Header connector with bus bar assembly

Abstract

A header connector (100) includes a header housing (100) extending between a mating end (116) and a terminating end (118). The mating end is configured to mate with a plug connector (200). The header housing has a cavity (114) between the mating end and the terminating end. The headstock housing is provided with a mounting flange (134), and the mounting flange (134) is configured to be mounted on a panel (20). The header connector includes a bus bar carrier assembly (150) including a bus bar carrier (160) and a bus bar (180) held by the bus bar carrier. The busbar carrier has a support wall (162) and a mounting portion (164). The bus bar is coupled to the support wall. The mounting portion is coupled to the terminating end of the header housing. When the mounting portion of the bus bar carrier is coupled to the termination end of the header housing, the bus bar is received in the cavity of the header housing to mate with the plug connector.

Description

Technical Field

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

[0002] The communication system includes an electrical connector that cooperates with various components of the electrical connection system. For example, a header connector can be mounted to a device, such as a chassis, a panel, a circuit board, or another substrate, for cooperation with a plug connector. The plug connector can be terminated to a wiring harness or another circuit board. The header connector generally includes a housing for holding a terminal or a busbar, which is configured to be terminated to a cable. The busbar is generally loaded into the header housing separately, which increases the number of components that the customer needs to install and assemble, which increases the assembly cost and complexity. During assembly, the header connector is generally loaded through an opening in the device (e.g., a panel opening). The opening has a certain shape / size, called a feed envelope, to feed the header connector during assembly. The size of the header connector is limited by the size of the feed envelope to fit through the opening. The size and shape of the busbar are limited by the size / shape of the feed envelope because the busbar needs to pass through the opening.

[0003] There remains a need for a header connector that can be assembled and installed in a cost-effective and reliable manner. Summary of the invention

[0004] In one embodiment, a header connector is provided, which includes a header housing extending between a mating end and a terminating end. The mating end is configured to mate with a plug connector. The header housing has a cavity between the mating end and the terminating end. The header housing has a mounting flange configured to be mounted to a panel. The header connector includes a busbar carrier assembly, which includes a busbar carrier and a busbar held by the busbar carrier. The busbar carrier has a support wall and a mounting portion. The busbar is connected to the support wall. The mounting portion is connected to the terminating end of the header housing. When the mounting portion of the busbar carrier is connected to the terminating end of the header housing, the busbar is received in the cavity of the header housing to mate with the plug connector. 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 perspective view of a communication system according to an exemplary embodiment.

[0007] Figure 2 is an exploded view of a header connector according to an exemplary embodiment.

[0008] Figure 3 is a front perspective view of a busbar carrier assembly in an assembled state according to an exemplary embodiment.

[0009] Figure 4 is a cross-sectional view of a busbar carrier assembly according to an exemplary embodiment.

[0010] Figure 5 is an exploded view of a header connector showing a busbar carrier assembly ready for coupling to a header housing according to an exemplary embodiment.

[0011] Figure 6 is a side view of a header connector showing a busbar carrier assembly ready for coupling to a header housing according to an exemplary embodiment.

[0012] Figure 7 is a rear perspective view of a header connector showing a busbar carrier assembly prepared for coupling to a header housing according to an exemplary embodiment.

[0013] Figure 8 Termination ends of bus bars having different shapes are shown according to exemplary embodiments. DETAILED DESCRIPTION

[0014] Figure 1 is a perspective view of a communication system 10 according to an exemplary embodiment. The communication system 10 includes a first electrical connector 100 and a second electrical connector 200 configured to mate with the first electrical connector 100. The communication system 10 may include a plurality of electrical connectors 100 and / or a plurality of electrical connectors 200. The electrical connector 200 is a mating electrical connector for the first electrical connector 100. Similarly, the first electrical connector 100 is considered to be a mating electrical connector for the second electrical connector 200.

[0015] In an exemplary embodiment, the first electrical connector 100 is a header connector and may be referred to as the header connector 100 hereinafter. The header connector 100 is mounted to a component or device, such as a panel 20. The panel 20 of the device is used to hold the header connector 100. The header connector 100 can be mounted to other components, such as a chassis, a wall, a circuit board, or another type of substrate. In an exemplary embodiment, the header connector 100 is an electrical connector disposed at the end of a power cable 102. In the illustrated embodiment, the header connector 100 is a straight through connector whose cable extends in a direction parallel to the mating direction with the second electrical connector 200. In alternative embodiments, other orientations are possible, such as right-angle connectors. In various other embodiments, the header connector 100 may be a board-mounted connector configured to be mounted to a circuit board.

[0016] In an exemplary embodiment, the second electrical connector 200 is a plug connector and may be referred to as the plug connector 200 hereinafter. The plug connector 200 is configured to be inserted into a socket or receptacle of the header connector 100. In an exemplary embodiment, the plug connector 200 is a cable connector disposed at the end of one or more cables 202. In the illustrated embodiment, the cables 202 extend from an end opposite to the mating end of the plug connector 200. In various other embodiments, the plug connector 200 may be a right angle connector having the cables 202 extending perpendicular to the mating end. In various other embodiments, the plug connector 200 may be a board mount connector configured to be mounted to a circuit board.

[0017] The plug connector 200 includes a plug housing 210 that holds a plurality of plug contacts 250. The plug connector 200 includes a plug latch 240 having a latching element for latchably coupling the plug connector 200 to the plug connector 200. In an exemplary embodiment, the plug housing 210 is made of a dielectric material. For example, the plug housing 210 can be molded from a plastic material. The plug housing 210 extends between a mating end 216 and a cable end 218. The mating end 216 is configured to be inserted into the header housing 110. The cable 202 extends from the cable end 218. In an exemplary embodiment, the plug contact 250 is a power contact. The plug contact 250 can be a socket contact configured to receive the mating end of the header contact of the header connector 100. Other types of contacts can be provided in alternative embodiments, such as blade contacts, pin contacts, spring beam contacts, busbars, etc. The plug contact 250 is terminated to the corresponding cable 202. For example, the plug contacts 250 may be soldered or crimped to the cable 202. The cable 202 may be a power cable.

[0018] The panel 20 provides a rigid support structure to support the header connector 100. In an exemplary embodiment, the panel 20 is a sheet of metal. However, the panel 20 can be made of other materials and construction methods. The panel 20 has a front surface 22 and a rear surface 24. The panel 20 has a thickness between the front surface 22 and the rear surface 24. The front surface 22 can face outward, such as facing the outside of the device, and the rear surface 24 can face inward, such as facing the interior portion of the device. In an exemplary embodiment, the panel 20 includes a panel opening 30 (in the middle) that receives the header connector 100. Figure 2 20). In an exemplary embodiment, the header connector 100 is front loaded into the panel opening 30 and mated to the front surface 22. The header housing 110 is sized and shaped to fit through the panel opening 30 during assembly. A portion of the header housing 110 is accessible in front of the panel 20 to mate with the plug connector 200. In an exemplary embodiment, the power cable 102 is located behind the panel 20, such as inside the device.

[0019] Figure 2 2 is an exploded view of a header connector 100 according to an exemplary embodiment. The header connector 100 is shown relative to the panel 20. Figure 2 A panel opening 30 is shown through the panel 20. The panel opening 30 is defined by an edge 32. In the illustrated embodiment, the panel opening 30 is oval. However, in alternative embodiments, the panel opening 30 may have other shapes. The shape of the panel opening 30 may correspond to the outer shape of the header connector 100.

[0020] The size and shape of the panel opening 30 define a feed envelope 34 that passes through the plane of the panel 20. The feed envelope 34 is a window that allows the header connector 100 to pass through the panel 20. The feed envelope 34 defines a boundary (e.g., size / shape) for allowing a portion of the header connector 100 to pass through the panel 20. The feed envelope 34 has a height 36 and a width 38. The width 38 can be greater than the height 36. In the illustrated embodiment, the feed envelope 34 is elliptical. However, in alternative embodiments, the feed envelope 34 can have other shapes.

[0021] The header connector 100 includes a header housing 110 and a busbar carrier assembly 150 coupled to the header housing 110. The busbar carrier assembly 150 includes a busbar carrier 160 that holds a plurality of busbars 180. The busbar carrier assembly 150 is removably coupled to the header housing 110. The busbar carrier assembly 150 allows the plurality of busbars 180 to be coupled to the header housing 110 as a unit in a single assembly process, rather than coupling the busbars 180 to the header housing 110 individually. In an exemplary embodiment, the busbar carrier assembly 150 allows the busbars 180 to be coupled to the header housing 110 from the rear (e.g., from behind the panel 20), regardless of coupling the header housing 110 to the panel 20. For example, the header housing 110 may be coupled to the front of the panel 20, and the busbar carrier assembly 150 may be coupled to the header housing 110 from the rear of the panel 20.

[0022] In an exemplary embodiment, the header housing 110 is made of a dielectric material. For example, the header housing 110 can be molded from a plastic material. The header housing 110 includes a plurality of walls 112 that form a cavity 114 that receives the plug connector 200. The header housing 110 extends between a mating end 116 and a termination end 118. The plug connector 200 is configured to be coupled to the mating end 116. The cavity 114 opens at the mating end 116 to receive the plug connector 200. In an exemplary embodiment, the busbar carrier assembly 150 is coupled to the termination end 118. The busbar 180 and the power cable 102 terminated to the busbar 180 extend from the termination end 118.

[0023] The header housing 110 includes a front portion 120 and a rear portion 122. In an exemplary embodiment, the header housing 110 includes a front portion 121 extending rearward from the front portion 120 and a rear portion 123 extending forward from the rear portion 122. The front portion 121 is disposed at the mating end 116. The rear portion 123 is disposed at the terminating end 118. The front portion 121 is configured to receive the plug connector 200. The rear portion 123 is configured to receive the busbar carrier assembly 150. The header housing 110 includes a top portion 124 and a bottom portion 126. The header housing 110 includes a side portion 128 between the top portion 124 and the bottom portion 126. The cavity 114 is open at the rear portion 122 to receive the busbar 180. The cavity 114 is open at the front portion 120 to receive the plug connector 200.

[0024] In an exemplary embodiment, latches 130 are provided at the top 124 for latchably coupling the plug connector 200 to the header connector 100. For example, the latches 130 are located along an outer surface of the top wall at the top 124 of the header housing 110. In alternative embodiments, other locations are possible.

[0025] In an exemplary embodiment, the header housing 110 includes guide features 132 to guide the mating of the plug connector 200 with the header connector 100. The guide features 132 can be disposed along the exterior and / or interior of the wall 112. The guide features 132 can be tabs, tracks, grooves, or other types of guide features. The guide features 132 can define keying features for keying with a particular plug connector 200.

[0026] In an exemplary embodiment, the header housing 110 includes a mounting flange 134 extending from the exterior of the header housing 110. The front portion 121 extends forward from the mounting flange 134. The rear portion 123 extends rearward from the mounting flange 134. The rear portion 123 is configured to be loaded through the panel opening 30 during assembly. In the illustrated embodiment, the mounting flange 134 extends completely around the header housing 110. For example, the mounting flange 134 extends from the top 124, the bottom 126, and the two side portions 128. However, in alternative embodiments, the mounting flange 134 can extend from fewer sides of the header housing 110. The mounting flange 134 is used to mount the header housing 110 to the panel 20. The mounting flange 134 includes a mounting surface 136. In the illustrated embodiment, the mounting surface 136 faces rearward. The mounting surface 136 of the mounting flange 134 is configured to engage the front surface 22 of the panel 20. The mounting surface 136 can be generally planar to be placed against the front surface 22 of the panel 20.

[0027] In an exemplary embodiment, a perimeter seal 138 can be coupled to the mounting flange 134. The perimeter seal 138 can extend around the perimeter of the header housing 110. The perimeter seal 138 is configured to seal against the header housing 110 and the panel 20. For example, the perimeter seal 138 can be received in a seal recess in the mounting flange 134 to face the front surface 22 of the panel 20. The perimeter seal 138 can be compressed between the front surface 22 of the panel 20 and the mounting flange 134.

[0028] In an exemplary embodiment, the header connector 100 includes a slide lock 140 for fixing the header connector 100 to the panel 20. The slide lock 140 is configured to be coupled to the panel 20. For example, the slide lock 140 can be coupled to the rear surface 24 of the panel 20. The slide lock 140 is positioned relative to the mounting flange 134 to capture the panel 20 between the mounting flange 134 and the slide lock 140. In an exemplary embodiment, the slide lock 140 includes a base 142 and an arm 144 extending from the base 142. The slide lock 140 forms a recess 146 between the arms 144. The recess 146 is configured to receive the rear portion 123 of the header housing 110. In an exemplary embodiment, the recess 146 is open between the arms 144 on a side opposite to the base 142. For example, the slide lock 140 can be C-shaped, which has an open side that allows the slide lock 140 to be side-loaded onto the header housing 110. The slide lock 140 is configured to be coupled to the header housing 110 in a direction perpendicular to the longitudinal axis of the mating axis for the header connector 100. For example, the slide lock 140 can be side-loaded onto the header housing 110. The slide lock 140 includes a locking feature 148 for fixing the slide lock 140 to the header housing 110. For example, the locking feature 148 can be a groove, a slot, an opening, a tab, a protrusion, a detent or other type of locking feature 148. In the illustrated embodiment, the locking feature 148 is a slot formed in the arm 144, which is configured to receive a protrusion 149 extending from the header housing 110, for example at the top 124 and / or the bottom 126. In an alternative embodiment, the locking feature 148 can include a deflectable latch. In various other embodiments, a fastener such as a threaded fastener can be used as the locking feature 148 to fix the slide lock 140 to the header housing 110.

[0029] In an exemplary embodiment, the busbar carrier assembly 150 can be coupled to the header housing 110 after the header housing 110 is coupled to the panel 20. After the sliding lock 140 is coupled to the header housing 110, the busbar carrier assembly 150 can be coupled to the header housing 110 to securely connect the header connector 100 to the panel 20. For example, the busbar carrier 160 is separated and discrete from the header housing 110. The busbar carrier 160 can be removably coupled to the rear portion 123 of the header housing 110. For example, a latch feature can be used to secure the busbar carrier 160 to the rear portion 123. The busbar carrier 160 can be removed from the rear portion 123, thereby releasing the latch feature.

[0030] Additional references Figure 3 and Figure 4 , Figure 3 is a front perspective view of the busbar carrier assembly 150 in an assembled state, Figure 4 1 is a cross-sectional view of a busbar carrier assembly 150, which includes a busbar carrier 160 and a plurality of busbars 180. In the illustrated embodiment, the busbar carrier assembly 150 includes a pair of busbars 180. In alternative embodiments, the busbar carrier assembly 150 may include more or fewer busbars 180, such as four busbars 180. The busbars 180 may be aligned, such as aligned in a plane. Alternatively, the busbars 180 may be arranged in another arrangement, such as in multiple rows. The busbars 180 may be oriented horizontally, such as parallel to each other. Alternatively, the busbars 180 may be in other orientations, such as perpendicular to each other.

[0031] The busbar carrier 160 includes a support wall 162 and a mounting portion 164 extending from the support wall 162. The support wall 162 includes a busbar channel 166 passing through the support wall 162. The busbars 180 are configured to be received in the corresponding busbar channels 166. The support wall 162 maintains the relative position of the busbars 180. The busbar channels 166 extend between the front and rear portions of the support wall 162, thereby allowing the busbars 180 to pass through the support wall 162. In an exemplary embodiment, the busbars 180 are retained in the busbar channels 166, such as using retaining barbs or other fixing features, such as snap-on locking features, clips, or fasteners. The busbars 180 can be sewn into the busbar channels 166, such as through the rear portion of the support wall 162. In various other embodiments, the busbar carrier 160 is overmolded on the busbars 180.

[0032] The mounting portion 164 extends from the support wall 162. In the illustrated embodiment, the mounting portion 164 extends completely circumferentially around the support wall 162. For example, the mounting portion 164 can be located above, below, and on both sides of the support wall 162. In alternative embodiments, the mounting portion 164 can have other shapes. For example, the mounting portion 164 can extend from the top and / or bottom and / or the first side and / or the second side of the support wall 162. In the illustrated embodiment, the mounting portion 164 forms a ring around the support wall 162.

[0033] In an exemplary embodiment, the mounting portion 164 includes an end wall 170 and an outer wall 172. The end wall 170 extends between the support wall 162 and the outer wall 172. In an exemplary embodiment, the end wall 170 is located at the rear of the busbar carrier 160, and the outer wall 172 extends forward from the distal end of the end wall 170. The outer wall 172 forms a ring around the support wall 162. In an exemplary embodiment, the outer wall 172 includes a slot 174 that divides the outer wall 172 into segments 176. The slot 174 allows the segments 176 to move relative to each other, such as for fixing to the rear portion 123 of the header housing 110.

[0034] In an exemplary embodiment, the outer wall 172 of the mounting portion 164 includes a latch feature 178 that is configured to latchably couple to the header housing 110. In the illustrated embodiment, the latch feature 178 is an opening that is configured to receive a latch extending from the rear portion 123 of the header housing 110. Other types of latch features may be used in alternative embodiments.

[0035] Each busbar 180 extends between a mating end 182 and a terminating end 184. The mating end 182 is configured to be connected to the plug connector 200. The terminating end 184 is configured to be connected to the power cable 102. In an exemplary embodiment, the busbar 180 is a stamped component. For example, the busbar 180 can be stamped from a sheet of metal. The busbar 180 can be substantially planar. In the illustrated embodiment, the busbar 180 forms a blade 186 at the mating end 182, which is configured to be inserted into the socket of the plug contact 250 of the plug connector 200. Other types of contacts, such as pins, sockets, spring beams, or other types of contacts, can be provided at the mating end 182. In an exemplary embodiment, the busbar 180 includes a tab 188 at the terminating end 184. The power cable 102 can be welded to the tab 188. In other embodiments, the tab 188 may include an opening configured to receive a fastener, such as a bolt for connecting the tab 188 to the power cable 102.

[0036] In an exemplary embodiment, the busbar 180 includes a retaining barb 190 extending from a side edge of the busbar 180. The retaining barb 190 is configured to retain or secure the busbar 180 in the busbar channel 166. For example, the retaining barb 190 can dig into the plastic material of the support wall 162 to retain the busbar 180 in the busbar carrier 160. In an exemplary embodiment, the busbar 180 can include a loading stop 192 extending from a side edge of the busbar 180. The loading stop 192 is configured to engage the support wall 162. The loading stop 192 positions the busbar 180 relative to the busbar carrier 160. For example, the busbar 180 can be loaded rearwardly into the busbar channel 166 until the loading stop 192 engages the rear surface of the support wall 162. Once the loading stop 192 abuts the support wall 162, the loading stop 192 prevents the busbar 180 from being loaded forwardly. Other types of locating features can be used in alternative embodiments.

[0037] Figure 5 is an exploded view of the header connector 100 showing the busbar carrier assembly 150 ready for coupling to the header housing 110 according to an exemplary embodiment. Figure 6 is a side view of the header connector 100 showing the busbar carrier assembly 150 ready for coupling to the header housing 110 according to an exemplary embodiment.

[0038] During assembly, the header housing 110 is coupled to the panel 20, for example, from the front surface 22 of the panel 20. The rear portion 123 is loaded through the panel opening 30. The size and shape of the rear portion 123 are designed to fit through the panel opening 30. For example, the size and shape of the rear portion 123 are set relative to the feed envelope of the panel opening 30 to allow the rear portion 123 to pass through the panel opening 30. For example, the rear portion 123 of the header housing 110 has a housing envelope having a height and a width. The housing envelope is smaller than the panel envelope, thereby allowing the rear portion 123 to pass through the panel opening 30. The header housing 110 moves backward toward the panel 20 until the mounting flange 134 bottoms out against the front surface 22 of the panel 20. The size (e.g., height and width) of the mounting flange 134 is larger than the feed envelope of the panel opening 30 in at least one direction (e.g., in all four directions in the illustrated embodiment) to bottom out against the panel 20 and not pass through the panel opening 30. The slide lock 140 is then coupled to the rear portion 123 of the header housing 110 to lock the header housing 110 to the panel 20. The dimensions (e.g., height and width) of the slide lock 140 are larger than the feed envelope of the panel opening 30 in at least one direction to bottom out against the panel 20 and not pass through the panel opening 30. The panel 20 is sandwiched between the mounting flange 134 and the slide lock 140. In an exemplary embodiment, the rear portion 123 extends behind the slide lock 140 for connection with the busbar carrier assembly 150.

[0039] During assembly, the busbars 180 are loaded into the busbar carrier 160. For example, the busbars 180 can be rear loaded into the busbar channel 166 in the support wall 162. The mating ends 182 of the busbars 180 extend in front of the support wall 162. The busbar carrier 160 holds the busbars 180 in a suitable position (e.g., spacing) relative to each other to mate with the plug connector 200. The busbar carrier assembly 150 is coupled to the rear portion 123 of the header housing 110. For example, the mating ends 182 of the busbars 180 are rearwardly loaded into the cavity 114 of the header housing 110. The mating ends 182 are loaded into the front of the header housing to mate with the plug connector 200. The mating ends 182 pass through the panel 20, for example, to a mating position located in front of the panel 20. The mating ends 182 are arranged in a spacing that fits within the panel housing. In an exemplary embodiment, the support wall 162 supports the busbars 180 in the cavity 114. For example, the header housing 110 does not directly engage the busbar 180, but the busbar 180 is suspended into the cavity 114 through the support wall 162 of the busbar carrier 160. The front portion of the support wall 162 can be loaded into the cavity 114. The mounting portion 164 is coupled to the rear portion 123 of the header housing 110. For example, the rear portion 123 can be inserted into the space between the outer wall 172 and the support wall 162. The section 176 can surround the rear portion 123. The latch feature 178 is configured to be latchably coupled to the latch 125 at the rear portion 123 to fix the busbar carrier 160 to the rear portion 123. The busbar carrier 160 is removably coupled to the termination end 118 of the header housing 110, for example, by releasing the latch feature 178 from the latch 125. The termination end 184 of the busbar 180 extends rearward from the busbar carrier 160. The termination end 184 is not loaded into the header housing 110 and can therefore have any size and / or shape. The size and shape of the termination end 184 is not controlled by the size and shape of the header housing because the termination end 184 does not have to pass through the header housing 110. In addition, the termination end 184 is not loaded through the panel opening 30 and can therefore have any size and / or shape. The size and shape of the termination end 184 is not controlled by the size and shape of the panel envelope because the termination end 184 does not have to pass through the panel opening 30. In this way, the termination end 184 can be expanded outward to connect or terminate to the power cable. For example, the termination end 184 can be expanded to space the power cables 102 from each other so that it is easier to terminate and / or prevent arc discharge between them.

[0040] Figure 7 is a rear perspective view of the header connector 100 showing the busbar carrier assembly 150 ready for coupling to the header housing 110 according to an exemplary embodiment. Figure 7The termination ends 184 of the busbars 180 having different shapes are shown. For example, the termination end 184 of one of the busbars 180 extends generally straight back from the support wall 162, while the termination end 184 of the other busbar 180 extends laterally away from the first busbar 180. By extending the busbars 180 to one side away from the center of the busbar carrier assembly 150, the power cables 102 can be terminated to the termination ends 184 at spaced-apart locations. The termination ends 184 can be located outside the housing envelope and / or outside the panel envelope of the panel opening 30. Being larger than the panel envelope in at least one dimension makes it difficult or impossible to load through the panel opening 30 in an assembled state. However, because the busbar carrier assembly 150 can be rear loaded and separately coupled to the header housing 110, the busbar carrier assembly 150 does not have to pass through the panel opening 30 and can therefore be larger than the panel envelope.

[0041] Figure 8 The termination ends 184 of the busbars 180 are shown to have different shapes. For example, the termination ends 184 of the busbars 180 all extend outwardly away from each other (e.g., to the right and to the left). By extending the busbars 180 to the sides away from the center of the busbar carrier assembly 150, the power cables 102 can be terminated to the termination ends 184 at spaced-apart locations. The termination ends 184 can be located outside the housing envelope and / or outside the panel envelope of the panel opening 30. Being larger than the panel envelope in at least one dimension makes it difficult or impossible to load through the panel opening 30 in an assembled state. However, because the busbar carrier assembly 150 can be rear loaded and separately coupled to the header housing 110, the busbar carrier assembly 150 does not have to pass through the panel opening 30 and can therefore be larger than the panel envelope.

[0042] CROSS-REFERENCE TO RELATED APPLICATIONS

[0043] This application claims the benefit of U.S. Application No. 63 / 645,465, filed on May 10, 2024, entitled “HEADER CONNECTOR WITH BUSBAR ASSEMBLY,” and U.S. Application No. 63 / 540,178, filed on September 25, 2023, entitled “HEADER WITH SEPARABLE BUSBAR CARRIER,” the subject matter of which is incorporated herein by reference in its entirety.

Claims

1. A header connector (100), comprising: A header housing (100) extending between a mating end (116) and a terminating end (118), the mating end being configured to mate with a plug connector (200), the header housing having a cavity (114) between the mating end and the terminating end, the header housing having a mounting flange (134) configured to be mounted to a panel (20); A busbar carrier assembly (150), comprising a busbar carrier (160) and a busbar (180) held by the busbar carrier, the busbar carrier having a support wall (162) and a mounting portion (164), the busbar being connected to the support wall, the mounting portion being connected to the terminating end of the header housing, wherein the busbar is received in the cavity of the header housing for mating with the plug connector when the mounting portion of the busbar carrier is connected to the terminating end of the header housing.

2. The header connector (100) of claim 1, wherein the busbar carrier (160) is latchably coupled to the terminating end (118) of the header housing (110).

3. The header connector (100) according to claim 1, wherein: The busbar carrier (160) is separate and discrete from the header housing (110), the busbar carrier being removably coupled to the terminating end (118) of the header housing.

4. The header connector (100) according to claim 1, wherein: The mating end (116) is disposed at the front (120) of the header housing (110), and the terminating end (118) is disposed at the rear (122) of the header housing, and when the busbar carrier (160) is connected to the header housing, the rear of the busbar (180) is loaded into the cavity (114) at the rear of the header housing.

5. The header connector (100) according to claim 1, wherein: The support wall (162) includes a busbar channel (166) in which the busbar (180) is received, with the mating end (116) of the busbar extending forward of the support wall and the terminating end (118) of the busbar extending rearward of the support wall.

6. The header connector (100) according to claim 1, wherein: The header housing (100) has a housing envelope having a height and a width, and the terminating end (118) of the busbar (180) extends outside the header envelope.

7. The header connector (100) according to claim 1, wherein: The panel (20) has a front surface (22) and a rear surface (24), the panel includes a panel opening (30) between the front surface and the rear surface, the panel opening has a feed envelope (34), the mounting flange (134) is larger than the feed envelope in at least one direction, the busbar (180) has a mating end (116) and a terminating end (118), the mating end is sized to be assembled within the feed envelope, and the terminating end is larger than the feed envelope in at least one direction.

8. The header connector (100) according to claim 1, wherein: The panel (20) has a front surface (22) and a rear surface (24), the panel including a panel opening (30) between the front surface and the rear surface, wherein the header housing (110) is configured to be front loaded into the panel opening to position the mounting flange (134) at the front surface of the panel, and the busbar carrier assembly (150) is rear loaded into the panel opening to connect the mounting portion (164) to the terminating end (118) of the header housing.

9. The header connector (100) according to claim 1, wherein: The busbar is a first busbar (180), and the busbar carrier (160) holds a second busbar.

10. The header connector (100) of claim 1 further comprising a sliding lock (140) coupled to the header housing (100), the sliding lock being positioned relative to the mounting flange (134) to capture the panel (20) between the sliding lock and the mounting flange.

11. The header connector (100) according to claim 1, wherein: The bus bar (180) includes retention barbs (190) that engage the support wall (162) to secure the bus bar to the bus bar carrier (160).

12. The header connector (100) of claim 1, further comprising a perimeter seal (138) coupled to the header housing (110), the perimeter seal configured to seal between the header housing and the panel (20).

13. A header connector (100), comprising: a header housing (100) extending between a front portion (120) and a rear portion (122), the header housing including a mating end (116) at the front portion and a terminating end (118) at the rear portion, the mating end being configured to mate with a plug connector (200), the header housing having a cavity (114) between the mating end and the terminating end, the header housing having a mounting flange (134) configured to be mounted to a front surface (22) of a panel (20), wherein a portion of the header housing extends through a panel opening (30) in the panel behind a rear surface (24) of the panel; A busbar carrier assembly (150), comprising a busbar carrier (160) and a busbar (180) held by the busbar carrier, the busbar carrier having a support wall (162) and a mounting portion (164), the busbar being connected to the support wall, the mounting portion being connected to the terminating end of the header housing at the rear of the panel, wherein the busbar is received in the cavity of the header housing for mating with the plug connector when the mounting portion of the busbar carrier is connected to the terminating end of the header housing.

14. The header connector (100) according to claim 13, wherein: The busbar carrier (160) is separate and discrete from the header housing (110), the busbar carrier being removably coupled to the terminating end (118) of the header housing.

15. The header connector (100) according to claim 13, wherein: The header housing (100) has a housing envelope having a height and a width, and the terminating end (118) of the busbar (180) extends outside the header envelope.

Images