Abstract: An electrical connector with a housing having a mounting opening with a mounting projection. An outwardly facing wall of the mounting projection has at least one detent. A fixed member has a fixed member opening. The fixed member opening has an inner surface with at least one deflectable member which extends from the inner surface into the fixed member opening. A gap is provided between the inner surface of the fixed member opening and the outwardly facing wall of the mounting projection. The mounting projections are able to float radially with the gap. The at least one deflectable member cooperates with the first detent to retain the electrical connector assembly in a pre-staged position.

Abstract: A power connector includes a housing having a terminal channel holding a terminal. The terminal includes a mating pin at a front of the terminal and a cable connector at a rear of the terminal. The mating pin is positioned in the terminal channel for mating with a charging connector. The power connector includes a power cable including a conductor terminated to the cable connector at the rear of the terminal. The power connector includes a cable heat exchanger thermally coupled to the conductor of the power cable. The cable heat exchanger includes a coolant channel for coolant flow through the cable heat exchanger for actively cooling the conductor of the power cable. A thermally conductive separator electrically isolates the cable heat exchanger from the conductor of the power cable.

Abstract: A cooling system for a power connector of a charging inlet assembly includes a cooling adapter coupled to a housing of the charging inlet assembly including an adapter body forming a cavity. The cooling adapter includes supply and return ports adjacent a cable exit. The cooling system includes a heat exchanger positioned in the cavity of the cooling adapter including a heat exchanger body configured to receive the power cable and/or the terminal. The heat exchanger body is thermally coupled to the power cable or the terminal to dissipate heat therefrom.

Abstract: An electrical connector includes a housing having a mating end and a wire end with a base and terminal channels extending through the base into the mating end. The terminal channels receive terminals mated with a mating electrical connector. The base has a wire support supporting wires extending from the terminals. The wire support includes support walls forming wire channels. A wire dress cover is coupled to the wire support and includes an end wall and wire pushers extending from the end wall. The wire pushers load the wires into the wire channels. The wire pushers are received in the wire channels to hold the wires in the wire channels. The wires are supported at the rear by the wire pushers and at both sides by the support walls to provide strain relief for the wires in the wire support.

Abstract: A power connector includes a housing having a terminal channel holding a terminal. The terminal includes a mating pin at a front of the terminal and a cable connector at a rear of the terminal. The mating pin is positioned in the terminal channel for mating with a charging connector. The power connector includes a power cable including a conductor terminated to the cable connector at the rear of the terminal. The power connector includes a cable heat exchanger thermally coupled to the conductor of the power cable. The cable heat exchanger includes a coolant channel for coolant flow through the cable heat exchanger for actively cooling the conductor of the power cable. A thermally conductive separator electrically isolates the cable heat exchanger from the conductor of the power cable.

Abstract: Pass-thru connector assembly includes a pass-thru body having a passage section and a loading section that are configured to be positioned in separate first and second spaces, respectively. The pass-thru body also includes a body channel that extends therethrough. The passage section defines an opening to the body channel in the first space. The pass-thru connector assembly also includes a header housing that is configured to mate with an electrical connector. The header housing is attached to the passage section and covers the opening to the body channel. An electrical cable extends through an aperture of a cable seal and into and through the cable portion of the body channel. The cable seal engages the outer jacket of the electrical cable at a sealed interface. The electrical contact is coupled to the header housing and positioned for engaging a corresponding contact of the electrical connector.

Abstract: Pass-thru connector assembly includes a pass-thru body having a passage section and a loading section that are configured to be positioned in separate first and second spaces, respectively. The pass-thru body also includes a body channel that extends therethrough. The passage section defines an opening to the body channel in the first space. The pass-thru connector assembly also includes a header housing that is configured to mate with an electrical connector. The header housing is attached to the passage section and covers the opening to the body channel. An electrical cable extends through an aperture of a cable seal and into and through the cable portion of the body channel. The cable seal engages the outer jacket of the electrical cable at a sealed interface. The electrical contact is coupled to the header housing and positioned for engaging a corresponding contact of the electrical connector.

Abstract: An electrical connector includes a housing that defines a cavity at a mating end. A terminal retention (TR) block is mounted to the housing within the cavity. The TR block defines multiple channels configured to receive contacts therein. The channels include deflectable retention latches configured to engage the contacts to retain the contacts in the channels. A terminal position assurance (TPA) clip is mounted to a distal end of the TR block within the cavity of the housing. The TPA clip is configured to block deflection of the retention latches to lock the contacts in the channels. The TPA clip has slots that align with the channels of the TR block and receive distal tips of the contacts therethrough. The slots have tapered lead-ins configured to guide the distal tips of the contacts from the channels into the slots.

Abstract: A sealed header assembly includes a housing having a cover shroud portion, a mounting portion, and a wire holder portion. The sealed header assembly includes a wire cover removably mounted to the housing. A seal is held within the housing by a seal cap. The housing and wire cover include wire guidance features for providing a path for the wire to exit the housing.

Abstract: A wire tray includes tray walls defining a tray channel configured to receive corresponding wires of a wire bundle. A wire cradle extends from a corresponding tray wall. The wire cradle has a cradle channel open to the tray channel having a wire exit at a front of the wire cradle. The wire cradle has a pocket and a protrusion aligned with the pocket on an opposite side of the cradle channel. The wire is routed in the cradle channel around the protrusion into the pocket to form at least two bends in the wire between the tray channel and the wire exit. The wire cradle includes a retention cap extending into the cradle channel that captures the wire in the cradle channel.

Abstract: A wire tray configured to support and route wires of a wire bundle between electrical components includes tray walls defining a channel configured to receive corresponding wires of the wire bundle. The tray walls includes a first side wall, a second side wall opposite the first side wall and a bottom wall extending between the first and second side walls. A cover is hingedly coupled to the first side wall. The cover extends across a top of the channel between the first and second side walls. The cover has a primary latch latchably coupled to the second side wall. The cover has a secondary latch engaging the first side wall to secure the cover to the first side wall.

Abstract: A sealed header assembly includes a housing having a cover shroud portion, a mounting portion, and a wire holder portion. The sealed header assembly includes a wire cover removably mounted to the housing. A seal is held within the housing by a seal cap. The housing and wire cover include wire guidance features for providing a path for the wire to exit the housing.

Abstract: A wire tray includes tray walls defining a tray channel configured to receive corresponding wires of a wire bundle. A wire cradle extends from a corresponding tray wall. The wire cradle has a cradle channel open to the tray channel having a wire exit at a front of the wire cradle. The wire cradle has a pocket and a protrusion aligned with the pocket on an opposite side of the cradle channel. The wire is routed in the cradle channel around the protrusion into the pocket to form at least two bends in the wire between the tray channel and the wire exit The wire cradle includes a retention cap extending into the cradle channel that captures the wire in the cradle channel.

Abstract: A connector assembly for mounting to a panel includes a cap connector having a cap housing, a cap terminal block held in the cap housing and holding a plurality of cap terminals and a mounting clip coupled to the cap housing to secure the cap housing to the panel. The cap housing has an inner shroud, an inner flange surrounding the inner shroud and an outer flange extending outward from the inner flange. The inner flange has panel retention features extending therefrom. The inner shroud is loaded through an opening in the panel until the panel retention features engage the panel and temporarily secure the cap housing to the panel between the panel retention features and the outer flange. The mounting clip is coupled to the cap housing to secure the cap housing to the panel between the mounting clip and the outer flange.

Abstract: A wire tray configured to support and route wires of a wire bundle between electrical components includes tray walls defining a channel configured to receive corresponding wires of the wire bundle. The tray walls includes a first side wall, a second side wall opposite the first side wall and a bottom wall extending between the first and second side walls. A cover is hingedly coupled to the first side wall. The cover extends across a top of the channel between the first and second side walls. The cover has a primary latch latchably coupled to the second side wall. The cover has a secondary latch engaging the first side wall to secure the cover to the first side wall.

Abstract: A process of manufacturing a card comprising: (a) placing a circuit board within a plastic panel and a metal panel, the metal panel having a plurality of tabs with barbs thereon, the plastic panel having one or more cavities adapted for receiving the tabs; (b) inserting the tabs within the one or more cavities; and (c) transmitting energy to the plastic around the tab such that the plastic flows at least partially around the barbs; and a card made from the above process.

Abstract: A modular jack connector assembly comprising: (a) a dielectric housing having a front and rear orientation and defining at least one receptacle adapted for receiving a mating plug; and (b) a plurality of contacts disposed in the housing, each contact being secured to the housing at a rear portion thereof, each contact extending forward from the rear portion to a free end such that a portion of the contact electrically connects with a mating plug when the mating plug is received within the receptacle.

Abstract: A process of manufacturing a card comprising: (a) placing a circuit board within a plastic panel and a metal panel, the metal panel having a plurality of tabs with barbs thereon, the plastic panel having one or more cavities adapted for receiving the tabs; (b) inserting the tabs within the one or more cavities; and (c) transmitting energy to the plastic around the tab such that the plastic flows at least partially around the barbs; and a card made from the above process.