Patent Description:
Current sensing is any one of several techniques used to measure electric current. Current sensors can measure current passively without interrupting the circuit by using the magnetic field to detect the current and generate an output that is proportional to the current.

The current sensors are placed around the conductor of current, such as a cable or busbar, to perform the measurement. The current sensors are kept in place using a mechanical fastener, such as a screw with a nut to fix the sensor onto the busbar or cable. If one or more portions of the mechanical fastener becomes loose or lost, the current sensor becomes loose on the conductor, resulting in unreliable results or even loss of function. Different ways of securing conductors in current sensors can be seen in <CIT>, <CIT>, <CIT> or <CIT>.

This Summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended as an aid in determining the scope of the claimed subject matter.

An exemplary embodiment of a snap-on assembly in accordance with the present disclosure may include a housing that holds an integrated circuit (IC) with a sensor. A connector supplies power to the IC and transmits a signal from the IC to an electronic circuit. An insert fits into an opening of the housing and secures a conductor in the housing without a mechanical fastener. The insert comprises a plurality of legs extending from a back surface of the insert, the plurality of legs comprising a first leg and a second leg to be placed on one side of the conductor as the insert is inserted into the opening of the housing, and a third leg and a fourth leg to be placed on an opposing side of the conductor as the insert is inserted into the opening of the housing.

The sensor measures a magnetic field resulting from a current traveling through the conductor.

Another exemplary embodiment of a snap-on assembly in accordance with the present disclosure may include a housing, an insert to fit into an opening of the housing, and two wire ties. The housing includes an IC with a sensor that measures a magnetic field resulting from a current traveling through a conductor. The insert secures the conductor in the housing without a mechanical fastener and includes a first extension to be placed on a first side of the housing and a second extension to be placed on a second, opposing side of the housing, the second side being opposite and parallel to the first side. The two extensions each include grooves. The first wire tie is to be looped around the first extension at the first groove and tightened. The second wire tie is to be looped around the second extension at the second groove and tightened. The conductor is inserted through the first extensions, through the insert, and through the second extension. The first and second wire ties secure the conductor in the housing.

A snap-on assembly, for sensing current on a conductor, is disclosed for fitting onto a cable or busbar. The snap-on assembly is affixed to the cable or busbar without need of a mechanical fastener. A single housing is used for either the cable or the busbar. The housing of the snap-on assembly is used with one (busbar) or two (cable) plastic inserts which may be customized for different cable or busbar designs. The plastic inserts include features to prevent movement of the cable or busbar once the snap-on assembly is in place. The housing of the snap-on assembly optionally includes extensions to hold wire ties for additional security against movement.

For the sake of convenience and clarity, terms such as "top", "bottom", "upper", "lower", "vertical", "horizontal", "lateral", "transverse", "radial", "inner", "outer", "left", and "right" may be used herein to describe the relative placement and orientation of the features and components of the electrical box, each with respect to the geometry and orientation of other features and components of the electrical box appearing in the perspective, exploded perspective, and cross-sectional views provided herein. Said terminology is not intended to be limiting and includes the words specifically mentioned, derivatives therein, and words of similar import.

<FIG> are representative drawings of a snap-on assembly for sensing current across a conductor, such as a cable or busbar, according to exemplary embodiments. <FIG> is an overhead view of snap-on assembly 100A for affixation on a cable; <FIG> is an overhead view of snap-on assembly 100B for affixation on a busbar (collectively, "snap-on assembly <NUM>"). The snap-on assembly <NUM> features a housing <NUM> with a first side <NUM>, a second side <NUM>, and a third side <NUM>, with first side <NUM> being connected at one end to second side <NUM>, first side <NUM> being perpendicular to second side <NUM>, second side <NUM> being connected at an opposing end to third side <NUM>, third side <NUM> being perpendicular to second side <NUM> at the opposing end, such that first side <NUM> and third side <NUM> are parallel to one another. From the overhead view, the first side <NUM>, second side <NUM>, and third side <NUM> look like a backwards letter "C" or a sideways letter "U".

The snap-on assembly 100A of <FIG> measures the current across a cable <NUM>. An inner insert <NUM> is placed in an opening <NUM> of the housing <NUM>, followed by the cable <NUM>, and an outer insert <NUM> is then placed in the housing. In exemplary embodiments, the inner insert <NUM> and the outer insert <NUM> surround the cable <NUM>, holding the cable in place inside the opening <NUM> of the housing <NUM>. In exemplary embodiments, the inner insert <NUM> and the outer insert <NUM> are made of a non-conductive material, such as plastic. The disclosed embodiments are not limiting in this regard.

The snap-on assembly 100B of <FIG> measures the current across a busbar <NUM>. In contrast to the two-insert embodiment of <FIG>, one insert <NUM> is placed in the opening <NUM> to hold the busbar <NUM> in place. In exemplary embodiments, the insert <NUM> is shaped to surround the busbar <NUM>, holding the busbar in place inside the opening <NUM> of the housing <NUM>. In exemplary embodiments, the insert <NUM> is made of a non-conductive material, such as plastic. The disclosed embodiments are not limiting in this regard.

The housing <NUM> of snap-on assembly 100A is not different from the housing of snap-on assembly 100B. Put another way, the housing <NUM> is interchangeable, whether the application is to perform current sensing of the cable <NUM> or of the busbar <NUM>. By simply removing the inner insert <NUM> and the outer insert <NUM> and replacing them with insert <NUM>, the application of the snap-on assembly <NUM> can change from the cable <NUM> to the busbar <NUM>, and vice-versa.

In exemplary embodiments, the outer insert <NUM> of the snap-on assembly 100A does not sit outside the threshold of the housing <NUM>, while the insert <NUM> of the snap-on assembly 100B does sit outside the threshold of the housing. Because the busbar <NUM> has a width, w<NUM>, that is slightly smaller than the width, w<NUM>, of the opening <NUM>, the insert <NUM> extends beyond the threshold of the housing <NUM>. For a smaller busbar, this may not be the case. In exemplary embodiments, the insert <NUM> is also customizable to fit the dimensions of the busbar <NUM>. Further, for a larger cable than the cable <NUM>, the outer insert <NUM> may extend beyond the threshold of the housing <NUM>. In exemplary embodiments, the outer insert <NUM> and the inner insert <NUM> are customizable to fit the circumferential dimension of the cable <NUM>. In some embodiments, if the cable <NUM> is not circular, but is oval or some other shape, the outer insert <NUM> and the inner insert <NUM> are modified to fit with the shape of the cable. Further, for very large cables or busbars, that is, those that exceed the dimensions of the opening <NUM>, the housing <NUM> of the snap-on assembly <NUM> is scaled to fit around the cables or busbars, in exemplary embodiments.

The inserts may be modified to support different sizes and shapes of the conductor, whether a cable or a busbar. The busbar may be rectangular in shape or be a rounded rectangular shape, for example. Or, the busbar may have an atypical shape, such as a busbar that is custom-made to support a particular application. Further, the cable may be isolated, such as with a sheath covering the copper cable. Or, the cable may be without isolation, such as for applications in which an increased current level is desired. As long as the cross-section of the cable or the busbar is able to be fit within the housing <NUM>, the snap-on assembly <NUM> may feature modified inserts to facilitate the size and shape of the conductor.

Sensors 108a and 108b (collectively, "sensors <NUM>") are disposed in the first side <NUM> and third side <NUM>, respectively, of the housing <NUM>. In some embodiments, the sensors <NUM> are Hall sensors, anisotropic magneto-resistive (AMR) sensors, or tunnel magnetoresistance (TMR) sensors. Magnetic field strength vectors B1 and B2 are shown for each sensor <NUM>. In one embodiment, the sensor 108b is optional, as the snap-on assembly <NUM> may operate with a single sensor 108a (non-compensated output signal) or may operate with both sensors (compensated output signal).

In exemplary embodiments, each sensor <NUM> is an integrated circuits (IC) including a magnet to perform current sensing based on the magnetic field formed around the cable or busbar. In exemplary embodiments, two sensors are used so that stray magnetic fields can be detected and subtracted from the measured magnetic field of the current through the cable <NUM> or busbar <NUM>. In exemplary embodiments, the sensors <NUM> send signals to an electronic circuit (not shown), for interpreting the measured current. In exemplary embodiments, the ICs can be placed on the top or bottom of the cable or busbar or placed on one side to share with the same printed circuit board assembly.

<FIG> are representative drawings of a second snap-on assembly for sensing current across a conductor, such as a cable or busbar, according to exemplary embodiments. <FIG> is an overhead view of snap-on assembly 200A for affixation on a cable; <FIG> is an overhead view of snap-on assembly 200B for affixation on a busbar (collectively, "snap-on assembly <NUM>"). The snap-on assembly <NUM> features a housing <NUM> with first side <NUM>, second side <NUM>, and third side <NUM>, with first side <NUM> being connected at one end and perpendicular to second side <NUM>, second side <NUM> being connected at one end and perpendicular to first side <NUM> and at the other end and perpendicular to third side <NUM>, such that first side <NUM> and third side <NUM> are parallel to on another. First side <NUM> and third side <NUM> may also be referred to herein as opposing sides. From the overhead view, the first side <NUM>, second side <NUM>, and third side <NUM> look like a backwards letter "C" or a sideways letter "U".

The snap-on assembly 200A of <FIG> measures the current across a cable <NUM>. An inner insert <NUM> is placed in an opening <NUM> of the housing <NUM>, followed by the cable <NUM>, and an outer insert <NUM> is then placed in the housing. In exemplary embodiments, the inner insert <NUM> and the outer insert <NUM> surround the cable <NUM>, holding the cable in place inside the opening <NUM> of the housing <NUM>. In exemplary embodiments, the inner insert <NUM> and the outer insert <NUM> are made of a non-conductive material, such as plastic. The disclosed embodiments are not limiting in this regard.

The housing <NUM> of snap-on assembly 200A is not different from the housing of snap-on assembly 200B. As with the examples of <FIG>, the housing <NUM> is interchangeable, whether the application is to perform current sensing of the cable <NUM> or of the busbar <NUM>. By simply removing the insert <NUM> and replacing it with the inner insert <NUM> and the outer insert <NUM>, the application of the snap-on assembly <NUM> can change from the busbar <NUM> to the cable <NUM>, and vice-versa.

The snap-on assembly 200B of <FIG> measures the current across a busbar <NUM>. A single insert <NUM> is placed in the opening <NUM> to hold the busbar <NUM> in place. In exemplary embodiments, the insert <NUM> is shaped to surround the busbar <NUM>, holding the busbar in place inside the opening <NUM> of the housing <NUM>. In exemplary embodiments, the insert <NUM> is made of a non-conductive material, such as plastic. The disclosed embodiments are not limiting in this regard.

Sensors 208a and 208b (collectively, "sensors <NUM>") are disposed adjacent to one another in the second side <NUM> of the housing <NUM>, with a concentrator <NUM> disposed against each sensor. In some embodiments, the sensors <NUM> are Hall sensors, anisotropic magneto-resistive (AMR) sensors, or tunnel magnetoresistance (TMR) sensors. Magnetic field strength vectors B1 and B2 are shown for each sensor <NUM>. In one embodiment, the sensor 208b is optional, as the snap-on assembly <NUM> may operate with a single sensor 208a. In exemplary embodiments, each sensor <NUM> is an integrated circuits (IC) including a magnet to perform current sensing based on the magnetic field formed around the cable or busbar. In exemplary embodiments, two sensors are used so that stray magnetic fields can be detected and subtracted from the measured magnetic field of the current through the cable <NUM> or busbar <NUM>. In exemplary embodiments, the sensors <NUM> send signals to an electronic circuit (not shown), for interpreting the measured current.

<FIG> and <FIG> are representative drawings of a snap-on assembly for sensing current across a conductor, such as a cable or busbar, according to exemplary embodiments. <FIG> is a perspective view of snap-on assembly 300A for affixation on a cable; <FIG> is a perspective view of snap-on assembly 300B for affixation on a busbar (collectively, "snap-on assembly <NUM>"). The snap-on assembly 300A may include the features of either the snap-on assembly 100A or 200A, and the snap-on assembly 300B may include the features of either the snap-on assembly 100B or 200B.

The snap-on assembly <NUM> features a housing <NUM> with first side <NUM>, second side <NUM>, and third side <NUM>. The housing <NUM> may be configured with the ICs disposed as in <FIG> or as in <FIG>. In <FIG>, cable <NUM> is shown disposed between the inner insert <NUM> and the outer insert <NUM>, with the inner insert connected to the outer insert within the housing <NUM>. In exemplary embodiments, the inner insert <NUM> and the outer insert <NUM> surround the cable <NUM>, holding the cable in place inside the housing <NUM>. A back surface <NUM> of the outer insert <NUM> mates with the first side <NUM> and third side <NUM> of the housing, thus forming a rectangular cube structure.

In <FIG>, busbar <NUM> is shown surrounded by insert <NUM>. In exemplary embodiments, the insert <NUM> is shaped to surround the busbar <NUM>, holding the busbar in place inside the housing <NUM>. In exemplary embodiments, the inner insert <NUM>, outer insert <NUM>, and insert <NUM> are made of a non-conductive material, such as plastic. The disclosed embodiments are not limiting in this regard. A back surface <NUM> of the insert <NUM> mates with the first side <NUM> and third side <NUM> of the housing, thus forming a rectangular cube structure.

In exemplary embodiments, the back surface <NUM> includes an opening <NUM> with depressions 342a and 342b (collectively, "depressions"). The depressions <NUM> are designed to press against the surface of the busbar <NUM>, so as to prevent axial or longitudinal movement of the busbar. Axial movement or longitudinal movement of the busbar would be along its length, that is, to either side of the housing <NUM>. The depressions <NUM> are described in more detail in conjunction with <FIG>, below.

A connector <NUM> is disposed at the top of the housing, for connecting the sensors inside the housing (not shown) to a power source. In one embodiment, in addition to supplying power to the snap-on assembly <NUM>, the connector <NUM> further includes a dedicated pin for communicating the current signal sensed by the sensor ICs to an electrical circuit (not shown).

<FIG> and <FIG> are representative drawings of the snap-on assembly <NUM> of <FIG> and <FIG>, according to exemplary embodiments. <FIG> is an exploded perspective view of the snap-on assembly 300A for affixation on the cable <NUM>; <FIG> is an exploded perspective view of the snap-on assembly 300B for affixation on the busbar <NUM>. The housing <NUM> includes the connector <NUM>, as before, for connecting the snap-on assembly <NUM> to a power source and for communicating the sensed current signal to an electrical circuit.

In <FIG>, the cable <NUM> is shown disposed between the inner insert <NUM> and the outer insert <NUM>, with the inside portion of the inner insert being exposed. In exemplary embodiments, the inner insert <NUM> include a cylindrical receptacle 422a including ribs <NUM> for receiving the cable <NUM> on one side. Similarly, the outer insert <NUM> includes a cylindrical receptacle 422b including ribs (not shown) for receiving the cable <NUM> on the other side (collectively, "cylindrical receptacles <NUM>"). The ribs <NUM> protrude somewhat from respective cylindrical receptacles <NUM> so that, when the cable <NUM> is pressed against the inner insert <NUM> and the outer insert <NUM> is pressed against the cable, the ribs <NUM> are pressed against the cable. In exemplary embodiments, the inner insert <NUM> and the outer insert <NUM> secure the cable <NUM> in the housing <NUM> of the snap-on assembly 300A. Further, in exemplary embodiments, the cylindrical receptacles <NUM> and the ribs <NUM> substantially prevent either rotational movement or axial movement of the cable <NUM> once the inner insert <NUM> and outer insert <NUM> are in place in the housing <NUM> of the snap-on assembly 300A.

In exemplary embodiments, the inner insert <NUM> further includes arms 424a and 424b (collectively, "arms <NUM>") and the outer insert <NUM> includes receiving sleeves 426a and 426b (collectively, 'receiving sleeves <NUM>"), where arm 424a fits into receiving sleeve 426a and arm 424b fits into receiving sleeve 426b. Further, the arm 424a is disposed on one side of the cable <NUM> (e.g., over the cable in <FIG>) while the arm 424b is disposed on the other side of the cable (e.g., under the cable).

In <FIG>, the busbar <NUM> is shown inserted into the opening (e.g., opening <NUM> of snap-on assembly <NUM> or opening <NUM> of snap-on assembly <NUM>, above) of the housing <NUM>. The insert <NUM> includes a first leg 428a, a second leg 428b, a third leg 428c, and a fourth leg 428d (collectively, "legs <NUM>"), which extend from the back surface <NUM> of the insert.

As shown in <FIG>, the back surface <NUM> of the insert <NUM> includes an opening <NUM> with depressions <NUM>. The depressions <NUM> are designed to press against the surface of the busbar <NUM>, so as to prevent axial movement (e.g., to either side of the housing <NUM>) of the busbar. The opening <NUM> and optional depressions <NUM> are not featured on the back surface <NUM> of insert <NUM> (<FIG> or <FIG>). This is because the ribs <NUM> in the cylindrical receptacles <NUM> work to control rotation of the cable <NUM>. Cable jackets tend to be elastic, which makes the ribs <NUM> stick to them quite well. Busbars, on the other hand, are rigid and so the depressions <NUM> are pushed against the busbar <NUM> when the insert <NUM> is pressed into the housing <NUM>.

In exemplary embodiments, the snap-on assembly 300B has additional features to control movement of the busbar <NUM>. For example, legs 428a and 428c are disposed on one side of the busbar <NUM> (e.g., above the busbar in <FIG>) while the legs 428b and 428d are disposed on the other side of the busbar (e.g., below the busbar). In exemplary embodiments, the legs 428a and 428b are disposed approximately a distance, w<NUM>, which corresponds to the width of the busbar <NUM>. Similarly, the legs 428c and 428d are disposed approximately a distance, w<NUM>, apart. This distance ensures that the legs <NUM> fit snugly around the busbar <NUM>. In exemplary embodiments, the legs <NUM> prevent up-and-down movement of the busbar <NUM>. In exemplary embodiments, the insert <NUM> secures the busbar <NUM> in the housing <NUM> of the snap-on assembly 300B. Further, in exemplary embodiments, the legs <NUM> of the insert <NUM> substantially prevent axial movement of the busbar <NUM> once the insert is in place in the housing <NUM> of the snap-on assembly 300B.

In exemplary embodiments, the legs <NUM> further include features to ensure that the busbar <NUM> does not move. Dimples, three of which are shown as dimple 430a on leg 428b and dimples 430b and 430c on leg 428d (collectively, "dimples <NUM>"), help to provide clamping force onto the busbar, to secure the busbar <NUM> in place axially, much as the ribs <NUM> do for the cable <NUM> (<FIG>). Orthogonal protrusions, two of which are shown, enhance the capacity of respective legs to grip the busbar <NUM> by giving support in another direction, that is, cross-wise, or along the shorter side of the busbar. As defined herein, cross-wise movement is perpendicular to axial movement, and up-and-down movement is perpendicular to both cross-wise and axial movement. The orthogonal protrusions <NUM> thus provide another of control over the movement of the busbar <NUM> than the depressions <NUM>. Orthogonal protrusion 432a is disposed at the end of leg 428a (opposite the back surface <NUM>) and orthogonal protrusion 432b is disposed at the end of leg 428d (collectively, "orthogonal protrusions <NUM>"). In one embodiment, the orthogonal protrusions <NUM> are oriented <NUM>° from the respective legs <NUM>. In other embodiments, the orthogonal protrusions <NUM> are oriented out of plane from the respective legs <NUM> by some non-zero degree. The dimples <NUM> and orthogonal protrusions <NUM> help the legs <NUM> of the insert <NUM> to prevent axial movement of the busbar <NUM>, in some embodiments. Further, the depressions <NUM> of the opening <NUM> are pushed against the busbar <NUM>, in some embodiments, which also controls axial movement. Exemplary embodiments of the snap-on assembly 300B may include one or more of these features to control movement of the busbar in the housing <NUM> in axial, cross-wise, and up-and-down movement. Put another way, these features control movement in the X-, Y-, and Z-directions.

In exemplary embodiments, the snap-on assemblies <NUM>, <NUM>, and <NUM> can be secured to a conductor, such as a cable or busbar, without the use of a mechanical fasteners. As used herein, mechanical fasteners are defined as hardware objects made of steel, iron, or other metal material, and may include bolts and nuts, screws, rivets, anchor fasteners, and the like. Legacy current sensors depend on a mechanical fastener to secure the sensor to the conductor. This dependence on mechanical fasteners can become problematic. For example, if the current sensor is secured to the conductor using a bolt and nut, and the nut becomes loose, the current sensor may move from its intended position on the conductor. Further, a loose nut is more likely to be lost, such as in an automotive environment where the system itself, the vehicle, is designed to move. Once the nut is lost, it may not be long before the bolt is lost as well. Without its mechanical fastener, the reliability of the current sensor is thus compromised and may even be nonexistent.

<FIG> and <FIG> are representative drawings of a snap-on assembly for sensing current across a conductor, such as a cable or busbar, according to exemplary embodiments. <FIG> is a perspective view of snap-on assembly 500A for affixation on a cable; <FIG> is a perspective view of snap-on assembly 500B for affixation on a busbar (collectively, "snap-on assembly <NUM>"). The snap-on assembly 500A may include the features, such as the IC arrangement, of either the snap-on assembly 100A or 200A, and the snap-on assembly 500B may include the features of either the snap-on assembly 100B or 200B. The snap-on assembly <NUM> features material, known generally as extensions, added to the insert(s) for gripping the cable or busbar, such that it is secure inside the housing.

Looking first at <FIG>, the snap-on assembly 500A is much like the snap-on assemblies <NUM>, <NUM>, and <NUM> shown and described above. The snap-on assembly 500A includes a C- or U-shaped housing <NUM> and a connector <NUM>, and an outer insert <NUM> is visible. Further, in some embodiments, the housing <NUM> features a cylindrical extension 528a connected to one side of the housing, and a cylindrical extension 528b connected to the opposing side of the housing (collectively, "cylindrical extensions <NUM>"). In exemplary embodiments, the cylindrical extensions are made of the same non-conductive material as the outer insert <NUM>, such as plastic. In some embodiments, the cylindrical extensions <NUM> are formed separately from the outer insert <NUM> and inner insert (not shown) but are fit into the outer and inner inserts. In other embodiments, the cylindrical extensions <NUM> are formed along with the outer insert <NUM> and the inner insert. In this case, the cylindrical extensions <NUM> would be made as two separate semi-circular structures on each side of the inner and outer inserts, with one semi-circular structure on each side of the inner insert being part of, and an extension of, the inner insert and molded as a unitary structure, while the other semi-circular structure on each side being part of, and an extension of, the outer insert <NUM> and molded as a unitary structure.

In exemplary embodiments, the snap-on assembly 500A also includes wire ties 526a and 526b (collectively, "wire ties <NUM>"), also known colloquially as "zip ties" or "flex cuffs". The wire ties <NUM> fit into grooves <NUM> of the cylindrical extensions <NUM> and are wrapped around the cylindrical extensions. The wire ties <NUM> is a strip of plastic material that is somewhat flat, with a rectangular cross-section. Each wire tie <NUM> features a rectangular opening at one end that is usually not much larger than the dimension of the rectangular cross-section. One-way teeth are disposed along the surface of the wire tie <NUM>. At the end opposite the rectangular opening is a somewhat flat, smooth lip. The lip end of the wire tie <NUM> is threaded through the rectangular opening, with the wire tie being positioned around an object to be secured, which is, in this example, one of the cylindrical extensions <NUM>. Once the wire tie <NUM> is pulled taut (tightened) against the cylindrical extension <NUM>, the one-way teeth prevent the wire tie from being loosened. The wire tie <NUM> is thus designed to be easy to fasten but difficult to release.

In exemplary embodiments, the wire ties <NUM> are looped and tightened, as described above, to fixably secure the cylindrical extensions <NUM> to the cable <NUM>. Because the cylindrical extensions <NUM> are connected to (or part of) the inserts <NUM> and <NUM>, and the inserts are disposed within the opening of the housing <NUM>, the cable will be secured within the housing of the snap-on assembly 500A. In contrast to mechanical fasteners such as nuts and bolts, the wire ties <NUM> are very reliable once secured around the cable <NUM>, and do not loosen or break, even in extreme environments, such as when used in an operating vehicle. In exemplary embodiments, the wire ties <NUM>, once secured to the cylindrical extensions <NUM>, prevent both rotational and axial movement of the cable <NUM> inside the housing <NUM>.

As illustrated in <FIG>, snap-on assembly 500B is much like the snap-on assemblies <NUM>, <NUM>, and <NUM> shown and described above. The snap-on assembly 500B includes a C- or U-shaped housing <NUM> and a connector <NUM>, and an insert <NUM> is visible. Further, in some embodiments, the housing <NUM> features a rectangular extension 530a connected to one side of the housing, and a rectangular extension 530b connected to the opposing side of the housing (collectively, "rectangular extensions <NUM>"). In exemplary embodiments, the rectangular extensions are made of the same non-conductive material as the insert <NUM>, such as plastic. In some embodiments, the rectangular extensions <NUM> are formed separately from the insert <NUM> but are fit into the insert. In other embodiments, the rectangular extensions <NUM> are formed along with the insert <NUM>. In this case, the rectangular extensions <NUM> would be disposed to the left and to the right of the insert <NUM> and molded as a unitary structure. And the busbar <NUM> would be threaded through one rectangular extension 530a, through the opening of the insert <NUM>, and through the rectangular extension 530b, or vice-versa, before being inserted into the opening of the housing <NUM>.

As with the cylindrical extensions <NUM> (<FIG>), the rectangular extensions <NUM> include grooves <NUM>, for receiving wire ties <NUM>, in exemplary embodiments. The wire ties <NUM> fit into grooves <NUM> of the rectangular extensions <NUM> and are looped and tightened, as described above, to fixably secure the busbar <NUM> to the housing <NUM> of the snap-on assembly 500B. In exemplary embodiments, the wire ties <NUM>, once secured to the rectangular extensions <NUM>, prevent axial movement of the busbar <NUM> inside the housing <NUM>.

Thus, a novel snap-on assembly flexibly supports a conductor, such as a cable or busbar. The snap-on assembly is affixed to the conductor without need of mechanical fasteners, such as a screw and nuts, as in prior art current sensors. The snap-on assembly supports one sensor IC, for non-compensated signal outputs, or two sensor ICs, for compensated signal outputs. For the cable assembly, the inserts feature ribs, cylindrical receptacles, arms, and receiving sleeves to facilitate secure affixation, preventing rotational, axial, and up-and-down movement of the cable. For the busbar assembly, the insert features legs, dimples, and orthogonal protrusions to facilitate secure affixation, preventing axial movement of the busbar. The inserts may be modified to support different sizes and shapes of both cables and busbars. The inserts may optionally be coupled with extensions for use with wire ties, for additional security of the cable or busbar.

Claim 1:
A snap-on assembly (100a, 100b, 200a, 200b, 300a, 300b) comprising:
a housing (<NUM>, <NUM>, <NUM>) comprising an integrated circuit, IC, the IC comprising a sensor;
a connector (<NUM>) to supply power to the IC and to transmit a signal from the IC to an electronic circuit; and
an insert (<NUM>, <NUM>, <NUM>) to fit into an opening of the housing, the insert to secure a conductor in the housing without a mechanical fastener, wherein the sensor measures a magnetic field resulting from a current travelling through the conductor,
characterized in the insert further comprising a plurality of legs (<NUM>) extending from a back surface of the insert, the plurality of legs comprising:
a first leg (428a) and a second leg (428b) to be placed on one side of the conductor as the insert is inserted into the opening of the housing; and
a third leg (428c) and a fourth leg (428d) to be placed on an opposing side of the conductor as the insert is inserted into the opening of the housing.