an adjacently located second side wall layer. The bottom wall includes a first bottom wall layer and an adjacently located second bottom wall layer. A single-layer contact spring extends from the first top wall layer, wherein the single-layer contact spring is bent to extend into a space located between the top wall and the bottom wall.
Claims19
A single-piece high voltage (HV) terminal frame comprising:
- a first top wall layer and a second top wall layer located adjacent the first top wall layer to form a top wall;
- a first bottom wall layer and a second bottom wall layer located adjacent the first bottom wall layer to form a bottom wall, wherein the bottom wall is located opposite the top wall;
- a first side wall layer and a second side wall layer located adjacent the first side wall layer to form a side wall, wherein the side wall extends between the top wall and the bottom wall;
- and
- a single-layer contact spring extending from the first top wall layer, wherein the single-layer contact spring is bent to extend into a space located between the top wall and the bottom wall, wherein the single-piece HV terminal frame is fabricated from a single, continuous layer of material bent to form the desired geometry of the single-piece HV terminal frame.
A method of fabricating a single-piece HV terminal frame, the method comprising:
- forming a single layer of material in a two-dimensional horizontal plane;
- and
- folding the single layer of material to form the single-piece HV terminal frame, wherein the HV terminal frame comprises:
- a first top wall layer and a second top wall layer located adjacent the first top wall layer to form a top wall;
- a first bottom wall layer and a second bottom wall layer located adjacent the first bottom wall layer to form a bottom wall, wherein the bottom wall is located opposite the top wall;
- a first side wall layer and a second side wall layer located adjacent the first side wall layer to form a side wall, wherein the side wall extends between the top wall and the bottom wall;
- and
- a single-layer contact spring extending from the first top wall layer, wherein the single-layer contact spring is bent to extend into a space located between the top wall and the bottom wall.
A high voltage (HV) terminal frame comprising:
- a first top wall layer and a second top wall layer located adjacent the first top wall layer to form a top wall;
- a first bottom wall layer and a second bottom wall layer located adjacent the first bottom wall layer to form a bottom wall, wherein the bottom wall is located opposite the top wall;
- a first side wall layer and a second side wall layer located adjacent the first side wall layer to form a side wall, wherein the side wall extends between the top wall and the bottom wall;
- a single-layer contact spring extending from the first top wall layer, wherein the single-layer contact spring is bent to extend into a space located between the top wall and the bottom wall;
- and
- a first conductive bus bar located adjacent to the bottom wall.
Dependencies are inferred from the claim text.