Abstract: An connector assembly includes a connector header configured to be attached to a mounting substrate by a first mounting stud extending through a first aperture defined by the connector header, a connector configured to mate and unmate with the connector header and having a mating assist lever configured to attach and detach the connector to and from the connector header, and a mounting tab defined by the connector and configured to attach the connector to the first mounting stud extending through a second aperture defined by the mounting tab. Methods of assembling such a connector assembly are also provided.

Abstract: An electrical connector assembly includes a connector housing defining a cavity and an opening providing access to the cavity, first and second direct current (DC) terminals disposed within the cavity, and first and second busbars electrically and mechanically attached directly to the first and second DC terminals respectively. The first and second busbars each have a rectangular cross section and wherein the first and second busbars extend through the opening such that portions of the first and second busbars are outside of the connector housing. A method of manufacturing an electrical connector assembly is also provided.

Abstract: A power inlet connector assembly configured for use in charging an electrical vehicle includes a housing subassembly containing a plurality of direct current (DC) electrical terminals configured to mate with corresponding direct current electrical terminals of a power outlet connector of an electrical vehicle charging device external to the electrical vehicle and a cover subassembly configured to be connected and disconnected from the housing subassembly. The cover subassembly contains electrical bus bars and alternating current (AC) electrical terminals having first ends configured to mate with corresponding AC electrical terminals of a power outlet connector of an electrical vehicle charging device. The electrical bus bars are configured to be connected and disconnected with the DC electrical terminals and the AC electrical terminals are configured to be inserted and removed from terminal cavities defined by the housing subassembly.

Abstract: An electrical connector assembly includes a connector housing defining a cavity in which an electrical busbar is disposed. The connector housing defines an opening to the cavity. The electrical connector assembly also includes a cover configured to enclose the cavity. The cover has an inlet port, an outlet port, and a coolant channel that is in fluidic communication with the inlet port and the outlet port. A portion of the cover is in intimate thermal contact with the electrical busbar.

Abstract: A splice connector assembly configured to conduct more than 1 kilowatt of electricity includes a terminal having a connection portion configured to interconnect with a corresponding mating terminal. The terminal also has an attachment portion. The attachment portion has a planar shape. The attachment portion is attached to a first wire electrical cable and is also attached to a second wire electrical cable. The first cable has a different cross-sectional area than the second cable. The splice connector assembly also includes a dielectric housing defining a cavity in which the terminal is disposed.

Abstract: A two-piece high voltage (HV) terminal frame having a terminal frame and a contact spring. The terminal frame includes at least a top portion, a bottom portion, and a middle portion forming an opening for receiving a first bus bar and a second bus bar. The contact spring is configured to engage the top portion of the terminal frame, wherein the contact spring includes a spring portion that extends into the opening of the terminal frame.

Abstract: An electrical connector assembly includes a connector housing, a planar busbar having a rectangular cross section defining two opposed major surfaces and four minor surfaces, a cooling plate that is sized, shaped, and arranged to be in conductive thermal contact with a first major surface of the planar busbar, and an L-shaped busbar partially disposed within the connector housing having a first end connected to an electrical terminal and having a second end attached to, and in conductive thermal contact with, a second major surface of the planar busbar. The cooling plate is configured to reduce a temperature of the planar busbar and the attached L-shaped busbar. A method of assembling such an electrical connector is also presented.

Abstract: An electrical connector assembly includes a connector housing and a busbar having a rectangular cross section defining two opposed major surfaces and two opposed minor surfaces disposed within the connector housing. A planar surface is defined by one of the two opposed major surfaces of the busbar. The electrical connector assembly further includes a cooling plate that is sized, shaped, and arranged to be in conductive thermal contact with the planar surface of the busbar. The cooling plate is configured to reduce a temperature of the busbar.

Abstract: A portable electric vehicle supply equipment (EVSE) includes a first line and a second line, a current sensor, a microcontroller, and at least one protective relay. The current sensor is connected to monitor at least one of the first line or the second line and a current module is connected to sample the monitored current. The microcontroller is configured to detect arc faults in the first line and/or the second line based on the sampled current and to selectively open the protective relay in response to a detected arc fault.

Abstract: A splice connector assembly configured to conduct more than 1 kilowatt of electricity includes a terminal having a connection portion configured to interconnect with a corresponding mating terminal. The terminal also has an attachment portion. The attachment portion has a planar shape. The attachment portion is attached to a first wire electrical cable and is also attached to a second wire electrical cable. The first cable has a different cross-sectional area than the second cable. The splice connector assembly also includes a dielectric housing defining a cavity in which the terminal is disposed.

Abstract: An electrical connector assembly includes a connector housing and a busbar having a rectangular cross section defining two opposed major surfaces and two opposed minor surfaces disposed within the connector housing. A planar surface is defined by one of the two opposed major surfaces of the busbar. The electrical connector assembly further includes a cooling plate that is sized, shaped, and arranged to be in conductive thermal contact with the planar surface of the busbar. The cooling plate is configured to reduce a temperature of the busbar.

Abstract: An electrical connector assembly includes a connector housing defining a cavity in which an electrical busbar is disposed. The connector housing defines an opening to the cavity. The electrical connector assembly also includes a cover configured to enclose the cavity. The cover has an inlet port, an outlet port, and a coolant channel that is in fluidic communication with the inlet port and the outlet port. A portion of the cover is in intimate thermal contact with the electrical busbar.

Abstract: An electrical plug assembly including a plug housing, a ground pin and a first power blade projecting from the surface of the plug housing; and a power socket disposed within the plug housing. The surface defines an aperture surrounding the power socket. The assembly further includes an adapter plate including a second power blade having a first portion projecting from a first surface and a second portion projecting from an opposed second surface. Ground pin and first power blade apertures extend through the adapter plate. The second portion of the second power blade is received within the power socket and the ground pin and the first power blade are received within the ground pin and first power blade apertures respectively. The ground pin and the first power blade each project from the first surface of the adapter plate. The adapter plate allows the plug assembly to meet NEMA 5-15P or 6-20P standards.

Abstract: An electrical outlet wall plate includes a plate having an outer surface, an inner surface, and a peripheral edge. The outlet wall plate defines a socket opening configured to receive an electrical outlet socket and defining a fastener opening configured to receive a fastener configured to secure the outlet wall plate to the outlet socket. The outlet wall plate further includes a plug stabilizing feature having an inner wall, an outer wall, and a top wall. The plug stabilizing feature projects from the outer surface of the plate and at least partially surrounding a perimeter of the socket opening. The outlet wall plate limits lateral and vertical movement of the plug terminals in the socket and protects the operator from inadvertent contact with plug terminals the as the plug is inserted into the socket.

Abstract: An electrical connector system including a male connector having a male terminal that defines a first blade longitudinally projecting from the male terminal and a second blade longitudinally projecting from the same male terminal. A first blade width is less than a second blade width and a first blade length is less than a second blade length. The male terminal further defines a pair of crimp wings configured to attach the male terminal to a wire cable. The system further includes a female connector having a first female terminal configured to receive the first blade and a second female terminal configured to receive the second blade, thereby electrically interconnecting the first female terminal, the second female terminal, and the wire cable.

Abstract: An electric vehicle supply equipment (EVSE) assembly for an electric vehicle (EV) or plug-in hybrid electric vehicle (PHEV), often referred to as, optionally having one of at least two interchangeable power supply cords with plugs that conform to different technical standards, such as National Electrical Manufacturers Association (NEMA) 5-15P or 6-20P. The interchangeable power supply cord plugs each include a thermistor adapted to monitor plug temperatures. The electronic module is configured to disable charging until a proper resistance of the thermistor in the plug is detected. The electronic module is also configured to automatically switch between 120 volt and 240 volt operation based on which of the interchangeable power supply cords is connected to the electronic module.

Abstract: A connector assembly, such as a high voltage electrical connector assembly, includes a first connector having a first housing and an intermediate housing attached to the first housing. The intermediate housing is moveable from a first position to a second position. A flexible retaining arm is configured to hold the intermediate housing in the first position. The connector assembly further includes a second connector having a second housing. The second housing defines a release wedge that engages and flexes the retaining arm, thereby releasing the intermediate housing from engagement with the retaining arm and allowing the intermediate housing to move from the first position to the second position as the first connector is connected to the second connector. A terminal in the first housing is enclosed within the intermediate housing in the first position, and protrudes from an aperture in a surface of the intermediate housing in the second position.

Abstract: An electrical plug assembly including a plug housing, a ground pin and a first power blade projecting from the surface of the plug housing; and a power socket disposed within the plug housing. The surface defines an aperture surrounding the power socket. The assembly further includes an adapter plate including a second power blade having a first portion projecting from a first surface and a second portion projecting from an opposed second surface. Ground pin and first power blade apertures extend through the adapter plate. The second portion of the second power blade is received within the power socket and the ground pin and the first power blade are received within the ground pin and first power blade apertures respectively. The ground pin and the first power blade each project from the first surface of the adapter plate. The adapter plate allows the plug assembly to meet NEMA 5-15P or 6-20P standards.

Abstract: A connector assembly, such as a high voltage electrical connector assembly, includes a first connector having a first housing and an intermediate housing attached to the first housing. The intermediate housing is moveable from a first position to a second position. A flexible retaining arm is configured to hold the intermediate housing in the first position. The connector assembly further includes a second connector having a second housing. The second housing defines a release wedge that engages and flexes the retaining arm, thereby releasing the intermediate housing from engagement with the retaining arm and allowing the intermediate housing to move from the first position to the second position as the first connector is connected to the second connector. A terminal in the first housing is enclosed within the intermediate housing in the first position, and protrudes from an aperture in a surface of the intermediate housing in the second position.

Abstract: An electrical plug assembly including a plug housing having a first set of pins projecting from a first surface and a second set of pins projecting from an opposed second surface. The electrical plug assembly also includes an enclosure slideably attached to the plug housing. The enclosure slides to expose one set of pins while enclosing the other set of pins. The electrical plug assembly further includes a hood pivotally attached to the plug housing and slideably attached to the enclosure. The enclosure is rotatable from a first position to a second position. As the hood rotates, it slides the enclosure from a first location wherein the first set of pins is exposed to a second location wherein the second set of pins is exposed. The first set of pins conform to one technical standard, e.g. NEMA 6-20P while the second set of pins conform to another technical standard, e.g. NEMA 5-15P.