Abstract: A connector assembly includes an inlet assembly and a plug assembly. The inlet assembly has a first electrical contact member. A plug assembly has a second electrical contact member. The plug assembly is movable to an inserted engaged position with the inlet assembly such that the first and second electrical contact members engage one another, and a retracted position such the plug assembly is retracted from the inlet assembly. The connector assembly includes an active locking device for retaining the plug assembly in the inlet assembly. A secondary locking device temporarily retains the plug assembly in the inlet assembly prior to activation of the active locking device.

Abstract: A heat conductor for use with an inverter in an electric or hybrid-electric vehicle, the inverter including a direct current link capacitor having multiple film capacitors configured in a stack to form a substantially polygonal prism. Each film capacitor has orthotropic characteristics. The heat conductor has a first substantially planar member configured to contact a first side of the polygonal prism formed by one of the film capacitors, and a second substantially planar member configured to contact a second side of the polygonal prism opposite the first side of the rectangular prism, the second side of the rectangular prism formed by another one of the film capacitors. The first and second planar member are thermally conductive for dissipating heat generated by the film capacitors, are attached by an interconnect, and have sufficient rigidity to confine expansion of the film capacitors across the thicknesses thereof.

Abstract: An electromagnetic device arrangement includes a transformer assembly having a core, windings, and a housing disposed around at least a portion of the core and windings. An enclosure at least partially encloses the transformer assembly. The transformer assembly is mounted to a first portion of the enclosure such that heat is transferred from the transformer assembly to the first portion of the enclosure. A second portion of the enclosure has an extension extending therefrom such that the extension is placed in thermal contact with the transformer assembly to transfer heat from the transformer assembly to the extension.

Abstract: A charger assembly is provided with a housing having a cavity with an opening. A cover is fastened to the housing for covering the opening. A heat transfer duct is mounted to the cover with an inlet end and an outlet end each extending through the cover. A plurality of heat sinks is mounted to the cover in contact with the heat transfer duct. A plurality of circuit board assemblies are each mounted to the cover in contact with the plurality of heat sinks.

Abstract: An electrical connector includes a connector body and at least two electric terminals. A fuse is supported on the connector body and at least one of the electric terminals is supported by the fuse.

Abstract: An electrical terminal includes a contact portion having a contact portion base with at least three sides forming a generally polyhedron structure. The contact portion has a plurality of contact arms, with at least one of the contact arms extending from at least some of the sides. The contact arms are arranged to receive a mating electrical component such that the mating electrical component contacts at least one of the contact arms associated with each side. A spring arrangement includes a plurality of spring arms, each having a spring head in contact with at least one respective contact arm near a distal end of the contact portion for applying a force thereto in a direction toward a central axis of the terminal, thereby increasing the retention force applied to the mating electrical component.

Abstract: An electrical terminal includes a contact portion having a contact portion base with at least three sides forming a generally polyhedron structure. At least one contact arm extends from at least some of the sides, and are arranged to receive a mating electrical component. A spring arrangement includes a plurality of spring arms extending from a spring base. Each of the spring arms includes a spring head in contact with at least one respective contact arm near a distal end of the contact portion for applying a force thereto in a direction toward a central axis of the terminal. The spring base includes a support structure configured to support the mating electrical component.

Abstract: A method of assembling an electrical terminal having a base and a spring member. The base is provided with a plurality of base beams. The spring member is provided with a plurality of spring beams. The spring member defines an axis such that the plurality of spring beams is spaced radially apart from the axis. The spring beams deflected radially outwardly. The base is inserted in the spring member to position the base beams adjacent to the spring beams. The spring beams are released such that the spring beams retract radially inwardly against the base beams.

Abstract: An electrical terminal assembly has a base and a spring member. The base defines an axis and including a plurality of base beams deflectable in a radial direction relative to the axis. The spring member has a main portion disposed over the base. The spring member includes a plurality of spring beams extending from a front end of the main portion. The spring beams bias the base beams radially inwardly towards the axis. The main portion is made from a folded blank having a first edge that is permanently secured to a second edge such that the edges cannot be pulled apart from one another.

Abstract: A coldplate for use with an inverter in an electric vehicle (EV) or a hybrid-electric vehicle (HEV). The inverter includes a direct current (DC) link capacitor comprising multiple film capacitors configured in a stack. The coldplate includes a first portion configured for attachment to at least one electronic component, the first portion having a perimeter and for dissipating heat generated by the electronic component. The coldplate includes a second portion oriented along the perimeter of the first portion and forming a conduit, the conduit having a chamber extending from the perimeter of the first portion and between two of the plurality of film capacitors of the DC link capacitor. The conduit has an inlet and an outlet to facilitate circulation of a coolant through the chamber of the conduit for dissipating heat generated by the DC link capacitor.

Abstract: A receptacle assembly for a vehicle charging inlet is provided having a base with apertures formed through, an external receptacle extending from the base in a first direction for receiving a charging cable connector, and an internal receptacle extending from the base in a second direction, opposite the first direction, for receiving a plurality of wires from a wire harness. The internal receptacle defines an internal cavity having at least one terminal receptacle formed about one of the apertures and at least one fuse receptacle. The internal receptacle includes wire channels for routing a wire having an inline fuse from the terminal receptacle to the fuse receptacle and from the fuse receptacle to a wire outlet. The inline fuse is received by the fuse receptacle.

Abstract: A connector having an optimized tip is disclosed. The tip may be optimized to facilitate insulating the connector and/or providing a low friction surface to facilitate insertion. The tip may be optimized with a non-conducting and/or low friction end cap configured to be positioned over the tip.

Abstract: An electrical connector includes an electrical terminal and a housing having a front end and a back end with an opening configured to receive the electrical terminal therethrough. The housing includes a first lock system configured to allow insertion of the electrical terminal into the housing and prohibit removal of the electrical terminal from the housing. The housing is configured such that the first lock system is accessible from the front of the housing to release the electrical terminal from the first lock system. A second lock system is configured for insertion into the housing to prohibit removal of the electrical terminal from the housing independently from the first lock system.

Abstract: A housing or other enclosure used to facilitate fluid cooling of a circuitry of a battery charger, such as but not limited to a battery charger of the type used to facilitate charging a high voltage vehicle battery with AC energy provided from a utility power grid. The housing may include a groove and seal arrangement operable to seal a fluid coolant chamber used to cool the circuitry from leaking fluid during use.

Abstract: An electrical terminal assembly includes a base having a body including a first end and a second end. First and second opposed base beams extend from the first end of the body in a first direction. A spring clamp has a clamp base and first and second opposed spring beams extending from the clamp base in the first direction and disposed over the first and second base beams biasing the first and second base beams toward one another. The body of the base is configured to permit the spring clamp to be inserted onto the base in a second direction normal the first direction.

Abstract: An electrical assembly includes a base having a body including a first end and a second end. First and second opposed base beams extend from the first end of the body in a first direction. The assembly further includes a spring clamp having a clamp base and first and second opposed spring beams extending from the clamp base in the first direction and disposed over the first and second base beams biasing the first and second base beams towards one another. The spring clamp is assembled onto the base by moving the spring clamp along the first direction onto the base. A locking feature is integrally formed in the base and the spring clamp preventing the removal of the spring clamp from the base along a second direction opposite the first direction. The locking feature also prevents movement of the spring clamp relative to the base in a lateral direction normal to the first direction.

Abstract: A housing or other enclosure used to facilitate fluid cooling of a circuitry of a battery charger, such as but not limited to a battery charger of the type used to facilitate charging a high voltage vehicle battery with AC energy provided from a utility power grid. The housing may include a groove and seal arrangement operable to seal a fluid coolant chamber used to cool the circuitry from leaking fluid during use.

Abstract: An electromagnetic interference shield assembly is provided with a first housing formed of a first conductive polymer. The first housing has a cavity sized to receive an electronic sub-assembly therein. A second housing is formed of a second conductive polymer. The second housing has a cavity sized to receive the first housing therein.

Abstract: An arbor operably configured to facilitate positioning an element within an open end of a terminal or other device. The arbor may be operable to position the element relative to a groove or another type of difficult to reach area interior the open end. The arbor may include an assembly operable to move the element through the open end to a desired position where the element is freed to be positioned within the groove or other portion of the open end. Optionally, in the event the element is resilient, the resiliency of the element may be relied upon to cause the element to free itself from the arbor using expansion and at the same time secure itself within the groove or other portion of the open end.

Abstract: A retainer is provided to retain an electrically conductive terminal within a receptacle. The retainer has a longitudinal body sized to be received by the receptacle and engage the terminal to retain the terminal within the receptacle. The body has an aperture formed therethrough sized to receive a pin through the aperture to contact the terminal. A shoulder extends transversely from the body to engage a distal end of the receptacle and position the body relative to the receptacle. A fastener extends longitudinally from the shoulder and is spaced apart from the body to fasten the retainer to the receptacle. A receptacle assembly is provided with a barb formed externally on a body. An electrically conductive terminal is received within the receptacle assembly. A retainer is provided on an opening of the receptacle to retain the terminal therein in engagement with the barb to fasten the retainer to the body.