Abstract: A resistor module includes a resistor module housing having an inner cavity. A proximity contact and a ground contact are received in the inner cavity and held by the resistor module housing. A proximity wire, electrically connected to a proximity terminal of the charging inlet assembly, is electrically connected to the proximity contact. A ground wire, electrically connected to a ground terminal of the charging inlet assembly, is electrically connected to the ground contact. A resistor element is received in the inner cavity and coupled to mating ends of the proximity and ground contacts. The resistor element is electrically connected to the proximity terminal through the proximity wire and the proximity contact and is electrically connected to the ground terminal through the ground wire and the ground contact.

Abstract: A battery distribution unit includes a housing having a bottom mounted to a battery case of a battery module and having a component cavity with a contactor therein. The contactor has fixed contacts having terminating ends extending from a bottom end of a contactor housing. The BDU includes terminals at the bottom end of the contactor coupled to the terminating ends and a heat exchanger cap at the bottom end of the contactor. The heat exchanger cap is provided in the component cavity in thermal communication with the fixed contacts and in thermal communication with the battery case of the battery module to dissipate heat from the fixed contacts into the battery case of the battery module.

Abstract: A charging inlet assembly for an electric vehicle includes a housing having a power connector including AC terminals and DC terminals. An AC terminal assembly is coupled to the housing and includes AC bus bars electrically connected to corresponding AC terminals at a separable mating interface. A DC connector is mechanically and electrically connect to the DC contact of the DC connector at a separable mating interface.

Abstract: A battery module frame includes first and second frame sections each having a main body, an upper side wall extending from the main body, and a lower side wall extending from the main body. The main body has a bus bar pad for a bus bar that is configured to be electrically connected to battery cells of the battery module. The upper and lower side walls include upper and lower mounting features. The first and second frame sections are coupled at a seam with the upper mounting features removably coupled together at an upper separable interface and with the lower mounting features removably coupled together at a lower separable interface. The first and second frame sections are coupled together with the bus bar pads of the main bodies coplanar.

Abstract: A cooling system for a power connector of a charging inlet assembly includes a cooling adapter coupled to a housing of the charging inlet assembly including an adapter body forming a cavity. The cooling adapter includes supply and return ports adjacent a cable exit. The cooling system includes a heat exchanger positioned in the cavity of the cooling adapter including a heat exchanger body configured to receive the power cable and/or the terminal. The heat exchanger body is thermally coupled to the power cable or the terminal to dissipate heat therefrom.

Abstract: A charging inlet assembly for an electric vehicle includes a housing having a power connector including AC terminals and DC terminals. An AC terminal assembly is coupled to the housing and includes AC bus bars electrically connected to corresponding AC terminals at a separable mating interface. A DC connector is mechanically and electrically connect to the DC contact of the DC connector at a separable mating interface.

Abstract: A battery module frame includes first and second frame sections each having a main body, an upper side wall extending from the main body, and a lower side wall extending from the main body. The main body has a bus bar pad for a bus bar that is configured to be electrically connected to battery cells of the battery module. The upper and lower side walls include upper and lower mounting features. The first and second frame sections are coupled at a seam with the upper mounting features removably coupled together at an upper separable interface and with the lower mounting features removably coupled together at a lower separable interface. The first and second frame sections are coupled together with the bus bar pads of the main bodies coplanar.

Abstract: A high voltage diagnostic connector includes a housing holding a positive terminal, a negative terminal and a ground terminal with a cover removably coupled to the housing. An HVIL assembly is in the housing having a HVIL contacts and an HVIL shunt. An HVIL switch is held by the housing including a shunt actuator operably coupled to the HVIL shunt to position the HVIL shunt in an un-shunted position to open an HVIL circuit when in the primary position and in a shunted position to close the HVIL circuit when in the secondary position. The shunt actuator is movable between the primary position and the secondary position when testing the positive terminal, the negative terminal and the ground terminal with the testing device during diagnostic testing of the high voltage diagnostic connector.

Abstract: A bus bar module of a battery system includes a bus bar, a sensing circuit carrier, and a fuse assembly. The bus bar is held by a tray and configured to electrically connect two battery cells of the battery system. The sensing circuit carrier includes at least a first electrical conductor and a dielectric insulator surrounding the first electrical conductor. The fuse assembly includes a first holder terminal, a second holder terminal, and a fuse disposed between and electrically connected to the first and second holder terminals. The first holder terminal is electrically connected to the first electrical conductor of the sensing circuit carrier, and the second holder terminal is electrically connected to the bus bar such that the fuse assembly defines a segment of a voltage sensing line from the bus bar through the sensing circuit carrier towards a control device.

Abstract: A battery distribution unit includes a housing having a bottom mounted to a battery case of a battery module and having a component cavity with a contactor therein. The contactor has fixed contacts having terminating ends extending from a bottom end of a contactor housing. The BDU includes terminals at the bottom end of the contactor coupled to the terminating ends and a heat exchanger cap at the bottom end of the contactor. The heat exchanger cap is provided in the component cavity in thermal communication with the fixed contacts and in thermal communication with the battery case of the battery module to dissipate heat from the fixed contacts into the battery case of the battery module.

Abstract: A cooling system for a power connector of a charging inlet assembly includes a cooling adapter coupled to a housing of the charging inlet assembly including an adapter body forming a cavity. The cooling adapter includes supply and return ports adjacent a cable exit. The cooling system includes a heat exchanger positioned in the cavity of the cooling adapter including a heat exchanger body configured to receive the power cable and/or the terminal. The heat exchanger body is thermally coupled to the power cable or the terminal to dissipate heat therefrom.

Abstract: A bus bar module of a battery system includes a bus bar, a sensing circuit carrier, and a fuse assembly. The bus bar is held by a tray and configured to electrically connect two battery cells of the battery system. The sensing circuit carrier includes at least a first electrical conductor and a dielectric insulator surrounding the first electrical conductor. The fuse assembly includes a first holder terminal, a second holder terminal, and a fuse disposed between and electrically connected to the first and second holder terminals. The first holder terminal is electrically connected to the first electrical conductor of the sensing circuit carrier, and the second holder terminal is electrically connected to the bus bar such that the fuse assembly defines a segment of a voltage sensing line from the bus bar through the sensing circuit carrier towards a control device.

Abstract: A high voltage diagnostic connector includes a housing holding a positive terminal, a negative terminal and a ground terminal with a cover removably coupled to the housing. An HVIL assembly is in the housing having a HVIL contacts and an HVIL shunt. An HVIL switch is held by the housing including a shunt actuator operably coupled to the HVIL shunt to position the HVIL shunt in an un-shunted position to open an HVIL circuit when in the primary position and in a shunted position to close the HVIL circuit when in the secondary position. The shunt actuator is movable between the primary position and the secondary position when testing the positive terminal, the negative terminal and the ground terminal with the testing device during diagnostic testing of the high voltage diagnostic connector.

Abstract: An electrical module is configured to be coupled to a tray of a battery distribution assembly. The electrical module includes a housing disposed along an outer surface of the tray. The electrical module also includes at least one electrical circuit device disposed within a cavity of the housing. The electrical module further includes multiple terminals electrically connected to the at least one electrical circuit device. The terminals project outward from the housing and extend through corresponding apertures in the tray for electrically connecting to one or more electrical conductors disposed along an inner surface of the tray.

Abstract: An electrical module is configured to be coupled to a tray of a battery distribution assembly. The electrical module includes a housing disposed along an outer surface of the tray. The electrical module also includes at least one electrical circuit device disposed within a cavity of the housing. The electrical module further includes multiple terminals electrically connected to the at least one electrical circuit device. The terminals project outward from the housing and extend through corresponding apertures in the tray for electrically connecting to one or more electrical conductors disposed along an inner surface of the tray.

Abstract: An electrical connector is shown having a housing having terminal receiving passageways, which receives a plurality of electrical terminals therein. The connector housing has a rear wire seal having a plurality of apertures at a rear face thereof for receiving terminals and a terminated conductor therethrough. At least one of the plurality of electrical terminal passageways is empty, and the sealing plug is positioned in the terminal receiving passageway to seal the cavity from the rear side thereof. The sealing plug also includes a latching surface for latching with the latch of the housing, and further provides a forward portion to deflect an installed shunt downwardly to prevent stubbing of a pin contact of a mating connector.

Abstract: An electrical connector assembly is shown having a housing member with a lever assist which rotatably draws complimentary connectors together. The lever assist is attached by way of mounting studs to a shroud on each side of the sidewall of the connector housing where the lever arms are positioned within the shroud to protect the lever arms and the gear teeth on the free ends of the lever arms.

Abstract: An electrical connector is shown having a housing having terminal receiving passageways, which receives a plurality of electrical terminals therein. The connector housing has a rear wire seal having a plurality of apertures at a rear face thereof for receiving terminals and a terminated conductor therethrough. At least one of the plurality of electrical terminal passageways is empty, and the sealing plug is positioned in the terminal receiving passageway to seal the cavity from the rear side thereof. The sealing plug also includes a latching surface for latching with the latch of the housing, and further provides a forward portion to deflect an installed shunt downwardly to prevent stubbing of a pin contact of a mating connector.

Abstract: An electrical connector assembly is shown having a housing member with a lever assist which rotatably draws complimentary connectors together. The lever assist is attached by way of mounting studs to a shroud on each side of the sidewall of the connector housing where the lever arms are positioned within the shroud to protect the lever arms and the gear teeth on the free ends of the lever arms.

Abstract: A lever mated connector assembly including a housing configured to mate with a header, a wire guide mounted to the housing having a latch with a retaining surface, a lever having a catch with a retaining surface and being coupled to the housing for rotational movement between an unlocked position and a locked position wherein the catch retaining surface engages the latch retaining surface to inhibit movement of the lever out of the locked position. The wire guide is provided with an overstress mechanism to prevent over extension of the latch to a position where the latch is plastically deformed.