Electric vehicle charging connector

Patent metadata

Field	Value
Publication number	US-11697353-B2
Application number	US-202016999776-A
Country	US
Kind code	B2
Filing date	Aug 21, 2020
Priority date	Aug 21, 2020
Publication date	Jul 11, 2023
Grant date	Jul 11, 2023

Abstract

An electrical connector includes a plurality of cylindrical electrical terminals connected to ends of a plurality of first electrical cables, a housing defining a plurality of housing terminal cavities in which the plurality of cylindrical electrical terminals is disposed, and a cover attached to the housing having a plurality of cover cavities that is axially aligned with the plurality of housing terminal cavities. The plurality of cover cavities is configured to receive the plurality of cylindrical electrical terminals as it is inserted within the plurality of housing terminal cavities.

First claim

The invention claimed is:

1. An electrical connector, comprising:
a plurality of cylindrical electrical terminals connected to ends of a plurality of first electrical cables;
a housing defining a plurality of housing terminal cavities in which the plurality of cylindrical electrical terminals is disposed, wherein the housing includes a printed circuit board assembly defining a plurality of circuit board apertures through which the plurality of cylindrical electrical terminals extends; and
a cover attached to the housing having a plurality of cover cavities that is axially aligned with the plurality of housing terminal cavities, the plurality of cover cavities configured to receive the plurality of cylindrical electrical terminals as it is inserted within the plurality of housing terminal cavities.

2. The electrical connector according to claim 1 , further comprising a terminal seal configured to provide an environmental seal between the plurality of cylindrical electrical terminals and the cover, the terminal seal disposed between the housing and the cover.

3. The electrical connector according to claim 1 , further comprising a plurality of terminal retainers surrounding the plurality of first electrical cables configured to cooperate with the plurality of cover cavities to hold the plurality of cylindrical electrical terminals within the plurality of housing terminal cavities.

4. The electrical connector according to claim 3 , further comprising a plurality of first cable seals surrounding the plurality of first electrical cables configured to provide an environmental seal between the plurality of first electrical cables, the plurality of terminal retainers, and inner walls of the plurality of cover cavities.

5. The electrical connector according to claim 3 , further comprising a yoke configured to separate the plurality of first electrical cables and configured to secure the plurality of terminal retainers within the plurality of cover cavities.

6. The electrical connector according to claim 1 , wherein the cover defines a plurality of cover terminal cavities configured to receive a plurality of planar electrical terminals attached to a plurality of second electrical cables and wherein the plurality of planar electrical terminals is attached to a plurality of conductive members disposed within the cover via a plurality of threaded fasteners.

7. The electrical connector according to claim 6 , wherein one planar electrical terminal of the plurality of planar electrical terminals is laterally and longitudinally offset from another planar electrical terminal of the plurality of planar electrical terminals.

8. The electrical connector according to claim 6 , wherein the cover defines an access portal located, sized, and arranged to allow tool access to the plurality of threaded fasteners.

9. The electrical connector according to claim 8 , further comprising a plurality of second cable seals surrounding the plurality of second electrical cables configured to provide an environmental seal between the plurality of second electrical cables and inner walls of the plurality of cover terminal cavities.

10. The electrical connector according to claim 9 , further comprising a plurality of second cable retainers configured to hold the plurality of second cable seals within the plurality of cover terminal cavities.

11. The electrical connector according to claim 9 , further comprising a removeable access plug configured to seal the access portal.

12. The electrical connector according to claim 6 , wherein the cover may be configured to dress the plurality of first electrical cables and the plurality of second electrical cables in a rightward direction, in a leftward direction, or in a downward direction.

13. The electrical connector according to claim 1 , wherein the printed circuit board assembly includes a connector header and wherein the connector header is sealed to the cover.

14. A method of assembling an electrical connector, comprising:
inserting a plurality of cylindrical electrical terminals connected to ends of a plurality of first electrical cables into plurality of housing terminal cavities of a connector device having a housing defining the plurality of housing terminal cavities and a cover attached to the housing having a plurality of cover cavities that is axially aligned with the plurality of housing terminal cavities, wherein the plurality of cover cavities receive the plurality of cylindrical electrical terminals as it is inserted within the plurality of housing terminal cavities; and
inserting the plurality of cylindrical electrical terminals through a plurality of circuit board apertures defined by a printed circuit board assembly disposed within the housing.

15. The method of claim 14 , further comprising:
attaching a plurality of terminal retainers to the plurality of first electrical cables, wherein the plurality of first electrical cables cooperates with the plurality of cover cavities to hold the plurality of cylindrical electrical terminals within the plurality of housing terminal cavities.

16. The method of claim 14 , further comprising:
inserting a plurality of planar electrical terminals attached to a plurality of second electrical cables within a plurality of cover terminal cavities defined by the cover; and
attaching plurality of planar electrical terminals to a plurality of conductive members disposed within the cover via a plurality of threaded fasteners.

17. The method of claim 16 , further comprising:
laterally and longitudinally offsetting one planar electrical terminal of the plurality of planar electrical terminals from another planar electrical terminal of the plurality of planar electrical terminals.

18. The method of claim 17 , further comprising:
inserting a removeable access plug into an access portal located, sized, and arranged to allow tool access to the plurality of threaded fasteners.

Assignees

• Aptiv Tech Ltd

Inventors

• Mathews Thomas
• Lovitz William C
• Fredrickson Mark
• Puhl Ronald A

Classifications

• B60L53/18

  Cables specially adapted for charging electric vehicles · CPC title

• H01R13/453

  Shutter or cover plate opened by engagement of counterpart · CPC title

• B60L53/16 Primary

  Connectors, e.g. plugs or sockets, specially adapted for charging electric vehicles · CPC title

• H01R13/5202

  Sealing means between parts of housing or between housing part and a wall, e.g. sealing rings · CPC title

• H01R13/52 Primary

  Dustproof, splashproof, drip-proof, waterproof, or flameproof cases · CPC title