Abstract: A header connector includes a header housing that includes a base having a terminal cavity. The header housing includes a mounting flange mounted to a first surface of a panel. The base is received in an opening in the panel. The header housing includes a shroud forming a chamber configured to receive a plug connector. The base includes a housing latching feature. The header connector includes a panel seal coupled to the header housing located between the mounting flange and the panel. The header connector includes a mounting clip having a plate mounted to a second surface of the panel. The mounting clip includes a clip latching feature interacting with the housing latching feature to secure the header housing to the panel. The mounting clip is secured to the base of the header housing such that the panel is captured between the plate of the mounting clip and the mounting flange of the header housing.

Abstract: A charging inlet assembly includes a housing extending between a front and a rear. The housing has a DC section includes DC terminal channels configured to receive DC terminals. The housing has an AC section including AC terminal channels configured to receive AC terminals. The DC section configured for mating with a DC charging connector at the front. The AC section configured for mating with an AC charging connector at the front. The housing includes an indicator opening. The charging inlet assembly includes a human machine interface (HMI) assembly coupled to the rear of the housing. The HMI assembly includes a charging indicator aligned with the indicator opening. The charging indicator is visible from the front of the housing to indicate a charging status of the charging inlet assembly.

Abstract: A power harness includes a housing configured to be mated with a mating harness connector. The power harness includes a power conductor extending from the housing and a power contact received in the housing having a terminating end terminated to the power conductor and a mating end for mating with a mating power contact of the mating harness connector. The power contact includes a base plate and side walls extending from the base plate on opposite sides of a gap with outer edges forming mating interfaces for mating engagement with the mating power contact. The power harness includes a threaded connector passing through the housing and located in the gap between the side walls for threadably coupling to a mating threaded connector of the mating harness connector.

Abstract: An electrical connector assembly includes a housing defining a front opening for receiving a mating connector in a mating direction, an electrical terminal arranged within an interior of the housing, and a terminal position assurance (TPA) device received within a rear opening of the housing in an installation direction. The TPA device includes a body defining a central opening for receiving a cable to be attached to the terminal, and an elastic element defined on a front end of the body. The elastic element includes a contact surface protruding from the front end of the body for engaging with the terminal in an installation direction of the TPA device. The contact surface engages with the terminal before the TPA device reaches an installed position within the housing in the installation direction.

Abstract: A power connector includes a housing having terminal channels holding charging terminals for mating with a charging connector. Power conductors are terminated to cable connectors of the corresponding charging terminals. The power connector includes a cooling module thermally coupled to the charging terminals. The cooling module includes a carrier having pockets. The cooling module includes phase change elements received in the corresponding pockets and held relative to each other by the carrier. The phase change elements are thermally coupled to the corresponding cable connectors to lower operating temperatures of the charging terminals during charging.

Abstract: A charging inlet assembly includes a charging inlet housing having terminal channels and cable channels. The charging inlet assembly includes charging terminals including a first charging terminal and a second charging terminal received in the corresponding terminal channels. The charging inlet assembly includes first and second cable assemblies received in the corresponding cable channels. The first cable assembly includes a first DC cable and a first AC cable both electrically connected to the first charging terminal. The second cable assembly includes a second DC cable and a second AC cable both electrically connected to the second charging terminal.

Abstract: A charging inlet assembly for an electric vehicle includes a charging inlet housing, charging terminals held in the charging inlet housing, and a temperature sensor plugged into the charging inlet housing for monitoring temperature of at least one of the charging terminals.

Abstract: A power harness for a charging inlet assembly includes a harness housing holding a power cable in a cable slot A ring insert of the power cable is aligned with a bore of a hub of the housing that receives a threaded bolt with an insulating cover and an insulating cap. A contact ring is received in the hub with a first end connected to the ring insert and a second end electrically connected to a charging terminal. A threaded socket is received in the hub and passes through the contact ring for threadably coupling to the charging terminal. The outer end of the threaded socket has a threaded bore receiving the threaded shaft of the threaded bolt.

Abstract: A power harness includes a cable having a ring insert received in an opening electrically connected to the cable body and having a cable seal sealed to the flat cable. The power harness includes a housing having a chamber with a cable slot and a bore passing through a hub. The power harness includes a threaded bolt received in the hub passing through the ring insert to threadably couple to a mating harness. The threaded bolt includes an insulating cover on the head and an insulating cap extending from the threaded shaft. The threaded bolt includes a bolt seal sealed to the housing. The power harness includes a contact ring received in the hub aligned with the ring insert with an opening that receives the threaded bolt. A first end engages and is electrically connected to the ring insert and a second end is electrically connected to the mating harness.

Abstract: A DC terminal module for a charging inlet assembly of an electric vehicle includes a housing having a housing base mounted to a charging inlet housing. The housing includes a cable mount at a bottom that receives a DC cable assembly from the bottom. The DC terminal module includes a DC terminal assembly received in a terminal chamber with a pin terminal extending into a receptacle of the charging inlet assembly for mating with the charging connector. The DC terminal assembly includes a terminal busbar extending from the pin terminal to the cable mount at the bottom of the DC housing for electrical connection to the DC cable assembly at the bottom of the DC housing.

Abstract: A wire harness for a charging inlet of a vehicle includes first and second high voltage wires having first and second conductors. An inline disconnect electrically connects the first and second conductors and is configured to allow the conductors to be disconnected. The inline disconnect includes a housing having a central cavity, a first chamber at a first end that receives the first high voltage wire, and a second chamber open to the central cavity at a second end that receives the second high voltage wire. First and second disconnect contacts terminated to the conductors are received in the central cavity. A connecting element couples the first and second disconnect contacts and is removable from the disconnect contacts to allow disconnection of the first and second disconnect contacts to electrically separate the first and second high voltage wires.

Abstract: A terminal assembly for a charging inlet assembly includes a terminal cable having a conductor. The terminal assembly includes a terminal having a pin at a mating end and a terminating end opposite the mating end terminated to the conductor at an end of the terminal cable. The terminal assembly includes a terminal cover having a cover body including a bore that receives the terminating end of the terminal and the end of the terminal cable. The terminal cover includes a latch configured to secure the terminal and the terminal cable to a housing of the charging inlet assembly. The terminal cover includes a terminal cover seal configured to be sealed to the housing of the charging inlet assembly.

Abstract: A charging inlet assembly includes a housing extending between a front and a rear. The housing has a DC section including DC terminal channels that are configured to receive DC terminals. The housing has an AC section including an AC module chamber. The DC section is configured for mating with a DC charging connector at the front. The AC section is configured for mating with an AC charging connector at the front. The charging inlet assembly includes an AC charging module removably received in the AC module chamber. The AC charging module includes an AC insert extending between an insert front and an insert rear. The AC insert includes AC terminal channels between the insert front and the insert rear. The AC charging module include AC terminals received in the AC terminal channels. The AC terminals are terminated to ends of AC cables extending from the insert rear. The AC terminals and the AC cables are removable from the housing with the AC insert.

Abstract: A charging inlet assembly for an electric vehicle includes a charging inlet housing having a chamber at the rear and a power connector at a front for receiving a charging connector. The power connector includes terminal channels. The charging inlet assembly includes charging terminals each having a mating pin and a terminating end. The charging inlet assembly includes a terminal position assurance device coupled to the charging inlet housing having a terminal locating plate located in the chamber to interface with the terminating ends of the charging terminals. The terminal position assurance device includes an actuator at an exterior of the charging inlet housing to operate the terminal position assurance device from the exterior of the charging inlet housing.

Abstract: A power harness includes a plug housing holding a power contact and a busbar received in a chamber of the plug housing. The power contact has a mating portion having a separable mating interface configured to be plugged into a header contact stack of header contacts of the header connector when mated with the header connector. The busbar is welded to a weld pad at a terminating portion of the power contact. A threaded bolt passes through the plug housing configured to be threadably coupled to a threaded connector of the header connector to secure the plug housing to the header connector.

Abstract: A cap for an electrical connector comprises a first cap body defining a first portion of a first circular opening, and a second cap body defining a second portion of a first circular opening. The second cap body is hingedly connected to the first cap body and movable between an open position and a closed position. In the closed position, first and second portions of the first cap body and the second cap body define a circular opening sized to receive a conductive cable therethrough.

Abstract: A power connector includes a housing having a terminal channel and a terminal received in the terminal channel including 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 cable connector includes a pad configured to be terminated to a power cable. The power connector includes a heat exchanger thermally coupled to the pad of the terminal. The heat exchanger includes a coolant channel for coolant flow through the heat exchanger for actively cooling the terminal. The heat exchanger includes a thermally conductive separator electrically isolating the heat exchanger from the pad of the terminal.

Abstract: A charging inlet assembly includes a housing extending between a front and a rear having a DC section configured for mating with a DC charging connector and an AC section configured for mating with an AC charging connector. The charging inlet assembly includes an AC charging module coupled to the rear of the housing at the AC section having an AC terminal holder holding AC terminals. The AC charging module is removable from the housing wherein the AC terminals are removed from the housing with the AC terminal holder. A DC charging module is coupled to the rear of the housing at the DC section having a DC terminal holder holding DC terminals. The DC charging module is removable from the housing wherein the DC terminals are removed from the housing with the DC terminal holder.

Abstract: An electrical connector assembly includes a housing defining a front opening for receiving a mating connector in a mating direction, an electrical terminal arranged within an interior of the housing, and a terminal position assurance (TPA) device received within a rear opening of the housing in an installation direction. The TPA device includes a body defining a central opening for receiving a cable to be attached to the terminal, and an elastic element defined on a front end of the body. The elastic element includes a contact surface protruding from the front end of the body for engaging with the terminal in an installation direction of the TPA device. The contact surface engages with the terminal before the TPA device reaches an installed position within the housing in the installation direction.

Abstract: A wire harness for a charging inlet of a vehicle includes first and second high voltage wires having first and second conductors. An inline disconnect electrically connects the first and second conductors and is configured to allow the conductors to be disconnected. The inline disconnect includes a housing having a central cavity, a first chamber at a first end that receives the first high voltage wire, and a second chamber open to the central cavity at a second end that receives the second high voltage wire. First and second disconnect contacts terminated to the conductors are received in the central cavity. A connecting element couples the first and second disconnect contacts and is removable from the disconnect contacts to allow disconnection of the first and second disconnect contacts to electrically separate the first and second high voltage wires.