Abstract: An electrical header for use in an electrical connector assembly includes a body for mounting to an object and having an opening formed therethrough for receiving an electrical terminal. The body further defines a plug on a first side thereof for engaging with a mating electrical connector of the assembly. The plug includes a pair of first opposing sidewalls extending from the body at a first height and defining a locking feature for engaging with a corresponding locking feature of the mating connector, and a pair of second opposing sidewalls extending from the body at a second height, less than the first height. The first and second pairs of opposing sidewalls are adapted to mate with a first mating connector oriented in a first direction, and mate with a second mating connector oriented in a second direction distinct from the first direction.

Abstract: An electrical header for use in an electrical connector assembly includes a body adapted to mount to an object and having an opening formed therethrough for receiving an electrical terminal. The body further defines a plug on a first side thereof and adapted to engage with a mating electrical connector of the assembly. The plug includes a pair of first opposing sidewalls extending from the body and defining a locking feature adapted to engage with a corresponding locking feature of the mating connector, and a pair of second opposing sidewalls extending from the body and defining a keying feature. The first and second pairs of opposing sidewalls are adapted to mate with a first mating connector oriented in a first direction, and mate with a second mating connector oriented in a second direction distinct from the first direction.

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: An electrical connector assembly comprises a header and a backing plate attachable thereto. The header includes a plug portion for connecting to a complementary mating connector, and a base having a plurality of mounting through holes for fixing the header to a mounting surface. The backing plate includes a plurality of mounting elements corresponding in location to the plurality of mounting holes of the header for fixing the backing plate to the header on an underside of the mounting surface, and a central opening corresponding in location to the plug portion of the header with the backing plate fixed to the header.

Abstract: A gasket assembly includes a substrate, such as a portion of a body of an electrical connector. The substrate defines a mating surface to which a gasket or gasket seal is mechanically fixed. The gasket defines at least one recess or other mounting feature thereon for engaging with a complementary feature of the substrate for fixing the gasket to the substrate. According to an embodiment, the gasket defines a sealing face or sealing wall opposing and/or abutting the mating surface of the substrate, and a sidewall extending from the sealing wall and defined about a perimeter thereof. The sealing wall and sidewall define a circumferential recess configured to receive a peripheral edge of the substrate for securing the gasket to and generally over the mating surface of the substrate.

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: An electrical header for mounting to an object such as an electrical device. The header comprises a body including a base, a first plug end defined on a first side of the base and adapted to mate with a mating connector, and a second plug end defined on a second side of the base and adapted to be inserted into the object. An elastic locking element is arranged on the second plug end and is adapted to engage with and secure the header to the object. The elastic locking element is sized and shaped to be elastically biased by the object in a direction transverse to an insertion direction of the header during removal of the header from the object.

Abstract: An electrical header for use in an electrical connector assembly includes a body for mounting to an object and having an opening formed therethrough for receiving an electrical terminal. The body further defines a plug on a first side thereof for engaging with a mating electrical connector of the assembly. The plug includes a pair of first opposing sidewalls extending from the body a first height and defining a locking feature for engaging with a corresponding locking feature of the mating connector, and a pair of second opposing sidewalls extending from the body at a second height, less than the first height. The first and second pairs of opposing sidewalls are adapted to mate with a first mating connector oriented in a first direction with respect to the header, and mate with a second mating connector oriented in a second direction with respect to the header and distinct from the first direction.

Abstract: A gasket assembly includes a substrate, such as a portion of a body of an electrical connector. The substrate defines a mating surface to which a gasket or gasket seal is mechanically fixed. The gasket defines at least one recess or other mounting feature thereon for engaging with a complementary feature of the substrate for fixing the gasket to the substrate. According to an embodiment, the gasket defines a sealing face or sealing wall opposing and/or abutting the mating surface of the substrate, and a sidewall extending from the sealing wall and defined about a perimeter thereof. The sealing wall and sidewall define a circumferential recess configured to receive a peripheral edge of the substrate for securing the gasket to and generally over the mating surface of the substrate.

Abstract: Electrical connector includes an electrical contact coupled to a connector body and configured to engage a respective contact of a mating connector. The electrical connector includes a seal gland secured to the connector body. The seal gland is shaped to engage the mating connector during the mating operation. The seal gland includes a lubricating section and a sealing section that are displaceable by the mating connector during the mating operation. The lubricating section is positioned in front of the sealing section such that the lubricating section initially engages the mating connector. The lubricating section has at least one of an added lubricant or an intrinsic lubricant. The seal gland is configured to provide a first frictional force as the mating connector engages the lubricating section and a second frictional force as the mating connector engages the sealing section. The second frictional force is greater than the first frictional force.

Abstract: Electrical connector includes an electrical contact coupled to a connector body and configured to engage a respective contact of a mating connector. The electrical connector includes a seal gland secured to the connector body. The seal gland is shaped to engage the mating connector during the mating operation. The seal gland includes a lubricating section and a sealing section that are displaceable by the mating connector during the mating operation. The lubricating section is positioned in front of the sealing section such that the lubricating section initially engages the mating connector. The lubricating section has at least one of an added lubricant or an intrinsic lubricant. The seal gland is configured to provide a first frictional force as the mating connector engages the lubricating section and a second frictional force as the mating connector engages the sealing section. The second frictional force is greater than the first frictional force.

Abstract: A battery module includes a plurality of battery cells and a cover assembly coupled to the battery cells. The battery cells are arranged in a stacked configuration. The cover assembly includes a housing, bus bars, and a temperature monitoring assembly. The bus bars engage corresponding positive and negative cell terminals of the battery cells to electrically connect adjacent battery cells. The temperature monitoring assembly is mounted to and extends along a mounting surface of the cover assembly that faces the battery cells. The temperature monitoring assembly includes an electrical cable, a temperature sensing device mounted to and electrically connected to the electrical cable, and a thermally conductive interface member covering the temperature sensing device. The thermally conductive interface member engages at least one of the battery cells, and the temperature monitoring assembly monitors a temperature of that at least one battery cell.

Abstract: A connector assembly for voltage monitoring of bus bars electrically connecting adjacent battery cells of a battery module includes a connector having a plurality of terminals configured to be mated with a control module connector associated with the battery module. A multi-wire planar cable extends from the connector. The multi-wire planar cable has a plurality of wires terminated to corresponding terminals and a common jacket for the plurality of wires. The jacket has grooves between adjacent wires for controlled separation of the wires and surrounding jacket portions at a sensor end of the multi-wire planar cable to define separated planar cable segments. The separated planar cable segments are routed to different areas for termination to different voltage sensors associated with corresponding bus bars.

Abstract: An electrical component includes a housing having a mounting end configured to be mounted to a structure and an electrical shield held by the housing and providing electrical shielding. The electrical shield is configured to be electrically grounded to the structure. The electrical shield has a mounting tab having a mounting area including an opening therethrough and a grounding feature in the mounting area near the opening. The grounding feature is configured to cut through a coated surface of the structure to directly engage a conductive layer of the structure to electrically connect the electrical shield to the structure through the coated surface.

Abstract: A plug connector includes a housing having a mating end and a cable end. The mating end is configured to be mated with a header connector in a mating direction. A tab terminal is held in the housing at the mating end. The tab terminal has a leading edge configured to be mated with the header terminal of the header connector when the plug connector is mated to the header connector. The leading edge is tapered such that the tab terminal sequentially mates with the header terminal during mating.

Abstract: A ferrule assembly for terminating an electrical connector to a cable includes an inner ferrule, an outer ferrule and an inner ferrule sleeve. The inner ferrule has an inner surface and an outer surface. The inner ferrule is conductive and provides electrical shielding. The outer ferrule is positioned radially outside of the inner ferrule such that a cable shield of the cable is received between the inner ferrule and the outer ferrule. The outer ferrule secures the cable shield between the inner ferrule and the outer ferrule. The inner ferrule sleeve is positioned radially inside of the inner ferrule. The inner ferrule sleeve substantially fills the space between the inner ferrule and an inner jacket of the cable. The inner ferrule sleeve is dielectric and electrically isolating the inner ferrule from an inner conductor of the cable.

Abstract: A power connector system includes a header connector having a header housing mounted to a chassis. The header housing holds a header terminal comprising a plurality of contact members arranged side-by-side in a stacked arrangement. Each contact member has a pair of spring beams defining sockets at a mating end of the contact member. The sockets of the contact members are aligned to define a tab socket of the header terminal. The power connector system includes a plug connector having a plug housing holding a tab terminal. The tab terminal has a mating end and a cable end. The mating end is received in a mating direction into the tab socket of the header terminal during mating to electrically connect the tab terminal with the header terminal.