A header seal for a header connector of an electrical power connector system

Abstract

A header connector includes a header housing having a mating end and a mounting end. The mounting end is configured to mount to a support structure. The header housing has a shroud wall forming a header chamber configured to receive a plug connector. The header connector includes a header seal coupled to the header housing having an upper portion with an upper seal surface and a lower portion with a lower seal surface. The upper portion extends into the header chamber and the upper seal surface is configured to interface with the plug connector to form a seal between the header housing and the plug connector. The lower portion extends to the mounting end and the lower seal surface is configured to interface with the support structure to form a seal between the header housing and the support structure.

Description

Technical Field

[0001] The main topic of this article is electrical connector systems. Background Technology

[0002] Power terminals are used to establish electrical connections between components in high-power applications, such as in electric or hybrid electric vehicles, between batteries and other components (e.g., motors, inverters, chargers, etc.). Power terminals are held together by a head connector and a plug connector that mates with the head connector. Due to the harsh environments in which power connectors are used in vehicles, environmental seals are typically provided. For example, head seals are usually located at the interface between the head connector and the chassis or other structure on which the head connector is mounted. Separate contact seals are typically located at the mating interface between the plug connector and the head connector. For example, a plug seal may surround the plug connector, which seals to the head connector when the power connector mates. The retention of plug seals is problematic. For example, the seal may have pinch points in its retention position, which affects the shape of the plug seal and thus its sealing performance. Furthermore, the plug seal is subjected to rolling or scooping during mating, resulting in an improper seal. Head seals suffer from similar problems; pinch points affect the shape of the head seal and thus its sealing performance.

[0003] There is still a need for a robust sealing arrangement for power connectors in power connector systems. Summary of the Invention

[0004] In one embodiment, a headstock connector is provided. The headstock connector includes a headstock housing having a mating end and a mounting end. The mounting end is configured to be mounted to a support structure. The headstock housing has a protective wall forming a headstock chamber configured to receive a plug connector. The headstock connector includes headstock terminals disposed within the headstock chamber to mate with the plug connector. The headstock connector includes a headstock seal coupled to the headstock housing. The headstock seal includes an upper portion having an upper sealing surface and a lower portion having a lower sealing surface. The upper portion extends into the headstock chamber. The upper sealing surface is configured to abut against the plug connector to form a seal between the headstock housing and the plug connector. The lower portion extends to the mounting end. The lower sealing surface is configured to abut against the support structure to form a seal between the headstock housing and the support structure.

[0005] In another embodiment, a headstock connector is provided. The headstock connector includes a headstock housing having a mating end and a mounting end. The mounting end has a flange configured to be mounted to a support structure. The headstock housing has a shield wall extending from the flange and forming a headstock chamber configured to receive a plug connector. The headstock housing has a sealing channel extending from the headstock chamber through the flange to the mounting end. The headstock connector includes headstock terminals disposed in the headstock chamber to mate with the plug connector. The headstock connector includes a headstock seal coupled to the headstock housing. The headstock seal is received in the sealing channel. The headstock seal includes an upper portion having an upper sealing surface and a lower portion having a lower sealing surface. The upper portion extends into the headstock chamber. The upper sealing surface is configured to abut against the plug connector to form a seal between the headstock housing and the plug connector. The lower portion extends to the mounting end. The lower sealing surface is configured to abut against the support structure to form a seal between the headstock housing and the support structure.

[0006] In another embodiment, a power connector system is provided. The power connector system includes a headstock connector, the headstock connector including a headstock housing having a mating end and a mounting end. The mounting end is configured to be mounted to a support structure. The headstock housing has a protective wall forming a headstock chamber. The headstock connector includes headstock terminals disposed within the headstock chamber. The headstock connector includes a headstock seal coupled to the headstock housing. The headstock seal includes an upper portion having an upper sealing surface and a lower portion having a lower sealing surface. The upper portion extends into the headstock chamber. The lower portion extends to the mounting end. The lower sealing surface is configured to abut against the support structure to form a seal between the headstock housing and the support structure. The power connector system includes a plug connector that mates with the headstock connector. The plug connector includes a plug housing that retains tab terminals. The plug housing has a sealing wall. The tab terminals have a cable end and a mating end. The mating end is coupled to the headstock terminals during mating to electrically connect the tab terminals to the headstock terminals. The plug housing is received in the headstock chamber such that the sealing wall abuts against the upper sealing surface of the upper portion of the headstock seal. Attached Figure Description

[0007] Figure 1 This is a perspective view of an electrical connector system in an assembled and mated state, formed according to an exemplary embodiment.

[0008] Figure 2 This is a perspective view of a power connector system in an uncooperative state according to an exemplary embodiment.

[0009] Figure 3 This is a perspective view of a portion of an exemplary power connector system, showing plug terminals and headstock terminals.

[0010] Figure 4 This is a top perspective view of the headstock seal according to an exemplary embodiment.

[0011] Figure 5 This is a top perspective view of a headstock connector according to an exemplary embodiment, showing the headstock seal.

[0012] Figure 6 This is a top perspective view of a portion of a headstock connector according to an exemplary embodiment, showing the headstock housing and headstock seal.

[0013] Figure 7 This is a bottom perspective view of a headstock connector according to an exemplary embodiment, showing the headstock seal.

[0014] Figure 8 This is a partial cross-sectional view of an exemplary embodiment of a power connector system, showing a plug connector that mates with a headstock connector.

[0015] Figure 9 This is a partial cross-sectional view of an exemplary embodiment of a power connector system, showing a plug connector that mates with a headstock connector.

[0016] Figure 10 This is a top perspective view of a portion of a headstock connector according to an exemplary embodiment, showing the headstock housing and headstock seal.

[0017] Figure 11 This is a top perspective view of a portion of a headstock connector according to an exemplary embodiment, showing the headstock housing and headstock seal. Detailed Implementation

[0018] Figure 1 This is a perspective view of an electrical connector system 100 in an assembled and mated state, formed according to an exemplary embodiment. Figure 2 This is a perspective view of a power connector system 100 in an unmated state. The power connector system 100 includes a head connector 102 and a plug connector 104, the plug connector 104 being configured to mate with the head connector 102. In an exemplary embodiment, the power connector system 100 is a high-power connector system used to transfer power between various components that are part of a high-power circuit. In a particular application, the power connector system 100 is a battery system, such as the battery system of a vehicle (e.g., an electric vehicle or a hybrid electric vehicle); however, the power connector system 100 is not limited to such battery systems.

[0019] Plug connector 104 is configured for electrical connection to component 110, for example, via one or more cables 106. For example, plug connector 104 may be electrically connected to a battery, charger, inverter, motor, or other type of component. Headstock connector 102 is configured for electrical connection to component 112, for example, via power bus 108 (also referred to herein as power bus 108); however, headstock connector 102 may be electrically connected to component 112 via other means, such as terminals, power cords, or other connectors. For example, headstock connector 102 may be electrically connected to a battery pack, for example, via a battery distribution unit, manual service disconnector, charger, inverter, motor, or other type of component. The battery distribution unit may manage the power capacity and functionality of the power connector system 100, for example, by measuring the current of the battery pack and regulating its power distribution.

[0020] In the illustrated embodiment, the power connector system 100 is a right-angle connector system, wherein connectors 102, 104 mate in a direction perpendicular to the power lines. In alternative embodiments, other mating orientations are possible, such as a vertical orientation, wherein cable 106 is parallel to the mating direction rather than perpendicular to it. Optionally, plug connector 104 may be removably connected to headstock connector 102 to disconnect high-power circuitry of one or more components (e.g., a vehicle's battery pack, motor, inverter, or other components), for example, for maintenance, repair, or for other reasons. When mated, one or more headstock terminals 114 of headstock connector 102 ( Figure 2 ) and the corresponding plug terminal 116 of the plug connector 104 (e.g. Figure 3 (As shown) mating, for example at its mating interface. Having a greater number of terminals 114 and / or 116 increases the current-carrying capacity of system 100. Optionally, each plug terminal 116 may terminate to a corresponding power cable 106.

[0021] In an exemplary embodiment, the head connector 102 and / or the plug connector 104 may include a high-voltage interlock (HVIL) circuit to control the high-voltage electrical circuitry during the opening and closing, or mating and disengaging of the connectors 102, 104. For example, both connectors 102, 104 may include corresponding HVIL terminals. The HVIL circuitry may be electrically connected to components 112 and / or 110. In an exemplary embodiment, the plug connector 104 utilizes a lever 118 to disengage and / or engage the connectors 102, 104, which may open / close the high-voltage circuitry and the HVIL circuitry during the mating / disengaging of the connectors 102, 104. During disengagement, the HVIL circuitry may be opened first to close the high-voltage circuitry before the terminals 116, 114 are opened or disengaged, which may reduce the likelihood of damage (e.g., from arc discharge). In an exemplary embodiment, the high-voltage conductive surfaces of the connectors 102, 104 are finger-proof and safe to touch.

[0022] The head connector 102 includes a head housing 120 having a mating end 122 and a mounting end 123. In the illustrated embodiment, the mating end 122 is opposite the mounting end 123; for example, the mating end 122 is at the top 121 of the head housing 120, and the mounting end 123 is at the bottom 125 of the head housing 120. In alternative embodiments, other orientations are possible, such as being located at the front and / or rear and / or sides of the head housing 120. The head housing 120 holds one or more head terminals 114. Optionally, the head terminals 114 may be fork-shaped terminals with receptacles defined by spring beams on both sides of the receptacle for mating with both sides of a plug terminal 116, as described in further detail below; however, other types of head terminals may be used in alternative embodiments. The head terminals 114 may be covered to protect them. For example, the head terminals 114 may have a cover or touch guard 124, making the head terminals 114 safe to access. The headstock housing 120 includes a flange 126 at the mounting end 123 for mounting the headstock housing 120 to a support structure 127, such as a chassis, panel, wall, mounting bracket, or other component of the vehicle. Optionally, the headstock connector 102 may be electrically grounded to the support structure 127. In an exemplary embodiment, the headstock connector 102 includes a headstock seal (e.g., ...) at the mounting end 123. Figure 4 As shown, it is configured as a sealed abutment support structure 127. Optionally, the headstock housing 120 can be mounted horizontally; however, other orientations are possible in alternative embodiments. In an exemplary embodiment, the plug housing 120 includes a guide feature 128 for guiding the mating of the plug connector 104 with the plug connector 102. For example, the guide feature 128 may be a rib, post, slot, keying feature, or other type of guide feature.

[0023] The plug connector 104 includes a plug housing 130 configured to engage with a headstock housing 120. The plug housing 130 includes a mating end 132 and a cable end 134. The mating end 132 mates with the mating end 122 of the headstock housing 120. In an exemplary embodiment, the plug housing 130 includes a sealing wall 133 at the mating end. Figure 2 The headstock housing 120 is configured to mate with a headstock seal inside the headstock housing 120 to form a sealed connection between the plug connector 104 and the headstock connector 102. A power cable 106 extends from cable end 134. In an exemplary embodiment, the housing 130 is a right-angled housing that holds the power cable 106 and the plug terminal 116 (e.g., [missing information]) perpendicular to the mating direction along the mating axis 136. Figure 3 (As shown). The power cable 106 is perpendicular to the mating axis 136. In alternative embodiments, other orientations are possible.

[0024] In an exemplary embodiment, lever 118 is rotatably coupled to housing 130. Lever 118 is configured to engage headstock housing 120, for example, a corresponding guide feature 128, to secure plug connector 104 to headstock connector 102. Optionally, lever 118 may include a slot receiving the corresponding guide feature 128 to control the engagement and disengagement of plug connector 104 with headstock connector 102. For example, when lever 118 is rotated closed, housing 130 can be pulled down onto headstock housing 120. Conversely, as lever 118 is raised, housing 130 can be pressed away from and disengaged from plug headstock 120. When plug connector 104 engages and disengages from headstock connector 102, the high-power circuitry and HVIL circuitry of the power connector system 100 can be opened and closed.

[0025] Figure 3 This is a perspective view of a portion of an electrical connector system 100, showing plug terminals 116 and headstock terminals 114. Headstock housing 120 and plug housing 130 are removed to show plug terminals 116 and headstock terminals 114.

[0026] Plug terminal 116 terminates to power cable 106. For example, plug terminal 116 may be soldered to power cable 106. In alternative embodiments, plug terminal 116 may be terminated to power cable 106 by other means (e.g., crimping). In the illustrated embodiment, plug terminal 116 is a tab terminal, which includes tabs or blades with a large surface area for mating with headstock terminal 114. Plug terminal 116 is referred to hereinafter as tab terminal 116. Each tab terminal 116 is generally planar (at least along the protrusion or blade portion) and extends between mating end 200 and cable end 202. In alternative embodiments, other types of plug terminals 116 may be used, such as receptacle terminals, socket terminals, or other types of terminals.

[0027] Headstock terminal 114 is configured to be electrically connected to tab terminal 116. In an exemplary embodiment, headstock terminal 114 is also electrically connected to headstock connector 102 (in... Figure 2 The power bus 108 is shown in the figure. However, in an alternative embodiment, the headstock terminal 114 may be integrated with the power bus 108. In the illustrated embodiment, the headstock terminal 114 is a double-ended fork terminal and may be referred to hereinafter as fork terminal 114.

[0028] Each headstock terminal 114 includes a series of contact members 210 arranged side-by-side in a stacked configuration. Each contact member 210 includes a body 220 between a first mating end 222 and a second mating end 224. Each contact member 210 includes a pair of spring beams 226 and a pair of spring beams 230, the pair of spring beams 226 defining a socket 228 at the first mating end 222 and the pair of spring beams 230 defining a socket 232 at the second mating end 224. When the contact members 210 are stacked together to define the headstock terminal 114, the sockets 228 of the contact members 210 are aligned within the headstock terminal 114 to define a tab socket 234 at the first mating end 222. The tab socket 234 at the first mating end 222 is configured to receive a mating edge of the tab terminal 116. Similarly, the sockets 232 of the individual contact members 210 are aligned within the plug terminal 114 to define a busbar socket 236 at the second mating end 224, which is configured to receive the mating end 238 of the corresponding power bus 108. In the illustrated embodiment, the spring beam 226 of the contact member 210 in each plug terminal 114 defines a first forked contact 223 at the first mating end 222, and the spring beam 230 of the contact member 210 defines a second forked contact 225 at the second mating end 224.

[0029] Spring beams 226 and 230 are deflectable to receive tab terminal 116 and power bus 108, respectively. When engaged, spring beams 226 and 230 are spring-biased against tab terminal 116 and power bus 108, respectively. Spring beam 226 is arranged on both sides of socket 228 to engage a first side 204 and a second side 206 of tab terminal 116.

[0030] In an exemplary embodiment, each spring beam 226 defines a mating interface 240 at or near its distal end. The mating interface 240 may be defined by a protrusion or projection at the distal end of the spring beam 226. In an exemplary embodiment, a fork-shaped contact 223 is defined by a plurality of stacked spring beams 226, each fork-shaped contact 223 including a plurality of contact points with the tab terminal 116. For example, each mating interface 240 on the stacked spring beams 226 defines a different contact point with the tab terminal 116. A plurality of contact members 210 disposed in each headstock terminal 114 create a plurality of contact points between the tab terminal 116 and the headstock connector 102.

[0031] Forked contacts 225 at the second mating end 224 (e.g., the power bus mating side) of each headstock terminal 114 provide multiple contact points with the power bus 108. For example, each spring beam 230 defines a mating interface 240 at or near its distal end. The mating interfaces 240 of the multiple spring beams 230 in the stack define different contact points with the power bus 108. The provision of multiple contact members 210 in each headstock terminal 114 creates multiple contact points between the power bus 108 and the headstock connector 102. Increasing the number of contact members 210 in each headstock terminal 114 and / or increasing the number of headstock terminals 114 increases the current carrying capacity of the headstock connector 102.

[0032] Optionally, the fork-shaped contacts 223, 225 of a single headstock terminal 114 may be identical, the tab terminal 116 may be configured to insert into a tab socket 234, and the power bus 108 may be configured to insert into a busbar socket 236. The headstock terminal 114 is easy to manufacture and assemble. For example, the contact members 210 may be stamped, and any number of contact members 210 may be arranged together in each of the headstock terminals 114. In alternative embodiments, other types of headstock terminals may be provided, such as socket terminals (e.g., box-type socket terminals) or one or more spring beam type terminals.

[0033] Figure 4 This is a top perspective view of a headstock seal 300 according to an exemplary embodiment. The headstock seal 300 is a multi-seal member having multiple sealing surfaces, configured to connect the headstock connector 102 (such as...) Figure 2 (As shown) is sealed with multiple components, such as plug connector 104 (e.g.) Figure 2 (as shown) and support structure 127 (as shown) Figure 2(As shown) Both. Using multiple seals to provide sealing for multiple components that use a single seal reduces the number of parts and makes the system easier to assemble and manufacture. In an exemplary embodiment, the headstock seal 300 is configured to be molded in situ onto the headstock housing 120 to form the headstock seal 300 in place and eliminate assembly steps, which reduces assembly time and reduces assembly errors due to incorrect or inconsistent positioning of the sealing structure.

[0034] The headstock seal 300 includes an upper portion 302, a lower portion 304, and one or more connecting portions 306 between the upper portion 302 and the lower portion 304. In an exemplary embodiment, the upper portion 302 and the lower portion 304 are separate and spaced apart from each other, with a gap 308 formed between the upper portion 302 and the lower portion 304. The connecting portion 306 spans the gap 308 between the upper portion 302 and the lower portion 304 to connect the upper portion 302 and the lower portion 304. In an exemplary embodiment, the headstock seal 300 is a monolithic structure, with the upper portion 302, the lower portion 304, and the connecting portion 306 co-molded and integrally formed. In an exemplary embodiment, the headstock seal 300 is made of an elastomeric material, such as rubber, fluorocarbon, etc.

[0035] The upper portion 302 includes an upper sealing surface 310 within its interior 312. The exterior 314 of the upper portion 302 is configured to engage with the headstock housing 120. The upper sealing surface 310 faces inward to abut against the plug housing 130 when the plug connector 104 mates with the headstock connector 102. When mating with the plug connector 104, the upper sealing surface 310 is deformable, for example, to conform to and seal against a sealing wall 133 of the plug housing 130. The upper portion 302 extends between a top 316 and a bottom 318. A connecting portion 306 extends from the bottom 318.

[0036] In an exemplary embodiment, the upper portion 302 includes a plurality of upper segments forming a rectangular (e.g., square) structure. In an alternative embodiment, the upper portion 302 may have other shapes, such as oval, circular, or other shapes. The upper portion 302 includes a first upper side segment 320 and a second upper side segment 322 opposite to the first upper side segment 320. The upper portion 302 includes a first upper end segment 324 and a second upper end segment 326 opposite to the first upper end segment 324. The first upper end segment 324 and the second upper end segment 326 extend between the first upper side segment 320 and the second upper side segment 322. The upper segments 320, 322, 324, and 326 surround an upper opening 328. The upper sealing surfaces 310 of the upper segments 320, 322, 324, and 326 face inward toward the upper opening 328.

[0037] In an exemplary embodiment, the upper sealing surface 310 includes sealing ribs 330 along the interior 312 of the upper portion 302. Optionally, each upper segment 320, 322, 324, 326 includes a plurality of sealing ribs 330. In various embodiments, the sealing ribs 330 may be chevron-shaped. For example, the sealing ribs 330 may form peaks at their inner ends. In various embodiments, the sealing ribs 330 may be asymmetrical. For example, the sealing ribs 330 may have different sizes and / or different shapes.

[0038] The lower portion 304 includes a lower sealing surface 340 at its bottom 342. The top 344 of the lower portion 304 is configured to engage with the headstock housing 120. A connecting portion 306 extends from the top 344. The lower sealing surface 340 faces downward to mate with the support structure 127 when the headstock connector 104 is mounted to the support structure 127. When mating with the support structure 127, the lower sealing surface 340 is deformable, for example, to conform to and seal the support structure 127. The lower portion 304 extends between an inner portion 346 and an outer portion 348.

[0039] In an exemplary embodiment, the lower portion 304 includes a plurality of upper segments forming a rectangular (e.g., square) structure. In an alternative embodiment, the lower portion 304 may have other shapes, such as circular, oval, or other shapes. The lower portion 304 includes a first lower side segment 350 and a second lower side segment 352 opposite to the first lower side segment 350. The lower portion 304 includes a first lower end segment 354 and a second lower end segment 356 opposite to the first lower end segment 354. The first lower end segment 354 and the second lower end segment 356 extend between the first lower side segment 350 and the second lower side segment 352. The lower segments 350, 352, 354, and 356 surround a lower opening 358. The lower sealing surface 340 of the lower segments 350, 352, 354, and 356 faces upward toward the lower opening 358.

[0040] In an exemplary embodiment, the lower sealing surface 340 includes sealing ribs 360 along the bottom 342 of the lower portion 304. Optionally, each lower segment 350, 352, 354, 356 includes a plurality of sealing ribs 360. In various embodiments, the sealing ribs 360 may be chevron-shaped. For example, the sealing ribs 360 may form a peak at their bottom ends. In various embodiments, the sealing ribs 360 may be asymmetrical. For example, the sealing ribs 360 may have different sizes and / or different shapes.

[0041] A connecting portion 306 extends between an upper portion 302 and a lower portion 304. Optionally, the connecting portion 306 may be approximately centered along the corresponding upper and lower segments. In various other embodiments, the connecting portion 306 may be located near the corners of the corresponding upper and lower segments. In an exemplary embodiment, the connecting portion 306 is formed during a molding process, allowing sealing material to flow from the lower portion 304 to the upper portion 302 during the formation of the headstock seal 300. The connecting portions 306 are periodically spaced around the headstock seal 300. The connecting portion 306 spans a gap 308 to connect the upper portion 302 to the lower portion 304. In an exemplary embodiment, the headstock seal 300 includes one or more first-side connecting portions 370, one or more second-side connecting portions 37, one or more first-end connecting portions 374, and one or more second-end connecting portions 376. The first-side connecting portions 370 extend between a first upper segment 320 and a first lower segment 350. The second side connecting portion 372 extends between the second upper side segment 322 and the second lower side segment 352. The first end connecting portion 374 extends between the first upper end segment 324 and the first lower end segment 354. The second end connecting portion 376 extends between the second upper end segment 326 and the second lower end segment 356.

[0042] Figure 5 This is a top perspective view of the headstock connector 102 according to an exemplary embodiment, showing the headstock seal 300. Figure 6 This is a top perspective view of a portion of the headstock connector 102 according to an exemplary embodiment, showing the headstock housing 120 and the headstock seal 300. Figure 7 This is a bottom perspective view of the headstock connector 102 according to an exemplary embodiment, showing the headstock seal 300.

[0043] The headstock housing 120 includes a plurality of shield walls 150 extending from the flange 126. The shield walls 150 define a headstock chamber 152 configured to receive a plug connector 104 (e.g., Figure 2 (as shown). In the illustrated embodiment, the shield wall 150 forms a rectangular (e.g., square) headstock chamber 152. However, the shield wall 150 may have other shapes, such as circular or oval. The headstock housing 120 includes a base plate 154 at the bottom of the headstock chamber 152. The base plate 154 may be generally aligned with the flange 126 at the bottom of the headstock connector 102. In an exemplary embodiment, the base plate 154 includes an opening 156 through it. Figure 6 Opening 156 receives (multiple) headstock terminals 114. For example, opening receiving terminal assembly 212 ( Figure 5 and Figure 7 The device includes headstock terminals 114. In an exemplary embodiment, terminal assembly 212 is a component separate from the headstock housing 120, which is received in and held by the headstock housing 120.

[0044] Terminal assembly 212 includes a terminal retainer 214, a headstock terminal 114 held by the terminal retainer 214, and a shield 216 surrounding the terminal retainer 214. The shield 216 provides electrical shielding for the headstock terminal 114. The shield 216 may extend into the headstock chamber 152 for electrical connection to the plug connector 104. The shield 216 may extend to the mounting end 123 for electrical connection to the support structure 127. For example, the shield 216 may be grounded to the support structure 127.

[0045] The headstock terminal 114 is received in the terminal channel 218 of the terminal holder 214. The terminal channel 218 is open at the top to receive the plug terminal 116 (e.g., Figure 3 (As shown). Terminal channel 218 is open at the bottom to receive power bus 108 (as shown). Figure 3 (As shown). The dielectric (e.g., plastic) material of the terminal retainer 214 supports the headstock terminal 114 and surrounds the headstock terminal 114 to define the headstock touch guard 124 so that the headstock connector 102 is safely accessible. For example, a support wall of the terminal retainer 214 may be provided along the side and / or end of the headstock terminal 114.

[0046] Optionally, the headstock connector 102 includes a plurality of headstock terminals 114. The headstock terminals 114 may define different circuits (e.g., positive and negative) or may be part of a common circuit. For example, two headstock terminals 114 configured to electrically connect to the same tab terminal 116 may be part of a common circuit, while headstock terminals 114 configured to mate to different tab terminals 116 may define different circuits. Optionally, providing a plurality of headstock terminals 114 may increase the current carrying capacity or capacitance of the headstock connector 102.

[0047] Headstock connector 102 includes an upper channel 162 for receiving the upper portion 302 of headstock seal 300. Figure 5 and Figure 6 ) and the lower channel 164 of the lower part 304 of the receiving head seat seal 300 ( Figure 7 The head connector 102 includes one or more connection channels 166 (e.g., ...) of a receiving connection portion 306 extending between the upper channel 162 and the lower channel 164. Figure 8(As shown). The upper channel 162 is located in the head seat chamber 152. For example, the upper channel 162 may be formed at least partially by the protective wall 150. The upper channel 162 may be open at the inner surface of the protective wall 150. In the illustrated embodiment, the upper channel 162 is located at the base plate 154. The upper channel 162 may extend at least partially into the base plate 154. The upper channel 162 may be open above the base plate 154. The upper portion 302 is formed in place in the upper channel 162. The upper sealing surface 310 of the upper portion 302 is located within the head seat chamber 152 to connect with the plug connector 104 (e.g., Figure 2 (As shown) mating. The lower channel 164 is located at the mounting end 123, for example, at the bottom 125 of the headstock housing 120. The lower channel 164 may extend at least partially into the bottom plate 154 and / or flange 126. A lower portion 304 is formed in place within the lower channel 164. The lower sealing surface 340 of the lower portion 304 is located at the bottom 125 to engage with the support structure 127 (as shown). Figure 2 (As shown) docking. The connecting channel 166 extends through the base plate 154 between the headstock chamber 152 and the bottom 125 of the headstock housing 120. The connecting portion 306 is formed in place in the connecting channel 166.

[0048] In an exemplary embodiment, the headstock housing includes stabilizing ribs 170. Figure 5 and Figure 6 A stabilizing rib 170 extends along the housing wall 150, for example, along the inner surface 172 of the housing wall 150. The stabilizing rib 170 is used to stabilize the housing wall 150. The stabilizing rib 170 can be used to position the plug connector 104 within the headstock chamber 152. For example, the inner surface of the stabilizing rib 170 can engage the plug connector 104 to position the headstock chamber 152 within the plug connector 104. The stabilizing rib 170 extends between the outer edge 174 (e.g., the top edge) of the housing wall 150 and the base plate 154. In an exemplary embodiment, the bottom edge of the stabilizing rib 170 is spaced apart from the base plate 154 and may be spaced apart from the outer edge 174 of the housing wall 150. The bottom edge 176 of the stabilizing rib 170 may be located directly above the upper portion 302 of the headstock seal 300 to retain the upper portion 302 within the headstock housing 120. For example, the stabilizing rib 170 can prevent the upper part 302 from being pulled out, for example, during the disengagement of the plug connector 104.

[0049] Figure 8 This is a partial cross-sectional view of an electrical connector system 100 according to an exemplary embodiment, showing a plug connector 104 that mates with a headstock connector 102. Figure 9 This is a partial cross-sectional view of an electrical connector system 100 according to an exemplary embodiment, showing a plug connector 104 that mates with a headstock connector 102.

[0050] The seat seal 300 is connected to the head housing 120 to seal against the plug connector 104 and the support structure 127. Figure 9 The upper part 302 is located in the upper channel 162, the lower part 304 is located in the lower channel 164, and the connecting part 306 is located in the connecting channel 106. Figure 8 The upper sealing surface 310 of the upper portion 302 is located within the headstock chamber 152 and extends along the inner surface 172 of the cover wall 150 to mate with the plug connector 104 (e.g., sealing wall 133). The lower sealing surface 340 is located below the headstock housing 120 and extends along the bottom 125 of the headstock housing 120 to mate with the support structure 127. The upper sealing surface 310 faces inward. The lower sealing surface 340 faces downward in a direction perpendicular to the inward direction.

[0051] Figure 10 This is a top perspective view of a portion of a headstock connector 102 according to an exemplary embodiment, showing a headstock housing 120 and a headstock seal 300. In the illustrated embodiment, the headstock seal 300 includes a damping rib 380 extending from the upper portion 302. The damping rib 380 extends along a base plate 154. Optionally, the damping rib 380 may be received in a recess 382 formed in the base plate 154. The damping rib 380 may extend to an opening 156. The plug connector 104 is configured such that when the plug connector 104 (e.g., Figure 2 When the connector 104 (as shown) mates with the head connector 102, it engages with the vibration damping rib 380. For example, the mating end 132 of the plug connector 104 (as shown) Figure 2 (As shown) can be seated on damping rib 380. Damping rib 380 is deformable to attenuate vibrations of plug connector 104 and / or headstock connector 102. For example, mating end 132 can be supported by damping rib 380 in an elevated position away from base plate 154, so that mating end 132 does not sit on the hard surface of base plate 154.

[0052] Figure 11 This is a top perspective view of a portion of a headstock connector 102 according to an exemplary embodiment, showing a headstock housing 120 and a headstock seal 300. In the illustrated embodiment, the headstock seal 300 includes a base plate gasket 390 extending from the upper portion 302. The base plate gasket 390 extends along and covers a base plate 154. The base plate gasket 390 may extend to an opening 156. The plug connector 104 is configured such that when the plug connector 104 (e.g., Figure 2 When the mating end 132 of the plug connector 104 (as shown) mates with the base plate washer 390, it engages with the head connector 102. For example, the mating end 132 of the plug connector 104 (as shown) Figure 2The connector 104 (as shown) can be seated on a base plate gasket 390. The base plate gasket 390 is deformable to dampen vibrations of the plug connector 104 and / or the headstock connector 102. For example, the mating end 132 can be supported by the base plate gasket 390 instead of sitting on the hard surface of the base plate 154. In an exemplary embodiment, the base plate gasket 390 can provide a sealing surface for testing equipment, such as during pressure testing of the headstock connector during component assembly and testing. The base plate gasket 390 defines a sealing surface separate from the upper sealing surface 310 to reduce damage to the upper sealing surface caused by the testing equipment.

[0053] It should be understood that the above description is intended to be illustrative and not restrictive. For example, the above embodiments (and / or aspects thereof) can be used in combination with each other. Furthermore, many modifications can be made to adapt particular situations or materials to the teachings of the invention without departing from its scope. The dimensions, material types, orientations of various parts, and quantities and positions of various parts described herein are intended to define parameters of certain embodiments and are by no means restrictive, but merely exemplary embodiments. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those skilled in the art upon reading the above description. Therefore, the scope of the invention should be determined by reference to the appended claims and the full scope of their equivalents. In the appended claims, the terms “comprising” and “wherein” are used as plain English equivalents of the corresponding terms “including” and “therein.” Furthermore, in the appended claims, the terms “first,” “second,” and “third,” etc., are used merely as labels and are not intended to impose numerical requirements on their objects. Furthermore, the limitations of the appended claims are not drafted in means plus function format and are not intended to be based on 35 U.SC §112(f), unless and until such a claim limitation expressly uses the phrase “means for…” followed by a statement of function, without further structure.

Claims

1. A head connector, comprising: A headstock housing has a mating end and a mounting end, the mounting end being configured to be mounted to a support structure. The headstock housing has a protective wall forming a headstock chamber configured to receive a plug connector. The headstock housing is configured to retain headstock terminals within the headstock chamber for mating with the plug connector. A headstock seal is coupled to the headstock housing, the headstock seal including an upper portion having an upper sealing surface and a lower portion having a lower sealing surface, the upper portion extending into the headstock chamber, the upper sealing surface being configured to mate with the plug connector to form a seal between the headstock housing and the plug connector, the lower portion extending to the mounting end, the lower sealing surface being configured to mate with the support structure to form a seal between the headstock housing and the support structure; The upper and lower portions of the headstock seal are integral monolithic structures, and the headstock seal includes a connecting portion that extends between the upper and lower portions to connect the upper and lower portions at spaced-out locations.

2. The head connector as claimed in claim 1, wherein the head seal is molded in situ within the head housing.

3. The head connector of claim 1, wherein the head housing includes an upper channel in the head chamber and a lower channel at the mounting end, the head housing includes at least one connection channel open between the upper channel and the lower channel, an upper portion of the head seal is received in the upper channel, a lower portion of the head seal is received in the lower channel, and the head seal includes at least one connection portion between the upper portion and the lower portion, the at least one connection portion being received in the at least one connection channel.

4. The head-mount connector of claim 1, wherein the protective wall includes an inner surface defining the head-mount chamber, the upper sealing surface extends along the inner surface and faces inward toward the head-mount chamber, the mounting end is at the bottom of the head-mount housing, and the lower sealing surface extends along the bottom and faces downward.

5. The head connector as claimed in claim 1, wherein the upper sealing surface faces a first direction and the lower sealing surface faces a second direction perpendicular to the first direction.

6. The head-mount connector of claim 1, wherein the upper portion is rectangular, having a first upper side segment and a second upper side segment, and a first upper end segment and a second upper end segment between the first upper side segment and the second upper side segment; the lower portion is rectangular, having a first lower side segment and a second lower side segment, and a first lower end segment and a second lower end segment between the first lower end segment and the second lower end segment; the upper portion and the lower portion are spaced apart; the head-mount seal includes a first side connection portion between the first upper side segment and the first lower side segment; the head-mount seal includes a second side connection portion between the second upper side segment and the second lower side segment; the head-mount seal includes a first end connection portion between the first upper end segment and the first lower end segment; and the head-mount seal includes a second end connection portion between the second upper end segment and the second lower end segment.

7. The head connector of claim 1, wherein the upper portion includes a sealing rib, the sealing rib being asymmetrical.

8. The head connector of claim 1, wherein the head housing includes a base plate at the bottom of the head chamber, and the head seal passes through the base plate to connect the upper and lower portions.

9. The head connector of claim 1, wherein the head housing includes a base plate at the bottom of the head chamber, and the head seal has a damping rib extending from the upper portion along the base plate, the damping rib being configured to engage the plug connector.

10. The head connector of claim 1, wherein the head housing includes a base plate at the bottom of the head chamber, and the head seal includes a base plate gasket extending from the upper portion along the base plate, the base plate gasket being configured to engage a mating end of the plug connector.

11. The head connector of claim 1, wherein the head housing includes a stabilizing rib extending from the shield wall into the head chamber, the stabilizing rib being located between the outer edge of the shield wall and the bottom plate of the head chamber, and the upper portion being located between the stabilizing rib and the bottom plate.

12. The head connector of claim 1, further comprising a removable transport cap received in the head chamber during transport and removable prior to loading the plug connector into the head chamber, the protective wall including a latching window that receives a latch of the transport cap to retain the transport cap in the head chamber.

13. The head-mount connector of claim 1, wherein the head-mount housing includes a flange at the mating end, the head-mount housing includes a base plate at the bottom of the head-mount chamber, the head-mount housing includes an opening in the base plate, the head-mount connector further includes a terminal retainer received in the opening, the terminal retainer being configured to retain the head-mount terminal, the terminal retainer being separate from and coupled to the head-mount housing, the upper portion circumferentially surrounding the terminal retainer and spaced apart from the terminal retainer above the base plate, and the lower portion circumferentially surrounding the terminal retainer and spaced apart from the terminal retainer below the base plate.

14. The head connector of claim 1, further comprising a head terminal received in a head chamber of the head housing, the head terminal comprising a plurality of contact members arranged in a stacked and side-by-side arrangement, each contact member having a pair of spring beams defining a receptacle at a mating end of the contact member, the receptacles of the contact members being aligned to define a tab receptacle of the head terminal, the tab receptacle being configured to receive a plug tab of the plug connector.

15. A head connector, comprising: A head base housing has a mating end and a mounting end, the mounting end having a flange configured for mounting to a support structure, the head base housing having a protective wall extending from the flange and forming a head base chamber configured to receive a plug connector, and the head base housing having a sealing channel extending from the head base chamber through the flange to the mounting end; Headstock terminals, disposed within the headstock chamber, for mating with the plug connector; and A headstock seal is coupled to the headstock housing and received in the seal channel. The headstock seal includes an upper portion having an upper sealing surface and a lower portion having a lower sealing surface. The upper portion extends into the headstock chamber. The upper sealing surface is configured to abut with the plug connector to form a seal between the headstock housing and the plug connector. The lower portion extends to the mounting end, and the lower sealing surface is configured to abut with the support structure to form a seal between the headstock housing and the support structure. The upper and lower portions of the headstock seal are integral monolithic structures, and the headstock seal includes a connecting portion that extends between the upper and lower portions to connect the upper and lower portions at spaced-out locations.

16. The head-mount connector of claim 15, wherein the sealing channel includes an upper channel in the head-mount chamber, a lower channel at the mounting end, and at least one connecting channel open between the upper channel and the lower channel, the upper portion of the head-mount seal being received in the upper channel, the lower portion of the head-mount seal being received in the lower channel, and the connecting portion being received in the at least one connecting channel.

17. A power connector system, comprising: A headstock connector includes a headstock housing having a mating end and a mounting end configured to be mounted to a support structure. The headstock housing has a protective wall forming a headstock chamber. The headstock connector includes headstock terminals disposed in the headstock chamber. The headstock connector includes a headstock seal coupled to the headstock housing. The headstock seal includes an upper portion having an upper sealing surface and a lower portion having a lower sealing surface. The upper portion extends into the headstock chamber, and the lower portion extends into the mounting end. The lower sealing surface is configured to abut against the support structure to form a seal between the headstock housing and the support structure. as well as A plug connector that mates with the head connector, the plug connector including a plug housing for retaining plug terminals, the plug housing having a sealing wall, the plug terminals having a cable end and a mating end, the mating end being engaged with the head terminal during mating to electrically connect the plug terminal to the head terminal, the plug housing being received in the head chamber such that the sealing wall abuts against the upper sealing surface of the upper part of the head seal; The upper and lower portions of the headstock seal are integral monolithic structures, and the headstock seal includes a connecting portion that extends between the upper and lower portions to connect the upper and lower portions at spaced-out locations.

18. The power connector system of claim 17, wherein the upper portion is fixed relative to the headstock housing, and when the plug connector is engaged with the headstock connector, the sealing wall of the plug housing moves to a sealing position against the upper portion of the headstock seal, and when the plug connector is disengaged from the headstock connector, the sealing wall of the plug housing moves away from the upper portion of the headstock seal.

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