Power connector system

Abstract

A power connector system (10) includes a plug connector (100) that includes a plug housing (150) that holds a plug terminal (110) that is terminated to an end of a power cable (102). The power cable exits the plug housing at the cable outlet. The plug connector includes a lever (300) rotatably coupled to the plug housing. The power connector system includes a header connector (200) including a header housing (250) that holds a header terminal (210), the header terminal (210) configured to be received in the header housing to mate with the header terminal when the header connector is mated with the header connector. The header connector includes a connection bolt (400) coupled to the header terminal. When the connecting bolt is screwed, the socket terminal is pressed into the plug terminal. The lever is actuated to tighten the connection bolt.

Description

Technical Field

[0001] The subject matter herein relates generally to electrical connectors. Background Art

[0002] An electrical connector typically includes a housing that holds terminals that are configured to mate with another electrical connector. For example, an electrical connector may include a socket connector mounted to an electrical component and a plug connector configured to be coupled to the socket connector. The housing of the electrical connector is typically provided with a cavity extending therethrough for receiving the terminals. The electrical connector needs to maintain a reliable electrical connection at the interface between the terminals. For example, the electrical connector may be subject to vibration during use. Some known electrical connectors use a deflectable mating element (e.g., a spring beam) to maintain an electrical connection. However, the spring beam may have a limited amount of current carrying capacity because the spring beam may be relatively thin to allow the spring beam to be deflectable. In addition, the manufacture and assembly of the terminals may be expensive. The terminals may take up a large amount of space.

[0003] There remains a need for an electrical connector system having a reliable electrical connection. Summary of the invention

[0004] In one embodiment, a power connector system is provided, which includes a plug connector, which includes a plug housing that holds a plug terminal. The plug housing includes a mating opening at a mating end. The plug terminal has a mating end aligned with the mating opening. The plug terminal has a terminating end that is terminated to the end of a power cable. The power cable leaves the plug housing at a cable outlet. The plug connector includes a lever rotatably connected to the plug housing. The power connector system includes a socket connector, which includes a socket housing that holds a socket terminal. The socket terminal is received in the mating opening to mate with the plug terminal when the plug connector mates with the socket connector. The socket connector includes a connecting bolt connected to the socket terminal. When the connecting bolt is screwed, the socket terminal is pressed into the plug terminal. The lever is actuated to tighten the connecting bolt. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] The present invention will now be described by way of example with reference to the accompanying drawings, in which:

[0006] Figure 1 is a rear perspective view of a power connector system according to an exemplary embodiment in an assembled and mated state.

[0007] Figure 2 is a front perspective view of a power connector system in an assembled and mated state according to an exemplary embodiment.

[0008] Figure 3 is an exploded view of a portion of a plug connector according to an exemplary embodiment.

[0009] Figure 4 is an exploded view of a portion of a plug connector according to an exemplary embodiment.

[0010] Figure 5 is a bottom perspective view of a plug connector according to an exemplary embodiment.

[0011] Figure 6 is a top perspective view of a header connector according to an exemplary embodiment.

[0012] Figure 7 is an exploded view of a header connector according to an exemplary embodiment.

[0013] Figure 8 is a front perspective view of a power connector system according to an exemplary embodiment showing a plug connector ready to mate with a header connector.

[0014] Fig. 9 is a rear perspective view of a portion of a power connector system according to an exemplary embodiment showing a plug terminal coupled to a header terminal.

[0015] Fig.10 is a front perspective view of a portion of a power connector system according to an exemplary embodiment showing a plug terminal coupled to a header terminal.

[0016] Fig.11 is a front perspective view of a portion of a power connector system according to an exemplary embodiment showing a lever coupled to a connecting bolt with the lever in an unlocked position.

[0017] Fig.12 is a front view of a portion of a power connector system showing a lever coupled to a connecting bolt, according to an exemplary embodiment, with the lever in an unlocked position.

[0018] Fig.13 is a front perspective view of a portion of a power connector system showing a lever coupled to a connecting bolt, with the lever in a locked position, according to an exemplary embodiment.

[0019] Fig.14 is an enlarged view of a mating interface between a plug terminal and a socket terminal in a decoupled state according to an exemplary embodiment.

[0020] Fig.15 is an enlarged view of a mating interface between a plug terminal and a socket terminal in a coupled state according to an exemplary embodiment. DETAILED DESCRIPTION

[0021] Figure 1 is a rear perspective view of the power connector system 10 according to an exemplary embodiment in an assembled and mated state. Figure 2 is a front perspective view of the power connector system 10 in an assembled and mated state. The power connector system 10 includes a header connector 200 and a plug connector 100 configured to mate with the header connector 200. In an exemplary embodiment, the power connector system 10 is a high-power connector system that is used to transmit power between various components that are part of a high-power circuit. In a particular application, the power connector system 10 is a battery system, such as a battery system of a vehicle (such as an electric vehicle or a hybrid electric vehicle); however, the power connector system 10 is not intended to be limited to such a battery system.

[0022] The plug connector 100 is configured to be electrically connected to the component 12, for example, through one or more power cables 102; however, the plug connector 100 can be electrically connected to the component 12 through other devices (e.g., terminals, bus bars, or other connectors). In various embodiments, the component 12 can be a battery, a charger, an inverter, a motor, or another type of component. The header connector 200 is configured to be electrically connected to the component 14, for example, through one or more power bus bars 202; however, the header connector 200 can be electrically connected to the component 14 through other devices (e.g., terminals, power cables, or other connectors). In an exemplary embodiment, the header connector 200 is configured to be directly mounted to the component 14, for example, using fasteners. In various embodiments, the header connector 200 can be electrically connected to a battery pack, for example, through a battery distribution unit, a manual service disconnect, a charger, an inverter, a motor, or another type of component. The battery distribution unit can manage the power capacity and function of the power connector system 10, for example, by measuring current and regulating power distribution to the battery pack.

[0023] In the illustrated embodiment, the power connector system 10 is a right angle connector system, wherein the connectors 100, 200 mate in a direction perpendicular to the power cable 102. In various embodiments, the mating direction may be a vertical mating direction, wherein the plug connector 100 is inserted into the header connector 200 from above. In alternative embodiments, other mating orientations are possible. In other embodiments, the power cable 102 may be oriented in other orientations relative to the mating direction, such as parallel to the mating direction rather than perpendicular to the mating direction.

[0024] In an exemplary embodiment, plug connector 100 is removably coupled to header connector 200 to disconnect high power circuits of one or more components (e.g., a battery pack, an electric motor, an inverter, or other components of a vehicle), such as for maintenance, repair, or other reasons. When mated, one or more header terminals 210 ( Figure 6 ) and the corresponding plug terminal 110 ( Figure 5) mate, for example at its mating interface. In an exemplary embodiment, the socket terminal 210 mates with the plug terminal 110 by a bolt connection. For example, the socket terminal 210 mates with the plug terminal 110 at a compression interface, such as at the side surfaces of the socket terminal 210 and the plug terminal 110. In various embodiments, the connectors 100, 200 include pairs of plug terminals 110 and socket terminals 210, respectively. However, more or fewer terminals may be utilized in alternative embodiments. Having multiple terminals increases the current carrying capacity of the system 10. In an exemplary embodiment, the socket connector 200 and / or the plug connector 100 may include a high voltage interlock (HVIL) circuit to control the high voltage power circuit during the opening and closing or mating and unmating of the connectors 100, 200.

[0025] In an exemplary embodiment, the plug connector 100 uses a lever 300 to fix the connectors 100, 200 in a mated state. The lever 300 can be used to lock the plug connector 100 to the tube socket connector 200. In various embodiments, the lever 300 can be used as a mating aid, for example to assist in the mating and unmating of the connectors 100, 200. In an exemplary embodiment, the lever 300 is used to form a bolt connection between the tube socket terminal 210 and the plug terminal 110. For example, the lever 300 is used to rotate or tighten the connection bolt 400 ( Figure 6 ), which tightens or presses the socket terminals 210 and the plug terminals 110 together to maintain a reliable electrical connection that can withstand vibration or other environmental issues. In an exemplary embodiment, the connectors 100, 200 are finger-proof and touch-safe.

[0026] Figure 3 1 is an exploded view of a portion of a plug connector 100 according to an exemplary embodiment. The plug connector 100 includes a plug housing 150 configured to hold a plug terminal 110 ( Figure 4 ). The lever 300 is configured to be coupled to the plug housing 150. For example, the lever 300 is configured to be rotatably coupled to the plug housing 150. In an exemplary embodiment, a latch 308 is coupled to the plug housing 150 to secure the lever 300 to the plug housing 150, for example, in a locked position.

[0027] The plug housing 150 includes a wall 152 that forms a cavity 154. The plug terminal 110 is configured to be located within the cavity 154. The plug housing 150 includes a mating end 156 that is configured to mate with the header connector 200 ( Figure 6 ). The plug housing 150 includes a cable end 158. The power cable 102 ( Figure 5) extends from the plug housing 150 at the cable end 158. In an exemplary embodiment, the plug connector 100 is a right angle connector having the cable end 158 perpendicular to the mating end 156. For example, the power cable 102 extends perpendicular to the mating direction. In the illustrated embodiment, the mating direction is a vertical or downward direction, or as the power cable 102 extends horizontally from the plug housing 150.

[0028] In an exemplary embodiment, the plug housing 150 includes a top 160 and a bottom 162. The plug housing 150 extends between a front 164 and a rear 166. The plug housing 150 includes sides 170, 172 extending between the front 164 and the rear 166. In an exemplary embodiment, the lever 300 is coupled to the plug housing 150 at the first side 170 and / or the second side 172. In an exemplary embodiment, the bottom 162 defines a mating end 156. The bottom 162 of the plug housing 150 is configured to be pluggably coupled to the header connector 200. In an exemplary embodiment, the plug housing 150 includes an opening 174 at the bottom 162. The opening 174 is configured to receive a portion of the header connector 200. In alternative embodiments, the mating end 156 may be located at other portions of the plug housing 150, such as the front 164. In an exemplary embodiment, the rear 166 defines the cable end 158. The plug housing 150 includes an opening 176 at the rear 166. The power cable 102 is configured to exit the plug housing 150 through the opening 176. In alternative embodiments, the cable end 158 may be located at other portions of the plug housing 150, such as the top 160.

[0029] In an exemplary embodiment, the plug housing 150 includes a lever opening 178 at the sides 170, 172. The lever opening 178 is configured to receive a portion of the lever 300. In the illustrated embodiment, the lever opening 178 is circular, allowing the lever 300 to rotate within the lever opening 178.

[0030] The lever 300 includes a handle 302. The handle 302 is used to actuate the lever 300, such as to move the lever 300 relative to the plug housing 150 when the lever 300 is coupled to the plug housing 150. The lever 300 includes a first lever arm 304 and a second lever arm 306 extending from opposite sides of the handle 302. The lever arms 304, 306 are configured to extend along the sides 170, 172 of the plug housing 150.

[0031] In an exemplary embodiment, the lever 300 includes a hub 310 at the distal end of the lever arms 304, 306. The hub 310 is configured to be received in a corresponding lever opening 178 of the plug housing 150. In various embodiments, the hub 310 is cylindrical. The hub 310 is configured to be rotatably coupled to the plug housing 150, for example at the sides 170, 172. Optionally, each hub 310 includes a hub seal 312, which is configured to seal between the hub 310 and the plug housing 150.

[0032] In an exemplary embodiment, the lever 300 includes a drive tool 320 at the inner end of the hub 310. The drive tool 320 is configured to engage with a corresponding connecting bolt 400 ( Figure 6 ) docking to actuate the connecting bolt 400. For example, when the lever 300 rotates relative to the plug housing 150, the driving tool 320 can rotate the connecting bolt 400. The driving tool 320 is used to tighten the connecting bolt 400 when the lever 300 rotates. In an exemplary embodiment, the driving tool 320 includes a driving wall 322 and a driving recess 324 between the driving walls 322. A portion of the connecting bolt 400 is configured to be received in the driving recess 324 between the driving walls 322. The driving wall 322 is configured to engage the connecting bolt 400 to rotate the connecting bolt 400 when the lever 300 rotates. In the illustrated embodiment, the gap 326 is located between the driving walls 322. The gap 326 is located at the bottom of the driving recess 324. The connecting bolt 400 is configured to be loaded into the driving recess 324 through the gap 326 when the plug connector 100 is mated with the tube socket connector 200.

[0033] Figure 4 is an exploded view of a portion of plug connector 100 according to an exemplary embodiment. Figure 4 The lever 300 is shown coupled to the plug housing 150 and positioned in an unlocked position. The lever 300 can be rotated (eg, approximately 90°) to a locked position ( Figure 5 ). Figure 4 The plug terminal 110 is shown terminated to the end of the power cable 102 and ready to be loaded into the plug housing 150. In the illustrated embodiment, a pair of plug terminals 110 and a pair of power cables 102 are provided. However, in alternative embodiments, more or fewer plug terminals 110 and power cables 102 may be provided. In the exemplary embodiment, the plug terminal 110 is welded to the end of the power cable 102. However, in alternative embodiments, the plug terminal 110 may be terminated to the power cable 102 by other means.

[0034] In an exemplary embodiment, a shield 104 is disposed at the end of each power cable 102. The shield 104 is configured to be inserted into a cavity 154 of the plug housing 150. The shield 104 can be electrically connected to a plug shield (not shown) of the plug connector 100, and the shield 104 provides shielding at the termination of the plug terminal 110 to the power cable 102.

[0035] In an exemplary embodiment, seal 106 is disposed at the end of power cable 102. Seal 106 is configured to seal to power cable 102 and plug housing 150. Seal 106 provides a sealed interface at cable end 158 of plug housing 150 to seal cavity 154 from moisture and / or debris.

[0036] In an exemplary embodiment, a cable grommet 108 is disposed at the end of the power cable 102. The cable grommet 108 is configured to be inserted into the cable end 158 of the plug housing 150, for example at the opening 176. The cable grommet 108 is used to secure the power cable 102 to the plug housing 150. Optionally, the cable grommet 108 may include a latch to latchably couple to the plug housing 150. The cable grommet 108 provides strain relief for the power cable 102. In an exemplary embodiment, the cable grommet 108 retains the seal 106. For example, the seal 106 seals between the cable grommet 108 and the plug housing 150. A separate cable seal may be provided between the cable grommet 108 and the outer jacket of the power cable 102. In various embodiments, a single cable grommet 108 is provided to retain a pair of power cables 102. However, in alternative embodiments, individual cable grommet 108 are provided, which retain corresponding individual power cables 102.

[0037] The plug terminal 110 is made of a conductive material, such as copper or aluminum. The plug terminal 110 may be a stamped component. In an exemplary embodiment, the plug terminal 110 is a sheet terminal. For example, the plug terminal 110 may be a flat sheet of metal. The plug terminal 110 is configured to be inserted into the socket connector 200 during mating with the socket connector 200.

[0038] The plug terminal 110 extends between a mating end 112 and a terminating end 114. The power cable 102 is terminated to the plug terminal 110 at the terminating end 114. For example, the center conductor of the power cable 102 can be soldered to the plug terminal 110 at the terminating end 114. In various embodiments, the plug terminal 110 includes a solder pad at the terminating end 114. However, in alternative embodiments, the plug terminal 110 can include a crimp barrel or other type of terminal.

[0039] In an exemplary embodiment, the plug terminal 110 includes a bolt hole 116 at the mating end 112. The bolt hole 116 is configured to receive a connecting bolt 400 ( Figure 6 ) to be compatible with the base terminal 210 ( Figure 6 ) forms a bolt electrical connection. The plug terminal 110 extends between the top edge 120 and the bottom edge 122. The plug terminal 110 includes a front edge 124 between the top edge 120 and the bottom edge 122. The plug terminal 110 includes opposite sides 126, 128 between the top edge 120 and the bottom edge 122. The conductor of the power cable 102 can be welded to one of the sides 126 or 128. In the illustrated embodiment, the first side 126 of one of the plug terminals 110 faces the second side 128 of the other plug terminal 110. In the illustrated embodiment, the bolt hole 116 opens at the bottom edge 122. For example, the bolt hole 116 is a bolt hole with a side opening. The connecting bolt 400 is configured to be received in the bolt hole 116 through the bottom edge 122.

[0040] Figure 5 is a bottom perspective view of plug connector 100 according to an exemplary embodiment. Figure 5 The lever 300 is shown coupled to the plug housing 150 and positioned in a locked position. Figure 5 The power cable 102 and the cable ferrule 108 are shown coupled to the cable end 158 of the plug housing 150 .

[0041] The plug housing 150 includes an opening 174 at the bottom 162 of the plug housing 150 at the mating end 156. The mating end 156 is configured to mate with the header connector 200 such that a portion of the header connector 200 is loaded into the cavity 154 through the opening 174. In an exemplary embodiment, the plug housing 150 includes a guide feature 180 to guide the mating with the header connector 200. In the illustrated embodiment, the guide feature 180 is a slot or groove at the mating end 156 that receives a tab or post of the header connector 200 to guide the mating of the plug connector 100 with the header connector 200.

[0042] In an exemplary embodiment, the plug housing 150 is a multi-piece housing. For example, the plug housing 150 includes an inner housing 182 and an outer housing 184 surrounding the inner housing 182. The inner housing 182 holds the plug terminals 110. In an exemplary embodiment, a gap 186 is provided between the inner housing 182 and the outer housing 184 at the mating end 156. The gap 186 receives a portion of the header connector 200. In an exemplary embodiment, the inner housing 182 includes an opening 188 that receives a portion of the header connector 200. For example, the header terminal 210 is loaded into the opening 188 to mate with the plug terminal 110.

[0043] In an exemplary embodiment, the plug connector 100 includes a shield held by the plug housing 150. The shield 190 provides shielding around the mating interface. The shield 190 can be electrically connected to the shield 104 of the power cable 102. The shield 190 is configured to mate with a shield of the header connector 200. In the illustrated embodiment, the shield 190 is coupled to the inner housing 182 and surrounds the opening 188.

[0044] In an exemplary embodiment, the plug connector 100 includes a mating seal 192 at the mating end 156. The mating seal 192 is configured to be coupled to the header connector 20 to provide a sealed interface between the plug connector 100 and the header connector 200. In the illustrated embodiment, the mating seal 192 is located in the gap 186 between the inner housing 182 and the outer housing 184. The mating seal 192 can seal to the inner housing 182 and / or the outer housing 184.

[0045] Figure 6 is a top perspective view of header connector 200 according to an exemplary embodiment. Figure 7 is an exploded view of a header connector 200 according to an exemplary embodiment. The header connector 200 includes a header housing 250 for holding header terminals 210. In the illustrated embodiment, the header connector 200 includes a pair of header terminals 210. However, in alternative embodiments, the header connector 200 may include more or fewer header terminals 210.

[0046] In an exemplary embodiment, the header connector 200 includes a shield 204 that provides shielding for the header terminals 210. The shield 204 is configured to be electrically connected to the shield 190 ( Figure 5 ). The shield 204 may be used to electrically common or ground the header connector 100 to the header connector 200. The shield 204 is configured to be electrically connected to the component 14 to ground the header connector 200 to the component 14.

[0047] The socket housing 250 includes a base 252 and a shroud 254 extending from the base 252. The shroud 254 surrounds the cavity 255. The shroud 254 is disposed at a mating end 256 of the socket housing 250. The base 252 is disposed at a mounting end 258 of the socket housing 250. The mating end 256 is configured to mate with the plug connector 100. For example, the shroud 254 can be inserted into the plug housing 150 of the plug connector 100 (e.g., inserted into the gap 186). The socket terminal 210 is disposed at the mating end 256 for mating with the plug terminal 110. The mounting end 258 is configured to be mounted to the component 14. In an exemplary embodiment, the base 252 includes a mounting flange 259 at the mounting end 258. The mounting flange 259 can be fixed to the component 14, for example, using a fastener.

[0048] In an exemplary embodiment, the tube base housing 250 extends between a top 260 and a bottom 262. The tube base housing 250 includes a front 264 and a rear 266. The tube base housing 250 includes a side 268 extending between the front 264 and the rear 266. In the illustrated embodiment, the mating end 256 is disposed at the top 260 and the mounting end 258 is disposed at the bottom 262. In alternative embodiments, other orientations are possible. The shield 254 includes corresponding shield walls at the front 264, the rear 266, and the side 268. Optionally, the front shield wall can be higher than the rear shield wall. The shield wall can include a guide feature, such as a tab extending from the shield wall, the tab being configured to be inserted into the plug connector 100 during mating to guide the mating of the plug connector 100 with the tube base connector 200.

[0049] In an exemplary embodiment, the header connector 200 includes a terminal retainer 230 configured to hold a header terminal 210. The terminal retainer 230 is configured to be inserted into the header housing 250, such as through the bottom 262. The terminal retainer 230 can be positioned in the cavity 255 and surrounded by the shield 254. The terminal retainer 230 includes a terminal channel 232 that receives the corresponding header terminal 210. The terminal retainer 230 includes a tower 234 located at the top of the terminal retainer 230, and the tower 234 surrounds the terminal channel 232 and the header terminal 210 received in the terminal channel 232. In an exemplary embodiment, the tower 234 has a slot 236 leading to the terminal channel 232. The slot 236 is open at the top and / or front and / or rear of the tower 234. The slot 236 is configured to receive the plug terminal 110 during mating. In an exemplary embodiment, the tower 234 includes a recess 238 at the side of the tower 234. Recess 238 leads to terminal passage 232. Recess 238 may receive a portion of connection bolt 400. Recess 238 may receive a threaded insert or knot configured to couple to threaded bolt 400. In an exemplary embodiment, tower 234 includes an opening 240 configured to receive threaded bolt 400.

[0050] The socket terminal 210 is made of a conductive material, such as copper or aluminum. The socket terminal 210 may be a stamped component. In an exemplary embodiment, the socket terminal 210 is a sheet-type terminal. For example, the socket terminal 210 may be a flat metal sheet.

[0051] The socket terminal 210 extends between a mating end 212 and a terminating end 214. The mating end 212 of the socket terminal is configured to be received in a terminal passage 232 of a terminal holder. The terminating end 214 may extend from the terminal holder 230, for example, below the terminal holder 230. The bus bar 202 ( Figure 1 and Figure 2 ) is terminated to the header terminal 210 at the terminating end 214. For example, the bus bar 202 may be welded or bolted to the terminating end 214.

[0052] In an exemplary embodiment, the tube socket terminal 210 includes a threaded portion 216 at the mating end 212. The threaded portion 216 is configured to receive the connecting bolt 400. In an exemplary embodiment, the threaded portion 216 includes a threaded insert 218 received in the tube socket terminal 210, the threaded insert 218 having a threaded hole configured to receive the connecting bolt 400. The threaded portion 216 is configured to be located in a recess 238 of the terminal retainer 230. The threaded portion 216 is positioned in the terminal retainer 230 so that the threaded hole is aligned with the opening 240 in the terminal retainer 230 to receive the connecting bolt 400. The threaded insert 218 can be pressed into the opening in the tube socket terminal 210. The threaded insert 218 can be welded to the tube socket terminal 210. In an alternative embodiment, the threaded portion 216 includes threads formed directly on the tube socket terminal 210, such as in an opening through the tube socket terminal 210.

[0053] The socket terminal 210 extends between a top portion 220 and a bottom portion 222. The socket terminal 210 includes an opening 224 between the top portion 220 and the bottom portion 222. The threaded portion 216 is disposed at the opening 224. For example, a threaded insert 218 is received in the opening 224. The socket terminal 210 includes opposing sides 226, 228 between the top portion 220 and the bottom portion 222. In an exemplary embodiment, the first side 226 is configured to face the plug terminal 110 and define a mating interface of the socket terminal 210. The threaded portion 216 may extend from the first side 226 and / or the second side 228.

[0054] In an exemplary embodiment, the tube socket connector 200 includes a pair of connecting bolts 400 associated with corresponding tube socket terminals 210. In alternative embodiments, more or fewer connecting bolts 400 may be provided. Each connecting bolt 400 includes a head 410 and a shaft 420 extending from the head 410. The shaft 420 is a threaded shaft having threads 422. The threads 422 are configured to be threadably coupled to the threaded portion 216 of the corresponding tube socket terminal 210. For example, the connecting bolt 400 can be tightened or loosened by rotating the connecting bolt 400 relative to the threaded portion 216. The shaft 420 is configured to be loaded into the opening 240 of the terminal retainer 230 after the tube socket terminal 210 is loaded into the terminal channel 232 to be received in the threaded portion 216. For example, the connecting bolt 400 can be loaded into the opening 240 from the opposite outer side of the tower 234 so that the head 410 is located on the outer side of the tower 234 to engage with the lever 300 ( Figure 3 ) connection.

[0055] The head 410 includes an inner surface 412 facing the terminal retainer 230. The inner surface 412 can abut against the side of the terminal retainer 230 to position the connecting bolt 400 relative to the terminal retainer 230. The head 410 includes a drive element 414 for driving (e.g., rotating) the connecting bolt 400. In the illustrated embodiment, the drive element 414 is an outer edge of the head 410. The drive element 414 is configured to engage with the drive tool 320 ( Figure 3 ) to rotate the connecting bolt 400 when the lever 300 moves between the unlocked position and the locked position. In the illustrated embodiment, the head 410 is a hexagonal shape with six drive elements 414. Other types of drive elements, such as slots or openings, may be used in alternative embodiments to receive drive tools of different shapes.

[0056] Figure 8 1 is a front perspective view of the power connector system 10, showing the plug connector 100 ready to be mated with the tube socket connector 200. The plug connector 100 is mated with the tube socket connector 200 in a mating direction, which is shown by an arrow. The mating end 156 of the plug housing 150 is aligned with the mating end 256 of the tube socket housing 250. When mated, the shield 254 is received in the opening 174 at the bottom 162 of the plug housing 150. The terminal retainer 230 and the tube socket terminal 210 are received in the plug connector 100 so that the tube socket terminal 210 is mated with the plug terminal 110. In an exemplary embodiment, the connecting bolt 400 is used to form a bolt connection between the tube socket terminal 210 and the plug terminal 110. For example, the connecting bolt 400 is tightened after the plug terminal 110 is received in the groove 236 of the terminal retainer 230 to form a bolt compression connection between the tube socket terminal 210 and the plug terminal 110. The connecting bolt 400 is tightened by rotating the connecting bolt 400. For example, the driving tool 320 of the lever 300 interfaces with the head 410 of the connecting bolt 400 to move the lever 300 from the unlocked position ( Figure 8 ) is rotated to the locked position and the connecting bolt 400 is rotated.

[0057] Fig. 9 is a rear perspective view of a portion of the power connector system 10 showing the plug terminal 110 coupled to the header terminal 210 . Fig.10 1 is a front perspective view of a portion of the power connector system 10, showing the plug terminal 110 coupled to the socket terminal 210. The plug housing 150 ( Figure 8 )exist Fig. 9 and Fig.10 1 is removed to show the plug terminal 110 and the power cable 102 terminated to the plug terminal 110. Fig.10 The header housing 250 is removed to show the terminal holder 230 and the header terminal 210 .

[0058] During mating, the plug terminal 110 is mated to the socket connector 200 in a mating direction (e.g., downward). The plug terminal 110 is loaded into the slot 236 of the terminal holder 230 so that the side 126 of the plug terminal 110 faces the side 226 of the socket terminal 210. The bolt hole 116 ( Figure 4 ) is provided at the bottom of the plug terminal 110 to receive the connection bolt 400 when the plug terminal 110 is loaded into the groove 236. The connection bolt 400 passes through the plug terminal 110 and is threadedly coupled to the socket terminal 210. When the connection bolt 400 is tightened, the socket terminal 210 is pressed into electrical contact with the plug terminal 110.

[0059] Fig.11 4 is a front perspective view of a portion of the power connector system 10 showing the lever 300 coupled to the connecting bolt 400 , with the lever 300 in an unlocked position. Fig.12 is a front view of a portion of the power connector system 10 showing the lever 300 coupled to the connecting bolt 400 , with the lever 300 in an unlocked position. Fig.13 1 is a front perspective view of a portion of the power connector system 10, showing the lever 300 coupled to the connecting bolt 400, wherein the lever 300 is in a locked position. The plug terminal 110 and the socket terminal 210 are in a Figure 11-13 however, the plug housing 150 and the header housing 250 are removed to show the internal components of the connectors 100 , 200 .

[0060] During mating, when the plug connector 100 is lowered onto the socket connector 200, the lever 300 engages with the connecting bolt 400. For example, the head 410 of the connecting bolt 400 is received in the driving recess 324 of the corresponding driving tool 320. The driving wall 322 engages with the driving element 414 of the connecting bolt 400. The rotation of the lever 300 from the unlocked position to the locked position causes the connecting bolt 400 to rotate. The rotation of the connecting bolt 400 tightens the threaded connection between the connecting bolt 400 and the corresponding threaded portion 216, which causes the socket terminal 210 and the head 410 of the connecting bolt 400 to move closer together, thereby pressing the socket terminal 210 against the plug terminal 110 to form a reliable electrical connection.

[0061] Fig.14 is an enlarged view of the mating interface between the plug terminal 110 and the socket terminal 210 in a decoupled state. Fig.15 FIG. 4 is an enlarged view of the mating interface between the plug terminal 110 and the socket terminal 210 in the connected state. Fig.14 is shown in the released state and in Fig.15300 is shown in a tightened state. For example, the connecting bolt 400 is rotated between a loose state and a tightened state by the driving tool 320 of the lever 300. When the plug connector 100 is mated with the socket connector 200, the head 410 of the connecting bolt 400 is received in the driving recess 324 of the driving tool 320. The driving wall 322 of the driving tool 320 engages the driving element 414 of the connecting bolt 400. The rotation (e.g., 90° rotation) of the lever 300 causes the rotation (e.g., 90° rotation) of the connecting bolt 400.

[0062] The shaft 420 of the connecting bolt 400 passes through the plug terminal 110, for example, through the bolt hole 116 ( Figure 4 ). The shaft 420 is threadedly coupled to the threaded portion 216. The plug terminal 110 is located in the gap 242 between the head 410 and the socket terminal 210. In the loosened state ( Fig.14 ), the gap 242 has a width. When the connecting bolt 400 is rotated and tightened to a tightened state ( Fig.15 ), the gap 242 has a narrower width. For example, when the connecting bolt 400 is tightened, the tube socket terminal 210 is pulled inward toward the head 410. As the tube socket terminal 210 is pulled inward, the tube socket terminal 210 is pressed against the plug terminal 110. For example, the side 226 of the tube socket terminal 210 is pressed against the side 126 of the plug terminal 110. The connecting bolt 400 holds the tube socket terminal 210 tightly against the plug terminal 110 to form a reliable electrical connection when the connecting bolt 400 is in a tightened state. The lever 300 can be locked in a locked position to keep the connecting bolt 400 in a tightened state to maintain a reliable electrical connection between the tube socket terminal 210 and the plug terminal 110. Even through the vibration of the power connector system 10, the tube socket terminal 210 is tightly held against the plug terminal 110. The mating interface between the tube socket terminal 210 and the plug terminal 110 is set to have no spring beam. Instead, a direct planar mating interface is defined between the side 226 of the header terminal 210 and the side 126 of the plug terminal 110 , allowing high current transfer between the header terminal 210 and the plug terminal 110 across the large planar surface area of ​​the sides 226 , 126 .

Claims

1. A power connector system (10), comprising: A plug connector (100) comprising a plug housing (150) holding a plug terminal (110), the plug housing comprising a mating opening (174) at a mating end (112), the plug terminal having a mating end aligned with the mating opening, the plug terminal having a terminating end (114) terminated to an end of a power cable (102), the power cable exiting the plug housing at a cable outlet, the plug connector comprising a lever (300) rotatably coupled to the plug housing; A socket connector (200) comprising a socket housing (250) holding a socket terminal (210), the socket terminal being received in the mating opening to mate with the plug terminal when the plug connector is mated with the socket connector, the socket connector comprising a connecting bolt (400) coupled to the socket terminal, the socket terminal being pressed into the plug terminal when the connecting bolt is tightened; Wherein, the lever is actuated to tighten the connecting bolt.

2. The power connector system (10) according to claim 1, wherein: The connecting bolt (400) forms a bolt connection between the socket terminal (210) and the plug terminal (110).

3. The power connector system (10) according to claim 1, wherein: The connection bolt (400) is tightened to form a compression connection between the socket terminal (210) and the plug terminal (110).

4. The power connector system (10) according to claim 1, wherein: The lever (300) is movable between an unlocking position and a locking position, and when moving from the unlocking position to the locking position, the lever causes the connecting bolt (400) to rotate.

5. The power connector system (10) according to claim 1, wherein: The plug terminal (110) includes a bolt hole (116) passing through the plug terminal, the bolt hole receiving the connection bolt (400).

6. The power connector system (10) according to claim 1, wherein: The connection bolt (400) includes a head (410) and a threaded shaft (420), the lever (300) engages the head to rotate the connection bolt, and the threaded shaft is threadably coupled to the socket terminal (210).

7. The power connector system (10) according to claim 6, wherein: The head (410) is separated from the socket terminal (210) by a gap (186) in which the plug terminal (110) is received, and when the connection bolt (400) is tightened, the width of the gap becomes narrower.

8. The power connector system (10) according to claim 6, wherein: When the connection bolt (400) is tightened to press the mating surface of the socket terminal into the mating surface of the plug terminal (110), the connection bolt pulls the socket terminal (210) toward the head (410).

9. The power connector system (10) according to claim 1, wherein: The tube seat terminal (210) includes a first side surface (226) and a second side surface (228), and the plug terminal (110) includes a first side surface (126) and a second side surface (128). The first side surface of the tube seat terminal faces the first side surface of the plug terminal. When the connecting bolt (400) is tightened to electrically connect the tube seat terminal and the plug terminal, the first side surface of the tube seat terminal is pressed against the first side surface of the plug terminal.

10. The power connector system (10) according to claim 1, wherein: The lever (300) includes a drive tool (320) that engages the connecting bolt (400) to rotate the connecting bolt when the lever moves between the unlocked position and the locked position.

11. The power connector system (10) of claim 1, wherein: The plug connector (100) includes a second plug terminal (110), and the tube socket connector (200) includes a second tube socket terminal (210) and a second connecting bolt (400) connected to the second tube socket terminal. When the lever is rotated from an unlocked position to a locked position, the lever engages the connecting bolt and the second connecting bolt to tighten the connecting bolt and the second connecting bolt. When the second connecting bolt is tightened, the second tube socket terminal is pressed into the second plug terminal.

12. The power connector system (10) of claim 1, wherein: The plug terminal (110) includes a bolt hole (116) opened at the bottom edge (122) of the plug terminal, and when the plug connector (100) is mated with the socket connector (200), the bolt hole receives the connecting bolt (400) through the bottom edge of the opening.

13. The power connector system (10) of claim 1, wherein: When the connection bolt (400) is tightened, the socket terminal (210) and the plug terminal (110) are relatively moved closer to each other.

14. The power connector system (10) of claim 1, wherein: The connecting screw (400) is completely surrounded by the plug housing (150) and the base housing (250).

15. The power connector system (10) of claim 1, wherein: The lever (300) extends into the tube base housing (250) to engage with the connecting bolt (400).

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