Aptiv Technologies Limited

Aptiv Technologies Ag

Delphi Technologies, Inc.

Aptiv Technologies (2) S.à R.l.

Nicholas A Durse

Adam Wolfgang

Patrick Joseph Reedy

William C Lovitz

Thomas Mathews

Don E Bizon

Jonathan D Weidner

Michael L Mellott

Steven William Marzo

Hoi Lui

Thomas S Huda

David R Peterson

Joseph Sudik, Jr

George Albert Drew

Terry A George

Bruce D Taylor

Glenn E Robison

Troy A Iler

Sylvain Bossuyt

Eric B Poma

Eric E Shasteen

Jeffrey A Janis

Keith B Adkins

Andrew Bohan

Jacob Martin

Thomas Matthews

A bus bar assembly includes a nonconductive terminal cap that is configured to secure to an electrically conductive terminal via an attachment feature. The terminal cap has a slot that is configured to expose a terminal portion of the terminal when in an assembled condition. A bus bar has an end that is configured to be received in and extend through the slot when in the assembled condition in which the end is in electrical contact with the terminal portion of the terminal. A nonconductive shroud encloses the bus bar.

Bus bar assembly

A bus bar assembly includes a nonconductive terminal cap configured to at least partially surround an electrically conductive terminal. The terminal cap has a perimeter wall configured to circumscribe at least a portion of the terminal to provide a gap configured to expose the terminal. The terminal cap includes a first attachment feature. The bus bar assembly also includes a bus bar having an end configured to mechanically and electrically engage the terminal in an assembled condition and a nonconductive shroud enclosing the bus bar. The shroud includes a second attachment feature configured to removably engage the first attachment feature in the assembled condition to secure the shroud to the terminal cap. A method of electrically connecting cells of a battery is also provided.

Battery module and bus bar assembly

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

A bus bar assembly includes a bus bar formed of a first electrically conductive material having a planar contact portion. The bus bar defines a first bore extending through the contact portion. The bus bar assembly further includes a contact insert formed of a second electrically conductive material that has a greater hardness than the first electrically conductive material. The contact insert defines a first surface that is mechanically and electrically connected to the contact portion of the bus bar. The contact insert defines a second surface this is plated with a third electrically conductive material which is different than the second electrically conductive material. The contact insert defines a smooth second bore coaxial with the first bore and extending from the first surface to the second surface.

Bus bar assembly with plated electrical contact surface

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.

Electrical connector assembly with modular cooling features

A busbar connection system comprises a plate member formed of a first material having a higher tensile strength than second and third materials of first and second busbars, respectively, and defining first and second apertures and first and second stud members securely inserted through the first and second apertures of the plate member, respectively, the first and second stud members being configured to be securely inserted through first and second apertures, respectively, in each of the first and second busbars, wherein the first and second stud members mitigate rotational movement between the first and second busbars when connected.

Busbar connection systems and methods

A backing plate, a corresponding electrical connector for mating with the backing plate, an electrical header, and an assembly thereof are described herein. The backing plate has an inner portion having a first thickness and an outer portion having a second thickness that is greater than the first thickness. The outer portion surrounds a perimeter of the inner portion and forms a cavity within the backing plate for acceptance of the electrical header. The backing plate also contains a connector attachment portion configured to attach the backing plate to the electrical connector and an intermediate surface attachment portion configured to attach the backing plate to the intermediate surface.

Backing plate for mounting and sealing an electrical connector to an intermediate surface

A bus bar assembly includes, among other things, a nonconductive terminal cap that is configured to at least partially surround an electrically conductive terminal. The terminal cap has a perimeter wall that is configured to circumscribe at least a portion of the terminal to provide a gap that is configured to expose the terminal. The terminal cap includes a first attachment feature. The terminal cap also includes a bus bar that has an end that is configured to mechanically and electrically engage the terminal in an assembled condition. The terminal cap further includes a nonconductive shroud that encloses the bus bar. The shroud includes a second attachment feature that is configured to removably engage the first attachment feature in the assembled condition to secure the shroud to the terminal cap.

Finger-proof battery module bus bar connector assembly

An electrical bus bar assembly includes an elongate flexible electrical conductor formed of a strip of electrically conductive material having a generally rectangular cross section and a width to thickness ratio of at least 20:1 and a dielectric material covering a central portion of the electrical conductor such that the electrical conductor has exposed distal portions at each end of the assembly. Further, a method for forming such as assembly includes the steps of forming a flexible strip from an electrically conductive sheet such that the strip has a generally rectangular cross section with a width to thickness ratio of at least 20:1 and covering a central portion of the strip with a dielectric material and leaving distal portions at each end exposed.

Flexible electrical bus bar and method of manufacturing the same

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

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.

A bus bar assembly includes a nonconductive terminal cap that is configured to secure to an electrically conductive terminal via an attachment feature. The terminal cap has a slot that is configured to expose a terminal portion of the terminal in an assembled condition. A bus bar has an end that is configured to be received in the slot in the assembled condition in which the end is in electrical contact with the terminal portion of the terminal. A nonconductive shroud encloses the bus bar. The end extends through shroud.

Bolted bus bar with finger-proofing

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.

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.

High voltage (HV) terminal frame and method of manufacturing the same

An electrical connector assembly includes an elongate planar terminal extending along a first longitudinal axis having a connection end configured to interconnect the terminal to a corresponding elongate planar mating terminal extending along a second axis and an attachment end configured to attach the terminal to an electrical conductor. The electrical connector assembly also includes a contact spring configured to exert a normal force between the terminal and the mating terminal when the mating terminal is arranged between the contact spring and the connection end such that second axis is parallel to the first axis or when the mating terminal is arranged between the contact spring and the connection end such that the second axis is perpendicular to the first axis.

Growing community of inventors

Youngstown, OH, United States of America

Nicholas A Durse