Abstract: An electrical connector includes a generally planar terminal and a U-shaped retainer. The electrical connector also includes a resilient spring disposed intermediate the terminal and the retainer. A contact insert distinct from the resilient spring is disposed intermediate the spring and the terminal. The contact insert defines an array of paired negative and positive protrusions. The spring is configured to exert a normal connection force on the array of paired negative and positive protrusions and form electrical contact points between the terminal and a planar mating terminal inserted into a gap between the spring and the contact insert through the array of paired negative and positive protrusions. An electrical connector assembly and a method of manufacturing such an electrical connector assembly are also provided.

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: A power terminal includes a contact portion, a connection portion, and an intermediate portion. The contact and intermediate portions include conductive layers stacked along a direction corresponding to their respective thicknesses. The contact portion includes a main top surface and at least one contact area protruding from the main top surface. Each layer in the contact portion includes at least one first embossed region, the at least one first embossed region of each layer being registered with the at least one first embossed region of an adjacent layer, and the at least one first embossed region of a top layer forming the at least one contact area. A set of power terminals including a plurality of such a power terminal and a connector including such a power terminal are also disclosed.

Abstract: A bus bar assembly includes a nonconductive terminal cap that is configured to secure to an electrically conductive terminal via an attachment feature. The terminal cap has a slot that is configured to expose a terminal portion of the terminal when in an assembled condition. A bus bar has an end that is configured to be received in and extend through the slot when in the assembled condition in which the end is in electrical contact with the terminal portion of the terminal. A nonconductive shroud encloses the bus bar.

Abstract: A shielded electrical connector assembly includes an electromagnetic shield integrally formed from a single sheet of conductive material. The shield has a main wall and four side walls surrounding the main wall. The shield defines an opening opposite the main wall having an opening perimeter that is greater than or equal to a main wall perimeter. One of the four side walls defines at least one side wall opening that is configured to receive a shielded wire cable. A method of manufacturing the shielded electrical connector assembly includes the steps of providing a single planar sheet of conductive material, providing a die and a punch, forming the sheet into a cupped shape having a main wall and four side walls surrounding the main wall using the die and the punch, and forming a side wall opening in one of the four side walls.

Abstract: An electrical connector assembly includes a connector housing defining a cavity in which a pair of electrical terminals is disposed. The assembly also includes a cover that is configured to enclose the cavity, thereby protecting the pair of electrical terminals and thermally manage heat within the cavity. The cover has a thermal management mechanism including one or more liquid ports configured to receive a liquid coolant flow.

Abstract: A bus bar assembly includes a nonconductive terminal cap that is configured to secure to an electrically conductive terminal via an attachment feature. The terminal cap has a slot that is configured to expose a terminal portion of the terminal in an assembled condition. A bus bar has an end that is configured to be received in the slot in the assembled condition in which the end is in electrical contact with the terminal portion of the terminal. A nonconductive shroud encloses the bus bar. The end extends through shroud.

Abstract: An electrical connector assembly includes a connector housing defining a cavity in which at least two electrical terminals are interconnected. The connector housing defines an opening configured to receive a cover that is configured to protect the at least two electrical terminals and thermally manage heat within the cavity. The connector housing may be configured to receive one cover configuration of a plurality of different cover configurations. A first cover configuration in the plurality of different cover configurations provides different mechanism to thermally manage heat within the cavity electrical connector assembly than a second cover configuration in this plurality of different cover configurations.

Abstract: A connector assembly includes a female connector body and a male connector body defining a shroud configured to receive the female connector body. The electrical connector assembly further includes a resilient seal axially surrounding a portion of the female connector body. The seal is disposed intermediate the female connector body and the shroud. The connector assembly additionally includes a seal retainer attached to the female connector body. The female connector body defines an outwardly extending retaining ledge on the forward portion of the female connector body. The seal defines an inwardly extending retaining hook engaging the retaining ledge. A portion of the retaining hook is disposed intermediate the female connector body and the seal retainer.

Abstract: An electrical connector assembly includes an elongate planar terminal extending along a first longitudinal axis having a connection end configured to interconnect the terminal to a corresponding elongate planar mating terminal extending along a second axis and an attachment end configured to attach the terminal to an electrical conductor. The electrical connector assembly also includes a contact spring configured to exert a normal force between the terminal and the mating terminal when the mating terminal is arranged between the contact spring and the connection end such that second axis is parallel to the first axis or when the mating terminal is arranged between the contact spring and the connection end such that the second axis is perpendicular to the first axis.

Abstract: A shielded electrical connector assembly includes an electromagnetic shield integrally formed from a single sheet of conductive material. The shield has a main wall and four side walls surrounding the main wall. The shield defines an opening opposite the main wall having an opening perimeter that is greater than or equal to a main wall perimeter. One of the four side walls defines at least one side wall opening that is configured to receive a shielded wire cable. A method of manufacturing the shielded electrical connector assembly includes the steps of providing a single planar sheet of conductive material, providing a die and a punch, forming the sheet into a cupped shape having a main wall and four side walls surrounding the main wall using the die and the punch, and forming a side wall opening in one of the four side walls.

Abstract: A bus bar assembly includes a nonconductive terminal cap that is configured to secure to an electrically conductive terminal via an attachment feature. The terminal cap has a slot that is configured to expose a terminal portion of the terminal in an assembled condition. A bus bar has an end that is configured to be received in the slot in the assembled condition in which the end is in electrical contact with the terminal portion of the terminal. A nonconductive shroud encloses the bus bar. The end extends through shroud.

Abstract: An electrical connector assembly includes a connector housing defining a cavity in which at least two electrical terminals are interconnected. The connector housing defines an opening configured to receive a cover that is configured to protect the at least two electrical terminals and thermally manage heat within the cavity. The connector housing may be configured to receive one cover configuration of a plurality of different cover configurations. A first cover configuration in the plurality of different cover configurations provides different mechanism to thermally manage heat within the cavity electrical connector assembly than a second cover configuration in this plurality of different cover configurations.

Abstract: A connector assembly includes a female connector body and a male connector body defining a shroud configured to receive the female connector body. The electrical connector assembly further includes a resilient seal axially surrounding a portion of the female connector body. The seal is disposed intermediate the female connector body and the shroud. The connector assembly additionally includes a seal retainer attached to the female connector body. The female connector body defines an outwardly extending retaining ledge on the forward portion of the female connector body. The seal defines an inwardly extending retaining hook engaging the retaining ledge. A portion of the retaining hook is disposed intermediate the female connector body and the seal retainer.

Abstract: An electrical connector assembly includes a planar terminal portion formed of a copper-based material having a connection end and an attachment end. The assembly also includes a U-shaped retainer portion having a first side wall attached to the connection end, a second side wall separated from and substantially parallel to the first side wall, and an end wall interconnecting the first side wall and the second side wall. The connection end is located intermediate the first side wall and the second side wall. The assembly further includes a resilient spring disposed intermediate the second side wall and the terminal portion and attached to the second side wall. The spring is configured to exert a normal connection force on the connection end and a mating connector inserted into a gap between the spring and the connection end.

Abstract: The present invention provides an electrical connector assembly and a method of mating the same. The electrical connector assembly includes a panel sub-assembly which mates to at least one electrical connector body. Preferably two cam leveraging devices which rotate in opposing directions are mounted rotatably to the panel sub-assembly for sliding engagement of respective cam studs engaged rigidly to the electrical connector body. Opposing rotations of the cam leveraging devices along respective and parallel rotation axes causes the panel sub-assembly to move linearly along a mating axis disposed orthogonally to the rotation axes and toward the electrical connector body to a staged position. During linear panel sub-assembly movement from the disconnected position to the staged position, the cam studs slide against a first portion of a track carried by respective cam levers and which generally spirals radially inward toward the rotation axis.

Abstract: A lamp socket includes a housing in the form of an elastomeric grommet that passes through a round hole of a panel to mount the lamp socket to the panel. The grommet has a head at one end that has an outer diameter that exceeds the diameter of the hole and engages the back side of the panel when the head is inserted through the hole. The outer portion of the head consists of a plurality of thick oblique ribs that fold inwardly to reduce the outer diameter of the head responsive to twisting movement of the head in the hole so that a relatively low engage force passes the head through the hole. The grommet further includes a conical shoulder which sealingly engages the front side of the panel and clamps the lamp socket in place.

Abstract: A common ground terminal is adapted for use with wedgebase lamp bulbs of either the single filament of dual filament type in a single filament lamp socket. The common ground terminal has a pair of opposed, upper and lower spring contact arms which biasingly engage opposite sides of a wedgebase when it is inserted into the space between the spring contact arms. The lower spring contact arm has a second spring tab which accommodates the presence of a second contact wire when the dual filament type of wedgebase lamp bulb is used.

Abstract: A lamp socket assembly comprises a lamp bulb having a wedge base, a lamp socket and two electrical terminals. The electrical terminals have receptacle portions which include spring contact arms which engage the contact wires of the lamp bulb and limit its insertion into the lamp socket. The receptacles also include spring detent arms which retain the wedge base in the terminals.

Abstract: A lamp socket assembly which includes a plastic socket body having a tubular portion adapted to receive a socket insert along a first axis and having a connector portion integral therewith which receives the wire terminals along a second axis which is substantially perpendicular to the first axis.