Abstract: A touch safe right angle power connector includes a header assembly that includes a conductive pin, an inner shroud that surrounds the pin, and an outer shroud that surrounds the inner shroud. The inner shroud has slots therethrough. The power connector includes a power terminal connector having a plug housing that has a cavity and an insert assembly that is received in the cavity. The insert assembly has a terminal body configured to be terminated to an end of a conductor of a power cable and is electrically connected to the pin of the header assembly. The insert assembly has a dielectric insert that holds the terminal body. The insert assembly has a shield that surrounds the dielectric insert and provides shielding for the terminal body. The plug housing has optional ribs which are received in corresponding slots to orient the power terminal with respect to the header assembly.

Abstract: A power terminal connector includes a multi-layered buss bar that has a first mounting portion, a second mounting portion and a flexible section between the first and second mounting portions. The flexible section has multiple layers of metal sheets in a stacked configuration. A first terminal assembly is coupled to the first mounting portion and a second terminal assembly is coupled to the second mounting portion. The first and second terminal assemblies are coupled to corresponding pins of corresponding power terminals. The multi-layered buss bar is configured to electrically interconnect the power terminals coupled to the first and second terminal assemblies.

Abstract: A power terminal connector includes a flexible conductor and first and second terminals. The terminals have terminal bodies each defining a receptacle and each being welded to a corresponding mounting portion of the flexible conductor to mechanically and electrically connect the terminals to the flexible conductor. The terminals have terminal body defining a receptacle and being welded to a corresponding mounting portion of the cable conductor to mechanically and electrically connect the terminals to the cable conductor. Each terminal has a contact spring received in the receptacle that is electrically connected to the terminal body. The contact spring has spring beams being configured to engage a power terminal plugged into the receptacle. The flexible conductor is configured to electrically interconnect the first and second power terminals. The cable conductor is configured to electrically interconnect the power terminal.

Abstract: A power terminal connector having a terminal body that has a socket configured to receive, and be electrically connected to, a pin of a power terminal. A spring clip is coupled to the terminal body. The spring clip is movable between a locking position and a clearance position. The spring clip is configured to engage the pin of the power terminal in the locking position to secure the power terminal connector to the power terminal. The spring clip is configured to be disengaged from the pin of the power terminal in the clearance position. A cap is coupled to the terminal body. The cap is coupled to the spring clip to move the spring clip between the locking position and the clearance position as the cap is actuated.

Abstract: A connector assembly includes an electrical connector having a housing that includes a mating end with an exterior profile being generally D-shaped. The housing has a pair of corners. The electrical connector further includes an insert held within the housing having a mating end. A high voltage interlock (HVIL) conductor is located in at least one of the corners of the housing. The HVIL conductor is configured to be electrically connected to a corresponding HVIL conductor of a second electrical connector when the electrical connector and the second electrical connector are coupled together. An interfacial seal is positioned forward of a locking finger of the electrical connector. The HVIL conductors are either in-line or shunted. The HVIL conductors may extend through the insert.

Abstract: A battery pack includes a plurality of battery cells each having positive and negative cell terminals and a carrier mounted over and spanning across the plurality of battery cells. The carrier has trays with openings therethrough exposing the positive and negative cell terminals. A plurality of buss bars are received in corresponding trays. The buss bars each have a positive plate laser welded to the positive cell terminal of a corresponding battery cell through the corresponding opening and a negative plate laser welded to the negative cell terminal of a different battery cell through the corresponding opening. The buss bars may be bimetal buss bars.

Abstract: A bimetal buss bar assembly includes a positive battery cell terminal having a flat pad, a negative battery cell terminal having a flat pad, and a buss bar having a negative end and a positive end. The buss bar is attached to the positive battery cell terminal at the positive end and attached to the negative battery cell terminal at the negative end. At least one of the positive battery cell terminal, negative battery cell terminal, and buss bar have a bimetal interface.

Abstract: A battery connector system includes a tray assembly configured to be mounted to a battery module made from a plurality of battery cells. The tray assembly has a tray and a plurality of busbars held by the tray. The tray has a tray connector defining a mating interface being configured to mate with an electrical connector. The electrical connector may be either a wire harness connector or a circuit board connector. The busbars are coupled to the tray and have plates being configured to be electrically connected to corresponding cell tabs of the battery cells. The busbars have fuse terminals positioned in the tray connector. A plurality of fuses are coupled to the fuse terminals. The fuses may be serviceable fuses or resettable fuses. The fuses are connected between the plates of the busbars and the electrical connector.

Abstract: A battery module includes battery cells arranged side-by-side in a stacked configuration, the battery cells having positive and negative cell terminals. Buss bars are electrically connected to corresponding cell terminals to electrically connect adjacent battery cells. A battery cover coupled to the battery cells. A module controller is held by the battery cover and is electrically connected to the buss bars to monitor a voltage of the corresponding buss bar.

Abstract: A battery module includes first and second battery cells having positive and negative cell terminals arranged adjacent one another. A buss bar connects the positive cell terminal of the first battery cell to the negative cell terminal of the second battery cell. The connection to the positive cell terminal is a threaded connection. The connection to the negative cell terminal is a quick connect connection.

Abstract: A battery connector system includes a tray assembly configured to be mounted to a battery module made from a plurality of battery cells. The tray assembly includes a tray and a plurality of busbars held by the tray. The tray having a base with channels extending through the base. The channels receive cell tabs from corresponding battery cells. The tray has a tray connector configured to mate with an electrical connector. The busbars are aligned with corresponding channels and configured to be electrically connected to corresponding cell tabs. The busbars are coupled to the tray. The busbars have pins positioned in the tray connector for direct connection with the electrical connector.

Abstract: A power terminal connector having a terminal body that has a socket configured to receive, and be electrically connected to, a pin of a power terminal. A spring clip is coupled to the terminal body. The spring clip is movable between a locking position and a clearance position. The spring clip is configured to engage the pin of the power terminal in the locking position to secure the power terminal connector to the power terminal. The spring clip is configured to be disengaged from the pin of the power terminal in the clearance position. A cap is coupled to the terminal body. The cap is coupled to the spring clip to move the spring clip between the locking position and the clearance position as the cap is actuated.

Abstract: A touch safe right angle power connector includes a header assembly that includes a conductive pin, an inner shroud that surrounds the pin, and an outer shroud that surrounds the inner shroud. The inner shroud has slots therethrough. The power connector includes a power terminal connector having a plug housing that has a cavity and an insert assembly that is received in the cavity. The insert assembly has a terminal body configured to be terminated to an end of a conductor of a power cable and is electrically connected to the pin of the header assembly. The insert assembly has a dielectric insert that holds the terminal body. The insert assembly has a shield that surrounds the dielectric insert and provides shielding for the terminal body. The plug housing has optional ribs which are received in corresponding slots to orient the power terminal with respect to the header assembly.

Abstract: A power terminal connector includes a multi-layered buss bar that has a first mounting portion, a second mounting portion and a flexible section between the first and second mounting portions. The flexible section has multiple layers of metal sheets in a stacked configuration. A first terminal assembly is coupled to the first mounting portion and a second terminal assembly is coupled to the second mounting portion. The first and second terminal assemblies are coupled to corresponding pins of corresponding power terminals. The multi-layered buss bar is configured to electrically interconnect the power terminals coupled to the first and second terminal assemblies.

Abstract: A connector assembly includes an electrical connector having a housing that includes a mating end with an exterior profile being generally D-shaped. The housing has a pair of corners. The electrical connector further includes an insert held within the housing having a mating end. A high voltage interlock (HVIL) conductor is located in at least one of the corners of the housing. The HVIL conductor is configured to be electrically connected to a corresponding HVIL conductor of a second electrical connector when the electrical connector and the second electrical connector are coupled together. An interfacial seal is positioned forward of a locking finger of the electrical connector. The HVIL conductors are either in-line or shunted. The HVIL conductors may extend through the insert.

Abstract: A conductive terminal is a feasible of making a reliable and cost effective electrical connection between the aluminum conductor and any metal conductor. The terminal includes a blank, a three dimensional structure formed from the blank, and multiple seams and a slit being sealed by a metal filler. It has a transition opening to allow melted metal to flow in and make a metallic bond between terminal and the aluminum conductor. The folded two arms with the metallic seals provide sealing surface for adhesive shrinkable tube. An assembly of terminal and the aluminum conductor includes a compressed the aluminum conductor within a terminal hollow tube, a metallic bond and coating, an metallic seals at a slit and multiple seams. The shrinkable adhesive tube seals the connection of the aluminum conductor and conductive terminal from environmental fluids at multiple locations.

Abstract: System, method and computer program product for estimating the cost of a product and/or service. The product and/or service comprises a multiplicity of components. One or more first components with no cost dependencies are determined and assigned to a first tier. One or more second components whose costs depend on the costs of the one or more first components are determined and assigned to a second tier. One or more third components whose costs depend on the one or more second components are determined and assigned to a third tier. A determination is made if any of the one or more third components were assigned to said second tier, and if so, such one or more third components are removed from the second tier. One or more fourth components whose costs depend on the one or more third components are determined and assigned to a fourth tier.

Abstract: The present invention provides an electrical power system comprising a plurality of battery modules in series connection between adjacent battery modules, wherein each of the battery modules comprises a positive male terminal, a negative male terminal, and a socket corresponding to each of the positive male terminals and the negative male terminals. The connectors connecting the adjacent battery modules include a sequence tab that provides an irreversible engagement sequence of the connectors into the sockets of the adjacent battery modules. The irreversible engagement sequence positions an insulating portion of the connectors housing on each positive male terminal of the battery modules that are in series connection in order to isolate the positive male terminals from human contact. The present invention also provides a female terminal including a canted coil spring positioned within a stamped groove that may be housed within the above-described connectors.

Abstract: The present invention provides a battery module system including a plurality of battery modules in a series electrical connection through a specified sequence, each battery module having a male connector and a female connector, the female connector of each battery module in electrical engagement into the male connector of an adjacent battery module, wherein the male connector and female connector are positioned along the sidewall of each battery module and have insulating structures that protect handlers of the battery modules from high voltage electrocution. The present invention also provides a battery module system in which the male and female connectors are attached to a top surface of each battery module.

Abstract: System, method and computer program product for estimating the cost of a product and/or service. The product and/or service comprises a multiplicity of components. One or more first components with no cost dependencies are determined and assigned to a first tier. One or more second components whose costs depend on the costs of the one or more first components are determined and assigned to a second tier. One or more third components whose costs depend on the one or more second components are determined and assigned to a third tier. A determination is made if any of the one or more third components were assigned to said second tier, and if so, such one or more third components are removed from the second tier. One or more fourth components whose costs depend on the one or more third components are determined and assigned to a fourth tier.