Abstract: An inline power connector for a power cable harness includes a socket assembly having a busbar, a socket terminal, and first and second cable terminators at opposite ends terminated to corresponding first and second cables of the power cable harness. The inline power connector includes an inner housing holding the socket assembly and an inline shield surrounding the inner housing and coupled to cable shields of the cables. The inline power connector includes an outer housing having a cavity receiving the inline shield, the inner housing, and the socket assembly. The cables extend into opposite ends of the outer housing. The outer housing includes a hub inline between the first end and the second end configured to receive a pin terminal that is configured to be coupled to the socket terminal of the socket assembly.

Abstract: A FFC harness assembly includes a main FFC having a main FFC cable and a main connector terminated to an end of the main FFC cable. The main FFC cable includes main flat wires and a main cable body. The FFC harness assembly includes a branch FFC separate and discrete from the main FFC. The branch FFC includes a branch FFC cable and a branch connector terminated to an end of the branch FFC cable. The branch FFC cable includes branch flat wires and a branch cable body. The FFC harness assembly includes an interconnect at a branch location between the main FFC and the branch FFC. The interconnect is located between the main FFC and the branch FFC and electrically connects at least one of the main flat wires with at least one of the branch flat wires to electrically connect the branch connector to the main connector.

Abstract: An electrical connector assembly includes a flat flexible cable (FFC) having a substrate holding conductors. The conductors have ends at an end of the FFC. The electrical connector assembly includes an electrical connector terminated to the end of the FFC. The electrical connector includes a housing holding terminals. The terminals are terminated to ends of the corresponding conductors. At least one of the terminals includes a passive electronic component in-line with the terminal.

Abstract: A connector assembly for a flat flexible cable (FFC) comprises a header and a plug receivable within the header. The header includes conductive contacts arranged therein. The plug includes conductive terminals and defines first openings and second openings. The first openings are defined on a first side of the plug and expose a weld pad of each of the terminals for electrically connecting each terminal to an exposed conductor of an FFC. The second openings are defined on a second side of the plug and expose a contact area of each of the terminals for electrically engaging with a respective one of the contacts of the header. The plug is insertable into the header between an initial position wherein the contacts are not in contact with the terminals, and a final position wherein the contacts are engaged with the terminals.

Abstract: A seal assembly includes a seal and an adhesive positioned in the seal. The seal has a first section and a second section extending from the first section. The seal has a sealing passageway extending through the first section and the second section along a longitudinal direction. The second section has an adhesive channel extending around the sealing passageway. The adhesive is positioned in the adhesive channel of the second section. The adhesive is disposed on an inner surface of the seal in the second section.

Abstract: A method of attaching a flat flexible cable (FFC) to a plurality of terminals of an electrical connector includes a step of arranging a plurality of terminals within a connector housing, with each terminal defining a weld area adapted to be electrically connected to a conductor of the FFC. The FFC is then positioned proximate the connector housing such that the weld areas of each terminal are arranged directly adjacent a respective one of a plurality of exposed conductors of the FFC. At least the weld areas of the plurality of terminals are heated with an inductive heating source for electrically connecting the plurality of conductors of the FFC to the plurality of terminals.

Abstract: A connector includes a housing and a locking device disposed in the housing. The housing has a body defining a body receiving space, a divider positioned in the body receiving space and defining a plurality of terminal receiving passageways with the body in a plurality of rows, and a latch extending from the body. The locking device has a base and a plurality of protrusions extending from the base. Each of the protrusions is received in one of the rows in an open position of the locking device and is inserted further into the terminal receiving passageways in a closed position of the locking device. The latch engages the locking device to secure the locking device in each of the open position and the closed position.

Abstract: A connector assembly for a flat flexible cable (FFC) comprises a header and a plug receivable within the header. The header includes conductive contacts arranged therein. The plug includes conductive terminals and defines first openings and second openings. The first openings are defined on a first side of the plug and expose a weld pad of each of the terminals for electrically connecting each terminal to an exposed conductor of an FFC. The second openings are defined on a second side of the plug and expose a contact area of each of the terminals for electrically engaging with a respective one of the contacts of the header. The plug is insertable into the header between an initial position wherein the contacts are not in contact with the terminals, and a final position wherein the contacts are engaged with the terminals.

Abstract: A cable housing for a flat flexible cable includes a first cable housing having a first orientation guide and a second cable housing having a second orientation opening. A plurality of flat conductors exposed in a window extending through an insulation material of the flat flexible cable are disposed between the first cable housing and the second cable housing. The first orientation guide abuts a pair of flat conductors of the plurality of flat conductors and rotates a rotated portion of each of the flat conductors to a rotated orientation when the first orientation guide moves into the second orientation opening and the first cable housing is in a mated position with the second cable housing. The rotated orientation of the rotated portion is disposed at an angle with respect to a planar portion of each of the flat conductors in the insulation material.

Abstract: A terminal includes a terminal body extending between a mating end and a terminating end. The mating end has a mating interface. The terminating end has an insulation displacement contact. The insulation displacement contact includes a first contact element having a first blade and a second contact element having a second blade. The first blade faces the second blade across a cable slot configured to receive a cable. The terminal includes a contact support extending along the insulation displacement contact. The contact support holds the first contact element relative to the second contact element.

Abstract: A battery module includes a battery case that has a cavity configured to hold at least one battery cell. The battery case has a fluid manifold allowing cooling fluid to flow through the cavity. The battery module includes a battery terminal coupled to the battery case. The battery terminal is configured to be electrically connected to the at least one battery cell. The battery terminal includes a mating element configured to be mated to and electrically connected to a mating power element to electrically connect the mating power element and the at least one battery cell. The battery terminal includes a cooling channel to form a fluid path through the mating element. The cooling channel is in flow communication with the fluid manifold for fluid to flow through the battery case.

Abstract: A power connector system has first and second busbar assemblies. The first busbar assembly includes a first busbar element and a pin terminal with an inner bore and a mating interface at an exterior surface of the pin terminal. The second busbar assembly has a second busbar element and a socket terminal having a socket opening that receives the pin terminal. The pin terminal includes a cooling channel in the inner bore configured to receive cooling fluid flow therethrough. The cooling channel is located in the socket terminal when the pin terminal is received in the socket opening of the socket terminal.

Abstract: An inline power connector for a power cable harness includes a socket assembly having a busbar, a socket terminal, and first and second cable terminators at opposite ends terminated to corresponding first and second cables of the power cable harness. The inline power connector includes an inner housing holding the socket assembly and an inline shield surrounding the inner housing and coupled to cable shields of the cables. The inline power connector includes an outer housing having a cavity receiving the inline shield, the inner housing, and the socket assembly. The cables extend into opposite ends of the outer housing. The outer housing includes a hub inline between the first end and the second end configured to receive a pin terminal that is configured to be coupled to the socket terminal of the socket assembly.

Abstract: A connector assembly includes a connector body defining an opening in communication with a cable space, and a cable insertion device insertable into the cable space of the connector body. Conductive contact surfaces of the connector are located on opposing sides of the cable space. The cable insertion device includes a body defining at least one elastic section, a first cable locating element arranged on a first side of the body, and a second cable locating element arranged on a second side of the body.

Abstract: A connector comprises a housing defining a receptacle sized to receive a flat flexible cable. A conductive terminal is arranged within the receptacle and adapted to contact an exposed conductor of the flat flexible cable received within the receptacle. A seal is positioned in contact with a front end of the housing and defines a cable receiving slot therethrough aligned with the receptacle. A cover is arranged over the seal and includes a slotted opening aligned with the cable receiving slot of the seal and the receptacle. The cover selectively fixed to the front end of the housing.

Abstract: A connector comprises a housing defining a receptacle sized to receive a flat flexible cable. A conductive terminal is arranged within the receptacle and adapted to contact an exposed conductor of the flat flexible cable received within the receptacle. A seal is positioned in contact with a front end of the housing and defines a cable receiving slot therethrough aligned with the receptacle. A cover is arranged over the seal and includes a slotted opening aligned with the cable receiving slot of the seal and the receptacle. The cover selectively fixed to the front end of the housing.

Abstract: A cable housing for a flat flexible cable includes a first cable housing having a first orientation guide and a second cable housing having a second orientation opening. A plurality of flat conductors exposed in a window extending through an insulation material of the flat flexible cable are disposed between the first cable housing and the second cable housing. The first orientation guide abuts a pair of flat conductors of the plurality of flat conductors and rotates a rotated portion of each of the flat conductors to a rotated orientation when the first orientation guide moves into the second orientation opening and the first cable housing is in a mated position with the second cable housing. The rotated orientation of the rotated portion is disposed at an angle with respect to a planar portion of each of the flat conductors in the insulation material.

Abstract: A pin terminal assembly includes a pin terminal having a retention section and a cavity adaptor formed of a non-conductive material and engaging the retention section. The cavity adaptor has an outer shape corresponding to a cavity of a housing in which the pin terminal is inserted. The cavity adaptor retains the pin terminal in the cavity.

Abstract: A connector for a flat flexible cable includes a cable housing and a contact having an elastic portion. The cable housing includes a first housing having a termination passage extending through the first housing and a second housing mated with the first housing. A flat conductor exposed in a window extending through an insulation material of the flat flexible cable is held between the first housing and the second housing. The elastic portion extends through the termination passage and elastically bears against the flat conductor to electrically connect the contact to the flat conductor.

Abstract: A pin terminal assembly includes a pin terminal having a retention section and a cavity adaptor formed of a non-conductive material and engaging the retention section. The cavity adaptor has an outer shape corresponding to a cavity of a housing in which the pin terminal is inserted. The cavity adaptor retains the pin terminal in the cavity.