阅读说明：本技术 用于配电总成的电力模块 (Power module for power distribution assembly ) 是由 N.杨 J.T.韦弗林 S.E.杰克逊 R.C.库尼 于 2019-09-06 设计创作，主要内容包括：一种用于印刷线路板总成的汇流条具有配电部分和供电部分。所述供电部分具有插座接触件,所述插座接触件在无需介入的接头部分的情况下与所述配电部分电连通,以限制安置于所述插座接触件中的供电插头和所述汇流条的所述配电部分之间的电阻。还描述了印刷线路板总成、配电总成和制造印刷配电总成的方法。(A bus bar for a printed wiring board assembly has a power distribution portion and a power supply portion. The power supply portion has receptacle contacts in electrical communication with the power distribution portion without an intervening tab portion to limit electrical resistance between a power supply plug disposed in the receptacle contacts and the power distribution portion of the bus bar. Printed wiring board assemblies, power distribution assemblies, and methods of manufacturing printed power distribution assemblies are also described.)

1. A bus bar for a Printed Wiring Board (PWB) assembly, comprising:

a power distribution section; and

a power supply portion having a receptacle contact, wherein the receptacle contact is in electrical communication with the power distribution portion without an intervening joint to limit electrical resistance between a power supply plug disposed in the receptacle contact and the power distribution portion of the bus bar.

2. The bus bar of claim 1, wherein the power distribution portion is angled relative to the power supply portion.

3. The bus bar of claim 1, wherein the bus bar has an L-shaped body defined by the power distribution portion and the power supply portion of the bus bar.

4. The bus bar of claim 1, wherein the length of the power supply portion and the receptacle contacts is less than the length of the power distribution portion.

5. The bus bar of claim 1, wherein the power distribution portion has a first tab and a second tab, the first tab electrically connecting the second tab in series with the receptacle contact.

6. The bus bar of claim 5, wherein an electrical cross-section of the second tab is smaller than an electrical cross-section of the first tab.

7. The bus bar of claim 5, further comprising a first terminal extending from the first tab and a second terminal extending from the second tab.

8. The bus bar of claim 5, further comprising a bracket portion connected in series with the receptacle contact by the second tab.

9. The bus bar of claim 5, wherein the power distribution portion includes a spine portion extending along at least the second tab to reinforce a PWB assembly that includes the bus bar.

10. The bus bar of claim 1, further comprising:

a first bracket disposed on a side of the power distribution part opposite to the power supply part for mounting the bus bar to a PWB body; and

a second bracket disposed at a side of the first bracket opposite to the power distribution part, for mounting the bus bar to the PWM body.

11. The bus bar of claim 1, further comprising an intermediate bracket disposed on the power supply portion between the receptacle portion and the power distribution portion of the bus bar for mounting the bus bar to a PWB body.

12. The bus bar of claim 1, further comprising a socket holder co-located with the socket contacts on one end of the power supply portion for mounting the bus bar to a PWB body.

13. The bus bar of claim 1, further comprising an insulator coupled to the bus bar for electrically insulating the bus bar from an external environment.

14. The bus bar of claim 1, wherein the receptacle contact defines a plug receptacle having an aperture on an end of the power supply portion opposite the power distribution portion, the plug receptacle tapering in width between the aperture and an interior of the receptacle contact.

15. The bus bar of claim 14, further comprising a foil body disposed within the plug receptacle for electrically connecting the receptacle contacts with a power supply plug.

16. A PWB assembly, comprising:

a PWB body having a tab end and a backplane end;

the bus bar of claim 1, mounted to the PWB body, wherein a socket contact is disposed at the backplane end of the PWB body for mating with a socket connector and a power supply plug in a power distribution assembly chassis.

17. The PWB assembly according to claim 16, wherein the bus bar has an L-shaped body defined by a power distribution portion and a power supply portion of the bus bar, wherein the length of the power supply portion and the receptacle contact is less than the length of the power distribution portion, wherein the receptacle contact defines a plug receptacle having an aperture located on an end of the power supply portion opposite the power distribution portion, the plug receptacle tapering in width between the aperture and an interior of the receptacle contact, and wherein the power distribution portion includes a spine portion extending along at least the second tab to reinforce the PWM assembly.

18. The PWB assembly according to claim 16, wherein the power distribution portion has a first tab and a second tab, the first tab electrically connecting the second tab in series with the receptacle contact, wherein the second tab has an electrical cross-section that is smaller than an electrical cross-section of the first tab, and further comprising:

a first terminal extending from the first tab and a second terminal extending from the second tab; and

a bracket portion electrically connected in series with the receptacle contact by the second tab.

19. The PWB assembly according to claim 16, further comprising:

a first bracket disposed on a side of the power distribution part opposite to the power supply part for mounting the bus bar to a PWB body;

a second bracket disposed at a side of the first bracket opposite to the power distribution part, for mounting the bus bar to the PWM body;

an intermediate bracket disposed on the power supply portion between the socket and the power distribution portion for mounting the bus bar to a PWB body; and

a socket contact holder co-located with the socket contacts on one end of the power supply portion for mounting the bus bar to a PWB body.

20. An electrical distribution assembly, comprising:

a chassis having a back plate;

a power plug located in the backplane of the chassis; and

the PWB of claim 16, said power plug being disposed in the receptacle contact such that the power distribution portion of the bus is in electrical communication with said power plug without the use of fasteners between the bus bar and said backplane.

1. Field of the invention

The present disclosure relates to power distribution systems, and more particularly, to bus bars for printed wiring board assemblies in power distribution systems.

2. Description of the related Art

Electrical systems, such as those on aircraft, typically employ switches to control the flow of electrical power to various loads that require electrical power. Power is typically supplied to the switches by a power bus electrically connected to each switch. In some electrical systems, such as in high current electrical systems, switches are grouped on cards. The card is housed in a card cage, typically in a backplane, and routes power to various electrical devices via switches. The secured connector typically electrically connects the card to a bus bar or cable.

The tightened joint allows for control of the tightness of the joint during assembly by twisting the fastener to a predetermined load. Joint tightness can then be monitored during service by checking the joint and fastener preload. Since the tightness of the fastener is generally a good indicator of the joint resistance of the current flowing between the module bus bar and the power supply bus bar, the resistance can be controlled. The tightened joint needs to be assembled when constructing the cassette. The secured joint also requires disassembly when the card needs to be repaired or replaced during the life of the card and the cassette.

Such conventional methods and systems are generally considered satisfactory for their intended purposes. However, there remains a need in the art for improved printed wiring board assemblies, methods of manufacturing printed wiring boards, and bus bars for printed wiring board assemblies. The present disclosure provides a solution to this need.

Background

Disclosure of Invention

A bus bar for a printed wiring board assembly has a power distribution portion and a power supply portion. The power supply portion has receptacle contacts in electrical communication with the power distribution portion without an intervening connector portion to limit electrical resistance between a power supply plug disposed in the receptacle contacts and the power distribution portion of the bus bar.

In certain embodiments, the receptacle contacts may define a plug receptacle having an aperture. The aperture may be located on an end of the power supply portion opposite the power distribution portion. The plug receptacle may taper in width between the aperture and the interior of the receptacle contact. The foil body may be disposed within the plug receptacle for electrically connecting the socket contacts with the power supply plug. An insulator may be coupled to the bus bar for electrically insulating the bus bar from an external environment.

According to certain embodiments, the power distribution portion may be angled with respect to the power supply portion. The bus bar may have an L-shaped body defined by the power distribution portion and the power supply portion of the bus bar. The lengths of the power supply portion and the socket contacts may be less than the length of the power distribution portion. The socket holder may be co-located with the socket contacts on one end of the power supply portion for mounting the bus bar to a Printed Wiring Board (PWB) body.

It is contemplated that the power distribution portion may have a first tab and a second tab. The first tab may electrically connect the second tab in series with the receptacle contact. The electrical cross-section of the second tab may be smaller than the electrical cross-section of the first tab. A first terminal may extend from the first tab for supplying power to the solid state switching device. A second terminal may extend from the second tab for supplying power to the solid state switching device. One or more solid state switching devices may be connected to the bus bar.

It is also contemplated that, according to certain embodiments, the bracket portion may be electrically connected in series with the receptacle contact by the second tab. The first bracket may be disposed at a side of the power distribution part opposite to the power supply part for mounting the bus bar to the PWB body. The second bracket may be disposed at a side of the first bracket opposite to the power distribution part for mounting the bus bar to the PWM body. An intermediate bracket may be disposed on the power supply portion between the receptacle portion and the power distribution portion of the bus bar for mounting the bus bar to the PWB body. The power distribution portion may include a spine portion extending along at least the second tab to reinforce the PWB assembly including the bus bar.

The PWB assembly includes a PWB body having a tab end and a backplane end. The bus bar as described above is mounted to the PWB body. Socket contacts are disposed at the backplane end of the PWB body for mating with the socket connectors with the power supply plugs in the power distribution assembly chassis.

In certain embodiments, the bus bar may have an L-shaped body defined by a power distribution portion and a power supply portion of the bus bar, the length of the power supply portion and the receptacle contact may be less than the length of the power distribution portion, and the receptacle contact may define a plug receptacle having an aperture located on an end of the power supply portion opposite the power distribution portion. The plug receptacle may taper in width between the aperture and the interior of the receptacle contact.

According to certain embodiments, the power distribution portion of the bus bar may have a first tab and a second tab, the first tab may electrically connect the second tab in series with the receptacle contact, and the electrical cross-section of the second tab may be smaller than the electrical cross-section of the first tab. The first terminal may extend from the first tab, the second terminal may extend from the second tab, and the bracket portion may be electrically connected in series with the receptacle contact by the second tab.

It is also contemplated that, according to some embodiments, a first bracket may be disposed on an opposite side of the power distribution portion from the power supply portion for mounting the bus bar to the PWB body, a second bracket may be disposed on an opposite side of the first bracket from the power distribution portion for mounting the bus bar to the PWM body, an intermediate bracket may be disposed on the power supply portion between the socket and the power distribution portion for mounting the bus bar to the PWB body, and the socket contact bracket may be co-located with the socket contacts on an end of the power supply portion of the bus bar for mounting the bus bar to the PWB body. The power distribution portion may include a spine portion extending along at least the second tab to reinforce the PWB assembly.

A power distribution assembly having a chassis and a backplane. The power supply plug is located in the back plate of the chassis. The PWB as described above is slidably received within the chassis. The power plug disposed in the receptacle contact enables the power distribution portion of the bus to be in electrical communication with the power plug without the use of fasteners between the bus bar and the back plane.

These and other features of the disclosed systems and methods will become more readily apparent to those skilled in the art from the following detailed description of the preferred embodiments, taken in conjunction with the accompanying drawings.

Drawings

In order that those skilled in the art to which the disclosure pertains will readily understand how to make and use the devices and methods of the present disclosure without undue experimentation, embodiments thereof will be described in detail below with reference to certain drawings, in which:

FIG. 1 is a schematic view of an exemplary embodiment of an electrical system having bus bars constructed in accordance with the present disclosure, showing bus bars mounted to a Printed Wiring Board (PWB) assembly and disposed within a power distribution assembly to selectively connect a power source with various electrical loads;

FIG. 2 is a schematic view of the power distribution assembly of FIG. 1, showing a plurality of PWB assemblies slidably received within a chassis of the power distribution assembly and electrically connected to a power supply plug without the need for fastened joints;

FIG. 3 is a plan view of the PWB assembly of FIG. 1 showing bus bars and solid state switching devices mounted to the PWB body of the PWB assembly, and signal connectors in communication with the solid state switching devices;

fig. 4 and 5 are perspective views of the outer surface of the bus bar and PWB surface of fig. 1, showing an L-shaped body having a power supply portion with socket contacts and a power distribution portion with a plurality of tabs and terminals for providing power to the solid state switching device; and

fig. 6 is a block diagram of a method of manufacturing an electrical distribution assembly, illustrating steps for manufacturing the electrical distribution assembly without the use of fasteners between the power plug and the bus bar mounted to the PWB assembly.

Detailed Description

Reference will now be made to the drawings wherein like reference characters identify like structural features or aspects of the disclosure. For purposes of explanation and illustration, and not limitation, a partial view of an exemplary embodiment of a bus bar for a Printed Wiring Board (PWB) assembly according to the present disclosure is shown in fig. 1 and is generally indicated by reference numeral 100. Other embodiments of PWB assemblies, power distribution assemblies, and methods of manufacturing power distribution assemblies according to the present disclosure, or aspects thereof, are provided in fig. 2-6 as will be described. The systems and methods described herein may be used for power distribution systems in vehicles, such as aircraft, although the present disclosure is not limited to aircraft.

Referring to FIG. 1, an electrical system 10, such as an aircraft electrical system, is shown. The electrical system 10 includes a generator 12, a power bus 14, and a plurality of electrical loads 16. The generator 12 is operatively associated with an engine 18 (e.g., an aircraft main engine or auxiliary power unit) and is arranged to provide a flow of electrical power 20 to the power bus 14. The power bus 14 is connected to the respective electrical loads 16 by a bus bar 100, which bus bar 100 is mounted to a PWB assembly 200 slidably received within a power distribution assembly 300. While an aircraft electrical system is shown in the exemplary embodiment shown, it is to be understood and appreciated that electrical systems in other types of vehicles as well as non-vehicular applications may also benefit from the present disclosure.

Referring to fig. 2, a power distribution assembly 300 is shown. The power distribution assembly 300 includes a chassis 302, a backplane 304, and a plurality of PWB assemblies 200. The chassis 302 has a service end 306 disposed on an end of the chassis 302 opposite the backplane 304, with a plurality of card slots 308 extending between the service end 306 and the backplane 304. A respective PWB assembly 200 is slidably received within chassis 302 in a respective card slot 308, the PWB assemblies 200 being laterally spaced apart from one another between service end 306 and backplane 304. A power plug 310 located on backplane 304 is connected to a respective PWB assembly 200 to provide power 20 (shown in fig. 1) to a respective bus bar 100 mounted on each PWM assembly 200. Optionally, a signal connector 312 on the backplane end 206 is connected to the solid state switching device 202 (shown in fig. 3) to electrically open and close the solid state switching device 202 as required by the operation of the electrical load 16 (shown in fig. 1).

Referring to fig. 3, a PWB assembly 200 is shown. The PWB assembly 200 includes a PWB body 204 having a tab end 208, an opposite backplane end 206, and a mounting surface 210. The tab 212 mounted on the tab end 208 is configured and adapted to secure the PWB assembly 200 to a service end 306 (shown in fig. 2) of the power distribution assembly 300 (shown in fig. 2). The PWB body 204 is constructed on an electrically insulating material 214, such as glass or FR-4, and includes one or more wiring traces 216 within its interior to provide electrical communication through the PWM body 204 formed from an electrically conductive material. As will be appreciated by those skilled in the art in view of this disclosure, the internal routing traces reduce (or eliminate altogether) the need for cabling, thereby simplifying assembly of the power distribution assembly 100. The bus bar 100 is mounted to the PWB body 204 on the mounting surface 210 such that the receptacle contacts 102 of the bus bar 100 are located adjacent to the signal connector 218 at the backplane end 206.

The solid state switching device 202 is mounted on a mounting surface 210 of the PWB body 204. Each solid state switching device 202 includes an input lead 220, an output lead 222, and a gate lead 224. The input lead 220 is electrically connected to the bus bar 100 for receiving power 20 (shown in fig. 1) from the bus bar 100. The output leads 222 are electrically connected to the respective electrical loads 16 (shown in fig. 1), such as through subsystem feed leads or routing traces 216. The gate lead 224 is electrically connected to the signal connector 218 for receiving an open/close command therethrough, in response to which the output lead 222 is electrically disconnected and electrically connected to the input lead 220 as required by the electrical load 16 (shown in fig. 1) connected to the output lead 222.

The connection of the gate leads 224 may be via discrete leads and/or routing traces 216, as appropriate for the intended application. The solid state switching devices 202 may be MOSFET solid state switching devices, IGBT solid state switching devices, or a combination of MOSFET and IGBT solid state switching devices. In the exemplary embodiment shown, the PWB assembly 200 includes eight (8) solid state switching devices, which allows the power distribution assembly 200 (shown in fig. 2) to be sized so that the power distribution assembly 200 can be used as a drop-in replacement or upgrade for a conventional electrical system. As will be appreciated by those skilled in the art in view of this disclosure, the PWM assembly 200 may include more or less than eight solid state switching devices, as is suitable for the intended application. As will be apparent to those skilled in the art in view of this disclosure, the PWB assembly 200 may also include transistor devices and/or electromechanical devices such as contactors, as appropriate for the intended application.

Referring to fig. 4, a perspective view of the top surface of the bus bar 100 is shown. The bus bar 100 has a power distribution portion 104 and a power supply portion 106. The receptacle contacts 102 are located on the power supply portion 106 and are in electrical communication with the power distribution portion 104 without an intervening tab portion 110 (shown in dashed outline) to limit electrical resistance between a power supply plug 310 (shown in fig. 2) seated in the receptacle contacts 102 and the power distribution portion 104 of the bus bar 100.

As shown in fig. 4, the bus bar 100 has an L-shaped body 108. The L-shaped body 108 facilitates packaging the PWB assembly 200 in the power distribution assembly 300 (shown in fig. 1), thereby providing compactness of the bus bar/PWB body arrangement. As will be apparent to those skilled in the art in view of this disclosure, other shapes are possible within the scope of the present disclosure.

The bus bar 100 includes a conductive material 112. The conductive material 112 monolithically defines the power supply portion 106 and the power distribution portion 104. The power supply portion 106 and the receptacle contacts 102 have a length 111 that is less than a length 113 of the power distribution portion 104 and are angled with respect to the power distribution portion 104. In the exemplary embodiment shown, the power supply portion 106 and the receptacle contacts 102 are angled, e.g., orthogonal, at about 90 degrees relative to each other relative to the power distribution portion 104. This limits the size of the PWB body 204 (shown in fig. 3) required to support the bus bar 100 to a size suitable for the solid state switching device 202 (shown in fig. 3) and allows the socket contacts 102 to extend longitudinally along the PWB body 204. Optionally, an insulator 114 may be coupled to the bus bar 100, covering the conductive material 112 and electrically isolating the bus bar 100 from the external environment 22.

The receptacle contacts 102 are monolithic in construction and define a plug receptacle 116 having an aperture 118. The aperture 118 and the plug receptacle 116 are configured and adapted to removably seat a service plug 310 (shown in fig. 2). The aperture 118 is located on an end 120 of the power supply portion 106 opposite the power distribution portion 104. The plug receptacle 116 tapers in width between the aperture 118 and the interior 122 of the receptacle contact 102. Optionally, a foil body 124 may be disposed within the plug receptacle 116 for electrically connecting the socket contacts 102 with the service plug 310 (shown in fig. 2).

The power distribution portion 104 has a plurality of tabs, i.e., tab portions having terminals. As shown in fig. 4, the power distribution portion 104 has a first tab 126, a second tab 128, and a spine portion 164 extending along the power distribution portion 104. The spine portion 164 spans at least the second tab 128 to provide additional rigidity to the PWM body 204. The first tab 126 is connected to the power supply portion 106 and has a terminal 134, a terminal 136, and a terminal 140 extending therefrom. The terminals 134, 136 and 140 are configured for connection to input leads of a solid state switching device 202 (shown in fig. 2) and are electrically connected in series with the power supply portion 106 by the first tab 136. The first tab 126 has an electrical cross-section 144 that corresponds to (e.g., is substantially identical to) the electrical cross-section of the power supply portion 106.

The second tab 128 is connected to the first tab 126 on a side of the first tab opposite the power supply portion 106 and has a terminal 138 and a terminal 146 extending therefrom. The terminals 138 and 146 are electrically connected in series with the power supply portion 106 through the second tab 128 and the first tab 126. The second tab has an electrical cross-section 142 that is smaller than the electrical cross-section 144 of the first tab 126, and the power distribution portion 104 has a stepped electrical cross-sectional area in a manner corresponding to the current flowing through the power distribution portion 104, i.e., one tab having a lower current than the other tab has a smaller electrical cross-section. The stepped electrical cross-sectional area limits the weight of the bus bar 100 by reducing the amount of current carried by the power distribution portion 104 with the continuous tab of the power distribution portion 104 (e.g., the electrical cross-section of the second tab 128 is smaller than the electrical cross-section of the first tab 126).

In the exemplary embodiment shown, the power distribution portion 104 has four (4) tabs. To this end, the power distribution portion 104 has a third tab 130 and a fourth tab 150. The third tab 130 has a terminal 132 and a terminal 133. The terminals 132 and 133 are connected in series with the power supply portion 106 via a third tab 130 through the second tab 128 and the first tab 126, the third tab 130 having an electrical cross-section 148 that is smaller than an electrical cross-section 142 of the second tab 128. In the exemplary embodiment shown, the spine portion spans the second tab 128, the third tab 130, and the fourth tab 150.

The fourth tab 150 has a terminal 152, a shelf portion 156, and an electrical cross-section 154. The terminal 152 is electrically connected in series with the power supply portion 106 by the third tab 150, the second tab 128, and the first tab 126. The electrical cross-section 154 is smaller than the electrical cross-section 148 of the third tab 130. A bracket portion 156 extends from the fourth tab 150 for securing the bus bar 100 to the PWM body 204 (shown in fig. 3). As will be apparent to those skilled in the art in view of this disclosure, a bus bar having a power distribution portion with four tabs allows for two rows of four solid state switching devices to be placed on the PWB body 204 (shown in fig. 3) such that the functionality of the PCB assembly 200 conforms to that of a conventional PWB assembly. As will be apparent to those skilled in the art in view of this disclosure, the bus bars described herein can have more than four tabs and less than four tabs and remain within the scope of this disclosure, as suitable for the intended application.

Referring to fig. 5, the mounting surface of the bus bar 100 is shown in a perspective view. The bus bar 100 has a plurality of brackets disposed along the length of the power distribution portion 104 and the power supply portion 106. To this end, the bus bar 100 has a bracket 156 that is electrically connected in series with the receptacle contacts 102 by tabs (e.g., the first tab 126 and the second tab 128) of the power distribution portion 104. The bracket portion 156, in turn, has a power distribution portion bracket 158 configured and adapted to mount the bus bar 100 to the PWB body 204. The power supply section bracket 160 is disposed on the bracket portion 156 of the bus bar 100, is configured and adapted to mount the bus bar 100 to the PWB body 204, and cooperates with the power distribution section bracket 158 to provide rigidity to the PWB body 204. As will be appreciated by those skilled in the art in view of the present disclosure, providing rigidity to PWB body 204 reduces (or completely eliminates) the need to provide stiffening elements to PWB body 204, thereby reducing the weight of PWB assembly 200.

In the exemplary embodiment shown, the power supply portion mount 160 is co-located with the socket contact 102, and the power supply portion 106 has an intermediate mount 162. The intermediate support 162 is disposed along the length of the bus bar 100 between the power supply section support 160 and the power distribution section support 158 to increase the rigidity provided to the PWB body 204. Further, it is contemplated that one of the plurality of tab terminals (e.g., terminal 132) may be arranged to electrically connect to a lead of the solid state switching device and receive a fastener, thereby further increasing the rigidity that the bus bar 100 provides to the PWB body 204. In the exemplary embodiment shown, bus bar 100 includes 12 brackets/terminals for mounting bus bar 100 to PWB body 204 and providing rigidity to PWB body 204. As will be apparent to those skilled in the art in view of this disclosure, the bus bar 100 may have more than 12 brackets/terminals or less than 12 brackets/terminals, as is suitable for the intended application.

Referring to fig. 6, a method 400 of manufacturing an electrical distribution assembly is shown. As indicated at block 410, the method 400 includes mounting a bus bar, such as bus bar 100 (shown in fig. 1), to a PWB body, such as PWB body 202 (shown in fig. 3). As shown in block 420, a PWB body, such as PWB body 200 (shown in fig. 3), is inserted into a power distribution assembly, such as power distribution assembly 300 (shown in fig. 2). As shown in block 422, the PWB assembly is received within a slot, such as card slot 308 (shown in FIG. 2). With the PWB assembly received in the slot, signal connections on the PWB body are placed on the signal pins, as shown in block 424. In addition, as indicated at block 426, with the PWB assembly received within the slot, socket contacts, such as socket contacts 102 (shown in fig. 4), are positioned on the power pins for providing power to the bus bars. As shown at block 428, the electrical connection is made without the use of fasteners.

As described above and shown in the drawings, the methods and systems of the present disclosure provide bus bars, PWB assemblies, and power distribution assemblies having superior performance, including the absence of joints between bus bar connections to power supply connectors and connections to corresponding solid state switching device input leads. While the apparatus and methods of the present disclosure have been shown and described with reference to preferred embodiments, it will be readily understood by those skilled in the art that changes and/or modifications may be made thereto without departing from the scope of the present disclosure.