Abstract: A tool configured to apply a lubricant includes an insert disposed within a shroud of an electrical connector. The insert has a central cavity and passages extending from the central cavity to portals defined in an outer surface of the insert and a spray valve disposed within the insert configured to dispense a lubricant mist into the central cavity, through the passages to the portals, and onto a seal wiping surface of the electrical connector.

Abstract: An electrical connector including a mounting flange defining a mounting hole extending therethrough that is configured to receive a threaded fastener and a deformable crush rib extending from the mount flange and surrounding the mounting hole is presented herein. A method of assembling an electrical connector to a panel including the steps of inserting a fastener within a mounting hole of a mounting flange defining the mounting hole extending therethrough and a crush rib surrounding the mounting hole, applying a clamping force to the mounting flange via the fastener, and deforming the crush rib via the clamping force applied by the fastener such that the deformed crush rib at least partially fills a gap between an inner wall of the mounting hole and the fastener is also presented herein.

Abstract: A tool configured to apply a lubricant includes an insert disposed within a shroud of an electrical connector. The insert has a central cavity and passages extending from the central cavity to portals defined in an outer surface of the insert and a spray valve disposed within the insert configured to dispense a lubricant mist into the central cavity, through the passages to the portals, and onto a seal wiping surface of the electrical connector.

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: A method of preparing a sealed connector system for connection is presented. The sealed connector system has a male connector body, a female connector body defining a shroud to receive the male connector body, and a resilient seal surrounding the male connector body. The method includes the steps of applying lubricant on a seal wiping surface on the shroud interior and inserting the male connector body within the female connector body such that the resilient seal is in compressive contact with the seal wiping surface. A tool to apply the lubricant includes an insert disposed within the shroud having a central cavity and passages extending from the central cavity to portals defined in an outer surface of the insert and a spray valve disposed within the insert configured to dispense a lubricant mist into the central cavity, through the passages to the portals, and onto the seal wiping surface.

Abstract: An electrical connector including a mounting flange defining a mounting hole extending therethrough that is configured to receive a threaded fastener and a deformable crush rib extending from the mount flange and surrounding the mounting hole is presented herein. A method of assembling an electrical connector to a panel including the steps of inserting a fastener within a mounting hole of a mounting flange defining the mounting hole extending therethrough and a crush rib surrounding the mounting hole, applying a clamping force to the mounting flange via the fastener, and deforming the crush rib via the clamping force applied by the fastener such that the deformed crush rib at least partially fills a gap between an inner wall of the mounting hole and the fastener is also presented herein.

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: A method of preparing a sealed connector system for connection is presented. The sealed connector system has a male connector body, a female connector body defining a shroud to receive the male connector body, and a resilient seal surrounding the male connector body. The method includes the steps of applying lubricant on a seal wiping surface on the shroud interior and inserting the male connector body within the female connector body such that the resilient seal is in compressive contact with the seal wiping surface. A tool to apply the lubricant includes an insert disposed within the shroud having a central cavity and passages extending from the central cavity to portals defined in an outer surface of the insert and a spray valve disposed within the insert configured to dispense a lubricant mist into the central cavity, through the passages to the portals, and onto the seal wiping surface.

Abstract: An electrical terminal connection system includes a first-housing and a second-housing. The first-housing has a first-electrical-terminal and a terminal-hood. The first-electrical-terminal has a first-planar-section having a rectangular cross-section. The terminal-hood encapsulates an inner-surface and edges of the first-electrical-terminal. The second-housing is configured to mate with the first-housing and has a second-electrical-terminal and a sliding-block. The second-electrical-terminal has a second-planar-section having a rectangular cross-section and overlays an outer-surface of the first-electrical-terminal. The second-housing includes a first-fastener element operable to engage a second-fastener element disposed within the first-housing. The second-housing is drawn into the first-housing when the first-fastener element and the second-fastener element are joined.

Abstract: A wire cable assembly, such as those used in electric or hybrid electric vehicles, having a plurality of shielded wire cables spliced together. The center conductors are joined together and enclosed in an inner insulator. The shield conductors of the cable are joined by an electrically conductive sleeve enclosing the inner insulator and attached to the shield conductors of the shielded wire cables. The sleeve separates the outer insulating layers of the shielded wire cables. The sleeve is encased by an outer insulator that is sealed to the outer insulating layers of the shielded wire cables. A method of splicing shielded wire cables together is also presented.

Abstract: An electrical adapter assembly including an adapter housing, an electrical receptacle defined by a first technical standard that is disposed within a first face of the adapter housing. The receptacle is configured to receive a first electrical plug defined by the first technical standard. The electrical adapter assembly also includes a second electrical plug defined by a second technical standard projecting from a second face of the adapter housing and electrically interconnected to the electrical receptacle and a thermally conductive member disposed within the adapter housing and projecting from the first face of the adapter housing. The electrical adapter assembly also contains features for detecting a connection of the electrical adapter assembly to the first plug.

Abstract: An electrical adapter device includes an electrical receptacle defined by a first technical standard, e.g. NEMA 6-15R, NEMA 5-20R, or NEMA 6-20R, disposed within a first face of the electrical adapter device and configured to receive a first electrical plug defined by the same first technical standard. The adapter also includes a second electrical plug, e.g. NEMA 5-15P defined by a second technical standard projecting from a second face of the electrical adapter device. The adapter further includes a moveable locking tang projecting from the first face of the electrical adapter device and configured to be received within a complementary aperture defined by a first plug housing containing the first electrical plug. The locking tang is removable from the aperture when in a disengaged position and the locking tang is secured within the aperture when in an engaged position.

Abstract: An electrical plug assembly including a plug housing having a first set of pins projecting from a first surface and a second set of pins projecting from an opposed second surface. The electrical plug assembly also includes an enclosure slideably attached to the plug housing. The enclosure slides to expose one set of pins while enclosing the other set of pins. The electrical plug assembly further includes a hood pivotally attached to the plug housing and slideably attached to the enclosure. The enclosure is rotatable from a first position to a second position. As the hood rotates, it slides the enclosure from a first location wherein the first set of pins is exposed to a second location wherein the second set of pins is exposed. The first set of pins conform to one technical standard, e.g. NEMA 6-20P while the second set of pins conform to another technical standard, e.g. NEMA 5-15P.

Abstract: A wire cable assembly, such as those used in electric or hybrid electric vehicles, having a plurality of shielded wire cables spliced together. The center conductors are joined together and enclosed in an inner insulator. The shield conductors of the cable are joined by an electrically conductive sleeve enclosing the inner insulator and attached to the shield conductors of the shielded wire cables. The sleeve separates the outer insulating layers of the shielded wire cables. The sleeve is encased by an outer insulator that is sealed to the outer insulating layers of the shielded wire cables. A method of splicing shielded wire cables together is also presented.

Abstract: A connector system including a first connector having a longitudinally extending lock arm defining a lock nib and attached to the first connector. The lock nib is configured to engage a primary lock tab of a second connector when the first and second connectors are in a fully mated position and the lock arm is in a resting position. The lock nib is configured to disengage the primary lock tab and engage a secondary lock tab of the second connector when the lock arm is moved from a resting to an activated position and the first and second connectors are moved to a partially mated position while the lock arm is in the activated position. The connector system generates an audible or tactile click only when the first connector is fully mated with the second connector. The connectors can be disconnected with bare hands, no tools are required.

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 method is provided for assembling a connector assembly to a case. The case includes an inside surface defining an inside of the case, an outside surface defining an outside of the case, and an aperture therethrough providing communication from the inside surface to the outside surface. The connector assembly includes an outer connector having a body with a passage therethrough, an electromagnetic shield, and an inner connector with a terminal therein with a conductor extending from the inner connector in electrical communication with the terminal. The method includes positioning the outer connector on the outside of the case to align the passage of the outer connector with the aperture of the case. The method also includes positioning the inner connector on the inside of the case. The method also includes inserting the inner connector into the passage of the outer connector from the inside of the case.

Abstract: A method is provided for assembling a connector assembly to a case. The case includes an inside surface defining an inside of the case, an outside surface defining an outside of the case, and an aperture therethrough providing communication from the inside surface to the outside surface. The connector assembly includes an outer connector having a body with a passage therethrough, an electromagnetic shield, and an inner connector with a terminal therein with a conductor extending from the inner connector in electrical communication with the terminal. The method includes positioning the outer connector on the outside of the case to align the passage of the outer connector with the aperture of the case. The method also includes positioning the inner connector on the inside of the case. The method also includes inserting the inner connector into the passage of the outer connector from the inside of the case.

Abstract: A first connector is matable to a second connector in an electrical connection system. The first connector has a connector body that contains a primary and a secondary latch. The respective latches and the connector body of the first connector are molded to form a single unitary piece. The single unitary piece is constructed to define a space intermediate the primary latch and the connector body. The space is adapted to fit a latch position assurance lock to prevent displacement of the primary latch. The primary and the secondary latch respectively communicate with at least one primary and at least one secondary latch ramp disposed on the second connector when at least the first connector is unmated from the second connector. A method to assemble an electrical connection system using the single unitary piece of the first connector is also provided.

Abstract: A circuit interruption device (110) is provided in which an interruption element (112) and a fuse element (114) are configured electrically in parallel. The interruption element includes an electrical conductor and a current interrupter capable of severing the electrical conductor to eliminate its capacity to carry current. An exemplary embodiment of a circuit interruption device is capable of detecting an interrupt control signal and actuating in response to the signal.