The electrical power distribution system is an important component of a wide variety of apparatus including motor vehicles, electrical appliances, industrial equipment and the like. Power distribution systems of any complexity typically include one or more buss bars which serve to carry relatively high levels of current to electrical devices such as fuses, relays and the like, from whence the electrical power is then conveyed to other components of the apparatus. The electrical systems of motor vehicles are of increasing complexity, and motor vehicles presently manufactured include an electrical distribution box having a number of buss bar assemblies therein. Presently, buss bars are fabricated from metal stampings. These buss bars are of relatively complex geometry and include a power connection terminal which is configured to engage a source of electrical power such as a battery or alternator, through a bolt or other such connection. Power buss bars further include a current carrying member having a number of connector prongs projecting there from, typically at right angles through the remainder of the assembly.

The complex geometrical shape of such buss bars precludes stacking.

This, together with the general fragility of the metal stamping complicates shipping and handling. Furthermore, such prior art buss bars must be uniquely configured for each application. Therefore, in the motor vehicle industry, manufacturers are often required to employ differently configured buss bar assemblies for various models of vehicle ; and in fact, a particular vehicle may require use of a number of discreetly configured buss bars. As a result, tooling and inventory problems associated with the use of prior art stamped metal buss bars are significant. In addition, prior art stamped metal buss bars are relatively heavy, and their manufacture typically generates a large amount of scrap metal which may not be easily recycled.

The present invention provides a buss bar system which allows for the assembly of buss bars of different electrical configurations from a number of standard, identical parts. The components of the system of the present invention are lightweight, rugged, and of generally planar geometry. As a result of the foregoing, problems of shipping, handling and inventory maintenance are greatly alleviated.

The system of the present invention allows buss bar assemblies to be easily configured for specific applications from a relatively small number of standard components. In addition, the system of the present invention minimizes the amount of scrap generated in buss bar fabrication, and permits the ready recycling or reuse of system components. The system of the present invention has particular utility in connection with the power distribution system of motor vehicles, and will be primarily described in that context; however, it is to be understood that the buss bar system of the present invention may be used with equal advantage in power distribution systems associated with industrial equipment, home appliances, communications, equipment and the like.

The buss bar system of the present invention is based upon the use of molded, preferably, polymeric, components which are metalized, preferably by the lamination of metal foils thereonto. Metalized polymeric components have previously been employed in a number of electrical and electronic applications; however, the prior art has not recognized that metalized components can be utilized to form a power distribution buss bar system. Patent 5,795,171 discloses a polymeric electrical terminal having a plated or screen-printed conductive coating thereon. Patent 5,873,751, discloses a molded circuit board which includes conductive traces formed thereon, preferably through the use of a curable, electrically conductive ink. Patent 5,427,532 discloses polymeric connectors which have metalized contact traces formed thereon, preferably by electroplating. Patent 5,777,850 discloses the use of an electrically conductive foil in connection with a circuit board disposed in a junction box, and Patent 5,457,057 discloses photovoltaic modules which includes flexible photovoltaic generators having copper foil buss bars adhered thereto. None of the prior art discloses a power distribution buss system of the type described herein below, which includes an assemblage of discrete plates having conductive foil traces laminated thereto.

As will be described hereinbelow, the present invention provides a power buss system which may be assembled into a variety of configurations, utilizing standard components. The system of the present invention is readily adaptable to modular power distribution systems, and has significant utility in complex power distribution systems of the type utilized in motor vehicles, industrial equipment, electrical appliances and the like. These and other advantages of the invention will be apparent from the discussion, description and drawings which follow.

There is disclosed herein a buss bar assembly for establishing electrical communication between a power supply, an electrical device, and an electrical circuit. The assembly of the present invention includes a first and a second buss bar plate. Each plate is a generally planar member fabricated from an electrically insulating material, such as an injection molder polymer. Each plate has at least one contact tab defined on an edge thereon. The tab projects from the edge and is coplanar with the remainder of the plate. A pattern of electrically conductive material, preferably a thermally embossed metal foil is disposed on a portion of each plate so that the conductive pattern extends onto, and covers at least some of the contact tab of each plate. The first plate includes a connector for establishing electrical communication between a battery or other source of electrical power and the conductive pattern on the plates so that the power can be conveyed to the contact tab. The second plate includes means for connecting an electrical circuit to the conductive pattern on that second plate. The connector means may comprise a connector tab projecting from the second plate. A spacer allows the plates to be secured to one another in a plane parallel relationship so that the conductive patterns on the plates are in a spaced-apart relationship. The spacer, in one embodiment, includes molded-in components on the plates such as pins and sockets.

In the assembly of the present invention, the contact tab of the first plate, and the contact tab of the second plate are configured to engage respective terminals of a fuse or other such electrical device. In this manner, an electrical device which is secured to the contact tabs bridges the first and second conductive patterns and allows for the flow of electrical current from the power supply to the remainder of an electrical circuit which is connected to the conductive pattern on

the second plate. In specific embodiments, the plates include a plurality of contact tabs, and they can further include a number of connector tabs which have the conductive pattern extending thereonto. The connector tabs are employed to establish electrical connection to the remainder of an electrical circuit. In specific embodiments, the connective pattern is formed from a copper metal foil. In specific embodiments, the plates are formed from an injection-molded thermoplastic material, which is a high-strength nylon or the like.

Also disclosed herein are methods for the fabrication and use of the buss bar assemblies.

Figure 1 is a perspective view of a buss bar assembly of the present invention taken from the side of the first plate thereof; Figure 2 is a plan view of the buss bar assembly of Figure 1 taken from the side of the second plate thereof; Figure 3 is a plan view of a buss bar plate which may be employed in the practice of the present invention, showing the first face thereof; and Figure 4 is a plan view of the buss bar plate of Figure 3 showing a second face thereof.

Figure 1 is a perspective view of one embodiment of buss bar assembly 10 structured in accord with the principles of the present invention. Buss bar assembly 10 of Figure 1 includes a first buss bar plate 12 and a second buss bar plate 14 disposed in a spaced apart generally plane parallel relationship. The buss bar assembly 10 functions to convey electrical power from a terminal 16, to one or more electrical circuits via one or more electrical devices, which in this instance are depicted as automotive fuses 18a and 18b of the type known in the art as J-type fuses.

The plates 12,14,, of the buss bar assembly 10 each include a number of contact tabs projecting from an upper edge thereof. As shown in Figure 1, the first buss bar plate 12 includes contact tabs 20a, 20b, and 20c and the second plate 14 includes contact tabs 22a, 22b, and 22c. Other tabs are covered by the fuses 18a, 18b. A pattern of electrically conductive material is disposed on each plate, and this pattern covers at least a portion of at least some of the contact tabs 20,22.

As shown in Figure 1, the pattern of electrically conductive material 24 extends so

as to cover all of the depicted contact tabs, 20a, 20b and 20c, as well as contact tabs which are covered by the fuses 18a, 18b. The conductive pattern 24 shown in Figure 1 also is an electrical contact with the power connection terminal 16.

Referring now to Figure 2, there is shown a plan view of the buss bar assembly 10 of Figure 1 taken from the side of the second plate 14. As shown in Figure 2, the second plate 14 has an electrically conductive pattern 26 formed thereon. In this case, the pattern 26 is comprised of five separate segments, 26a-26e. The pattern covers the contact tabs 22a, 22b, 22c of the second plate 14.

The pattern also covers two other contact tabs which, in this Figure, are not visible since they are engaged by fuses 18a, 18b.

The conductive pattern on the second plate 14 also extends so as to cover a set of connector tabs 28a-28f which project from a bottom edge of the plate 14. As depicted, the conductive pattern establishes an electrical connection between various of the contact tabs 22 and the connector tabs 28. As illustrated, the conductive pattern can establish contact between one contact tab and connector tab, as for example, between tabs 22a and 28a. Likewise, the conductive pattern can establish electrical communication between more than one pair of tabs. For example, the segment of the pattern 26c establishes electrical communication between contact tab 22c and connector tabs 28c and 28b. Still other configurations are possible within the context of this invention.

The connector tabs 28 are used to establish electrical contact with one or more electrical circuits. As illustrated, connector tabs 28 form blade terminals which can engage a corresponding socket. Other configurations of connector means are also possible within the context of this invention. For example, the connector tabs 28 can provide points for soldered contacts to be made, or they can provide points for the affixation of variously configured connector terminals by means of rivets, bolts, or the like. In yet other embodiments of the present invention, the connector tab 28 may be eliminated or otherwise configured, and connector terminals such as pin connectors, socket connectors, frictional connectors, or the like may be incorporated onto or into the plate 14 to provide means for connecting an electrical circuit.

Referring back to Figure 1, it will be noted that the first plate 14 also

includes a set of connector tabs 30a-30f projecting therefrom; however, in this particular embodiment of the invention, no conductive pattern extends to these tabs.

However, it is to be understood that in some embodiments, these tabs may have a conducting pattern extending thereon to so as to be functional for providing power to a circuit connected thereto.

The buss bar assembly of Figures 1 and 2 is particularly well suited for use in a power distribution box of a motor vehicle. As illustrated, the buss bar assembly provides a support for a number of fuses, for example, fuses 18a and 18b, and allows these fuses to be connected to electrical circuits supplying power to various components of the vehicle. It should be noted that as illustrated, only two fuses 18a and 18b are shown as affixed to the assembly. In most practicable applications, electrical devices will be affixed to all of the contact tabs. Also, while the buss bar is illustrated as used in connection with fuses, it may likewise be used to establish electrical path which includes resistors, relays, diodes, switches, or any other electrical device.

In the operation of the buss bar 10 of Figures 1 and 2, electrical power is supplied to the power terminal 16, as for example, by connection of the terminal 16 to a battery or alternator. Electrical current flows through the conductive pattern 24 on the first plate 12, to the contact tabs 20 of the first plate..

It flows through the electrical device, for example, fuse 18a, to a corresponding contact tab 22 on the second plate 14, and from thence to a connector tab associated therewith, in this instance, tab 28e. In this manner, the fuse element 18a is inserted in series in an electrical circuit established between the power terminal 16 and electrical system coupled to connector tab 28c.

In a preferred embodiment of the invention, the pattern of electrically conductive material is formed from a metal foil which is thermally laminated onto the respective buss bar plates 12,14. Lamination may be accomplished by a combination of heat and pressure. In some instances, an adhesive may be employed to assure that the foil is retained in contact with the plate; although, in those instances where the plate is formed from a relatively thermoplastic material itself, lamination may be accomplished by heat and pressure, without the use of any additional adhesive. One metal foil having particularly utility in the present

invention is a material sold under the designation IvotapeK by the Cusolar Corporation of Chesterfield, Michigan. This particular product comprises an electrically conductive metal foil tape which can be hot embossed or stamped onto thermoplastic materials. In a most preferred embodiment, the tape is a copper foil tape having a thickness in the range of 10-150 microns. In specific instances, the tape is a copper tape having a thickness in the range of 35 to 100 microns. The tape may include a coating which facilitates bonding. In some instances, the coating is a hot-melt adhesive coating; however, one particularly preferred coating comprises a carbon coating, an oxide coating, or a combination of carbon and oxide. In some instances, the copper foil is provided with a nickel, a tin or gold-plated layer thereatop to enhance solderability and/or and environmental integrity. Other metal foils such as nickel foil, gold foil, and the like may be employed in particular applications. In one preferred embodiment, the foil is stamped and embossed in a single step utilizing a heated die which severs the foil along predetermined lines, and simultaneously embosses the foil onto buss bar plates.

While the metal foil comprises a preferred material for fabrication of the electrically conductive pattern, other materials such as conductive inks may be likewise employed. Also, plating processes or other metalization processes such as thermochemical deposition may be employed to form the conductive pattern.

The buss bar plates can be fabricated from any electrically insulating material which is capable of having the metallic patterns formed or applied thereto, and which has sufficient strength and integrity to function for this application. The polymers, particularly high-strength engineering polymers are some of the preferred materials for the practice of the present invention. One particularly preferred material comprises nylon 66. Other preferred polymeric materials comprise ABS polymers, and composite materials such glass or fiber-filled polymers. Most preferably, the plates are fabricated from an injection moldable thermoplastic material.

Referring now to Figures 3 and 4, there are shown plan views of first and second face of an unmetalized buss bar plate, which may be employed in the practice of the present invention. Figure 3 depicts the first face of a typical plate

12. In the assembly shown in Figure 1, this face would be the inside face, that is to say the face directed towards the second plate 14. As will be seen from Figure 3, the plate 12 includes contact tabs 20a-20e, and connector tabs 30a-30f. The plate 12 further include spacers, 32a, 32b which are integrally molded therein. Each spacer includes a collar portion 34a, 34b. These collar portions are of a first diameter, and are disposed directly upon the face of the plate 12. Each spacer 32 further includes a pin portion, 36a, 36b. Pin portions 36 project from the collar portions 34. In the illustrated embodiment, the length dimension of the plate is approximately 9 centimeters, and the width dimension, exclusive of the tabs, is approximately 4 centimeters. Height of the collar potion 34 is approximately 1-2 millimeters, and the length of the pin 36, approximately 2-4 millimeters. The plate 12 further includes a first socket 38 and a second socket 40 defined therethrough.

The sockets 38,40 are of a size configured to receive the pins 36 of a corresponding plate. It will be noted that as illustrated, socket 38 is configured as a hole and socket 40 as a slot. The plate further includes a first, relatively large hole defined therethrough 42 and a second, relatively smaller hole 44 defined therethrough.

Figure 4 depicts the same plate 12 as viewed from the second face thereof, which face in a typical application, bears the conductive pattern thereon.

Shown in Figure 4 are the contact tabs 20, connector tabs 30, the large opening 42 and the small opening 44, as well as the openings 38 and 40 which receive the spacer pins 36.

It is a notable feature of the present invention that the buss bar assembly may be implemented utilizing two identical members as the first and second plates. For example, a pair of plates, generally similar to those shown in Figures 3 and 4 can be disposed in a face-to-face relationship so that first faces thereof are closest to one another, and so that the spacer pins 36 of a first plate fit into the spacer pins sockets 38, 40 of a like second plate. In this regard, the slotting of the second socket 40 facilitates alignment and assembly. When the plates are thus assembled, the large hole 42 of one plate will be superimposed over the small hole 42 of corresponding plates, and the plates will be maintained in a spaced apart, generally plane parallel relationship by means of the collars 34 of the

spacers 32. The superimposed holes 42 and 44 permit a bolt or other fastener to be passed between the plates so as to fixedly join the plates. In addition, this bolt can be used to secure a power connect terminal to at least one of the plates, as illustrated in Figure 1. Depending on the particular application, either one or both 42,44 can be used in this manner. It is to be understood that the plates may be otherwise fastened together. For example, adhesive may be employed to join the plates together, or the pins 36,38 may be configured to provide a positive retention.

As explained above, the spaced apart plates provide paired contact and connector tabs which may be employed as discussed above.

Yet other configurations of the present invention may be implemented. For example, the plates may be made larger or smaller, and the number and placement of the tabs varied. In some instances, the tabs may be configured so that unneeded tabs can be snapped off. In other instances, the spacer can be a separate member. For example, a spacer washer may be inserted between the plates and fastened with a bolt or other such member which passes through the pair of plates.

In some instances, the buss bar plates of the present invention may be fabricated as an extended body of material which can be broken or cut to a length as needed. In such instance, it will be appreciated that a single body of stock material can be configured to form buss bar assemblies of different lengths. In yet other instances, a plurality of first plate members, and a plurality of second plate members can be joined together in a staggered relationship so that a portion of two separate first plate members overlays, and is spaced from a single second plate member, so that the tabs of the first plate member, and the second plate member are aligned. In this manner, a large number of plates may be joined together to form a relatively long buss bar assembly. There are other modifications and variations which will be readily apparent to one of skill in the art.

The buss bar assembly of the present invention will thus be seen to provide a buss bar system which can be assembled into a plurality of different configurations. The assembly of the present invention readily lends itself to the fabrication of modular power distribution systems and eliminates the need for a manufacturer to stock a large number of specifically configured buss bar members.

The bar plates of the present invention can readily be produced in various custom lengths through the use of modular tooling. The buss assemblies can be customized for specific current requirements by selecting the size and thickness of the current carrying metal foil patterns. Because of the configuration of the buss bar assembly of the present invention, surface-mounted devices such as diodes, relays and the like can be directly incorporated onto the buss bar plates thereby decreasing the size and complexity of a power distribution system.

In view of the disclosure and discussion presented herein, it will be apparent to one of skill in the art that numerous other modifications and variations of the present invention may be implemented. The foregoing drawings and descriptions are illustrative of particular embodiments of the invention, but are not meant to be limitations upon the practice thereof. It is the following claims, including all equivalents, which define the scope of the invention.