High voltage (hv) terminal frame

Abstract

A two-piece high voltage (HV) terminal frame having a terminal frame and a contact spring. The terminal frame includes at least a top portion, a bottom portion, and a middle portion forming an opening for receiving a first bus bar and a second bus bar. The contact spring is configured to engage the top portion of the terminal frame, wherein the contact spring includes a spring portion that extends into the opening of the terminal frame.

1 . A high voltage (HV) terminal frame comprising:
 a terminal frame having at least a top portion, a bottom portion, and a middle portion forming an opening for receiving at least a first bus bar; and   a contact spring configured to engage the top portion of the terminal frame, wherein the contact spring includes a first spring portion extending into the opening of the terminal frame.   
     
     
         2 . The HV terminal frame of  claim 1 , wherein the terminal frame is fabricated from a first material having a first uniform thickness and the contact spring is fabricated from a second material having a second uniform thickness. 
     
     
         3 . The HV terminal from of  claim 2 , wherein the first uniform thickness is greater than the second uniform thickness. 
     
     
         4 . The HV terminal frame of  claim 2 , wherein the first material and the second material are dissimilar. 
     
     
         5 . The HV terminal frame of  claim 2 , wherein the first material and the second material are stainless steel. 
     
     
         6 . The HV terminal frame of  claim 1 , wherein the contact spring is C-shaped and includes a first portion, a middle portion and a second portion, wherein the first portion and the second portion are configured to wrap around opposite ends of the top portion of the terminal frame to prevent movement in a forward and backward direction. 
     
     
         7 . The HV terminal frame of  claim 1 , wherein the contact spring includes a cut-out formed in the middle portion and a spring extending across the cut-out, wherein the spring is bent to contact the top portion of the terminal frame. 
     
     
         8 . The HV terminal frame of  claim 7 , wherein the top portion of the terminal frame includes a groove configured to the receive the spring extending across the cut-out, wherein engagement of the spring within the groove prevents movement of the contact spring along a direction the contact spring is slid over the top portion of the terminal frame. 
     
     
         9 . The HV terminal frame of  claim 1 , wherein the middle portion of the terminal frame includes an aperture configured to receive a header side bus bar. 
     
     
         10 . The HV terminal frame of  claim 8 , wherein the contact spring includes a second spring portion extending into the opening of the terminal frame, wherein the first spring portion is configured to contact the first bus bar positioned in a first orientation and the second spring portion is configured to contact the first bus bar positioned in a second orientation. 
     
     
         11 . A header assembly comprising:
 a housing assembly having at least a first opening for receiving a first bus bar;   a two-piece terminal assembly including a terminal frame and a contact spring engaged with the terminal frame, wherein the two-piece terminal assembly is positioned within the housing assembly; and   a terminal position assurance (TPA) positioned within the housing assembly adjacent to the two-piece terminal assembly.   
     
     
         12 . The header assembly of  claim 11 , wherein the terminal frame is fabricated from a first material having a first uniform thickness and the contact spring is fabricated from a second material having a second uniform thickness, wherein the second thickness is less than the first thickness. 
     
     
         13 . The header assembly of  claim 11 , wherein the terminal frame is fabricated from a first material and the contact spring is fabricated from a second material. 
     
     
         14 . The header assembly of  claim 13 , wherein the first material and the second material are dissimilar. 
     
     
         15 . The header assembly of  claim 13 , wherein the first material and the second material are stainless steel. 
     
     
         16 . The header assembly of  claim 11 , wherein the terminal frame includes at least a top portion, a bottom portion, and a middle portion forming an opening for receiving a first bus bar and a second bus bar, and wherein the contact spring is C-shaped and includes a first portion, a middle portion and a second portion, wherein the first portion and the second portion are configured to wrap around opposite ends of the top portion of the terminal frame to prevent movement in a forward and backward direction. 
     
     
         17 . The header assembly of  claim 16 , wherein the contact spring includes a cut-out formed in the middle portion and a spring extending across the cut-out, wherein the spring is bent to contact the top portion of the terminal frame. 
     
     
         18 . The header assembly of  claim 17 , wherein the top portion of the terminal frame includes a groove configured to the receive the spring extending across the cut-out, wherein engagement of the spring within the groove prevents movement of the contact spring along a direction the contact spring is slid over the top portion of the terminal frame. 
     
     
         19 . The header assembly of  claim 11 , wherein the terminal frame includes at least a top portion, a bottom portion, and a middle portion, wherein the middle portion of the terminal frame includes an aperture configured to receive a header side bus bar. 
     
     
         20 . The header assembly of  claim 19 , wherein the contact spring includes a first spring portion and a second spring portion located adjacent to the first spring portion, wherein both the first spring portion and the second spring portion extend into the opening of the terminal frame, wherein the first spring portion is configured to contact the first bus bar oriented in a first orientation and the second spring portion is configured to contact the first bus bar oriented in a second orientation opposite the first orientation.