Abstract: An electrical header for use in an electrical connector assembly includes a body for mounting to an object and having an opening formed therethrough for receiving an electrical terminal. The body further defines a plug on a first side thereof for engaging with a mating electrical connector of the assembly. The plug includes a pair of first opposing sidewalls extending from the body at a first height and defining a locking feature for engaging with a corresponding locking feature of the mating connector, and a pair of second opposing sidewalls extending from the body at a second height, less than the first height. The first and second pairs of opposing sidewalls are adapted to mate with a first mating connector oriented in a first direction, and mate with a second mating connector oriented in a second direction distinct from the first direction.

Abstract: An electrical header for use in an electrical connector assembly includes a body adapted to mount to an object and having an opening formed therethrough for receiving an electrical terminal. The body further defines a plug on a first side thereof and adapted to engage with a mating electrical connector of the assembly. The plug includes a pair of first opposing sidewalls extending from the body and defining a locking feature adapted to engage with a corresponding locking feature of the mating connector, and a pair of second opposing sidewalls extending from the body and defining a keying feature. The first and second pairs of opposing sidewalls are adapted to mate with a first mating connector oriented in a first direction, and mate with a second mating connector oriented in a second direction distinct from the first direction.

Abstract: A power harness includes a plug housing holding a power contact and a busbar received in a chamber of the plug housing. The power contact has a mating portion having a separable mating interface configured to be plugged into a header contact stack of header contacts of the header connector when mated with the header connector. The busbar is welded to a weld pad at a terminating portion of the power contact. A threaded bolt passes through the plug housing configured to be threadably coupled to a threaded connector of the header connector to secure the plug housing to the header connector.

Abstract: A header power connector includes a header housing assembly including an inner housing received in a cavity of an outer housing. The inner housing has upper and lower openings open to a terminal channel configured to receive busbars. The inner housing is movable relative to the outer housing to accommodate misalignment of the busbars in the terminal channel. A terminal is received in the terminal channel having a terminal base, an upper mating end and a lower mating end. The upper mating end includes an upper socket flanked by upper spring beams that receives the first busbar and the lower mating end includes a lower socket flanked by lower spring beams that receives the second busbar. The terminal is movable in the terminal channel to accommodate misalignment of the first busbar and the second busbar in the terminal channel.

Abstract: An electrical connector assembly comprises a header and a backing plate attachable thereto. The header includes a plug portion for connecting to a complementary mating connector, and a base having a plurality of mounting through holes for fixing the header to a mounting surface. The backing plate includes a plurality of mounting elements corresponding in location to the plurality of mounting holes of the header for fixing the backing plate to the header on an underside of the mounting surface, and a central opening corresponding in location to the plug portion of the header with the backing plate fixed to the header.

Abstract: A charging inlet assembly includes a housing extending between a front and a rear. The housing has DC terminal channels and AC terminal channels. The charging inlet assembly includes AC terminals, include a proximity terminal and a ground terminal, received in the corresponding AC terminal channels. The charging inlet assembly includes DC terminals received in the corresponding DC terminal channels. The charging inlet assembly includes a proximity resistor assembly having a plug body holding a resistor, a first resistor conductor and a second resistor conductor. The first resistor conductor is coupled between the resistor and the terminating end of the proximity terminal. The second resistor conductor is coupled between the resistor and the terminating end of the ground terminal.

Abstract: A header power connector includes a header housing assembly including an inner housing received in a cavity of an outer housing. The inner housing has upper and lower openings open to a terminal channel configured to receive busbars. The inner housing is movable relative to the outer housing to accommodate misalignment of the busbars in the terminal channel. A terminal is received in the terminal channel having a terminal base, an upper mating end and a lower mating end. The upper mating end includes an upper socket flanked by upper spring beams that receives the first busbar and the lower mating end includes a lower socket flanked by lower spring beams that receives the second busbar. The terminal is movable in the terminal channel to accommodate misalignment of the first busbar and the second busbar in the terminal channel.

Abstract: A header connector includes a header housing having a mating end and a mounting end. The mounting end is configured to be mounted to a supporting structure. The header housing has shroud walls forming a header chamber configured to receive a plug connector. The header connector includes a header seal coupled to the header housing having an upper portion with an upper sealing surface and a lower portion with a lower sealing surface. The upper portion extends into the header chamber and the upper sealing surface is configured to interface with the plug connector to form a seal between the header housing and the plug connector. The lower portion extends to the mounting end and the lower sealing surface is configured to interface with the supporting structure to form a seal between the header housing and the supporting structure.

Abstract: A header connector includes a header housing having a mating end and a mounting end. The mounting end is configured to be mounted to a supporting structure. The header housing has shroud walls forming a header chamber configured to receive a plug connector. The header connector includes a header seal coupled to the header housing having an upper portion with an upper sealing surface and a lower portion with a lower sealing surface. The upper portion extends into the header chamber and the upper sealing surface is configured to interface with the plug connector to form a seal between the header housing and the plug connector. The lower portion extends to the mounting end and the lower sealing surface is configured to interface with the supporting structure to form a seal between the header housing and the supporting structure.

Abstract: An electrical header for use in an electrical connector assembly includes a body for mounting to an object and having an opening formed therethrough for receiving an electrical terminal. The body further defines a plug on a first side thereof for engaging with a mating electrical connector of the assembly. The plug includes a pair of first opposing sidewalls extending from the body a first height and defining a locking feature for engaging with a corresponding locking feature of the mating connector, and a pair of second opposing sidewalls extending from the body at a second height, less than the first height. The first and second pairs of opposing sidewalls are adapted to mate with a first mating connector oriented in a first direction with respect to the header, and mate with a second mating connector oriented in a second direction with respect to the header and distinct from the first direction.

Abstract: A power terminal includes a terminal body having a mating portion including plates with a mating space therebetween. A spring clip is coupled to the mating portion and includes inner spring plates extending along the plates in the mating space with a slot therebetween. The inner spring plates directly engage and electrically connect to the terminal body and to a tab terminal received in the slot. The spring clip includes at least one cantilevered contact spring configured to be spring biased against and electrically connected to the tab terminal. The spring clip includes at least one stabilization contact spring spring biased against and electrically connected to the corresponding plate and configured to be spring biased against and electrically connected to the tab terminal. The stabilization contact spring provides a greater contact normal force against the tab terminal than the cantilevered contact spring.

Abstract: A plug connector includes a housing having a mating end and a cable end. The mating end is configured to be mated with a header connector in a mating direction. A tab terminal is held in the housing at the mating end. The tab terminal has a leading edge configured to be mated with the header terminal of the header connector when the plug connector is mated to the header connector. The leading edge is tapered such that the tab terminal sequentially mates with the header terminal during mating.

Abstract: A power connector system includes a header connector having a header housing mounted to a chassis. The header housing holds a header terminal comprising a plurality of contact members arranged side-by-side in a stacked arrangement. Each contact member has a pair of spring beams defining sockets at a mating end of the contact member. The sockets of the contact members are aligned to define a tab socket of the header terminal. The power connector system includes a plug connector having a plug housing holding a tab terminal. The tab terminal has a mating end and a cable end. The mating end is received in a mating direction into the tab socket of the header terminal during mating to electrically connect the tab terminal with the header terminal.

Abstract: A connector assembly includes an electrical connector and a shipping cap. The electrical connector includes a housing and a lever pivotably coupled to the housing. The lever is pivotable relative to the housing between an open position and a closed position. The lever has a guideway configured to receive a guide journal of a mating connector that mates to the electrical connector. The shipping cap is removably mounted to a mating end of the housing when the electrical connector is not mated to the mating connector. The shipping cap includes a lid that covers a mating opening of the housing. The shipping cap further includes a blocking tab that is received in the guideway of the lever when the lever is in the open position. The blocking tab in the guideway engages the lever to block the lever from pivoting to the closed position.

Abstract: A connector assembly includes an electrical connector and a shipping cap. The electrical connector includes a housing and a lever pivotably coupled to the housing. The lever is pivotable relative to the housing between an open position and a closed position. The lever has a guideway configured to receive a guide journal of a mating connector that mates to the electrical connector. The shipping cap is removably mounted to a mating end of the housing when the electrical connector is not mated to the mating connector. The shipping cap includes a lid that covers a mating opening of the housing. The shipping cap further includes a blocking tab that is received in the guideway of the lever when the lever is in the open position. The blocking tab in the guideway engages the lever to block the lever from pivoting to the closed position.

Abstract: A power terminal includes a terminal body having a mating portion including plates with a mating space therebetween. A spring clip is coupled to the mating portion and includes inner spring plates extending along the plates in the mating space with a slot therebetween. The inner spring plates directly engage and electrically connect to the terminal body and to a tab terminal received in the slot. The spring clip includes at least one cantilevered contact spring configured to be spring biased against and electrically connected to the tab terminal. The spring clip includes at least one stabilization contact spring spring biased against and electrically connected to the corresponding plate and configured to be spring biased against and electrically connected to the tab terminal. The stabilization contact spring provides a greater contact normal force against the tab terminal than the cantilevered contact spring.

Abstract: A power connector system includes a header connector having a header housing mounted to a chassis. The header housing holds a header terminal comprising a plurality of contact members arranged side-by-side in a stacked arrangement. Each contact member has a pair of spring beams defining sockets at a mating end of the contact member. The sockets of the contact members are aligned to define a tab socket of the header terminal. The power connector system includes a plug connector having a plug housing holding a tab terminal. The tab terminal has a mating end and a cable end. The mating end is received in a mating direction into the tab socket of the header terminal during mating to electrically connect the tab terminal with the header terminal.

Abstract: A plug connector includes a housing having a mating end and a cable end. The mating end is configured to be mated with a header connector in a mating direction. A tab terminal is held in the housing at the mating end. The tab terminal has a leading edge configured to be mated with the header terminal of the header connector when the plug connector is mated to the header connector. The leading edge is tapered such that the tab terminal sequentially mates with the header terminal during mating.

Abstract: A receptacle terminal includes a terminal body with a cable end configured to be terminated to a cable and a mating end configured to be mated with a blade terminal. The terminal body includes a receptacle at the mating end. The receptacle has a first wall and a second wall generally parallel to, and spaced apart from, the first wall. The receptacle has a receiving space between the first and second walls configured to receive the blade terminal. A contact spring is separately provided from, and coupled to, the terminal body and has a spring wall received in the receiving space that is positioned between the first wall and the blade terminal. The spring wall has an inner surface and an outer surface. The inner surface is spring biased against the first wall. The outer surface is configured to be spring biased against the blade terminal.

Abstract: A header assembly is provided that includes an outer housing that has a mating end and a harness end. The outer housing has a cavity at the mating end and a flange configured to be mounted to a panel of a device. The outer housing is configured to be exposed to an exterior of the device for mating with a plug assembly. A shield is received in the cavity that has a front and a rear. An inner housing is received in the cavity with the shield surrounding at least a portion of the inner housing. The inner housing has a front and a rear and has a latch engaging the front of the shield. The latch allows the inner housing to be released from the shield to remove the inner housing from the cavity.