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: 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 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 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: A two-piece high voltage (HV) terminal frame having a terminal frame and a contact spring. The terminal frame includes at least a top portion, a bottom portion, and a middle portion forming an opening for receiving a first bus bar and a second bus bar. The contact spring is configured to engage the top portion of the terminal frame, wherein the contact spring includes a spring portion that extends into the opening of the terminal frame.

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 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 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 single-piece high voltage (HV) terminal frame includes a top wall, a bottom wall, and a side wall extending between the top wall and the bottom wall. The top wall includes a first top wall layer and an adjacently located second top wall layer. The side wall includes a first side wall layer and an adjacently located second side wall layer. The bottom wall includes a first bottom wall layer and an adjacently located second bottom wall layer. A single-layer contact spring extends from the first top wall layer, wherein the single-layer contact spring is bent to extend into a space located between the top wall and the bottom wall.

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 single-piece high voltage (HV) terminal frame includes a top wall, a bottom wall, and a side wall extending between the top wall and the bottom wall. The top wall includes a first top wall layer and an adjacently located second top wall layer. The side wall includes a first side wall layer and an adjacently located second side wall layer. The bottom wall includes a first bottom wall layer and an adjacently located second bottom wall layer. A single-layer contact spring extends from the first top wall layer, wherein the single-layer contact spring is bent to extend into a space located between the top wall and the bottom wall.

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 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 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: 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 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 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.