Abstract: A contactor includes first and second fixed contacts coupled to a housing having mating ends located in the cavity. The contactor includes a movable contact movable within the cavity between a mated position and an unmated position. The movable contact engages the second mating end in the mated position and is separated from the second fixed contact in the unmated position. The contactor includes a coil assembly in the cavity operated to move the movable contact. The contactor includes a magnetic shroud coupled to at least one of the movable contact and the second fixed contact to provide a magnetic holding force to hold the movable contact relative to the second fixed contact in the mated position.

Abstract: A header power connector includes a header housing assembly including an inner housing received in a cavity of an outer housing. The inner housing has upper and lower openings open to a terminal channel configured to receive busbars. The inner housing is movable relative to the outer housing to accommodate misalignment of the busbars in the terminal channel. A terminal is received in the terminal channel having a terminal base, an upper mating end and a lower mating end. The upper mating end includes an upper socket flanked by upper spring beams that receives the first busbar and the lower mating end includes a lower socket flanked by lower spring beams that receives the second busbar. The terminal is movable in the terminal channel to accommodate misalignment of the first busbar and the second busbar in the terminal channel.

Abstract: A contactor includes a housing and first and second fixed contacts coupling to the housing having mating ends received in the cavity of the housing and terminating ends outside of the housing. A movable contact is movable within the cavity between a mated position and an unmated position that engages the mating end of the second fixed contact in the mated position and is separated from the second fixed contact in the unmated position. A flexible busbar is coupled to the first mating end and coupled to the movable contact. The flexible busbar electrically connects the first fixed contact and the movable contact in both the mated position and the unmated position. A coil assembly in the cavity operates to move the movable contact between the unmated position and the mating position.

Abstract: A battery distribution unit includes a housing having a bottom mounted to a battery case of a battery module and having a component cavity with a contactor therein. The contactor has fixed contacts having terminating ends extending from a bottom end of a contactor housing. The BDU includes terminals at the bottom end of the contactor coupled to the terminating ends and a heat exchanger cap at the bottom end of the contactor. The heat exchanger cap is provided in the component cavity in thermal communication with the fixed contacts and in thermal communication with the battery case of the battery module to dissipate heat from the fixed contacts into the battery case of the battery module.

Abstract: A contactor includes first and second fixed contacts coupled to a housing having mating ends located in the cavity. The contactor includes a movable contact movable within the cavity between a mated position and an unmated position. The movable contact engages the second mating end in the mated position and is separated from the second fixed contact in the unmated position. The contactor includes a coil assembly in the cavity operated to move the movable contact. The contactor includes a magnetic shroud coupled to at least one of the movable contact and the second fixed contact to provide a magnetic holding force to hold the movable contact relative to the second fixed contact in the mated position.

Abstract: A header power connector includes a header housing assembly including an inner housing received in a cavity of an outer housing. The inner housing has upper and lower openings open to a terminal channel configured to receive busbars. The inner housing is movable relative to the outer housing to accommodate misalignment of the busbars in the terminal channel. A terminal is received in the terminal channel having a terminal base, an upper mating end and a lower mating end. The upper mating end includes an upper socket flanked by upper spring beams that receives the first busbar and the lower mating end includes a lower socket flanked by lower spring beams that receives the second busbar. The terminal is movable in the terminal channel to accommodate misalignment of the first busbar and the second busbar in the terminal channel.

Abstract: A header power connector includes a header housing assembly including an outer housing having cavities that receive corresponding inner housings, which hold terminals for electrically connecting upper and lower busbars. The inner housings are movable relative to the outer housing to accommodate misalignment of the corresponding upper and lower busbars. The terminals are movable in the terminal channels of the inner housings to accommodate misalignment of the corresponding upper and lower busbars.

Abstract: A header power connector includes a header housing assembly including an inner housing received in a cavity of an outer housing. The inner housing has upper and lower openings open to a terminal cavity configured to receive busbars. The inner housing is movable relative to the outer housing to accommodate misalignment of the busbars in the terminal cavity. A terminal is received in the terminal cavity having a terminal base, an upper mating end and a lower mating end. The upper mating end includes an upper socket flanked by upper spring beams that receives the first busbar and the lower mating end includes a lower socket flanked by lower spring beams that receives the second busbar. The terminal is movable in the terminal cavity to accommodate misalignment of the first busbar and the second busbar in the terminal cavity.

Abstract: A header power connector includes a header housing assembly including an inner housing received in a cavity of an outer housing. The inner housing has upper and lower openings open to a terminal cavity configured to receive busbars. The inner housing is movable relative to the outer housing to accommodate misalignment of the busbars in the terminal cavity. A terminal is received in the terminal cavity having a terminal base, an upper mating end and a lower mating end. The upper mating end includes an upper socket flanked by upper spring beams that receives the first busbar and the lower mating end includes a lower socket flanked by lower spring beams that receives the second busbar. The terminal is movable in the terminal cavity to accommodate misalignment of the first busbar and the second busbar in the terminal cavity.

Abstract: A power distribution unit includes a housing, a main contactor in a main cavity of the housing, and a pre-charge assembly in a secondary cavity of the housing. The main contactor includes first and second fixed contacts and a movable contact configured to electrically connect the first and second fixed contacts in a mated position. The main contactor includes a coil assembly energized to move the movable contact. The pre-charge assembly includes a pre-charge resistor and a pre-charge switch coupled to the pre-charge resistor. The power distribution unit includes a controller received in the housing. The controller includes a main contactor driver for powering the main contactor and a pre-charge driver for powering the pre-charge switch.

Abstract: A contactor includes a housing defining a cavity. The contactor includes a switch assembly received in the cavity. The switch assembly includes first and second fixed contacts received in the cavity and a movable contact movable within the cavity between a mated position and an unmated position. The movable contact engages the first and second fixed contacts to electrically connect the first and second fixed contacts in the mated position. The switch assembly includes a coil assembly in the cavity operated to move the movable contact between the unmated position and the mating position. The contactor includes a heat transfer device coupled to the housing. The heat transfer device is thermally coupled to the first fixed contact and the second fixed contact to dissipate heat from the first fixed contact and the second fixed contact.

Abstract: A power distribution unit includes a housing having walls defining a main cavity provided at a first side and a secondary cavity provided at a second side. The power distribution unit includes a main contactor received in the main cavity having first and second fixed contacts and a movable contact movable between a mated position and an unmated position to electrically connect the first and second fixed contacts. The main contactor includes a coil assembly energized to move the movable contact. The power distribution unit includes a pre-charge assembly received in the secondary cavity having a control circuit board, a pre-charge resistor coupled to the control circuit board, and a pre-charge switch coupled to the control circuit board. The power distribution unit includes a cover coupled to the housing to enclose the pre-charge assembly in the secondary cavity.

Abstract: A battery module frame includes first and second frame sections each having a main body, an upper side wall extending from the main body, and a lower side wall extending from the main body. The main body has a bus bar pad for a bus bar that is configured to be electrically connected to battery cells of the battery module. The upper and lower side walls include upper and lower mounting features. The first and second frame sections are coupled at a seam with the upper mounting features removably coupled together at an upper separable interface and with the lower mounting features removably coupled together at a lower separable interface. The first and second frame sections are coupled together with the bus bar pads of the main bodies coplanar.

Abstract: A power distribution unit includes a housing, a main contactor in a main cavity of the housing, and a pre-charge assembly in a secondary cavity of the housing. The main contactor includes first and second fixed contacts and a movable contact configured to electrically connect the first and second fixed contacts in a mated position. The main contactor includes a coil assembly energized to move the movable contact. The pre-charge assembly includes a pre-charge resistor and a pre-charge switch coupled to the pre-charge resistor. The power distribution unit includes a controller received in the housing. The controller includes a main contactor driver for powering the main contactor and a pre-charge driver for powering the pre-charge switch.

Abstract: A power distribution unit includes a housing having walls defining a main cavity provided at a first side and a secondary cavity provided at a second side. The power distribution unit includes a main contactor received in the main cavity having first and second fixed contacts and a movable contact movable between a mated position and an unmated position to electrically connect the first and second fixed contacts. The main contactor includes a coil assembly energized to move the movable contact. The power distribution unit includes a pre-charge assembly received in the secondary cavity having a control circuit board, a pre-charge resistor coupled to the control circuit board, and a pre-charge switch coupled to the control circuit board. The power distribution unit includes a cover coupled to the housing to enclose the pre-charge assembly in the secondary cavity.

Abstract: A battery module frame includes first and second frame sections each having a main body, an upper side wall extending from the main body, and a lower side wall extending from the main body. The main body has a bus bar pad for a bus bar that is configured to be electrically connected to battery cells of the battery module. The upper and lower side walls include upper and lower mounting features. The first and second frame sections are coupled at a seam with the upper mounting features removably coupled together at an upper separable interface and with the lower mounting features removably coupled together at a lower separable interface. The first and second frame sections are coupled together with the bus bar pads of the main bodies coplanar.

Abstract: A battery distribution unit includes a housing having a bottom mounted to a battery case of a battery module and having a component cavity with a contactor therein. The contactor has fixed contacts having terminating ends extending from a bottom end of a contactor housing. The BDU includes terminals at the bottom end of the contactor coupled to the terminating ends and a heat exchanger cap at the bottom end of the contactor. The heat exchanger cap is provided in the component cavity in thermal communication with the fixed contacts and in thermal communication with the battery case of the battery module to dissipate heat from the fixed contacts into the battery case of the battery module.

Abstract: A battery terminal connector for terminating to a battery post of a battery. The battery terminal connector includes a cable attachment portion, a flange portion having a tightening member provided thereon, and a post engaging portion. A guard member is mounted on the flange portion. The guard member is moveable between a first position and a second position. The guard member has a projection which extends over the tightening member when the guard member is in the first position. The projection is removed from the tightening member when the battery terminal connector is properly positioned relative to the battery post and the guard member is in the second position. The battery terminal connector can only be terminated to the battery post when the battery terminal connector is properly positioned relative to the battery post.

Abstract: A battery terminal connector for terminating to a battery post of a battery. The battery terminal connector includes a cable attachment portion, a flange portion having a tightening member provided thereon, and a post engaging portion. A guard member is mounted on the flange portion. The guard member is moveable between a first position and a second position. The guard member has a projection which extends over the tightening member when the guard member is in the first position. The projection is removed from the tightening member when the battery terminal connector is properly positioned relative to the battery post and the guard member is in the second position. The battery terminal connector can only be terminated to the battery post when the battery terminal connector is properly positioned relative to the battery post.

Abstract: A connector having a pin guide and method are disclosed. The connector includes a housing, terminals and a pin guide. The terminals include securing sections and substrate mating ends. The securing sections are positioned to maintain the terminals in the terminal receiving recesses. The substrate mating ends extend from the housing. The pin guide is removably attached to the housing, the pin guide having terminal receiving cavities for receiving the substrate mating ends of the terminals therein. The method of assembly and installing a connector includes: inserting terminals into housing; bending a portion of the terminals which extend outward from the housing; and positioning a pin guide over the bent ends of the terminals, whereby the bent ends are retained in cavities of the pin guide.