Abstract: A charging inlet includes a power terminal, a holder member, and a thermal sensor. The power terminal is configured to releasably engage a mating contact of an external power source. The holder member is proximate to the power terminal, and has an electrically insulative material. The holder member defines at least a portion of a pocket that is fully enclosed. The thermal sensor is disposed within the pocket for monitoring a temperature of the power terminal.

Abstract: A power connector includes a housing having a terminal channel holding a terminal. The terminal includes a mating pin at a front of the terminal and a cable connector at a rear of the terminal. The mating pin is positioned in the terminal channel for mating with a charging connector. The power connector includes a power cable including a conductor terminated to the cable connector at the rear of the terminal. The power connector includes a cable heat exchanger thermally coupled to the conductor of the power cable. The cable heat exchanger includes a coolant channel for coolant flow through the cable heat exchanger for actively cooling the conductor of the power cable. A thermally conductive separator electrically isolates the cable heat exchanger from the conductor of the power cable.

Abstract: A charging inlet includes a power terminal and a thermal sensor for monitoring a temperature of the power terminal. The power terminal is configured to releasably engage a mating contact of an external power source. The power terminal includes a cylindrical shaft. The thermal sensor includes a substrate and a sensing element mounted on the substrate. The substrate is flexible and curves along at least a portion of an outer surface of the cylindrical shaft.

Abstract: A power connector includes a housing having a terminal channel holding a terminal. The terminal includes a mating pin at a front of the terminal and a cable connector at a rear of the terminal. The mating pin is positioned in the terminal channel for mating with a charging connector. The power connector includes a power cable including a conductor terminated to the cable connector at the rear of the terminal. The power connector includes a cable heat exchanger thermally coupled to the conductor of the power cable. The cable heat exchanger includes a coolant channel for coolant flow through the cable heat exchanger for actively cooling the conductor of the power cable. A thermally conductive separator electrically isolates the cable heat exchanger from the conductor of the power cable.

Abstract: An electrical connector includes a housing and a presentation block. The presentation block is mounted to the housing along an outer surface of the housing. The presentation block has a three-dimensional shape with a display surface that is angled transverse to an area of the outer surface of the housing on which the presentation block is mounted. The presentation block includes a graphic identifier that is computer-readable and disposed on the display surface.

Abstract: A charging inlet includes a power terminal, a holder member, and a thermal sensor. The power terminal is configured to releasably engage a mating contact of an external power source. The holder member is proximate to the power terminal, and has an electrically insulative material. The holder member defines at least a portion of a pocket that is fully enclosed. The thermal sensor is disposed within the pocket for monitoring a temperature of the power terminal.

Abstract: A charging inlet includes a power terminal and a thermal sensor for monitoring a temperature of the power terminal. The power terminal is configured to releasably engage a mating contact of an external power source. The power terminal includes a cylindrical shaft. The thermal sensor includes a substrate and a sensing element mounted on the substrate. The substrate is flexible and curves along at least a portion of an outer surface of the cylindrical shaft.

Abstract: An electrical connector includes a housing and a presentation block. The presentation block is mounted to the housing along an outer surface of the housing. The presentation block has a three-dimensional shape with a display surface that is angled transverse to an area of the outer surface of the housing on which the presentation block is mounted. The presentation block includes a graphic identifier that is computer-readable and disposed on the display surface.

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: An electrical connector matable to and unmatable from a separable mating electrical connector includes a housing having a terminal channel and an auxiliary terminal channel with a power terminal received in the terminal channel and an auxiliary power terminal received in the auxiliary terminal channel. A TPA device is movably coupled to the housing between an open position and a blocking position for blocking removal of the power terminal from the terminal channel. A protective thermal coupler is held by and movable with the TPA device. The protective thermal coupler has a variable resistive member electrically coupled between the power terminal and the auxiliary power terminal. The variable resistive member provides a shunt so that arcing does not occur when the power terminal is disconnected from the mating power terminal of the mating electrical connector.

Abstract: A power terminal includes a terminal beam having a mating surface. A protective thermal coupler bridge is positioned adjacent the terminal beam having a bridge conductor, an insulating substrate and a bridge pad. The bridge pad has a mating surface. A variable resistive member is electrically coupled between the terminal beam and the bridge conductor to provide a shunt so that arcing does not occur when the power terminal is disconnected from the mating power terminal. The mating surface of the terminal beam is separable before the mating surface of the bridge pad is disconnected so that the resistance in the variable resistive member increases after disconnection of the main power terminal from the mating power terminal and prior to disconnection of the bridge pad from the mating power terminal to shunt the current through the bridge conductor and the variable resistive member during unmating.

Abstract: An electrical connector matable to and unmatable from a separable mating electrical connector includes a housing having a terminal channel and an auxiliary terminal channel with a power terminal received in the terminal channel and an auxiliary power terminal received in the auxiliary terminal channel. A TPA device is movably coupled to the housing between an open position and a blocking position for blocking removal of the power terminal from the terminal channel. A protective thermal coupler is held by and movable with the TPA device. The protective thermal coupler has a variable resistive member electrically coupled between the power terminal and the auxiliary power terminal. The variable resistive member provides a shunt so that arcing does not occur when the power terminal is disconnected from the mating power terminal of the mating electrical connector.

Abstract: A power terminal includes a terminal beam having a mating surface. A protective thermal coupler bridge is positioned adjacent the terminal beam having a bridge conductor, an insulating substrate and a bridge pad. The bridge pad has a mating surface. A variable resistive member is electrically coupled between the terminal beam and the bridge conductor to provide a shunt so that arcing does not occur when the power terminal is disconnected from the mating power terminal. The mating surface of the terminal beam is separable before the mating surface of the bridge pad is disconnected so that the resistance in the variable resistive member increases after disconnection of the main power terminal from the mating power terminal and prior to disconnection of the bridge pad from the mating power terminal to shunt the current through the bridge conductor and the variable resistive member during unmating.

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.