Abstract: A contactor includes first and second fixed contacts coupled to a housing having mating ends located in the cavity. The contactor includes a movable contact movable within the cavity between a mated position and an unmated position. The movable contact engages the second mating end in the mated position and is separated from the second fixed contact in the unmated position. The contactor includes a coil assembly in the cavity operated to move the movable contact. The contactor includes a magnetic shroud coupled to at least one of the movable contact and the second fixed contact to provide a magnetic holding force to hold the movable contact relative to the second fixed contact in the mated position.

Abstract: A contactor includes a housing and first and second fixed contacts coupling to the housing having mating ends received in the cavity of the housing and terminating ends outside of the housing. A movable contact is movable within the cavity between a mated position and an unmated position that engages the mating end of the second fixed contact in the mated position and is separated from the second fixed contact in the unmated position. A flexible busbar is coupled to the first mating end and coupled to the movable contact. The flexible busbar electrically connects the first fixed contact and the movable contact in both the mated position and the unmated position. A coil assembly in the cavity operates to move the movable contact between the unmated position and the mating position.

Abstract: A battery distribution unit includes a housing having a bottom mounted to a battery case of a battery module and having a component cavity with a contactor therein. The contactor has fixed contacts having terminating ends extending from a bottom end of a contactor housing. The BDU includes terminals at the bottom end of the contactor coupled to the terminating ends and a heat exchanger cap at the bottom end of the contactor. The heat exchanger cap is provided in the component cavity in thermal communication with the fixed contacts and in thermal communication with the battery case of the battery module to dissipate heat from the fixed contacts into the battery case of the battery module.

Abstract: A contactor includes first and second fixed contacts coupled to a housing having mating ends located in the cavity. The contactor includes a movable contact movable within the cavity between a mated position and an unmated position. The movable contact engages the second mating end in the mated position and is separated from the second fixed contact in the unmated position. The contactor includes a coil assembly in the cavity operated to move the movable contact. The contactor includes a magnetic shroud coupled to at least one of the movable contact and the second fixed contact to provide a magnetic holding force to hold the movable contact relative to the second fixed contact in the mated position.

Abstract: An electrical connector assembly having a first electrical connector or header including a base and a shroud extending therefrom. The shroud defines a first opening arranged opposite the base and a second lateral opening defined between two ends thereof. A second or mating connector of the assembly includes a mating end received within the first opening of the shroud in an insertion direction. A body of the second electrical connector is received within the second lateral opening of the shroud and includes a pair of covers or hoods with channels for receiving and mechanically joining the two ends of the shroud.

Abstract: An electrical connector assembly having a first electrical connector or header including a base and a shroud extending therefrom. The shroud defines a first opening arranged opposite the base and a second lateral opening defined between two ends thereof. A second or mating connector of the assembly includes a mating end received within the first opening of the shroud in an insertion direction. A body of the second electrical connector is received within the second lateral opening of the shroud and includes a pair of covers or hoods with channels for receiving and mechanically joining the two ends of the shroud.

Abstract: A bus bar module of a battery system includes a bus bar, a sensing circuit carrier, and a fuse assembly. The bus bar is held by a tray and configured to electrically connect two battery cells of the battery system. The sensing circuit carrier includes at least a first electrical conductor and a dielectric insulator surrounding the first electrical conductor. The fuse assembly includes a first holder terminal, a second holder terminal, and a fuse disposed between and electrically connected to the first and second holder terminals. The first holder terminal is electrically connected to the first electrical conductor of the sensing circuit carrier, and the second holder terminal is electrically connected to the bus bar such that the fuse assembly defines a segment of a voltage sensing line from the bus bar through the sensing circuit carrier towards a control device.

Abstract: A battery distribution unit includes a housing having a bottom mounted to a battery case of a battery module and having a component cavity with a contactor therein. The contactor has fixed contacts having terminating ends extending from a bottom end of a contactor housing. The BDU includes terminals at the bottom end of the contactor coupled to the terminating ends and a heat exchanger cap at the bottom end of the contactor. The heat exchanger cap is provided in the component cavity in thermal communication with the fixed contacts and in thermal communication with the battery case of the battery module to dissipate heat from the fixed contacts into the battery case of the battery module.

Abstract: A bus bar module of a battery system includes a bus bar, a sensing circuit carrier, and a fuse assembly. The bus bar is held by a tray and configured to electrically connect two battery cells of the battery system. The sensing circuit carrier includes at least a first electrical conductor and a dielectric insulator surrounding the first electrical conductor. The fuse assembly includes a first holder terminal, a second holder terminal, and a fuse disposed between and electrically connected to the first and second holder terminals. The first holder terminal is electrically connected to the first electrical conductor of the sensing circuit carrier, and the second holder terminal is electrically connected to the bus bar such that the fuse assembly defines a segment of a voltage sensing line from the bus bar through the sensing circuit carrier towards a control device.