Abstract: A method of forming a shielded electrical terminal configured to receive a corresponding shielded electrical terminal. The terminal includes an inner shield defining a shield cavity about a longitudinal axis. The shield cavity is configured to receive the corresponding shielded electrical terminal. The inner shield has a longitudinal inner seam substantially that is parallel to the longitudinal axis. The inner shield defines a plurality of resilient contact springs that protrude into the shield cavity. The contact springs are configured to contact the corresponding shielded electrical terminal. The terminal also includes an outer shield integrally formed with the inner shield and covering at least a portion of the inner shield. The terminal formed by this method is also presented.

Abstract: A method of forming a shielded electrical terminal configured to receive a corresponding shielded electrical terminal. The terminal includes an inner shield defining a shield cavity about a longitudinal axis. The shield cavity is configured to receive the corresponding shielded electrical terminal. The inner shield has a longitudinal inner seam substantially that is parallel to the longitudinal axis. The inner shield defines a plurality of resilient contact springs that protrude into the shield cavity. The contact springs are configured to contact the corresponding shielded electrical terminal. The terminal also includes an outer shield integrally formed with the inner shield and covering at least a portion of the inner shield. The terminal formed by this method is also presented.

Abstract: An electrical connector assembly includes male and female connector bodies formed with a plurality of terminal cavities in which electrical cables are disposed with the terminals secured against removal from the cavities by flexible lances engaging walls within the terminal cavities. A seal on the cables closes and seals the cavities in which they are installed. At least one of the cavities is unoccupied by a cable and is closed by a non-electrically conductive locking cavity plug. The locking cavity plug has a flexible lance that engages a wall within the unoccupied cavity in which it is installed to secure the plug against removal and carries a seal which engages and seals the unoccupied cavity.

Abstract: An electrical connector assembly includes male and female connector bodies formed with a plurality of terminal cavities in which electrical cables are disposed with the terminals secured against removal from the cavities by flexible lances engaging walls within the terminal cavities. A seal on the cables closes and seals the cavities in which they are installed. At least one of the cavities is unoccupied by a cable and is closed by a non-electrically conductive locking cavity plug. The locking cavity plug has a flexible lance that engages a wall within the unoccupied cavity in which it is installed to secure the plug against removal and carries a seal which engages and seals the unoccupied cavity.

Abstract: A connector system including a first connector having a longitudinally extending lock arm defining a lock nib and attached to the first connector. The lock nib is configured to engage a primary lock tab of a second connector when the first and second connectors are in a fully mated position and the lock arm is in a resting position. The lock nib is configured to disengage the primary lock tab and engage a secondary lock tab of the second connector when the lock arm is moved from a resting to an activated position and the first and second connectors are moved to a partially mated position while the lock arm is in the activated position. The connector system generates an audible or tactile click only when the first connector is fully mated with the second connector. The connectors can be disconnected with bare hands, no tools are required.

Abstract: A shielded electrical header assembly is provided. The header is configured to be coupled to a first connector connected to a shielded electrical cable and second connector. The header is also configured to be attached to an electrically conductive panel, such as an aluminum battery pack in a hybrid or electric vehicle. The header includes a conductive shield contact that connects the outer conductor of the shielded cable to the panel and a conductive outer connector body that is also connected to the panel and surrounds the terminals and the shield contact of the header, thus providing electromagnetic shielding to the terminals of the header and the connectors. The shield contact is formed of a sheet metal to provide a lower resistance connection between the outer conductor and the panel. A method of manufacturing such a header is also provided.

Abstract: An electrical connection assembly includes a first connector which includes a first electrical contact surrounded by a first connector wall defining a first connector cavity. The first connector wall includes a plurality of ribs extending into the first connector cavity. A second connector is matable with the first connector along a mating axis and includes a second electrical contact in electrical communication with the first electrical contact when the first connector is mated with the second connector. The second connector includes a second connector body surrounding the second electrical contact.

Abstract: A shielded electrical header assembly is provided. The header is configured to be coupled to a first connector connected to a shielded electrical cable and second connector. The header is also configured to be attached to an electrically conductive panel, such as an aluminum battery pack in a hybrid or electric vehicle. The header includes a conductive shield contact that connects the outer conductor of the shielded cable to the panel and a conductive outer connector body that is also connected to the panel and surrounds the terminals and the shield contact of the header, thus providing electromagnetic shielding to the terminals of the header and the connectors. The shield contact is formed of a sheet metal to provide a lower resistance connection between the outer conductor and the panel. A method of manufacturing such a header is also provided.

Abstract: A method is provided for assembling a connector assembly to a case. The case includes an inside surface defining an inside of the case, an outside surface defining an outside of the case, and an aperture therethrough providing communication from the inside surface to the outside surface. The connector assembly includes an outer connector having a body with a passage therethrough, an electromagnetic shield, and an inner connector with a terminal therein with a conductor extending from the inner connector in electrical communication with the terminal. The method includes positioning the outer connector on the outside of the case to align the passage of the outer connector with the aperture of the case. The method also includes positioning the inner connector on the inside of the case. The method also includes inserting the inner connector into the passage of the outer connector from the inside of the case.

Abstract: An electrical connector assembly for mating with a mating connector includes a housing having spaced apart sidewalls and first and second slides slide slideably supported in the housing. The first and second slides each include at least one mating slot adapted to receive a mating portion of the mating connector and slideable with respect to the housing between a pre-staged position where the electrical connector is removable from the mating connector and an engaged position where said electrical connector assembly is locked to said mating connector. A slide assist lever is pivotally interconnected with the housing and each of the slides to move the slides between the pre-staged position and the engaged position such that recesses are formed in the housing with the slides when said slides are in the engaged position. The electrical connector assembly also includes an environmental cover positionable to substantially prevent debris from entering the recesses.

Abstract: A connector system including a first connector having a longitudinally extending lock arm defining a lock nib and attached to the first connector. The lock nib is configured to engage a primary lock tab of a second connector when the first and second connectors are in a fully mated position and the lock arm is in a resting position. The lock nib is configured to disengage the primary lock tab and engage a secondary lock tab of the second connector when the lock arm is moved from a resting to an activated position and the first and second connectors are moved to a partially mated position while the lock arm is in the activated position. The connector system generates an audible or tactile click only when the first connector is fully mated with the second connector. The connectors can be disconnected with bare hands, no tools are required.

Abstract: An electrical connector assembly for mating with a mating connector includes a housing having spaced apart sidewalls and first and second slides slide slideably supported in the housing. The first and second slides each include at least one mating slot adapted to receive a mating portion of the mating connector and slideable with respect to the housing between a pre-staged position where the electrical connector is removable from the mating connector and an engaged position where said electrical connector assembly is locked to said mating connector. A slide assist lever is pivotally interconnected with the housing and each of the slides to move the slides between the pre-staged position and the engaged position such that recesses are formed in the housing with the slides when said slides are in the engaged position. The electrical connector assembly also includes an environmental cover positionable to substantially prevent debris from entering the recesses.

Abstract: A method is provided for assembling a connector assembly to a case. The case includes an inside surface defining an inside of the case, an outside surface defining an outside of the case, and an aperture therethrough providing communication from the inside surface to the outside surface. The connector assembly includes an outer connector having a body with a passage therethrough, an electromagnetic shield, and an inner connector with a terminal therein with a conductor extending from the inner connector in electrical communication with the terminal. The method includes positioning the outer connector on the outside of the case to align the passage of the outer connector with the aperture of the case. The method also includes positioning the inner connector on the inside of the case. The method also includes inserting the inner connector into the passage of the outer connector from the inside of the case.

Abstract: An electrical connection assembly includes a first connector which includes a first electrical contact surrounded by a first connector wall defining a first connector cavity. The first connector wall includes a plurality of ribs extending into the first connector cavity. A second connector is matable with the first connector along a mating axis and includes a second electrical contact in electrical communication with the first electrical contact when the first connector is mated with the second connector. The second connector includes a second connector body surrounding the second electrical contact.

Abstract: A suspension damper system is provided. The damper system includes a damper with a damper rod, a portion of which extends from the proximal end of the damper. The damper rod includes a bore and an electrode disposed within the bore. A fastener for securing the damper rod to a vehicle is also provided. The fastener is disposed over the damper rod and includes a circumferential groove. An electrical connector which includes an electrically conducting terminal is connected to the electrode. The connector includes a lock which mates with the groove in the fastener and includes a ground terminal which is connected to the damper rod.

Abstract: A suspension damper system is provided. The damper system includes a damper with a damper rod, a portion of which extends from the proximal end of the damper. The damper rod includes a bore and an electrode disposed within the bore. A fastener for securing the damper rod to a vehicle is also provided. The fastener is disposed over the damper rod and includes a circumferential groove. An electrical connector which includes an electrically conducting terminal is connected to the electrode. The connector includes a lock which mates with the groove in the fastener and includes a ground terminal which is connected to the damper rod.

Abstract: A suspension damper system is provided. The damper system includes a damper with a damper rod, a portion of which extends from the proximal end of the damper. The damper rod includes a bore and an electrode disposed within the bore. A fastener for securing the damper rod to a vehicle is also provided. The fastener is disposed over the damper rod and includes a circumferential groove. An electrical connector which includes an electrically conducting terminal is connected to the electrode. The connector includes a lock which mates with the groove in the fastener and includes a ground terminal which is connected to the damper rod.

Abstract: A suspension damper system is provided. The damper system includes a damper with a damper rod, a portion of which extends from the proximal end of the damper. The damper rod includes a bore and an electrode disposed within the bore. A fastener for securing the damper rod to a vehicle is also provided. The fastener is disposed over the damper rod and includes a circumferential groove. An electrical connector which includes an electrically conducting terminal is connected to the electrode. The connector includes a lock which mates with the groove in the fastener and includes a ground terminal which is connected to the damper rod.

Abstract: A suspension damper system is provided. The damper system includes a damper with a damper rod, a portion of which extends from the proximal end of the damper. The damper rod includes a bore and an electrode disposed within the bore. A fastener for securing the damper rod to a vehicle is also provided. The fastener is disposed over the damper rod and includes a circumferential groove. An electrical connector which includes an electrically conducting terminal is connected to the electrode. The connector includes a lock which mates with the groove in the fastener and includes a ground terminal which is connected to the damper rod.

Abstract: A suspension damper system is provided. The damper system includes a damper with a damper rod, a portion of which extends from the proximal end of the damper. The damper rod includes a bore and an electrode disposed within the bore. A fastener for securing the damper rod to a vehicle is also provided. The fastener is disposed over the damper rod and includes a circumferential groove. An electrical connector which includes an electrically conducting terminal is connected to the electrode. The connector includes a lock which mates with the groove in the fastener and includes a ground terminal which is connected to the damper rod.