Abstract: A bus bar connector system and an electrical distribution center suitable for use in a motor vehicle including such a bus bar connection system is presented. The bus bar connector system includes a first bus bar, a second bus bar, and a spring clip configured to apply a contact force to the first and second bus bars effective to bring at least a portion the first and second bus bars into intimate contact with one another. The spring clip may comprise two longitudinal spring arms each extending from a lateral spring base interconnecting the spring arms. These spring arms are angled toward one another and end portions of the spring arms may be angled away from one another, thereby forming an hourglass or X-shaped spring clip. The end portions of the spring arms may be configured to retain the spring clip within a slot defined by a connector housing.

Abstract: An electrical distribution center having a base connected to one or several wiring harnesses and a connector body that is configured to be electrically and mechanically connected to the base. The connector body houses electrical devices such as relays, fuses, and control modules. The connector body is secured to the base by a pair of slides having dog-leg shaped slots that engage studs on the base. A single slide lever having two arms attached to each of the slides is pivotably attached to the connector body and the slides and is configured to simultaneously move the dog-leg shaped slots relative to the studs on the base, thereby securing the connector body to the base.

Abstract: A mechanically assisted electrical connector including a lever and a slider. The slider is coupled to the lever such that movement of the lever moves the slider. The slider defines a slot that is configured to cooperate with a post of a mating connector in a manner effective to urge the electrical connector and the mating connector together when the lever is moved from a first position to a second position. A ramp angle of the slot is varied to reduce a peak value of an applied force to advance the lever from the first position to the second position when connecting the electrical connector to the mating connector.

Abstract: An electrical assembly, such as a high voltage electrical center that controls the flow of electricity between a battery pack and the propulsion system of an electric or hybrid electric vehicle. The assembly includes a plurality of electrical connectors configured to receive and mate with a plurality of corresponding mating connectors and a housing containing a plurality of electrical devices interconnected to the plurality of electrical connectors. The housing includes a bulkhead defining a plurality of connector shrouds that axially surrounds each connector in the plurality of electrical connectors. Each connector shroud is configured to receive a connector body of a corresponding mating connector. The plurality of connector shrouds is integral to the bulkhead. The bulkhead, and thereby the shrouds, may be formed of a composite conductive material containing electrically conductive fibers within a dielectric matrix.

Abstract: A mechanically assisted electrical connector including a lever and a slider. The slider is coupled to the lever such that movement of the lever moves the slider. The slider defines a slot that is configured to cooperate with a post of a mating connector in a manner effective to urge the electrical connector and the mating connector together when the lever is moved from a first position to a second position. A ramp angle of the slot is varied to reduce a peak value of an applied force to advance the lever from the first position to the second position when connecting the electrical connector to the mating connector.

Abstract: An electrical distribution center having a base connected to one or several wiring harnesses and a connector body that is configured to be electrically and mechanically connected to the base. The connector body houses electrical devices such as relays, fuses, and control modules. The connector body is secured to the base by a pair of slides having dog-leg shaped slots that engage studs on the base. A single slide lever having two arms attached to each of the slides is pivotably attached to the connector body and the slides and is configured to simultaneously move the dog-leg shaped slots relative to the studs on the base, thereby securing the connector body to the base.

Abstract: A battery pack containing a plurality of battery cells having a housing and defining an opening within the housing and a battery control module configured to be disposed within the opening of the battery pack. The battery control module may contain circuitry for controlling a connection between the battery pack and an electric load or electric source and for controlling the charging of the battery cells. The circuitry within the battery control module is connected by rigid conductors, such as conductive traces on a circuit board or bus bars rather than flexible wire cables. The battery control module may be configured to be removed for serving the battery pack without removing the battery pack housing. The battery pack may further include a battery voltage monitor configured to monitor a terminal voltage of each battery cell and send a digital signal representing the voltage to the battery control module.

Abstract: An electrical connection header for an electrical device and a method for assembling the same are disclosed herein. A connection header may include a plurality of electrical pins, each of which has a first portion and a second portion oriented generally orthogonal to each other. The pins may be inserted to a connector shroud which defines a plurality of apertures for receiving the first portions of the pins. A hood may be secured to the connector shroud such that the hood extends beyond a bend point of at least one of the pins.

Abstract: An electrical connection header for an electrical device and a method for assembling the same are disclosed herein. A connection header may include a plurality of electrical pins, each of which has a first portion and a second portion oriented generally orthogonal to each other. The pins may be inserted to a connector shroud which defines a plurality of apertures for receiving the first portions of the pins. A hood may be secured to the connector shroud such that the hood extends beyond a bend point of at least one of the pins.

Abstract: An electrical inter-connection is provided such that a terminal pin which is positioned in a pin block extends through a plated through-hole in a circuit board substrate and is connected with the circuit board using a conductive bonding agent such as solder. The terminal pin is capable of inter-connection with conductive elements located on each major side of the circuit board and eliminates the need for an interference fit between the terminal pin and circuit board. The pin block includes a body and at least one stand-off. The stand-off maintains the body a sufficient distance from the circuit board substrate to enable a solder fillet to form between the plated through-hole and the terminal pin during re-flow processing. The electrical inter-connection further includes an eccentric aperture in the circuit board suitable for interference fit inter-connection with a protruding cylindrical feature such as on an electrical ground that has poor solderability characteristics.

Abstract: An electrical connector has a connector body. A pin block disposed in the connector body supports a plurality of terminal pins that are arranged in horizontal rows that are vertically spaced with the terminal pins in each row being laterally spaced from each other. The terminal pins have contact portions projecting out a forward end of the pin block and tail portions projecting out a rearward end of the pin block. The tail portions of the terminal pins in an uppermost row of the plurality of terminal pins have straight tail portions. The connector body has a socket at a forward end, an intermediate retainer section holding the pin block and a tail guard at a rearward end for protecting the projecting tail portions of the terminal pins.

Abstract: An electrical inter-connection is provided such that a terminal pin which is positioned in a pin block extends through a plated through-hole in a circuit board substrate and is connected with the circuit board using a conductive bonding agent such as solder. The terminal pin is capable of inter-connection with conductive elements located on each major side of the circuit board and eliminates the need for an interference fit between the terminal pin and circuit board. The pin block includes a body and at least one stand-off. The stand-off maintains the body a sufficient distance from the circuit board substrate to enable a solder fillet to form between the plated through-hole and the terminal pin during re-flow processing. The electrical inter-connection further includes an eccentric aperture in the circuit board suitable for interference fit inter-connection with a protruding cylindrical feature such as on an electrical ground that has poor solderability characteristics.

Abstract: An electrical inter-connection is provided such that a terminal pin which is positioned in a pin block extends through a plated through-hole in a circuit board substrate and is connected with the circuit board using a conductive bonding agent such as solder. The terminal pin is capable of inter-connection with conductive elements located on each major side of the circuit board and eliminates the need for an interference fit between the terminal pin and circuit board. The pin block includes a body and at least one stand-off. The stand-off maintains the body a sufficient distance from the circuit board substrate to enable a solder fillet to form between the plated through-hole and the terminal pin during re-flow processing. The electrical inter-connection further includes an eccentric aperture in the circuit board suitable for interference fit inter-connection with a protruding cylindrical feature such as on an electrical ground that has poor solderability characteristics.