Tyco Electronics Corporation

Te Connectivity Solutions Gmbh

Te Connectivity Corporation

Te Connectivity Services Gmbh

Kevin John Peterson

Aaron James De Chazal

Clara Marguerite Rhodes

Hurley Chester Moll

Matthew Bryan Hitchcock

Randy Gray Simmons

Nathan Philip Myer

David Bruce Sarraf

David Allen Klein

Victor Eugene Slack

Kurt Thomas Zarbock

Eric Charles Laurer

Joseph Edward Geniac

Jeremy Christin Patterson

Ryan David Hetrick

Andrew Jacob Vasbinder

David Charles Strausser

Paul David Roman, Jr

Thomas Wojtacki

Michael G Pacyga

Kenneth Wade Long, Jr

William John Remaley

William J Remaley

Michael Warren Fogg

Adam Price Tyler

Aurelio J Gutierrez

Robert D Irlbeck

Lyle Stanley Bryan

Jeremy Christian Patterson

Abraham Shocket

Rohan Narang

Ronald Louis Marion

John Steven Cowan

David M Wiebking

Tracy Everette Wilson

Don Kevin Willis

Ram Kishore Venkatesan

Sameh Lotfy Mankaryos

Sameh Mankaryos

James Smith

John Mark Myer

Jr Kenneth Wade Long

Robert Daniel Irlbeck

A power harness for a charging inlet assembly includes a harness housing holding a power cable in a cable slot A ring insert of the power cable is aligned with a bore of a hub of the housing that receives a threaded bolt with an insulating cover and an insulating cap. A contact ring is received in the hub with a first end connected to the ring insert and a second end electrically connected to a charging terminal. A threaded socket is received in the hub and passes through the contact ring for threadably coupling to the charging terminal. The outer end of the threaded socket has a threaded bore receiving the threaded shaft of the threaded bolt.

Charging inlet assembly having a power harness

A charging inlet assembly includes a housing extending between a front and a rear. The housing has DC terminal channels and AC terminal channels. The charging inlet assembly includes AC terminals, include a proximity terminal and a ground terminal, received in the corresponding AC terminal channels. The charging inlet assembly includes DC terminals received in the corresponding DC terminal channels. The charging inlet assembly includes a proximity resistor assembly having a plug body holding a resistor, a first resistor conductor and a second resistor conductor. The first resistor conductor is coupled between the resistor and the terminating end of the proximity terminal. The second resistor conductor is coupled between the resistor and the terminating end of the ground terminal.

Charging inlet assembly having a proximity resistor assembly

A charging inlet assembly includes a housing having a DC section having DC terminals received in DC terminal channels for mating with the DC charging connector and AC terminals received in AC terminal channels for mating with the AC charging connector. The DC terminals include a proximity terminal and a ground terminal. The proximity and ground terminals include terminating ends received in a rear cavity of the housing. The charging inlet assembly includes a proximity resistor assembly received in the rear cavity having a resistor, a first resistor conductor coupled between the resistor and the terminating end of the proximity terminal, and a second resistor conductor coupled between the resistor and the terminating end of the ground terminal.

A terminal assembly for a charging inlet assembly includes a terminal cable having a conductor. The terminal assembly includes a terminal having a pin at a mating end and a terminating end opposite the mating end terminated to the conductor at an end of the terminal cable. The terminal assembly includes a terminal cover having a cover body including a bore that receives the terminating end of the terminal and the end of the terminal cable. The terminal cover includes a latch configured to secure the terminal and the terminal cable to a housing of the charging inlet assembly. The terminal cover includes a terminal cover seal configured to be sealed to the housing of the charging inlet assembly.

Terminal covers for terminals of charging inlet assembly

A power harness includes a cable having a ring insert received in an opening electrically connected to the cable body and having a cable seal sealed to the flat cable. The power harness includes a housing having a chamber with a cable slot and a bore passing through a hub. The power harness includes a threaded bolt received in the hub passing through the ring insert to threadably couple to a mating harness. The threaded bolt includes an insulating cover on the head and an insulating cap extending from the threaded shaft. The threaded bolt includes a bolt seal sealed to the housing. The power harness includes a contact ring received in the hub aligned with the ring insert with an opening that receives the threaded bolt. A first end engages and is electrically connected to the ring insert and a second end is electrically connected to the mating harness.

Power harness

A charging inlet assembly includes a housing having a DC section with DC terminals received in DC terminal channels for mating with a DC charging connector and AC terminals, including a proximity terminal, received in AC terminal channels for mating with an AC charging connector. The charging inlet assembly includes an HMI assembly coupled to the rear of the housing having a control circuit board, a charging indicator coupled to the control circuit board visible from the front of the housing to indicate a charging status of the charging inlet assembly, and a proximity resistor assembly coupled to the housing. The proximity resistor assembly includes a resistor coupled to the control circuit board and a cable connector connected between the control circuit board and the proximity terminal.

A charging inlet assembly includes a housing extending between a front and a rear. The housing has a DC section includes DC terminal channels configured to receive DC terminals. The housing has an AC section including AC terminal channels configured to receive AC terminals. The DC section configured for mating with a DC charging connector at the front. The AC section configured for mating with an AC charging connector at the front. The housing includes an indicator opening. The charging inlet assembly includes a human machine interface (HMI) assembly coupled to the rear of the housing. The HMI assembly includes a charging indicator aligned with the indicator opening. The charging indicator is visible from the front of the housing to indicate a charging status of the charging inlet assembly.

Charging inlet assembly having a human machine interface (HMI) assembly

An electrical connector assembly includes a housing defining a front opening for receiving a mating connector in a mating direction, an electrical terminal arranged within an interior of the housing, and a terminal position assurance (TPA) device received within a rear opening of the housing in an installation direction. The TPA device includes a body defining a central opening for receiving a cable to be attached to the terminal, and an elastic element defined on a front end of the body. The elastic element includes a contact surface protruding from the front end of the body for engaging with the terminal in an installation direction of the TPA device. The contact surface engages with the terminal before the TPA device reaches an installed position within the housing in the installation direction.

Rear-loaded terminal position assurance device for crimped terminals

A wire harness for a charging inlet of a vehicle includes first and second high voltage wires having first and second conductors. An inline disconnect electrically connects the first and second conductors and is configured to allow the conductors to be disconnected. The inline disconnect includes a housing having a central cavity, a first chamber at a first end that receives the first high voltage wire, and a second chamber open to the central cavity at a second end that receives the second high voltage wire. First and second disconnect contacts terminated to the conductors are received in the central cavity. A connecting element couples the first and second disconnect contacts and is removable from the disconnect contacts to allow disconnection of the first and second disconnect contacts to electrically separate the first and second high voltage wires.

High voltage wire harness having an inline disconnect

A charging inlet assembly includes a housing extending between a front and a rear. The housing has a DC section including DC terminal channels that are configured to receive DC terminals. The housing has an AC section including an AC module chamber. The DC section is configured for mating with a DC charging connector at the front. The AC section is configured for mating with an AC charging connector at the front. The charging inlet assembly includes an AC charging module removably received in the AC module chamber. The AC charging module includes an AC insert extending between an insert front and an insert rear. The AC insert includes AC terminal channels between the insert front and the insert rear. The AC charging module include AC terminals received in the AC terminal channels. The AC terminals are terminated to ends of AC cables extending from the insert rear. The AC terminals and the AC cables are removable from the housing with the AC insert.

Charging inlet assembly having an AC charging module

A charging inlet assembly for an electric vehicle includes a charging inlet housing having a chamber at the rear and a power connector at a front for receiving a charging connector. The power connector includes terminal channels. The charging inlet assembly includes charging terminals each having a mating pin and a terminating end. The charging inlet assembly includes a terminal position assurance device coupled to the charging inlet housing having a terminal locating plate located in the chamber to interface with the terminating ends of the charging terminals. The terminal position assurance device includes an actuator at an exterior of the charging inlet housing to operate the terminal position assurance device from the exterior of the charging inlet housing.

Terminal position assurance device for a charging inlet assembly

A cap for an electrical connector comprises a first cap body defining a first portion of a first circular opening, and a second cap body defining a second portion of a first circular opening. The second cap body is hingedly connected to the first cap body and movable between an open position and a closed position. In the closed position, first and second portions of the first cap body and the second cap body define a circular opening sized to receive a conductive cable therethrough.

Hinged seal cap

A power connector includes a housing having a terminal channel and a terminal received in the terminal channel including a mating pin at a front of the terminal and a cable connector at a rear of the terminal. The mating pin is positioned in the terminal channel for mating with a charging connector. The cable connector includes a pad configured to be terminated to a power cable. The power connector includes a heat exchanger thermally coupled to the pad of the terminal. The heat exchanger includes a coolant channel for coolant flow through the heat exchanger for actively cooling the terminal. The heat exchanger includes a thermally conductive separator electrically isolating the heat exchanger from the pad of the terminal.

Heat exchanger for a power connector

A charging inlet assembly for an electric vehicle includes a housing having a power connector including AC terminals and DC terminals. An AC terminal assembly is coupled to the housing and includes AC bus bars electrically connected to corresponding AC terminals at a separable mating interface. A DC connector is mechanically and electrically connect to the DC contact of the DC connector at a separable mating interface.

Charging inlet assembly

A cooling system for a power connector of a charging inlet assembly includes a cooling adapter coupled to a housing of the charging inlet assembly including an adapter body forming a cavity. The cooling adapter includes supply and return ports adjacent a cable exit. The cooling system includes a heat exchanger positioned in the cavity of the cooling adapter including a heat exchanger body configured to receive the power cable and/or the terminal. The heat exchanger body is thermally coupled to the power cable or the terminal to dissipate heat therefrom.

Growing community of inventors

Kernersville, NC, United States of America

Kevin John Peterson