Eaton Intelligent Power Limited

Royal Precision Products, LLC

James Dawson

Brantley Natter

Jason Degen

Slobodan Pavlovic

Mohamad Zeidan

Jeffrey Chojnacki

Jamie Houmard

Neal Devine

A busbar cooling system includes an enclosure and a conductive assembly. The enclosure has a first non-conductive housing and a second non-conductive housing that are configured to permit fluid to flow through the busbar cooling system, the upper housing having an upper internal wall arrangement and the lower housing having a lower internal wall arrangement, wherein the upper and lower internal wall arrangements collectively define a plurality of distinct and concentrically arranged cavities. The conductive assembly is configured to permit electrical current to pass through the busbar cooling system, said conductive assembly includes an internal cooling core having a plurality individual conductors that are concentrically arranged in a spaced apart relationship to one another, and wherein each cavity is configured to receive a substantial extent of one of the conductors of the internal cooling core.

Busbar cooling system for a vehicle battery pack

A connector system for electrically connecting a power source to other power distribution components or assemblies, for example in a motor vehicle. This connector system includes a male connector assembly with an electrically conductive male terminal assembly having a male terminal body and an internal spring assembly. The male terminal body includes contact arms with irregular outer peripheries configured to reduce the insertion force associated with the male terminal body. The internal spring assembly includes a spring member and a spring holder that ensures and maintains proper relative positioning or alignment of the internal spring member within the male terminal assembly. The connector system also includes a female connector assembly with a female terminal assembly that receives the male terminal assembly and the spring assembly.

Electrical connector system with cylindrical terminal body

A power distribution assembly with boltless busbar system for electrically and mechanically connecting a component to a power source is disclosed. The power distribution assembly includes an interconnecting busbar segment that connects two boltless busbar system together. Each boltless busbar system includes a male busbar assembly and a female busbar assembly. The male busbar assembly includes a male terminal, internal spring member, internal male housing, and external male housing that receives an extent of the male terminal, the internal spring member, and the internal male housing. This male terminal includes a side wall arrangement that defines a receiver and further includes at least one contact arm. An internal spring member with at least one spring arm resides within the male terminal receiver. The female busbar assembly includes a female terminal with a receptacle that is dimensioned to receive both the male terminal and the spring member in a connected position to secure the female busbar assembly to the male busbar assembly.

Power distribution assembly with boltless busbar system

The invention generally provides a connector recording system or platform that includes a recording system designed to interact with a connector system to read an indicia and then transfer, store, and display information associated with the positioning of the connector system in the installed component or device. The connector system includes a male housing assembly, a female housing assembly coupled to the male housing assembly in a connected state, and a connector position assurance assembly with the indicia and a locking member that is movable between locked and unlocked positions. In the locked position, the locking member secures the male housing assembly to the female housing assembly and the indicia can be read by the scanner to signal that the connector position assurance assembly is in the locked position. In the unlocked position, the indicia is in a state that does not allow the scanner to obtain information from the indicia.

Connector recording system with readable and recordable indicia

A shielded electrical connector system is disclosed. A male connector assembly includes a male terminal, a non-conductive internal male, and a conductive external male housing that receives an extent of the internal male housing. The male terminal includes a side wall arrangement defining a receiver and including at least one contact arm. An internal spring member resides within the male terminal receiver. A female connector assembly includes a female terminal with a receptacle that receives the male terminal and the spring member. Wherein in a connected position, the male terminal, the spring member, and the female terminal reside within an external female housing; the male terminal and the spring member reside within an internal female housing; the male terminal and the spring member reside within the internal male housing; and a major extent of both the male terminal and the spring member extend beyond the external male housing.

Shielded electrical connector system with internal spring component

A busbar for use in mechanically and electrically connecting components in a device or system. The busbar includes a plurality of conductors arranged to provide two opposed end portions and an intermediate portion, wherein each of the conductors has a plurality of intermediate extents that traverse the intermediate portion. The intermediate portion including: (A) an unfused segment where no intermediate extents of the conductors are fused together to form a single consolidated conductor, and (B) a fused segment that includes (i) a partial solidification zone where a majority of the intermediate extents of the conductors are fused together to form a partially solidified region that provides a single consolidated conductor, (ii) a full solidification zone where all of intermediate extents of the conductors are fused together to form a fully solidified region that provides a single consolidated conductor, and (iii) an unsolidified region where all of the intermediate extents of the conductors are not fused together.

Electrical busbar and method of fabricating the same

A busbar for electrically connecting components in a power distribution system. The busbar includes a plurality of conductors formed from a first material and having a first end, a second end, and an intermediate portion. The first end, the second end, and the intermediate portion can be integrally formed with one another and stacked to provide the busbar with a first geometry. The intermediate portion includes a handling section with a rigidity that is less than a rigidity of a corresponding section of a reference busbar that has (a) a geometry that substantially matches the first geometry and (b) has a single conductor formed from a material substantially similar to the first material. The handling section is formed using an edge-based fusion process that fuses a portion of the conductors together to form a single consolidated conductor in that section of the busbar.

The present disclosure relates to a connector system that provides a sealed and grounded electrical connection for a component of a power management system, like those found in a battery-powered motor vehicle. The connector system includes a male connector assembly and an adaptor assembly. The adaptor assembly includes: (i) a capacitor assembly, (ii) a female terminal assembly, and (iii) a busbar assembly. An internal electrical connection state is defined when: (a) the female terminal assembly is electrically coupled to the capacitor assembly, (b) the capacitor assembly is electrically coupled to the busbar assembly, and (c) the busbar assembly is electrically coupled to an extent of the component of the power management system. In the internal electrical connection state, the electrical couplings are sealed from the external environment which increases the operating life, durability and reliability of the adaptor assembly, the connector system and the power management system component.

Connector system for a component in a power management system in a motor vehicle

The connector system is configured for use in a power distribution system of a motor vehicle, and wherein the connector system includes a female housing, female terminal assembly, and a female interlock (FIL) assembly. The female housing having an arrangement of side walls that define a receptacle that is configured to receive the female terminal assembly. The female interlock (FIL) assembly positioned within the female terminal assembly that resides within the receptacle of the female housing to define a fully assembled female state S, whereby the FIL assembly is configured to be coupled to an interlock circuit that prevents electrical current from flowing through the female terminal assembly prior to connection of the female terminal assembly to a male terminal assembly.

Connector system including an interlock system

An electrical connector assembly for electrically and mechanically connecting a component to a power source is disclosed. The connector assembly includes a male terminal with side walls defining a receiver. The side wall includes a contact arm that extends across an aperture in the side wall. The assembly also includes an internal spring member dimensioned to reside within the receiver of the male terminal. The spring member has at least one spring arm that extends from a base portion. The assembly further includes a female terminal with a receptacle dimensioned to receive both the male terminal and the spring member residing within the receiver of the male connector to define a connected position. In the connected position, the spring arm exerts an outwardly directed biasing force on the contact arm of the male terminal to outwardly displace it into engagement with an inner surface of the receptacle to ensure connectivity.

Electrical connector assembly with internal spring component

An electrical connector system for electrically and mechanically connecting with a component in a motor vehicle is disclosed. The connector system includes a motor vehicle component and a male connector assembly with a male housing that receives a male terminal. This terminal includes a receiver and side walls with a contact arm that extends across an aperture in the side wall. An internal spring member with at least one spring arm resides within the male terminal receiver. A female connector assembly includes a female terminal with a receptacle that receives both the male terminal and the spring member. A female housing receives the female terminal and an extent of the male connector assembly. When the connector system moves from the partially assembled state to a connected position for connection of the vehicle component, the male connector assembly is inserted into female housing, the contact arm is brought into sliding engagement with an angled internal segment of the female housing, and the contact arm is inwardly displaced as the contact arm slidingly engages with the angled internal segment.

Growing community of inventors

Carol Stream, IL, United States of America

James Dawson