Abstract: A female wire terminal includes a box extending longitudinally from a crimp end to an open forward end that is configured to receive a male wire terminal. The box is provided by upper and lower walls joined by a first lateral wall. A second lateral wall is joined to the lower wall opposite the first lateral wall. The upper wall provides a protrusion that is configured to cooperate with an electrical connector. The upper wall overlaps and abuts at a rearward end of a longitudinal edge of the second lateral wall opposite the first lateral wall. The rearward end is opposite the open end.

Abstract: A female wire terminal includes a box extending longitudinally from a crimp end to an open forward end that is configured to receive a male wire terminal. The box is provided by upper and lower walls joined by a first lateral wall. A second lateral wall is joined to the lower wall opposite the first lateral wall. The upper wall provides a protrusion that is configured to cooperate with an electrical connector. The upper wall overlaps and abuts at a rearward end of a longitudinal edge of the second lateral wall opposite the first lateral wall. The rearward end is opposite the open end.

Abstract: An electrical assembly including a first element, such as a connector body, formed of a conductive composite material and a second element formed of a solid metallic material, such as a sheet metal electromagnetic interference shield, defining a fibrous conductive region formed of a plurality of metallic filaments. The conductive composite material forming the first element completely surrounds a portion of the fibrous conductive region. Conductive fibers in the conductive composite material are in intimate contact with the fibrous conductive region, forming a very high number of electrical contact points between the conductive fibers in the conductive composite material and the fibrous conductive region and thereby providing a robust electrical connection between the first element and the second element.

Abstract: An electrical assembly including a first element, such as a connector body, formed of a conductive composite material and a second element formed of a solid metallic material, such as a sheet metal electromagnetic interference shield, defining a fibrous conductive region formed of a plurality of metallic filaments. The conductive composite material forming the first element completely surrounds a portion of the fibrous conductive region. Conductive fibers in the conductive composite material are in intimate contact with the fibrous conductive region, forming a very high number of electrical contact points between the conductive fibers in the conductive composite material and the fibrous conductive region and thereby providing a robust electrical connection between the first element and the second element.

Abstract: A shielded electrical header assembly is provided. The header is configured to be coupled to a first connector connected to a shielded electrical cable and second connector. The header is also configured to be attached to an electrically conductive panel, such as an aluminum battery pack in a hybrid or electric vehicle. The header includes a conductive shield contact that connects the outer conductor of the shielded cable to the panel and a conductive outer connector body that is also connected to the panel and surrounds the terminals and the shield contact of the header, thus providing electromagnetic shielding to the terminals of the header and the connectors. The shield contact is formed of a sheet metal to provide a lower resistance connection between the outer conductor and the panel. A method of manufacturing such a header is also provided.

Abstract: A shielded electrical header assembly is provided. The header is configured to be coupled to a first connector connected to a shielded electrical cable and second connector. The header is also configured to be attached to an electrically conductive panel, such as an aluminum battery pack in a hybrid or electric vehicle. The header includes a conductive shield contact that connects the outer conductor of the shielded cable to the panel and a conductive outer connector body that is also connected to the panel and surrounds the terminals and the shield contact of the header, thus providing electromagnetic shielding to the terminals of the header and the connectors. The shield contact is formed of a sheet metal to provide a lower resistance connection between the outer conductor and the panel. A method of manufacturing such a header is also provided.