Abstract: A liquid-cooled charging system for a vehicle is configured to dissipate heat generated during charging (including fast-charging) of an electrically-powered vehicle. The liquid-cooled charging system includes a charging assembly having an interface assembly configured to support a charging plug of a charging station and an energy transfer assembly configured to electrically couple the charging station to the battery of the vehicle during charging. Components of the charging assembly and energy transfer assembly also define a fluid circuit. A coolant system of the liquid-cooled charging system is fluidly connected to the fluid circuit, allowing coolant to flow through the fluid circuit to dissipate heat from the charging assembly components during charging of the vehicle.

Abstract: A connector assembly includes a first connector and a second connector. The first connector includes a first locking mechanism. The second connector includes a housing and a seal shroud. The housing includes a seal positioned along an exterior surface of the housing. The seal shroud surrounds the housing and includes a second locking mechanism configured to mate with the first locking mechanism. The seal shroud is movable between a first position and a second position while the first locking mechanism is mated with the second locking mechanism. The seal shroud at least partially covers the seal of the housing in the first position and the seal shroud exposes the seal to an interior facing surface of the first connector in the second position.

Abstract: A connector assembly includes a first connector and a second connector. The first connector includes a first locking mechanism. The second connector includes a housing and a seal shroud. The housing includes a seal positioned along an exterior surface of the housing. The seal shroud surrounds the housing and includes a second locking mechanism configured to mate with the first locking mechanism. The seal shroud is movable between a first position and a second position while the first locking mechanism is mated with the second locking mechanism. The seal shroud at least partially covers the seal of the housing in the first position and the seal shroud exposes the seal to an interior facing surface of the first connector in the second position.

Abstract: An assembly includes a plug at least partially disposed in a cavity of a connector at a front end of the connector. The plug ultrasonically welded to the connector in a configuration. The plug includes an inset portion and a recess formed within the inset portion. The inset portion extends axially into a body of the plug. The recess has a first closed surface forming an outer surface and configured to engage with a tool for aligning the plug with the cavity. The plug encloses the cavity with a second closed surface, such that the cavity is free from receiving a terminal or an electrical wire in the configuration.

Abstract: An arc suppression pre-charge circuit includes a source for providing energy to a load and a main contactor selectively closed to provide energy from the source to the load, wherein the main contactor provides an alternate current path from the source to the load and bypasses a pre-charge branch of the circuit when the main contactor is closed. The pre-charge branch includes a voltage-controlled resistor and a control circuit configured to control a resistance of the voltage-controlled resistor.

Abstract: A liquid-cooled charging system for a vehicle is configured to dissipate heat generated during charging (including fast-charging) of an electrically-powered vehicle. The liquid-cooled charging system includes a charging assembly having an interface assembly configured to support a charging plug of a charging station and an energy transfer assembly configured to electrically couple the charging station to the battery of the vehicle during charging. Components of the charging assembly and energy transfer assembly also define a fluid circuit. A coolant system of the liquid-cooled charging system is fluidly connected to the fluid circuit, allowing coolant to flow through the fluid circuit to dissipate heat from the charging assembly components during charging of the vehicle.

Abstract: A grommet assembly includes a wire harness and a grommet including a hollow channel configured to receive the wire harness therein. At least one rib extends inwards from and substantially annularly about the interior surface of the hollow channel. At least one port configured to fluidly couple the hollow channel with an exterior environment is defined by the grommet. Material is injected into the channel through the port to secure the grommet relative to the wire harness. The material injected into the channel flows through interstices located between adjacent wires that define the wire harness so as to encapsulate the wires. The injected material also flows into other voids and openings located within the hollow channel. Upon setting, the injected material is configured to prevent movement of the grommet relative to the wire harness and to prevent the passage of contaminants through the grommet assembly.

Abstract: A liquid-cooled charging system for a vehicle is configured to dissipate heat generated during charging (including fast-charging) of an electrically-powered vehicle. The liquid-cooled charging system includes a charging assembly having an interface assembly configured to support a charging plug of a charging station and an energy transfer assembly configured to electrically couple the charging station to the battery of the vehicle during charging. Components of the charging assembly and energy transfer assembly also define a fluid circuit. A coolant system of the liquid-cooled charging system is fluidly connected to the fluid circuit, allowing coolant to flow through the fluid circuit to dissipate heat from the charging assembly components during charging of the vehicle.

Abstract: An assembly includes a plug at least partially disposed in a cavity of a connector at a front end of the connector. The plug ultrasonically welded to the connector in a configuration. The plug includes an inset portion and a recess formed within the inset portion. The inset portion extends axially into a body of the plug. The recess has a first closed surface forming an outer surface and configured to engage with a tool for aligning the plug with the cavity. The plug encloses the cavity with a second closed surface, such that the cavity is free from receiving a terminal or an electrical wire in the configuration.

Abstract: An electrical connector assembly includes a connector defining a front end and an opposing rear end. The connector includes a cavity defined therein, the cavity extending from the front end to the rear end and configured to receive at least one of a terminal or an electrical wire therein. The assembly further includes a plug at least partially disposed in the cavity and ultrasonically welded to the connector.

Abstract: A grommet includes a body portion defining a first aperture and a second aperture. A hollow channel extends between the first aperture and the second aperture. The channel is defined by an interior surface of the body portion. One or more engagement structures are defined by the interior surface of the grommet body portion, and are configured to engage one or more corresponding engagement structures provided about an exterior surface of a mounting structure engaged about and elongated member that is positioned within the hollow channel of the grommet.

Abstract: A connector assembly for a vehicle charging system includes a first housing defining a charge port of the vehicle charging system and a second housing coupled to the first housing. The second housing is configured to receive an electrical wire including a power terminal therein. The connector assembly further includes a flexible tube coupled to the second housing and a phase change material disposed therein. The phase change material is configured to surround at least a portion of the electrical wire. The phase change material is configured to store heat energy from at least one of the electrical wire or the power terminal. The connector assembly further includes a cover coupled to the second housing for facilitating the injection of the phase change material into the flexible tube.

Abstract: Some embodiments are directed to an apparatus for detecting and suppressing DC electric arcs at a component, and are particularly adapted for vehicle wiring harnesses. The apparatus can include a detector circuit electrically connected to input and output terminals so as to be electrically connected in parallel to the component, the detector circuit being configured to detect a significant voltage spike across the component upon the component actuating between open and closed positions. The detector circuit can also be configured to transmit a control signal upon detecting the significant voltage spike. The detector circuit can include multiple circuit elements, enabling both the detection of the significant voltage spike and the transmission of the control signal, that are directly electrically connected to each other. A switching circuit conducts electricity from the power source side of the component to the load side of the component upon receipt of the control signal.

Abstract: A power distribution box assembly can include a power distribution box housing, a fuse block, and a plurality of eyelet terminals. The fuse block can include a stamped busbar assembly, a plurality of studs, and a housing. The stamped busbar assembly can include a main power supply portion, a plurality of fuse elements, and a plurality of terminal connecting portions coupled to the plurality of fuse elements. Each of the plurality of terminal connecting portions can: (i) extend from its respective fuse element in a terminal direction that is orthogonal to both directions that the main power supply portion and the fuse elements extend.

Abstract: A cantilever system comprises a snapping body configured to ensure a persistent contact with a receiving body. The snapping body includes a supporting body extending from the snapping body, a step extending from the supporting body, the step configured to lock the snapping body and the receiving body in an engaged position, and a constant contact protrusion extending into the step, wherein the constant contact protrusion is configured to maintain engagement of the snapping body and the receiving body.

Abstract: A cantilever system comprises a snapping body configured to ensure a persistent contact with a receiving body. The snapping body includes a supporting body extending from the snapping body, a step extending from the supporting body, the step configured to lock the snapping body and the receiving body in an engaged position, and a constant contact protrusion extending into the step, wherein the constant contact protrusion is configured to maintain engagement of the snapping body and the receiving body.

Abstract: A method for molding a component. The method includes: providing a mold tool having a sprue and a cavity; heating the mold tool to a predetermined mold temperature; placing the heated mold tool into a pressure vessel; pouring a material through the sprue into the cavity of the heated mold tool; prior to complete polymerization of the material in the cavity of the heated mold tool, elevating an internal pressure of the pressure vessel to a predetermined pressure to apply a force to the material in the heated mold tool; completely polymerizing the material in the cavity in heated mold tool to form the molded component; and removing the molded component from the mold tool.

Abstract: A power distribution box assembly can include a power distribution box housing, a fuse block, and a plurality of eyelet terminals. The fuse block can include a stamped busbar assembly, a plurality of studs, and a housing. The stamped busbar assembly can include a main power supply portion, a plurality of fuse elements, and a plurality of terminal connecting portions coupled to the plurality of fuse elements. Each of the plurality of terminal connecting portions can: (i) extend from its respective fuse element in a terminal direction that is orthogonal to both directions that the main power supply portion and the fuse elements extend.

Abstract: A self-aligning busbar assembly includes a housing, a busbar having a first terminal connecting end, a second terminal connecting end, and a jog portion disposed therebetween, and a front holder coupled to the housing and the busbar. The front holder includes an inner wall defining a busbar receiving aperture to receive at least a portion of the busbar, and at least one flexible tab extending inwardly from the inner wall into the busbar receiving aperture. The at least one flexible tab is configured to bias and center the at least a portion of the busbar within the busbar receiving aperture. At least one clearance is defined in the busbar receiving aperture between the inner wall and the busbar and is configured to enable at least one of the first and second terminal connecting ends to move to account for tolerances and/or variances during installation of the busbar assembly.

Abstract: An electrical connector assembly comprises a housing, a terminal position assurance (TPA) member, and a slide clip. The housing can comprise (i) at least one terminal insertion cavity for receiving an electrical terminal, (ii) a primary locking member that engages with the electrical terminal to retain the electrical terminal therein, (iii) a slide clip receiver, and (iv) a plurality of latching members. The TPA member can couple with the housing. The slide clip can couple with the housing via the slide clip receiver. In an assembled condition, the electrical terminal can retained within the at least one terminal insertion cavity by the primary locking member, the TPA member can inhibit movement of the primary locking member, and the slide clip can be coupled with the slide clip receiver such that the TPA member is constrained between the housing and the slide clip to inhibit disengagement of the TPA member.