US 12,489,260 B2Granted

Multi-layered flexible bus bar

AssigneeStafl Systems, LLC

InventorsBenjamin Michael Levy, Andrew Kenji McIntosh, Kadir Toksoy

Life of this patent

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Abstract

A flexible bus bar system for connecting printed circuit boards (PCBs), especially suited for high-power applications. The bus bar is constructed from multiple stacked thin sheets of conductive material, imparting flexibility and reducing mechanical stress on connected PCBs in applications prone to shock and/or vibration, such as electric vehicle power systems. The sheets may be laser-cut, optionally enabling formation of intricate geometries and/or integrated direct mounting apertures, potentially eliminating the need for additional connectors or crimps. One or more radiused curves are introduced into a central portion of the bus bar, holding the layers in alignment and providing flexibility and/or elasticity. The assembly may be reinforced with an adhesive-backed heat shrink. Methods of fabrication are also disclosed.

Claims20

Dependent claims

A flexible bus bar comprising:

a plurality of stacked conductive sheets;
each of said stacked conductive sheets having a plurality of curves formed in a central portion thereof;
and
each of said stacked conductive sheets having at least a first mounting point on a first side of the central portion, and at least a second mounting point on a second side of the central portion opposite the first side, each of the first and second mounting points configured for electrically-conductive attachment to a printed circuit board (PCB);
and
a coupling component configured to secure the stacked conductive sheets together at a portion of the stacked conductive sheets between the first mounting point and the second mounting point prior to installation;
wherein said stacked conductive sheets are each separable until being secured together by the coupling component prior to installation and are further sandwiched together upon installation by mounting hardware at the first mounting point and the second mounting point.

4 more elements

Dependencies are inferred from the claim text.

Facts

Application: 18/525,094Filed 30 Nov 2023
Published: US 2025/0183604 A15 Jun 2025
Granted: 2 Dec 2025
Term ends: Not estimatedThe source records don’t support an estimate.

Classification11 codes

H01R 12/52
For rigid printed circuits or like structures: connecting to other rigid printed circuits or like structures
H01R 25/145
Rails or bus-bars constructed so that the counterparts can be connected thereto at any point along their length: details, e.g. end pieces or joints
H01M 50/505
Interconnectors for connecting terminals of adjacent batteries; Interconnectors for connecting cells outside a battery casing: comprising a single…
H01R 12/7047
Locking or fixing a connector to a PCB: with a fastener through a screw hole in the coupling device