Delphi Technologies, Inc.

Aptiv Technologies Limited

Aptiv Technologies Ag

Don E Bizon

Rangarajan Sundarakrishnamachari

Nicholas A Durse

Anthony Raschilla

Thomas Mathews

Patrick Joseph Reedy

Terry A George

William C Lovitz

Troy A Iler

Christopher Adrian Margrave

Michael L Mellott

John Thomas Kightlinger

Steven A Musick

Steven William Marzo

William C Ketterer

Kenneth B Germ

William T Madden

Eric E Shasteen

Jeffrey S Kiko

Mark Fredrickson

Ryan E White

John Kightlinger

Jacob Friedrich

Steve Marzo

Mark A Plant

Anthony C Raschilla

John Pechatsko

Brandon M Moore

Thomas Matthews

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.

Hybrid electric charging inlet

An electrical connector assembly includes a connector housing, a planar busbar having a rectangular cross section defining two opposed major surfaces and four minor surfaces, a cooling plate that is sized, shaped, and arranged to be in conductive thermal contact with a first major surface of the planar busbar, and an L-shaped busbar partially disposed within the connector housing having a first end connected to an electrical terminal and having a second end attached to, and in conductive thermal contact with, a second major surface of the planar busbar. The cooling plate is configured to reduce a temperature of the planar busbar and the attached L-shaped busbar. A method of assembling such an electrical connector is also presented.

High power electrical header connector with cooling features

An electrical power supply cord includes a wire cable comprising a plurality of separate conductors, a plurality of plug terminals connected to the plurality of separate conductors, a molded inner plug encasing a connection between the plurality of plug terminals and the plurality of separate conductors, and an in-mold bonding adhesive disposed intermediate the connection between the plurality of plug terminals and the plurality of separate conductors and the molded inner plug.

Electric vehicle supply equipment power supply cord

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.

Electrical connector assembly with liquid cooling features

A splice connector assembly configured to conduct more than 1 kilowatt of electricity includes a terminal having a connection portion configured to interconnect with a corresponding mating terminal. The terminal also has an attachment portion. The attachment portion has a planar shape. The attachment portion is attached to a first wire electrical cable and is also attached to a second wire electrical cable. The first cable has a different cross-sectional area than the second cable. The splice connector assembly also includes a dielectric housing defining a cavity in which the terminal is disposed.

Splice connector

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.

An electrical plug assembly including a plug housing, a ground pin and a first power blade projecting from the surface of the plug housing; and a power socket disposed within the plug housing. The surface defines an aperture surrounding the power socket. The assembly further includes an adapter plate including a second power blade having a first portion projecting from a first surface and a second portion projecting from an opposed second surface. Ground pin and first power blade apertures extend through the adapter plate. The second portion of the second power blade is received within the power socket and the ground pin and the first power blade are received within the ground pin and first power blade apertures respectively. The ground pin and the first power blade each project from the first surface of the adapter plate. The adapter plate allows the plug assembly to meet NEMA 5-15P or 6-20P standards.

Adaptable electrical plug assembly

An electrical outlet wall plate includes a plate having an outer surface, an inner surface, and a peripheral edge. The outlet wall plate defines a socket opening configured to receive an electrical outlet socket and defining a fastener opening configured to receive a fastener configured to secure the outlet wall plate to the outlet socket. The outlet wall plate further includes a plug stabilizing feature having an inner wall, an outer wall, and a top wall. The plug stabilizing feature projects from the outer surface of the plate and at least partially surrounding a perimeter of the socket opening. The outlet wall plate limits lateral and vertical movement of the plug terminals in the socket and protects the operator from inadvertent contact with plug terminals the as the plug is inserted into the socket.

Electrical socket outlet plate having plug stabilizing features

An electrical connector system including a male connector having a male terminal that defines a first blade longitudinally projecting from the male terminal and a second blade longitudinally projecting from the same male terminal. A first blade width is less than a second blade width and a first blade length is less than a second blade length. The male terminal further defines a pair of crimp wings configured to attach the male terminal to a wire cable. The system further includes a female connector having a first female terminal configured to receive the first blade and a second female terminal configured to receive the second blade, thereby electrically interconnecting the first female terminal, the second female terminal, and the wire cable.

Electrical connector system

An electric vehicle supply equipment (EVSE) assembly for an electric vehicle (EV) or plug-in hybrid electric vehicle (PHEV), often referred to as, optionally having one of at least two interchangeable power supply cords with plugs that conform to different technical standards, such as National Electrical Manufacturers Association (NEMA) 5-15P or 6-20P. The interchangeable power supply cord plugs each include a thermistor adapted to monitor plug temperatures. The electronic module is configured to disable charging until a proper resistance of the thermistor in the plug is detected. The electronic module is also configured to automatically switch between 120 volt and 240 volt operation based on which of the interchangeable power supply cords is connected to the electronic module.

Electric vehicle power supply equipment with interchangeable power supply cords conforming to different technical standards

A connector assembly, such as a high voltage electrical connector assembly, includes a first connector having a first housing and an intermediate housing attached to the first housing. The intermediate housing is moveable from a first position to a second position. A flexible retaining arm is configured to hold the intermediate housing in the first position. The connector assembly further includes a second connector having a second housing. The second housing defines a release wedge that engages and flexes the retaining arm, thereby releasing the intermediate housing from engagement with the retaining arm and allowing the intermediate housing to move from the first position to the second position as the first connector is connected to the second connector. A terminal in the first housing is enclosed within the intermediate housing in the first position, and protrudes from an aperture in a surface of the intermediate housing in the second position.

Right angle connector with terminal contact protection

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.

An electrical connector system having a male and female connector. The male connector includes a U-shaped shroud axially surrounding a male terminal having an opening generally perpendicular to the male terminal's longitudinal axis. The female connector includes a female terminal having two openings, one generally parallel with the female terminal's longitudinal axis and another generally perpendicular to that axis. The male and female terminals mate in a parallel configuration having the male terminal axis generally parallel to the female terminal axis or in a perpendicular configuration having the male terminal axis generally perpendicular to the female terminal axis. A connector body holds the female terminal. The connector body defines a locking means that releasably secures the connector body to the shroud in both the parallel and perpendicular mating configurations. The locking means may include a triangular shaped lock tab that engages a similarly shaped lock aperture.

Electrical connector system connectable in a straight or right angle configuration

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.

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Boardman, OH, United States of America

Don E Bizon