Multilayer copper bus bars with soldered through hole components
AssigneeROLLS-ROYCE plc
InventorsShuai Wang, Chandana J. Gajanayake, David R. Trawick
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Abstract
An electrical assembly, such as a multi-layer bus bar, includes an electrical connection pin and a plurality of electrically conductive layers. Each of the electrically conductive layers is formed to define a cutout therein to receive the electrical connection pin and allow access for joining material to join the electrical connection pin with the plurality of electrically conductive layers. Each of the cutouts is formed to include a first portion arranged around the electrical connection pin and a second portion located radially outward of the first portion.
Claims20
A multi-layer bus bar assembly comprising,
- a capacitor having a body and a first electrical connection pin that extends away from the body along an axis,
- a multi-layer bus bar that includes
- a positive rail that includes a plurality of first conductive layers and a plurality of first inter-insulation layers, wherein each of the plurality of first inter-insulation layers is located axially between neighboring first conductive layers included in the plurality of first conductive layers,
- a negative rail that includes a plurality of second conductive layers and a plurality of second inter-insulation layers, wherein each of the plurality of second inter-insulation layers is located axially between neighboring second conductive, and
- a main insulation layer positioned between the positive rail and the negative rail,
- wherein the plurality of first conductive layers are formed to assist in the joining of the plurality of first conductive layers with the first electrical connection pin, the plurality of first conductive layers include a first layer and a second layer axially neighboring the first layer, the first layer formed to define a first cutout shaped with a soldering pattern arranged about the axis, and the second layer formed to define a second cutout shaped with the soldering pattern, and
- wherein the soldering pattern includes a first portion that extends circumferentially at least partway around the first electrical connection pin at a first radial distance relative to the axis and a second portion that extends circumferentially at least partway about the first electrical connection pin at a second radial distance relative to the axis.
A multi-layer electrical component assembly comprising
- an electrical connection pin that extends along an axis,
- a first conductive layer formed to define a first cutout that extends axially through the first conductive layer, and the first cutout includes a first portion arranged around the electrical connection pin and a second portion located radially outward of the first portion,
- a second conductive layer that axially neighbors the first conductive layer, the second conductive layer formed to define a second cutout that extends axially through the second conductive layer, the second cutout includes a third portion arranged around the electrical connection pin and a fourth portion located radially outward of the third portion, and the fourth portion is at least partially circumferentially aligned with the second portion of the first cutout to allow joining material to be provided axially between the fourth portion and the second portion.
A method of making a multi-layer bus bar assembly, the method comprising
- arranging a first cutout formed in a first electrically conductive layer around an electrical connection pin that extends along an axis, the first cutout having a first portion that extends circumferentially at least partway around the electrical connection pin relative to the axis and a second portion located radially outward from the first portion,
- arranging a second cutout formed in a second electrically conductive layer around the electrical connection pin, the second cutout having a third portion that extends circumferentially at least partway around the electrical connection pin relative to the axis and a fourth portion located radially outward from the second portion,
- applying joining material in the first portion of the first cutout to cause the joining material to engage the first electrically conductive layer and the electrical connection pin, and
- applying the joining material in the second portion of the first cutout to cause a portion of the joining material to pass through the second portion of the first cutout and enter the fourth portion of the second cutout to allow the joining material to engage the second electrically conductive layer.
Dependencies are inferred from the claim text.