BusFLEXX™ Flexible and Conforming Bus Bar Connectors

Electrical connections utilizing bus bars and other mechanical fixtures often face challenges of thermal expansion, tight tolerances, and the stress of vibration based on the environment they are deployed in. This can negatively effect the performance, reliability, and longevity of the application. Mersen’s BusFLEXX line of conforming connectors is custom designed to help eliminate these challenges. A large variety of unique flexible and conforming connection features can be strategically designed into our bus bars to meet customers' specific requirements.

Mersen’s innovative BusFLEXX connectors allow for connectivity of cables to bus bars, electrical/electronic components to bus bars and even bus bar to bus bars wherever there is a need for mechanical gap tolerances and/or thermal compensation. The connectors can have static or +/-1mm dynamic properties up to three rotational axis (X,Y and Z) and provide a cost effective yet long lasting connection methods. Mersen design engineers can work closely with customers to solve their specific design needs for custom-made conforming connectors. In addition, connectors can be designed with certain amount of flexibility and spring tension, reducing the harsh effect of vibration/harmonics on hard connections.

There are several performance indicators that should be considered when designing a bus bar and connector assembly. Key parameters are noted in the example spider diagrams below that help in choosing which connection feature will work for your specific application.

Articulating Plate

This is an example of a power distribution connection that can be considered for applications where compensation for thermal cycling and system harmonics exist. As shown above, the articulating plate can provide the required features.

Conformal Tab

This is an example of a power electronics connection that can be considered for applications that require a large degree of freedom due to a floating nut and flexible tab. The conformal tab can be fabricated in the bus bar or surface mounted.

This example demonstrates the articulating plate connectors in a bus bar assembly mounted to independent distribution blocks handling harmonics or thermal movement (expansion & contraction).

• Handles independent tolerance mismatches
• Louver band technology for positive current flow
• Ease of assembly
• Collapsible design to meet difficult assembly situations