Patent Publication Number: US-11387586-B2

Title: High voltage (HV) terminal frame and method of manufacturing the same

Description:
BACKGROUND 
     The present disclosure is directed to a high voltage terminal frame and in particular to a single piece high voltage terminal frame. 
     High voltage terminal frames include a rigid outer housing and a more compliant contact spring. Typically, the rigid outer housing is separate from the more compliant contact spring, made of different materials, and requiring assembly at manufacture. This type of HV frame is a two-piece assembly. In some embodiments, a conductive bus bar is crimped to the rigid outer housing, resulting in a three-piece assembly. It would be beneficial to develop a high voltage terminal frame that provides the same functionality but that does not require separate components for the rigid outer housing and the more compliant contact spring. 
     SUMMARY 
     According to one aspect, a single-piece high voltage (HV) terminal frame includes a top wall, a bottom wall, and a side wall extending between the top wall and the bottom wall. The top wall includes a first top wall layer and a second top wall layer located adjacent the first top wall layer. The bottom wall includes a first bottom wall layer and a second bottom wall layer located adjacent the first bottom wall layer to form a bottom wall, wherein the bottom wall is located opposite the top wall. The side wall includes a first side wall layer and a second side wall layer located adjacent the first side wall layer. A single-layer contact spring extends from the first top wall layer, wherein the single-layer contact spring is bent to extend into a space located between the top wall and the bottom wall. 
     According to another aspect, a method of fabricating a single-piece HV terminal frame includes forming a single layer of material in a two-dimensional horizontal plane and then folding the single layer of material to form the single-piece HV terminal frame. The HV terminal frame includes a top wall, a bottom wall, and a side wall extending between the top wall and the bottom wall. The top wall includes a first top wall layer and a second top wall layer located adjacent the first top wall layer. The bottom wall includes a first bottom wall layer and a second bottom wall layer located adjacent the first bottom wall layer. The side wall includes a first side wall layer and a second side wall layer located adjacent the first side wall layer. A single-layer contact spring extending from the first top wall layer, wherein the single-layer contact spring is bent to extend into a space located between the top wall and the bottom wall. 
     According to another aspect, a high voltage (HV) terminal frame is comprised of a top wall, a bottom wall located opposite the top wall, and a side wall extending between the top wall and the bottom wall. The top wall includes a first top wall layer and a second top wall layer located adjacent the first top wall layer. The bottom wall includes a first bottom wall layer and a second bottom wall layer located adjacent the first bottom wall layer. A single-layer contact spring extends from the first top wall layer, wherein the single-layer contact spring is bent to extend into a space located between the top wall and the bottom wall. In addition, a first conductive bus bar located adjacent to the bottom wall. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  is an isometric view of a high voltage (HV) terminal assembly according to some embodiments;  FIG. 1B  is an isometric view of a high voltage (HV) terminal assembly with an outer covering removed illustrate a high voltage (HV) terminal frame according to some embodiments; and  FIG. 1C  is a cross-sectional view of a high voltage (HV) terminal assembly according to some embodiments, 
         FIG. 2  is a front isometric view of a high voltage (HV) terminal frame according to some embodiments. 
         FIG. 3  is a rear isometric view of a high voltage (HV) terminal frame with attached header side bus bar according to some embodiments. 
         FIG. 4  is a cross-sectional view of a high voltage (HV) terminal frame with attached header side bus bar according to some embodiments. 
         FIG. 5  is an isometric view of a high voltage (HV) terminal frame with attached header side bus bar according to some embodiments. 
         FIG. 6  is an isometric view illustrating insertion of a header side bus bar into a high voltage (HV) terminal frame according to some embodiments. 
         FIG. 7  is a magnified isometric view of the header side bus bar connected to the high voltage (HV) terminal frame according to some embodiments. 
         FIG. 8  is an isometric view of a high voltage (HV) terminal frame illustrating connection of a connector side bus bar according to some embodiments. 
         FIG. 9  is a cross-sectional view illustrating retention of a connector side bus bar and header side bus bar within a high voltage (HV) terminal frame according to some embodiments. 
         FIG. 10  is an isometric view illustrating a high voltage (HV) terminal having a connector side bus bar and header side bus bar extending therefrom according to some embodiments. 
         FIG. 11  is an isometric view illustrating the folding of a single piece of material to form a high voltage (HV) terminal frame according to some embodiments. 
         FIG. 12  is an isometric view of a high voltage (HV) terminal frame utilizing rib and/or gusset features according to some embodiments. 
         FIG. 13  is an isometric view of a high voltage (HV) terminal frame utilizing a clinch pin feature according to some embodiments. 
     
    
    
     DETAILED DESCRIPTION 
     According to some aspects, the present invention is directed to a high voltage (HV) terminal assembly and in particular to a HV terminal frame. In some embodiments, the HV terminal assembly is fabricated from a single piece of material, wherein complex bending/folding of the material provides an HV terminal frame having double-sided walls forming the rigid housing member of the frame and a single wall member forming the more compliant contact spring. 
     Referring now to  FIGS. 1A-1C , a HV terminal assembly  100  is provided that utilizes a pair of HV terminal frames  108   a ,  108   b . In this example, the HV terminal assembly  100  is a right-angle assembly. Terminal ports  102   a ,  102   b  are configured to receive a corresponding terminal (not shown) in a first longitudinal or horizontal direction. A conductive bus bar  104  extends in a vertical direction at a right-angle to the direction of connection associated with the terminal ports  102   a ,  102   b.    
     In the embodiment shown in  FIG. 1B , a portion of the housing associated with the HV terminal frame  100  is removed to expose the HV terminal frames  108   a ,  108   b . In this embodiment, a connector side bus bar  106   a ,  106   b  extends longitudinally from the HV terminal frames  108   a ,  108   b , respectively. Likewise, the header side bus bars  104   a ,  104   b  extend in a downward direction from the HV terminal frames  108   a ,  108   b . As described in more detail below, in some embodiments the header side bus bars  104   a ,  104   b  are pass through bus bars that do not require crimping of the bus bars to the HV terminal frames  108   a ,  108   b , respective. In some embodiments, the connector side bus bar  106   a ,  106   b  is slid downward into the HV terminal  108   a ,  108   b , respectively, and is pressed into contact with the header side bus bars  104   a ,  104   b , respectively, by contact springs ( 110   a ,  110   b , shown in  FIG. 1C ). 
     Referring now to  FIGS. 2 through 11 , various views of the single piece HV terminal frame  108  are provided. In some embodiments, HV terminal frame  108  is fabricated through complex bending of a single sheet of material (shown in  FIG. 11 ) having a uniform thickness. In some embodiments, the material is stainless steel, but other materials may be utilized as well. As a result of the bending operation, some walls of the HV terminal frame  108  are twice as thick as other walls due to the single sheet of material being folded over at some locations. For the purpose of this discussion, walls are labeled ‘a’ and ‘b’ to designate the two layers associated with a wall. For example, the top wall  200  includes a first layer  200   a  (first top wall layer  200   a ) and a second layer  200   b  (second top wall layer  200   b ). Likewise, the side wall  202  includes a first layer  202   a  (first side wall layer  202   a ) and a second layer  202   b  (second side wall layer  202   b ), and the bottom wall  204  includes a first layer  204   a  (first bottom wall layer  204   b ) and a second layer  204   b  (second bottom wall layer  204   b ). Other portions of the HV frame  108   a  include only a single layer of material, including guide/retention rail  206 , guide arms  208  and  210 , forward stop feature  212 , contact spring  214 , and roll joint  216 . Those walls or features comprised of two layers of the material are characterized by increased rigidity as compared with the single layer materials. As a result, the walls or features comprising only a single layer of material are characterized by more compliance or flexibility. In some embodiments, this is beneficial for elements and features such as the contact spring  214 . The roll joint  216  represents the location at which the single piece of material is folded back on itself to provide two layers along desired walls. In some embodiments, the curvature of the roll joint  216  is dictated by the material being used to ensure that the roll joint  216  does not crack or break. 
     As shown in  FIG. 3 , the header side bus bar  104  is located adjacent to the bottom wall  204  (in particular, second bottom wall layer  204   b  of the bottom wall  204 ). In some embodiments, the header side bus bar  104  is a pass-through copper bus bar that extends forward to the forward stop feature  212 . In addition, the header side bus bar  104  is retained on a side opposite the side wall  202  by guide/retention rail  206 . In some embodiments, guide/retention rail  206  may be a single layer—rather than two layers—as it is not required to provide rigid support. In other embodiments, guide/retention rail  206  may also make use of two layers of material. In some embodiments, guide arms  208  and  210 —located opposite one another and extending forward of the bottom wall  204 —are utilized to guide the insertion of the header side bus bar  104  into the HV terminal frame  108   a  according to some embodiments. In some embodiments, guide arms  208  and  210  are flared at the ends to simplify insertion of the header side bus bar  104 . In some embodiments, the guide arms  208  and  210  are both single layer as they are not required to provide rigidity or support. In other embodiments the guide arms  208  and  210  may be comprised of a double layer if additional rigidity is required. 
     As shown in the cross-sectional view of  FIG. 4 , connector side bus bar  106  is inserted into the HV terminal frame  108  and pressed into contact with the header side bus bar  104  by contact spring  214 . In some embodiments, the connector side bus bar  106  includes one or more bumps  300  that ensure contact between the connector side bus bar  106  and the header side bus bar  104 . In the embodiment shown in  FIG. 3 , the contact spring  214  generates a normal force (i.e., downward) that presses the connector side bus bar  106  into contact with the header side bus bar  104 . Because the contact spring  214  is a single layer of material, the contact spring  214 —being more compliant—allows for the contact spring  214  to act as a spring capable of receiving the connector side bus bar. In some embodiments, the contact spring  214  extends from the first top wall layer  200   a  of the top wall  200 . As shown in  FIGS. 2 and 4 , the thickness of the first top wall layer  200   a  is equal to the thickness of the second top wall layer  200   b . The thickness of the contact spring is equal to the thickness of the second top wall layer  200   b , and as a result is half the overall thickness of the top wall  200 . In this way, the top wall  200  provides rigidity as a result of the overall thickness of the top wall and the contact spring  214  provides the desired springiness or compliance as a result of the single layer thickness. 
     As shown in  FIG. 5 , the header side bus bar  104  is retained by the guide arms  208  and  210 . In some embodiments, guide arms  208  and  210  are U-shaped and act to retain the header side bus bar  104  on three sides. In other embodiments, guide arms  208  and  210  may be L-shaped, providing support to the header side bus bar  104  on two sides. In addition, in some embodiments a single layer tab  218  extends from the second side wall layer  202   b  and wraps around the outer side wall layer  202   a . In some embodiments, the single layer tab  218  acts to secure the first side wall layer  202   a  to the second side wall layer  202   b —preventing the side wall layers as well as the other layers from pulling apart from one another. 
     Referring now to  FIGS. 6 and 7 , the insertion of the header side bus bar  104  bar is shown. In particular, in the embodiment shown in  FIG. 6  the header side bus bar  104  is shown being inserted into the HV terminal frame  108 . In some embodiments, guide arms  208  and  210  capture the header side bus bar  104  and guide the insertion of the header side bus bar  104  into place against the forward stop feature  212 . As shown in  FIG. 7 , the forward stop feature  212  prevents the header side bus bar  104  from extending beyond the HV terminal frame  108 . In some embodiments, the forward stop feature  212  is a single layer feature that extends from second bottom wall layer  204   b  of the bottom wall  204 . In some embodiments, the header side bus bar  104  is not crimped or otherwise secured to the HV terminal frame  108 . That is, in some embodiments the header side bus bar  104  is a pass through bus bar. In some embodiments, the header side bus bar  104  is secured within the housing of the HV terminal assembly  100  (shown in  FIG. 1A ). 
     Referring now to  FIGS. 8-10 , the insertion of the connector side bus bar  106  into the HV terminal frame  108   a  is shown. As shown in  FIG. 8 , the direction of the arrow illustrates the direction of insertion of the connector side bus bar  106 . The connector side bus bar  106  is slid into the HV terminal frame  108 . A first side of the connector side bus bar  106  (not visible) comes into contact with the contact spring  214 . The opposite side of the connector side bus bar  106  includes first and second bumps  300  that are brought into contact with the header side bus bar  104  (already inserted into the HV terminal frame  108 ). The contact spring  214  acts to generate a normal force on the connector side bus bar  106  that forces the connector side bus bar  106  into contact with the header side bus bar  104 . In this embodiment, the header side bus bar  104  extends in a first direction along the longitudinal axis of the HV terminal frame  108   a , and connector side bus bar  106  extends at an angle of approximately 90° relative to the header side bus bar  104 . 
     In the cross-sectional view shown in  FIG. 9 , contact spring  214  is shown in in contact with the connector side bus bar  106 . In some embodiments, connector side bus bar  106  includes features for receiving the contact spring  214  (e.g., an indentation or groove  302 ). When fully inserted, the contact sprig  214  is captured within the indentation  302  and prevents pull out of the connector side bus bar  106 . 
     As shown in  FIG. 10 , the connector side bus bar  106  is fully inserted within the HV terminal frame  108   a  and in contact with the header side bus bar  104 . As discussed above, the HV terminal frame  108   a  forms a right-angle connection between the respective bus bars. Header side bus bar  104  is a pass through bus bar retained within the HV terminal frame  108   a  by guide arms  208  and  210  and forward stop feature  212 , and connector side bus bar  104  is forced into contact with the header side bus bar  104 . In some embodiments the header side bus bar  104  is positioned at a right angle to the connector side bus bar  106 . In other embodiments, however, the HV terminal frame  108   a  is also capable of accepting bus bars that are axial or in-line with one another—rather than at a right angle—with no change to the structure of the HV terminal frame  108   a.    
       FIG. 11  is a diagram illustrating the complex folding of a single layer into the HV terminal frame  108   a . At step  1000 , a single layer of material is provided. As a discussed above, in some embodiments, the single layer of material is stainless steel having a uniform thickness. In some embodiments, other materials may be utilized. In some embodiments, the geometry shown at step  1000  is created through a stamping process. For the sake of clarity, the various walls are labeled according to their eventual location as part of the HV terminal frame  108   a . Starting at the top of the single piece and moving downward is the first bottom wall layer  204   a  of the bottom wall  204 , the first side wall layer  202   a  of the side wall  202 , the first top wall layer  200   a  of the top wall  200 , the second top wall layer  200   b  of the top wall  200 , the second side wall layer  202   b  of the side wall  200 , and the second bottom wall layer  204   b  of the bottom wall  204 . Extending from the first top wall layer  200   a  is the contact spring  214  and extending from the second bottom wall layer  204   b  are guide arms  208  and  210  and forward stop  212 . 
     At step  1002 , a first bend between the first side wall layer  202   a  and the second side wall layer  202   b  is provided. As a result, first top wall layer  204   a , first side wall layer  202   a , and first top wall layer  200   a  are oriented vertically. At step  1004 , the frame is rotated 90° so that the first bottom wall layer  204   a , the first side wall layer  202   a , and the first top wall layer  200   a  are oriented horizontally. A second bend is formed between the second top wall layer  200   b  and the second side wall layer  202   b . As a result, the first top wall layer  200   b  is oriented vertically and the second side wall layer  202   b  and second bottom wall layer  204   b  are oriented horizontally. 
     At step  1006 , a third bend is formed between the second bottom wall layer  204   b  and the second side wall layer  202   b  (with the second bottom wall layer  204   b  remaining motionless in this step). In addition, side rail  206  extending from the second bottom wall layer  204   b  is bent to provide the desired geometry. At step  1008 , the forward stop feature  212  is bent as desired to provide the desired geometry of the stop feature. Likewise, the contract spring  214  is bent to provide the desired geometry of the contract spring  214 . 
     At step  1010 , the product is rotating 180° and a fourth bend is formed between the first top wall layer  200   a  and curved portion  216  and a fifth bend is formed between the first top wall layer  200   a  and the first side wall layer  202   a . As a result, the first top wall layer  200   a  is located adjacent to the second top wall layer  200   b  to form the two layer top wall  200  and the first side wall layer  202   a  is located adjacent to the second side wall layer  202   b  to form the two-layer side wall  202 . 
     At step  1012 , a sixth bend is formed between the first side wall layer  202   a  and the first bottom wall layer  204   a . As a result, the first bottom wall layer  204   a  is brought into contact with the second bottom wall layer  204   b  to form the two layer bottom wall  204 . In addition, at step  1012  the guide arms  208  and  210  extending from the second bottom wall layer  204   b  are bent to form the desired geometry. In this way, a single layer of material (stamped or otherwise cut to provide the desired geometry) is bent through a series of actions to provide the desired HV terminal frame  108   a  geometry. In particular, the steps shown in  FIG. 11  provide an HV terminal frame geometry having the desired characteristics, including rigid walls and flexible or at least more compliant contact spring and guide arms. Benefits include relatively inexpensive manufacturing costs while maintaining the desired characteristics of the HV terminal frame. 
     In some embodiments, the HV terminal frame  108   a  is fabricated as shown in  FIG. 11  through the series of bending steps without more. However, in some embodiments post-processing of the HV terminal frame  108   a  may be utilized to provide additional rigidity to the walls (e.g., one or more of the top wall  200 , side wall  202 , and bottom wall  204 ) of the HV terminal frame  108   a . In some embodiments, additional rigidity is provided by welding respective layers together to prevent movement between the respective layers. For example, in some embodiments the first top wall layer  200   a  and the second top wall layer  200   b  are welded together to provide additional rigidity to the top wall  200 . In some embodiments, the respective layers are spot welded. In other embodiments the respective layers are laser welded. Likewise, welding may be provided between first side wall layer  202   a  and second side wall layer  202   b  and between first bottom wall layer  204   a  and second bottom wall layer  204   b . The purpose of the welding is to prevent movement of the respective layers (e.g., first top wall layer  200   a  and second top wall layer  200   b ) relative to one another. This increases the overall rigidity of the top wall  200  of the HV terminal frame  108   a  without changing the compliance features of the contact spring  214 . In addition to utilizing techniques to adhere the respective layers to one another (e.g., welding, adhesives, etc.), in other embodiments one or more stamping features (features fabricated using a stamping process or a similar process) may be utilized to prevent movement between the respective layers and increase the overall rigidity of the walls (e.g., top wall, side wall, and/or bottom wall) of the HV terminal frame  108   a , as shown in  FIGS. 12 and 13 , described below. 
     Referring now to  FIGS. 12 and 13 , various stamping features are illustrated for providing additional rigidity between layers making up one or more of the walls. In the embodiment shown in  FIG. 12 , the HV terminal frame  108   a    FIG. 12  is an isometric view of a high voltage (HV) terminal frame utilizing rib and/or gusset features according to some embodiments. As discussed above, the top wall  200 , side wall  202  and bottom wall  204  are each comprised of a first layer and a second layer. For example, the top wall  200  is comprised of a first top wall layer  200   a  and a second top wall layer  200   b . As shown in  FIG. 11 , the HV terminal frame  108   a  is fabricated through the complex bending of a single layer of material, resulting in layers of the material being located adjacent to each other (e.g., first top wall layer  200   a , second top wall layer  200   b ). In some embodiments, to further increase rigidity of the walls, one or more of the features shown in  FIGS. 12 and 13  may be utilized. In part, these features act to prevent the respective layers from moving relative to one another. For example, in the embodiment shown in  FIG. 12  a rib feature  1200  is formed on the top wall  200 . In this embodiment, the rib feature  1200  is an oval shaped indentation formed in both the first top wall layer  200   a  and the second top wall layer  200   b  that prevents the first top wall layer  200   a  and the second top wall layer  200   b  from moving relative to one another. In other embodiments, the rib feature  1200  may alternatively or in addition be formed in the side wall  202  and/or the bottom wall  204 . In addition, although the rib feature  1200  shown in  FIG. 12  is oval in shape, in other embodiments other geometries may be utilized. Importantly, rather than the first top wall layer  200   a  and second top wall layer  200   b  being planar relative to one another, the rib feature  1200  creates a non-planar region that prevents movement of the respective layers relative to one another and therefore increases rigidity of the top wall  200  (as well as the overall rigidity of the HV terminal frame  108   a ). 
     In some embodiments, the HV terminal frame  108   a  may either in addition or separately include one or more gusset features  1202   a ,  1202   b . In some embodiments, the gusset features  1202   a ,  1202   b  are formed in the transition region  1204  between the top wall  1200  and the side wall  1202 . The gusset features  1202   a ,  1202   b  act to provide additional reinforcement/support to the transition region  1204  located between the top wall  200  and the side wall  202 . In other embodiments, gusset features may also be located in the transition region  1206  between the side wall  202  and the bottom wall  204 . 
     In addition to providing support to the transition region  1206 , the gusset features  1202   a ,  1202   b  formed in the first and second layers of material act to prevent the layers from moving relative to one another similar to the support provided by the rib feature  1200 . That is, instead of the first and second layers being adjacent to one another in a plane, the gusset features  1202   a ,  1202   b  provides a non-planar region that prevents the respective layers from sliding relative to one another. 
     In some embodiments, the rib feature  1200  is fabricated using a press operation after the first top wall layer  200   a  and the second top wall layer  200   b  are brought together. In some embodiments, fabrication of the rib feature  1200  is performed after folding of the single sheet to form the HV terminal frame  108   a . In other embodiments, fabrication of the rib feature  1200  is performed during folding of the single sheet to form the HV terminal frame  108   a  after the first top wall layer  200   a  and the second top wall layer  200   b  are brought into contact with one another. Likewise, the gusset features  1202   a ,  1202   b  may be fabricated using a press operation after the first top wall layer  200   a  and the second top wall layer  200   b  as well as the first side wall layer  202   a  and the second side wall layer  202   b  have been brought together. In some embodiments, the fabrication of the gusset features  1202   a ,  1202   b  is performed after folding the single sheet to form the HV terminal frame  108   a . In other embodiments, the gusset features  1202   a ,  1202   b  may be formed as soon as the top wall  1200  and the side wall  1202  have been formed. Likewise, if the gusset feature is formed in the transition region  1206  between the side wall  202  and the bottom wall  204 , the feature may be formed as soon as the first side wall layer  202   a  and second side wall layer  202   b  and first bottom wall layer  204   a  and second bottom wall layer  204   b  are brought together. 
     In the embodiment shown in  FIG. 13 , additional rigidity is provided to the HV terminal frame  1208   a  through the addition of clinch pin features  1300   a ,  1300   b  formed in the top wall  200  and clinch pin features  1302   a ,  1302   b  formed in the side wall  202 . Likewise, the second clinchIn some embodiments, the clinch pin feature In part, these features act to prevent the respective layers from moving relative to one another. For example, in the embodiment shown in  FIG. 12  a rib feature  1200  is formed on the top wall  200 . In this embodiment, the rib feature  1200  is an oval shaped indentation formed in both the first top wall layer  200   a  and the second top wall layer  200   b  that prevents the first top wall layer  200   a  and the second top wall layer  200   b  from moving relative to one another. In other embodiments, the rib feature  1200  may alternatively or in addition be formed in the side wall  202  and/or the bottom wall  204 . In addition, although the rib feature  1200  shown in  FIG. 12  is oval in shape, in other embodiments other geometries may be utilized. Importantly, rather than the first top wall layer  200   a  and second top wall layer  200   b  being planar relative to one another, the rib feature  1200  creates a non-planar region that prevents movement of the respective layers relative to one another and therefore increases rigidity of the top wall  200  (as well as the overall rigidity of the HV terminal frame  108   a ). 
       FIG. 13  is an isometric view of a high voltage (HV) terminal frame utilizing a first clinch pin feature  1300   a ,  1300   b  and a second clinch pin feature  1302   a ,  1302   b  according to some embodiments. In the embodiment shown in  FIG. 13 , first clinch pin features  1300   a ,  1300   b  are formed in the top wall  200 . As discussed above with respect to the rib feature and gusset features shown in  FIG. 12 , the first clinch pin features  1300   a ,  1300   b  are formed in the first top wall layer  200   a  and the second top wall layer  200   b . Likewise, the second clinch pin features  1302   a ,  1302   b  are formed in the first side wall layer  202   a  and the second side wall layer  202   b . In addition, in some embodiments, the bottom wall  204  may also include clinch pin features, either alone or in combination with the clinch pin features utilized on the top wall  200  and the side wall  202 . These features act to prevent the respective layers from moving relative to one another. Importantly, rather than the first top wall layer  200   a  and second top wall layer  200   b  being planar relative to one another, the clinch pin features  1300   a ,  1300   b  creates a non-planar region that prevents movement of the respective layers relative to one another and therefore increases rigidity of the top wall  200  (as well as the overall rigidity of the HV terminal frame  108   a ). 
     In some embodiments, the clinch pin features  1300   a ,  1300   b  (as well as clinch pin features  1302   a ,  1302 ) are fabricated using a pressing operation after the respective layers (e.g., first top wall layer  200   a  and second top wall layer  200   b ) are brought into contact with one another. In some embodiments, the first clinch pin features  1300   a ,  1300   b  are formed after the HV terminal frame  108   a  is fabricated. In other embodiments, the first clinch pin features  1300   a ,  1300   b  may be fabricated as soon as the first top wall layer  200   a  and the second top wall layer  200   b  are located adjacent to one another. Likewise, the second clinch pin features  1302   a ,  1302   b  may be fabricated as soon as the first side wall layer  202   a  and the second side wall layer  202   b  are located adjacent to one another. 
     While the invention has been described with reference to an exemplary embodiment(s), it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment(s) disclosed, but that the invention will include all embodiments falling within the scope of the appended claims. 
     Discussion of Possible Embodiments 
     The following are non-exclusive descriptions of possible embodiments of the present invention. 
     According to one aspect, a single-piece high voltage (HV) terminal frame includes a top wall, a bottom wall, and a side wall extending between the top wall and the bottom wall. The top wall includes a first top wall layer and a second top wall layer located adjacent the first top wall layer. The bottom wall includes a first bottom wall layer and a second bottom wall layer located adjacent the first bottom wall layer to form a bottom wall, wherein the bottom wall is located opposite the top wall. The side wall includes a first side wall layer and a second side wall layer located adjacent the first side wall layer. A single-layer contact spring extends from the first top wall layer, wherein the single-layer contact spring is bent to extend into a space located between the top wall and the bottom wall. 
     The single-piece HV terminal frame of the preceding paragraph can optionally include, additionally and/or alternatively any, one or more of the following features, configurations, and/or additional components. 
     For example, in some embodiments, the single-piece HV terminal frame may include a forward stop feature extending from a forward side of the second bottom wall layer and positioned to act as a stop to a bus bar received by the single-piece HV terminal frame. 
     In some embodiments, the single-piece HV terminal frame may include a guide rail extending from a first side of the second bottom wall layer, the guide rail positioned to guide a bus bar received by the single-piece HV terminal frame. 
     In some embodiments, the single-piece HV terminal frame may include first and second guide arms extending from a rear side of the second bottom wall layer, wherein the first and second guide arms are positioned to guide a bus bar received by the single-piece HV terminal frame. 
     In some embodiments, the single-piece HV terminal frame is fabricated from a single, continuous layer of material bent to form the desired geometry of the single-piece HV terminal frame. 
     In some embodiments, the single-piece HV terminal frame is fabricated from a single, continuous layer of stainless steel. 
     In some embodiments, the single-piece HV terminal frame includes one or more stamping features fabricated on one or more of the top wall, the side wall or the bottom wall. 
     According to another aspect, a method of fabricating a single-piece HV terminal frame includes forming a single layer of material in a two-dimensional horizontal plane and then folding the single layer of material to form the single-piece HV terminal frame. The HV terminal frame includes a top wall, a bottom wall, and a side wall extending between the top wall and the bottom wall. The top wall includes a first top wall layer and a second top wall layer located adjacent the first top wall layer. The bottom wall includes a first bottom wall layer and a second bottom wall layer located adjacent the first bottom wall layer. The side wall includes a first side wall layer and a second side wall layer located adjacent the first side wall layer. A single-layer contact spring extending from the first top wall layer, wherein the single-layer contact spring is bent to extend into a space located between the top wall and the bottom wall. 
     The method of the preceding paragraph can optionally include, additionally and/or alternatively any, one or more of the following features, configurations, and/or additional components. 
     For example, in some embodiments the step of forming the single layer of material in a two-dimensional horizontal plane includes cutting the material in a desired geometry. 
     In some embodiments, the single-layer of material is cut using a punch operation. 
     In some embodiments, the single-layer of material is stainless steel. 
     In some embodiments, the method further includes welding one or more of the first top wall layer to the second top wall layer, the first side wall layer to the second side wall layer, or the first bottom wall layer to the second bottom wall layer. 
     In some embodiments, the method further includes fabricating one or more stamping features on the HV terminal frame, wherein the stamping features are located on one or more of the top wall, the side wall, the bottom wall, and/or on transition regions located between the top wall and the side wall and between the side wall and the bottom wall. 
     According to another aspect, a high voltage (HV) terminal frame is comprised of a top wall, a bottom wall located opposite the top wall, and a side wall extending between the top wall and the bottom wall. The top wall includes a first top wall layer and a second top wall layer located adjacent the first top wall layer. The bottom wall includes a first bottom wall layer and a second bottom wall layer located adjacent the first bottom wall layer. A single-layer contact spring extends from the first top wall layer, wherein the single-layer contact spring is bent to extend into a space located between the top wall and the bottom wall. In addition, a first conductive bus bar located adjacent to the bottom wall. 
     The HV terminal frame of the preceding paragraph can optionally include, additionally and/or alternatively any, one or more of the following features, configurations, and/or additional components. 
     For example, in some embodiments the HV terminal frame may include a forward stop feature extending from a forward side of the second bottom wall layer and positioned to act as a stop to the first conductive bus bar. 
     In some embodiments, the HV terminal frame may include a guide rail extending from a first side of the second bottom wall layer, the guide rail positioned to retain the first conductive bus bar on a side opposite the side wall. 
     In some embodiments, the HV terminal frame includes first and second guide arms extending from a rear side of the second bottom wall layer, wherein the first and second guide arms retain the first conductive bar. 
     In some embodiments, the top wall, the side wall, the bottom wall and contact spring are formed from a single, continuous piece of material folded to the desired shape. 
     In some embodiments, the HV terminal frame further includes a second conductive bus bar received by the HV terminal frame, wherein the second conductive bus bar is forced into contact with the first conductive bus bar by the contact spring. 
     In some embodiments, the HV terminal frame further includes one or more stamping features located on one or more of the top wall, the side wall, the bottom wall, a transition region between the top wall and the side wall, and a transition region between the side all and the bottom wall.