Abstract: An electrical connector assembly includes a connector housing defining a cavity and an opening providing access to the cavity, first and second direct current (DC) terminals disposed within the cavity, and first and second busbars electrically and mechanically attached directly to the first and second DC terminals respectively. The first and second busbars each have a rectangular cross section and wherein the first and second busbars extend through the opening such that portions of the first and second busbars are outside of the connector housing. A method of manufacturing an electrical connector assembly is also provided.

Abstract: An electrical charging inlet assembly includes a circuit board assembly, a filler material, and a heater core. The circuit board assembly includes a heater. The filler material that is thermally-conductive and disposed around the heater. The heater core thermally-engages the filler material.

Abstract: An electrical connector assembly includes a connector housing in which a pair of electrically conductive busbars are disposed, a metallic cooling plate in thermal communication with major surfaces of the pair of electrically conductive busbars, and a dielectric structure that is configured to prevent electrical contact between the pair of electrically conductive busbars and the cooling plate.

Abstract: The disclosure shows an electrical connector assembly including a connector housing with a cavity housing an electrical terminal, and a cover designed to enclose the cavity for protection and thermal management. The cover features a thermal management mechanism with multiple pneumatic ports strategically positioned to guide airflow through the cavity. This innovative design ensures efficient heat dissipation within the cavity, enhancing the overall performance and longevity of the electrical connector assembly.

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: An electric vehicle charging system includes a temperature sensor for measuring the temperature of an inlet terminal of an electric vehicle charging inlet and an electronic controller configured to obtain an initial temperature value of the temperature sensor, obtain a current temperature value of the temperature sensor, calculate the inlet terminal temperature based on the initial temperature value, the current temperature value, a predetermined temperature sensor normalization factor, and a predetermined terminal normalization factor for the time after application of electrical power to the inlet terminal, and regulate the application of electrical power to the inlet terminal to maintain the inlet terminal temperature below a predetermined temperature threshold based on the calculated inlet terminal temperature. A method and a computer readable medium containing program instructions for determining an inlet terminal temperature of an electric vehicle charging inlet are also disclosed.

Abstract: An electrical connector assembly includes a connector housing defining a cavity and an opening providing access to the cavity, first and second direct current (DC) terminals disposed within the cavity, and first and second busbars electrically and mechanically attached directly to the first and second DC terminals respectively. The first and second busbars each have a rectangular cross section and wherein the first and second busbars extend through the opening such that portions of the first and second busbars are outside of the connector housing. A method of manufacturing an electrical connector assembly is also provided.

Abstract: An electrical connector includes a plurality of cylindrical electrical terminals connected to ends of a plurality of first electrical cables, a housing defining a plurality of housing terminal cavities in which the plurality of cylindrical electrical terminals is disposed, and a cover attached to the housing having a plurality of cover cavities that is axially aligned with the plurality of housing terminal cavities. The plurality of cover cavities is configured to receive the plurality of cylindrical electrical terminals as it is inserted within the plurality of housing terminal cavities.

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 power inlet connector assembly configured for use in charging an electrical vehicle includes a housing subassembly containing a plurality of direct current (DC) electrical terminals configured to mate with corresponding direct current electrical terminals of a power outlet connector of an electrical vehicle charging device external to the electrical vehicle and a cover subassembly configured to be connected and disconnected from the housing subassembly. The cover subassembly contains electrical bus bars and alternating current (AC) electrical terminals having first ends configured to mate with corresponding AC electrical terminals of a power outlet connector of an electrical vehicle charging device. The electrical bus bars are configured to be connected and disconnected with the DC electrical terminals and the AC electrical terminals are configured to be inserted and removed from terminal cavities defined by the housing subassembly.

Abstract: An electrical connector assembly includes a connector housing defining a cylindrical terminal cavity, an electrical terminal having a cylindrical portion, and an electrical terminal seal. The electrical terminal seal includes a base formed of a compliant material and a cylindrical protrusion integrally formed with the base and extending from a major surface of the base. The electrical terminal seal defines a cylindrical aperture extending through the protrusion. The protrusion includes a first circumferential rib that is integrally formed with the protrusion. The first circumferential rib extends into the aperture from an inner surface of the protrusion.

Abstract: An electrical connector assembly includes a connector housing in which a pair of electrically conductive busbars are disposed, a metallic cooling plate in thermal communication with major surfaces of the pair of electrically conductive busbars, and a dielectric structure that is configured to prevent electrical contact between the pair of electrically conductive busbars and the cooling plate.

Abstract: An electrical connector assembly includes a connector housing defining a cavity in which an electrical busbar is disposed. The connector housing defines an opening to the cavity. The electrical connector assembly also includes a cover configured to enclose the cavity. The cover has an inlet port, an outlet port, and a coolant channel that is in fluidic communication with the inlet port and the outlet port. A portion of the cover is in intimate thermal contact with the electrical busbar.

Abstract: An electrical connector assembly includes a connector housing and a busbar having a rectangular cross section defining two opposed major surfaces and two opposed minor surfaces disposed within the connector housing. A planar surface is defined by one of the two opposed major surfaces of the busbar. The electrical connector assembly further includes a cooling plate that is sized, shaped, and arranged to be in conductive thermal contact with the planar surface of the busbar. The cooling plate is configured to reduce a temperature of the busbar.

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: 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 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 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 includes a plurality of cylindrical electrical terminals connected to ends of a plurality of first electrical cables, a housing defining a plurality of housing terminal cavities in which the plurality of cylindrical electrical terminals is disposed, and a cover attached to the housing having a plurality of cover cavities that is axially aligned with the plurality of housing terminal cavities. The plurality of cover cavities is configured to receive the plurality of cylindrical electrical terminals as it is inserted within the plurality of housing terminal cavities.

Abstract: An electrical connector assembly includes a connector housing defining a cylindrical terminal cavity, an electrical terminal having a cylindrical portion, and an electrical terminal seal. The electrical terminal seal includes a base formed of a compliant material and a cylindrical protrusion integrally formed with the base and extending from a major surface of the base. The electrical terminal seal defines a cylindrical aperture extending through the protrusion. The protrusion includes a first circumferential rib that is integrally formed with the protrusion. The first circumferential rib extends into the aperture from an inner surface of the protrusion.