Abstract: A power connector includes a housing having terminal channels holding charging terminals for mating with a charging connector. Power conductors are terminated to cable connectors of the corresponding charging terminals. The power connector includes a cooling module thermally coupled to the charging terminals. The cooling module includes a carrier having pockets. The cooling module includes phase change elements received in the corresponding pockets and held relative to each other by the carrier. The phase change elements are thermally coupled to the corresponding cable connectors to lower operating temperatures of the charging terminals during charging.

Abstract: A charging inlet assembly includes a charging inlet housing having terminal channels and cable channels. The charging inlet assembly includes charging terminals including a first charging terminal and a second charging terminal received in the corresponding terminal channels. The charging inlet assembly includes first and second cable assemblies received in the corresponding cable channels. The first cable assembly includes a first DC cable and a first AC cable both electrically connected to the first charging terminal. The second cable assembly includes a second DC cable and a second AC cable both electrically connected to the second charging terminal.

Abstract: A charging health monitoring device for monitoring a health of a charging component for an electric vehicle includes a testing sensor held by a charging terminal and including a testing probe interfacing with a mating charging terminal. The charging health monitoring device includes a control circuit for controlling a charging operation and a testing operation. The control circuit measures a terminal voltage of the charging terminal and a sensor voltage of the testing sensor to determine resistance of the charging terminal and provide a test signal. The control circuit includes an electrically isolated switch receiving the test signal and generating a control signal based on the test signal for controlling a charging operation of the charging component. The control circuit performs the testing operation simultaneously with the charging operation.

Abstract: A charging inlet assembly for an electric vehicle includes a charging inlet housing, charging terminals held in the charging inlet housing, and a temperature sensor plugged into the charging inlet housing for monitoring temperature of at least one of the charging terminals.

Abstract: A power harness includes a cable having a ring insert received in an opening electrically connected to the cable body and having a cable seal sealed to the flat cable. The power harness includes a housing having a chamber with a cable slot and a bore passing through a hub. The power harness includes a threaded bolt received in the hub passing through the ring insert to threadably couple to a mating harness. The threaded bolt includes an insulating cover on the head and an insulating cap extending from the threaded shaft. The threaded bolt includes a bolt seal sealed to the housing. The power harness includes a contact ring received in the hub aligned with the ring insert with an opening that receives the threaded bolt. A first end engages and is electrically connected to the ring insert and a second end is electrically connected to the mating harness.

Abstract: A DC terminal module for a charging inlet assembly of an electric vehicle includes a housing having a housing base mounted to a charging inlet housing. The housing includes a cable mount at a bottom that receives a DC cable assembly from the bottom. The DC terminal module includes a DC terminal assembly received in a terminal chamber with a pin terminal extending into a receptacle of the charging inlet assembly for mating with the charging connector. The DC terminal assembly includes a terminal busbar extending from the pin terminal to the cable mount at the bottom of the DC housing for electrical connection to the DC cable assembly at the bottom of the DC housing.

Abstract: A resistor module includes a resistor module housing having an inner cavity. A proximity contact and a ground contact are received in the inner cavity and held by the resistor module housing. A proximity wire, electrically connected to a proximity terminal of the charging inlet assembly, is electrically connected to the proximity contact. A ground wire, electrically connected to a ground terminal of the charging inlet assembly, is electrically connected to the ground contact. A resistor element is received in the inner cavity and coupled to mating ends of the proximity and ground contacts. The resistor element is electrically connected to the proximity terminal through the proximity wire and the proximity contact and is electrically connected to the ground terminal through the ground wire and the ground contact.

Abstract: A wire harness for a charging inlet of a vehicle includes first and second high voltage wires having first and second conductors. An inline disconnect electrically connects the first and second conductors and is configured to allow the conductors to be disconnected. The inline disconnect includes a housing having a central cavity, a first chamber at a first end that receives the first high voltage wire, and a second chamber open to the central cavity at a second end that receives the second high voltage wire. First and second disconnect contacts terminated to the conductors are received in the central cavity. A connecting element couples the first and second disconnect contacts and is removable from the disconnect contacts to allow disconnection of the first and second disconnect contacts to electrically separate the first and second high voltage wires.

Abstract: A terminal assembly for a charging inlet assembly includes a terminal cable having a conductor. The terminal assembly includes a terminal having a pin at a mating end and a terminating end opposite the mating end terminated to the conductor at an end of the terminal cable. The terminal assembly includes a terminal cover having a cover body including a bore that receives the terminating end of the terminal and the end of the terminal cable. The terminal cover includes a latch configured to secure the terminal and the terminal cable to a housing of the charging inlet assembly. The terminal cover includes a terminal cover seal configured to be sealed to the housing of the charging inlet assembly.

Abstract: A charging inlet assembly includes a housing extending between a front and a rear. The housing has a DC section including DC terminal channels that are configured to receive DC terminals. The housing has an AC section including an AC module chamber. The DC section is configured for mating with a DC charging connector at the front. The AC section is configured for mating with an AC charging connector at the front. The charging inlet assembly includes an AC charging module removably received in the AC module chamber. The AC charging module includes an AC insert extending between an insert front and an insert rear. The AC insert includes AC terminal channels between the insert front and the insert rear. The AC charging module include AC terminals received in the AC terminal channels. The AC terminals are terminated to ends of AC cables extending from the insert rear. The AC terminals and the AC cables are removable from the housing with the AC insert.

Abstract: A charging inlet assembly for an electric vehicle includes a charging inlet housing having a chamber at the rear and a power connector at a front for receiving a charging connector. The power connector includes terminal channels. The charging inlet assembly includes charging terminals each having a mating pin and a terminating end. The charging inlet assembly includes a terminal position assurance device coupled to the charging inlet housing having a terminal locating plate located in the chamber to interface with the terminating ends of the charging terminals. The terminal position assurance device includes an actuator at an exterior of the charging inlet housing to operate the terminal position assurance device from the exterior of the charging inlet housing.

Abstract: A resistor module includes a resistor module housing having an inner cavity. A proximity contact and a ground contact are received in the inner cavity and held by the resistor module housing. A proximity wire, electrically connected to a proximity terminal of the charging inlet assembly, is electrically connected to the proximity contact. A ground wire, electrically connected to a ground terminal of the charging inlet assembly, is electrically connected to the ground contact. A resistor element is received in the inner cavity and coupled to mating ends of the proximity and ground contacts. The resistor element is electrically connected to the proximity terminal through the proximity wire and the proximity contact and is electrically connected to the ground terminal through the ground wire and the ground contact.

Abstract: A charging inlet assembly includes a housing extending between a front and a rear having a DC section configured for mating with a DC charging connector and an AC section configured for mating with an AC charging connector. The charging inlet assembly includes an AC charging module coupled to the rear of the housing at the AC section having an AC terminal holder holding AC terminals. The AC charging module is removable from the housing wherein the AC terminals are removed from the housing with the AC terminal holder. A DC charging module is coupled to the rear of the housing at the DC section having a DC terminal holder holding DC terminals. The DC charging module is removable from the housing wherein the DC terminals are removed from the housing with the DC terminal holder.

Abstract: An electrical connector assembly includes a housing defining a front opening for receiving a mating connector in a mating direction, an electrical terminal arranged within an interior of the housing, and a terminal position assurance (TPA) device received within a rear opening of the housing in an installation direction. The TPA device includes a body defining a central opening for receiving a cable to be attached to the terminal, and an elastic element defined on a front end of the body. The elastic element includes a contact surface protruding from the front end of the body for engaging with the terminal in an installation direction of the TPA device. The contact surface engages with the terminal before the TPA device reaches an installed position within the housing in the installation direction.

Abstract: A wire harness for a charging inlet of a vehicle includes first and second high voltage wires having first and second conductors. An inline disconnect electrically connects the first and second conductors and is configured to allow the conductors to be disconnected. The inline disconnect includes a housing having a central cavity, a first chamber at a first end that receives the first high voltage wire, and a second chamber open to the central cavity at a second end that receives the second high voltage wire. First and second disconnect contacts terminated to the conductors are received in the central cavity. A connecting element couples the first and second disconnect contacts and is removable from the disconnect contacts to allow disconnection of the first and second disconnect contacts to electrically separate the first and second high voltage wires.

Abstract: A charging inlet assembly includes a housing extending between a front and a rear. The housing has DC terminal channels and AC terminal channels. The charging inlet assembly includes AC terminals, include a proximity terminal and a ground terminal, received in the corresponding AC terminal channels. The charging inlet assembly includes DC terminals received in the corresponding DC terminal channels. The charging inlet assembly includes a proximity resistor assembly having a plug body holding a resistor, a first resistor conductor and a second resistor conductor. The first resistor conductor is coupled between the resistor and the terminating end of the proximity terminal. The second resistor conductor is coupled between the resistor and the terminating end of the ground terminal.

Abstract: A charging inlet for an electric vehicle (EV) includes a body defining an opening having a conductive terminal arranged therein. A sealing cover is pivotally attached to the body and is moveable between an open position exposing the opening and conductive terminal, and a closed position sealing the opening and the conductive terminal with respect to an external environment. A sealing element of the cover defines a sealing plug including an angled sealing rib defined about an outer periphery thereof. The sealing plug and sealing rib are configured to engage with the opening of inlet body for sealing the opening with the cover in the closed position.

Abstract: A DC charging module for a charging inlet assembly includes a module housing extending between a front and a rear. The module housing has an inner chamber between the front and the rear. The DC charging module includes a terminal having a mating pin at a front of the terminal and a cable connector at a rear of the terminal. The cable connector is located in the inner chamber of the module housing. The mating pin extends forward of the module housing into the charging inlet assembly for mating with a charging connector coupled to the charging inlet assembly. The DC charging module includes a power cable extending into the inner chamber of the module housing to electrically connect to the cable connector of the terminal. The DC charging module includes a heat exchanger received in the inner chamber of the module housing. The heat exchanger is thermally coupled to the cable connector of the terminal.

Abstract: A charging inlet assembly includes a housing having a DC section with DC terminals received in DC terminal channels for mating with a DC charging connector and AC terminals, including a proximity terminal, received in AC terminal channels for mating with an AC charging connector. The charging inlet assembly includes an HMI assembly coupled to the rear of the housing having a control circuit board, a charging indicator coupled to the control circuit board visible from the front of the housing to indicate a charging status of the charging inlet assembly, and a proximity resistor assembly coupled to the housing. The proximity resistor assembly includes a resistor coupled to the control circuit board and a cable connector connected between the control circuit board and the proximity terminal.

Abstract: A charging inlet assembly includes a housing having a DC section having DC terminals received in DC terminal channels for mating with the DC charging connector and AC terminals received in AC terminal channels for mating with the AC charging connector. The DC terminals include a proximity terminal and a ground terminal. The proximity and ground terminals include terminating ends received in a rear cavity of the housing. The charging inlet assembly includes a proximity resistor assembly received in the rear cavity having a resistor, a first resistor conductor coupled between the resistor and the terminating end of the proximity terminal, and a second resistor conductor coupled between the resistor and the terminating end of the ground terminal.