Power receptacle assembly and method of assembling power receptacle assembly

Abstract

The invention relates to a power receptacle assembly and a method of assembling a power receptacle assembly. A power receptacle assembly includes a receptacle housing that holds a power terminal that includes a socket at a mating end and a crimp barrel crimped to a power cable. The power receptacle assembly includes a rear cover coupled to a rear portion of the receptacle housing. Optionally, the rear cover contains a TPA element received in the cavity to interface with the power terminals in the cavity and ensure proper positioning thereof. Optionally, the rear covers are fed on the carrier tape, with a connecting tape between the plurality of rear covers, with the rear covers being split from the connecting tape to separate the rear covers from the carrier tape for coupling to the rear of the socket housing.

Description

Technical Field

[0001] The subject matter herein relates generally to power socket assemblies. Background Art

[0002] Power socket assemblies are used in a variety of different applications for providing power to components. For example, power socket assemblies can be used in appliances, automotive applications, industrial applications, etc. Power socket assemblies typically include a housing that holds terminals that are electrically connected to power cables. In the case of assembling the terminals in the housing, problems may arise. For example, if the terminals are not correctly loaded into the housing, a poor or bad electrical connection may occur. If the terminals are not correctly positioned within the housing, the electrical connection with the mating connector may fail over time. Some known power socket assemblies provide covers to hold the terminals in the housing. However, connectors with covers are not without disadvantages. For example, assembly may be difficult or time consuming. The cover may not properly secure the terminals in the housing. After the cover is installed, it may be difficult to repair or replace components of the connector.

[0003] There remains a need for a power socket assembly that can be manufactured in a cost-effective and reliable manner. Summary of the invention

[0004] In one embodiment, a power socket assembly is provided, and the power socket assembly includes a socket housing having a housing wall forming a cavity. The socket housing extends between a front and a rear portion. The socket housing has a front opening at the front, and the front opening is configured to receive a mating power contact. The socket housing has a rear opening at the rear. The socket housing includes a power cable outlet. The power socket assembly includes a power cable extending from the power cable outlet. The power socket assembly includes a power terminal received in the cavity through the rear opening. The power terminal has a socket at the mating end, and the mating end is configured to mate with the mating power contact. The power terminal includes a crimping barrel crimped to the power cable. The power socket assembly includes a rear cover coupled to the rear of the socket housing to cover the rear opening. The rear cover includes a terminal position assurance (TPA) element. The TPA element is received in the cavity to interface with the power terminal and ensure the correct positioning of the power terminal in the cavity.

[0005] In another embodiment, a power socket assembly is provided, and the power socket assembly includes a socket housing having a housing wall forming a cavity. The socket housing extends between a front and a rear portion. The socket housing has a front opening at the front, and the front opening is configured to receive a mating power contact. The socket housing has a rear opening at the rear. The socket housing includes a power cable outlet. The power socket assembly includes a power cable extending from the power cable outlet. The power socket assembly includes a power terminal received in the cavity through the rear opening. The power terminal has a socket at a mating end, and the mating end is configured to mate with a mating power contact. The power terminal includes a crimping barrel crimped to the power cable. The power socket assembly includes a rear cover configured to be coupled to the rear of the socket housing to cover the rear opening. The rear cover is fed on a carrier strip, wherein a plurality of rear covers have a connecting strip between the rear covers. The rear cover is configured to be segmented from the connecting strip to separate the rear cover from the carrier strip for coupling to the rear of the socket housing.

[0006] In another embodiment, a method for assembling a power socket assembly is provided. The method provides a socket housing having a housing wall forming a cavity. The socket housing extends between a front and a rear portion. The socket housing has a front opening at the front, the front opening being configured to receive a mating power contact. The socket housing has a rear opening at the rear portion. The socket housing includes a power cable outlet. The method loads a power terminal into the cavity through the rear opening so that the socket of the power terminal faces the front opening for mating with the mating power contact, and so that the crimp barrel of the power terminal faces the rear opening. The method presents a carrier strip having a plurality of rear covers connected in series by a connecting strip. The method separates one of the rear covers from the carrier strip by separating the rear cover from the connecting strip. The method couples the separated rear cover to the rear of the socket housing to cover the rear opening, thereby storing the power terminal in the cavity. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 A power socket assembly according to an exemplary embodiment is illustrated.

[0008] Figure 2 is an exploded view of a power receptacle assembly according to an exemplary embodiment.

[0009] Figure 3 Illustrated is a schematic diagram of a rear view 100 of a power receptacle assembly according to an exemplary embodiment.

[0010] Figure 4 A side view of a power receptacle assembly is illustrated in accordance with an exemplary embodiment.

[0011] Figure 5is a front perspective view of a plurality of rear covers arranged along a carrier strip according to an exemplary embodiment.

[0012] Figure 6 is a rear perspective view of a carrier strip showing one of the rear covers ready for assembly with a socket housing of a corresponding power socket assembly according to an exemplary embodiment. DETAILED DESCRIPTION

[0013] Figure 1 A power socket assembly 100 according to an exemplary embodiment is illustrated. The power socket assembly 100 is disposed at one end of a power cable 102. The power socket assembly 100 is configured to mate with a mating connector 104 and is configured to receive a mating power contact 106 of the mating connector 104. The mating power connector 106 is configured to be inserted into the power socket assembly 100. The power socket assembly 100 can be used to power an electrical appliance. For example, the mating connector 104 can be disposed at the electrical appliance, and the power socket assembly 100 is coupled to the mating connector 104 to supply power to the electrical appliance. In alternative embodiments, the power socket assembly 100 can be used in other applications, such as automotive applications and industrial applications or other types of applications.

[0014] In an exemplary embodiment, the power socket assembly 100 is a right angle connector. For example, the power cable 102 can extend along a cable axis 110, and the power socket assembly 100 mates with the mating connector 104 along a mating axis 112 that is perpendicular to the cable axis 110. In alternative embodiments, other orientations are possible. In an exemplary embodiment, the power socket assembly 100 is a logo connector with a logo terminal orientation. In an exemplary embodiment, the power socket assembly 100 includes a socket terminal configured to mate with a mating power contact 106. For example, the mating power contact 106 can be a tab or a blade-type contact.

[0015] The power socket assembly 100 includes a socket housing 120 that receives a power cable 102 and a power terminal 200. In an exemplary embodiment, the power terminal 200 is a socket terminal; however, in an alternative embodiment, the power terminal 200 may be another type of power terminal, such as a pin terminal, a blade terminal, a spring beam terminal, etc. The socket housing 120 includes a cavity 122 that receives an end of the power cable 102 and the power terminal 200. The socket housing 120 includes a power cable outlet 124, such as at one of the sides of the socket housing 120. The power cable 102 exits the socket housing 120 through the power cable outlet 124.

[0016] The power socket assembly 100 includes a rear cover 300 coupled to the socket housing 120 to cover the power terminals 200. In an exemplary embodiment, the rear cover 300 holds the power terminals 200 in the cavities 122 of the socket housing 120. In an exemplary embodiment, the rear cover 300 includes a terminal position assurance (TPA) element 310 ( Figure 2 ), and ensures the correct positioning of the power terminal 200 in the cavity 122. In an exemplary embodiment, the rear cover 300 is removably coupled to the socket housing 120 to allow the socket housing 120 to be opened to repair or replace components. For example, the rear cover 300 can be lockably coupled to the socket housing 120.

[0017] Figure 2 is an exploded view of a power receptacle assembly 100 according to an exemplary embodiment. Figure 2 The socket housing 120, the power terminal 200, the power cable 102, and the rear cover 300 are illustrated. During assembly, the power cable 102 is terminated to the power terminal 200. The power cable 102 and the power terminal 200 are configured to be loaded into the cavity 122 of the socket housing 120. After the power terminal 200 is loaded into the cavity 122, the rear cover 300 can be coupled to the socket housing 120.

[0018] In an exemplary embodiment, the socket housing 120 is made of a dielectric material, such as a plastic material. In various embodiments, the socket housing 120 can be a molded component, such as a molded plastic component. The socket housing 120 extends between a front portion 130 and a rear portion 132. The front portion 130 is configured to mate with the mating connector 104 ( Figure 1 ) is a mating end of a socket housing 120 that is mated with the power terminal 200. The socket housing 120 includes a top 134 and a bottom 136. The socket housing 120 includes a first side 138 and a second side 140. In the illustrated embodiment, the power cable outlet 124 is disposed at the second side 140. However, in alternative embodiments, the power cable outlet 124 may be located at another position, such as the rear 132, the top 134, the bottom 136, or the first side 138. In an exemplary embodiment, the socket housing 120 is L-shaped or flag-shaped. For example, the socket housing 120 may be wider at the rear 132 and narrower at the front 130. The wider portion of the socket housing 120 accommodates the power terminals 200 and the power cable 102. The narrower portion of the socket housing 120 is configured to mate with the mating connector 104. For example, the narrower portion at the front 130 may be inserted into an appliance or other device to mate with the mating connector 104.

[0019] The socket housing 120 includes a front opening 142 at the front 130 and a rear opening 144 at the rear 132. The rear opening 144 is configured to receive the power terminal 200 during assembly. The rear cover 300 is configured to be coupled to the socket housing 120 to close or cover the rear opening 144. The front opening 142 provides access to the cavity 122 and the power terminal 200 in the cavity 122 for mating the mating power contact 106 with the power terminal 200. In various embodiments, the front opening 142 is a slot configured to receive the plate portion of the mating power contact 106. The socket housing 120 may include a guide feature at the front opening 142 to guide the mating power contact 106 into the front opening 142.

[0020] In an exemplary embodiment, the socket housing 120 includes a latching element 150 for securing the rear cover 300 to the socket housing 120. In various embodiments, the latching element 150 is located along the top 134 and / or the bottom 136. The latching element 150 can be a catch feature, such as a protrusion including a ramp surface at a catch surface that is configured to receive a latch of the rear cover 300. The latching element 150 can be located near the rear 132.

[0021] Additional references Figure 3 (which is a rear view of the power socket assembly 100) and Figure 4 (which is a side view of the power socket assembly 100), the power terminal 200 is shown ready for loading into the cavity 122 of the socket housing 120. The power terminal 200 is made of a metal material and is conductive. For example, the power terminal 200 can be made of copper or a copper alloy, or aluminum or an aluminum alloy. Optionally, the power terminal 200 can be plated. In an exemplary embodiment, the power terminal 200 is a stamped and formed part stamped from a metal sheet and formed into a specific shape. The power terminal 200 is configured to terminate to the power cable 102 and is configured to mate with the mating power contact 106.

[0022] The power terminal 200 extends between a mating end 210 and a terminating end 220. The mating end 210 is configured to mate with a mating power contact 106. In the illustrated embodiment, the mating end includes a socket 212 configured to receive a blade of a mating power contact 106. In various embodiments, the mating end 210 is a quick connect terminal. The mating end 210 may include a crimped mating beam 214 at opposite sides of the power terminal 200 that form the socket 212. In an alternative embodiment, the mating end 210 may include a box-like structure that forms the socket 212 and has one or more mating beams extending into the box-like structure for mating engagement with the mating power contact 106.

[0023] In an exemplary embodiment, the terminating end 220 includes a crimp barrel 222 configured to be crimped to the end of the power cable 102. In an exemplary embodiment, the crimp barrel 222 includes a cable crimping portion 224 crimped to the insulator 114 of the power cable 102 and a conductor crimping portion 226 crimped to the conductor 116 of the power cable 102. In various embodiments, the crimp barrel 222 is a C-shaped crimping structure. The crimp barrel 222 includes a plurality of crimping beams 228 configured to be folded or bent on the power cable 102 to form a mechanical and / or electrical connection with the power cable 102. In an exemplary embodiment, the power terminal 200 includes a connecting arm 230 between the sockets 212 in the crimp barrel 222. The connecting arm 230 orients and / or positions the crimp barrel 222 relative to the sockets 212, such as at a right angle.

[0024] In an exemplary embodiment, the power terminal 200 is a right angle terminal. For example, the mating end 210 is oriented perpendicular to the termination end 220. For example, the socket 212 is configured to receive the mating power contact 106 along the mating axis 112, and the crimp barrel 222 is configured to receive the power cable 102 along the cable axis 110 perpendicular to the mating axis 112. Like this, the power cable 102 can leave the socket housing 120 at the side 140, so that the area behind the power socket assembly 100 is open and there is no power cable 102. Like this, the power socket assembly 100 has a low profile between the front 130 and the rear 132. Other components can be positioned behind the power socket assembly 100, such as for the assembly of the power socket assembly 100 and / or the mating of the power socket assembly 100 with the mating connector 104. For example, a device or installer may press on the rear of the power receptacle assembly 100 for mating with the mating connector 104 , and the rear cover 300 provides a flat surface for pressing on the power receptacle assembly 100 during such mating operations.

[0025] Return to reference Figure 2 , the rear cover 300 is shown ready for coupling to the socket housing 120. The rear cover 300 includes a cover body 302. In an exemplary embodiment, the cover body 302 is made of a dielectric material, such as a plastic material. The cover body 302 can be manufactured by a molding process. In an exemplary embodiment, the cover body 302 of the rear cover 300 includes a cover plate 320, a TPA element 310 extending from the cover plate 320, and a latch 340 extending from the cover plate 320.

[0026] The cover plate 320 includes an inner surface 322 and an outer surface 324. Optionally, the outer surface 324 is planar. The inner surface 322 is configured to face the socket housing 120. When the rear cover 300 is coupled to the socket housing 120, the inner surface 322 can be close to the rear 132 of the socket housing 120. The cover plate 320 can correspond to the height and width profile of the socket housing 120 to follow the general track or profile of the rear 132 of the socket housing 120. The cover plate 320 extends between a first side 326 and a second side 328. The cover plate 320 includes a first portion 330 at the first side 326 and a second portion 332 at the second side 328. In the illustrated embodiment, the first portion 330 is shorter than the second portion 332. However, in an alternative embodiment, the cover plate 320 can have a uniform height. Optionally, the first portion 330 can be wider than the second portion 332, or vice versa. However, in alternative embodiments, the first and second portions 330, 332 may have substantially equal widths.

[0027] The TPA element 310 extends from the inner surface 322 and is configured to be inserted into the cavity 122 of the socket housing 120 to interface with the power terminal 200. In an exemplary embodiment, the TPA element 310 is co-molded with the cover plate 320 as part of a single molding operation. The TPA element 310 is integral with the cover plate 320 to form a single, unitary structure. However, in alternative embodiments, the TPA element 310 can be separate and discrete from the cover plate 320 and coupled thereto. The TPA element 310 extends forward of the cover plate 320. The TPA element includes a terminal interface 312 configured to interface with the power terminal 200. In an exemplary embodiment, the terminal interface 312 is disposed at a distal end 314 of the TPA element 310.

[0028] In an exemplary embodiment, the TPA element 310 includes a cable crimp filler 316 that is configured to engage the cable crimper 224 of the power terminal 200 and ensure that the cable crimper 224 is fully loaded into the cavity 122 of the socket housing 120. For example, if the power terminal 200 is only partially loaded into the cavity 122, the cable crimp filler 316 engages the cable crimp 224 and cannot be fully loaded into the cavity 122, which limits the coupling of the rear cover 300 to the socket housing 120 and provides a visual indication to the installer that the power terminal 200 is not fully loaded into the socket housing 120. In such a situation, the rear cover 300 can be pressed inwardly onto the power terminal 200 to fully load the cable crimp 224 of the power terminal 200 into the cavity 122 and allow the rear cover 300 to be lockably coupled to the socket housing 120.

[0029] In an exemplary embodiment, the TPA element 310 includes a conductor crimp filler 318 that is configured to engage the conductor crimp 226 of the power terminal 200 and ensure that the conductor crimp 226 is fully loaded into the cavity 122 of the socket housing 120. For example, if the power terminal 200 is only partially loaded into the cavity 122, the conductor crimp filler 318 engages the conductor crimp 226 and cannot be fully loaded into the cavity 122, which limits the coupling of the rear cover 300 to the socket housing 120 and provides a visual indication to the installer that the power terminal 200 is not fully loaded into the socket housing 120. In such a situation, the rear cover 300 can be pressed inwardly onto the conductor crimp 226 of the power terminal 200 to fully load the power terminal 200 into the cavity 122 and allow the rear cover 300 to be lockably coupled to the socket housing 120.

[0030] In an exemplary embodiment, the TPA element 310 is contoured to match the shape of the power terminal 200. For example, the cable crimp filler 316 can be offset relative to the conductor crimp filler 318. For example, the distal end 314 at the cable crimp filler 316 is offset from the distal end 314 at the conductor crimp filler 318. In the illustrated embodiment, the conductor crimp filler 318 extends further forward than the cable crimp filler 316. The cable crimp filler 316 is sized and shaped to interface with the cable crimp 224, and the conductor crimp filler 318 is sized and shaped to interface with the conductor crimp 226. For example, the cable crimp filler 316 and / or the conductor crimp filler 318 can include an enlarged area (e.g., a higher area) that is configured to interface with the crimp beam 228 along the cable crimp 224 and the conductor crimp 226, respectively. In the exemplary embodiment, the TPA element 310 includes a guide feature 319 to guide loading of the TPA element 310 into the cavity 122. The guide surface 319 engages a feature or surface of the socket housing 120 in the cavity 122 to position the rear cover 300 relative to the socket housing 120.

[0031] The latch 340 is configured to lockably couple the rear cover 300 to the socket housing 120. The latch 340 is positioned on the rear cover 300 to be connected to the corresponding latch element 150 through an interface. In an exemplary embodiment, a plurality of latches 340 are provided. For example, the latch 340 can be arranged along the top edge and / or the bottom edge of the cover plate 320. The latch 340 can be arranged near the first side 326 and / or the second side 328. In an exemplary embodiment, the latch 340 is a deflectable latch. Each latch 340 can include an opening 342 for receiving the corresponding latch element 150. In an alternative embodiment, other types of latch features can be used. The latch 340 is configured to be released from the latch element 150 to allow the rear cover 300 to be removed, such as to repair and / or replace the power terminal 200 and / or the power cable 102, and to allow the rear cover 300 to be reused after repair and / or replacement.

[0032] Figure 5 is a front perspective view 300 of a plurality of rear covers arranged along a carrier strip 350 . Figure 6 is a rear perspective view showing the carrier strip 350 of one of the rear covers 300 ready for assembly with the socket housing 120 of the corresponding power socket assembly 100 .

[0033] In an exemplary embodiment, the rear cover 300 is manufactured in a strip form on a carrier tape 350. The carrier tape 350 includes a connecting strip 352 between each of the rear covers 300. The connecting strip 352 is co-molded with the rear cover 300 to form the carrier tape 350. For example, the connecting strip 352 and the rear cover 300 are integral and have a single integral structure. The rear cover 300 is divided by cutting or breaking the rear cover 300 from the connecting strip 352 (for example, at the dotted line). The carrier tape 350 can be wound on a reel and supplied to an automatic assembly machine configured to divide the rear cover 300 and couple the rear cover 300 to the socket housing 120. Optionally, during the same assembly step, the separation or cutting action can occur simultaneously with the coupling action, such as using an assembly device configured to cut and press the rear cover 300 onto the socket housing 120. Such automated assembly eliminates the need for an assembler to have to pick up a loose piece of rear cover, orient it, and manually press it onto the assembly.The planar outer surface 324 of the rear cover 300 provides a flat, ergonomic push surface for assembling the rear cover 300 and the socket housing 120.

[0034] A method of assembling a power socket assembly may include the following steps: providing a socket housing having a housing wall forming a cavity, the socket housing extending between a front and a rear, the socket housing having a front opening at the front, the front opening being configured to receive a mating power contact, the socket housing having a rear opening at the rear, the socket housing including a power cable outlet; loading a power terminal into the cavity through the rear opening so that a socket of the power terminal faces the front opening for mating with the mating power contact and so that a crimp barrel of the power terminal faces the rear opening; presenting a carrier strip having a plurality of rear covers connected in series by a connecting strip; severing one of the rear covers from the carrier strip by separating the rear cover from the connecting strip; and coupling the detached rear cover to the rear of the socket housing to cover the rear opening, thereby retaining the power terminal in the cavity. Optionally, in a single step, the rear cover may be severable from the connecting strip and pressed onto the socket housing. The rear cover may be coupled to the rear of the socket housing such that a terminal position assurance (TPA) element extending from an inner surface of the rear cover is loaded into the cavity to interface with the power terminal to ensure proper positioning of the power terminal in the cavity. The method may include the step of locking the rear cover to the socket housing to secure the rear cover to the socket housing. The slicing step may include cutting the carrier strip between the rear cover and the connector strip.

[0035] It is to be understood that the above description is intended to illustrate, not to limit. For example, the embodiments described above (and / or aspects thereof) may be used in combination with one another. In addition, without departing from the scope of the present invention, many modifications may be made to adapt specific situations or materials to the teachings of the present invention. The dimensions, material types, orientations, and quantity and position of the various components described herein are intended to define the parameters of certain embodiments, and are by no means restrictive, and are merely exemplary embodiments. Upon reading the above description, many other embodiments and modifications within the spirit and scope of the claims will be apparent to those skilled in the art. Therefore, the scope of the present invention should be determined with reference to the full range of equivalents to which the attached claims and such claims are entitled. In the attached claims, the terms "comprising" and "in..." are used as the plain English equivalents of the corresponding terms "including" and "wherein". In addition, in the attached claims, the terms "first", "second", and "third", etc., are used only as labels, and are not intended to impose numerical requirements on their objects. Furthermore, the appended claim limitations are not drafted in a means-plus-function format and are not intended to be interpreted based on 35 U.S.C. §112(f) unless and until such claim limitations expressly use the phrase “means for…” followed by a recitation of functionality without further structure.

Claims

1. A power socket assembly, comprising: a socket housing having a housing wall forming a cavity, the socket housing extending between a front portion and a rear portion, the socket housing having a front opening at the front portion, the front opening being configured to receive a mating power contact, the socket housing having a rear opening at the rear portion, the socket housing containing a power cable outlet; A power cable extending from the power cable outlet: a power terminal received in the cavity through the rear opening, the power terminal having a socket at a mating end, the mating end being configured to mate with the mating power contact, the power terminal including a crimp barrel crimped to the power cable; as well as A rear cover coupled to the rear of the socket housing to cover the rear opening, the rear cover including a terminal position assurance (TPA) element received in the cavity to interface with the power terminal and ensure proper positioning of the power terminal in the cavity.

2. The power socket assembly according to claim 1, wherein: The rear covers are fed on a carrier tape, wherein a plurality of the rear covers have connecting strips between the rear covers, and the rear covers are configured to be segmented from the connecting strips to separate the rear covers from the carrier tape for coupling to the rear of the socket housing.

3. The power socket assembly according to claim 1, wherein: The rear cover includes an inner surface and an outer surface, and the TPA element extends from the inner surface.

4. The power socket assembly according to claim 1, wherein: The rear cover includes an inner surface and an outer surface, the outer surface being generally planar.

5. The power socket assembly according to claim 1, wherein: The socket housing includes a latch element and the rear cover includes a latch that interfaces with the latch element to secure the rear cover to the socket housing.

6. The power socket assembly according to claim 1, wherein: The crimping barrel includes a cable crimping portion crimped to the insulator of the power cable and a conductor crimping portion crimped to the conductor of the power cable, and the TPA element includes a cable crimping filling portion engaged with the cable crimping portion and a conductor crimping filling portion engaged with the conductor crimping portion to ensure the correct positioning of the power terminal in the cavity.

7. The power socket assembly according to claim 6, wherein: The distal end of the cable crimping filler is offset from the distal end of the conductor crimping filler.

8. The power socket assembly according to claim 1, wherein: The crimp barrel extends along a cable axis, and the socket is configured to receive the mating power contact along a mating axis perpendicular to the cable axis.

9. The power socket assembly according to claim 1, wherein: The rear cover extends between a first side and a second side, the rear cover including a first portion at the first side and a second portion at the second side, the first portion being shorter than the second portion.

10. A power socket assembly, comprising: a socket housing having a housing wall forming a cavity, the socket housing extending between a front portion and a rear portion, the socket housing having a front opening at the front portion, the front opening being configured to receive a mating power contact, the socket housing having a rear opening at the rear portion, the socket housing containing a power cable outlet; A power cable extending from the power cable outlet: a power terminal received in the cavity through the rear opening, the power terminal having a socket at a mating end, the mating end being configured to mate with the mating power contact, the power terminal including a crimp barrel crimped to the power cable; as well as a rear cover configured to be coupled to the rear of the socket housing to cover the rear opening, the rear cover being fed on a carrier tape, wherein a plurality of the rear covers have a connecting tape between the rear covers, wherein the rear covers are configured to be segmented from the connecting tape to separate the rear covers from the carrier tape for coupling to the rear of the socket housing.

11. The power socket assembly according to claim 10, wherein: The rear cover includes a terminal position assurance (TPA) element received in the cavity to interface with the power terminal and ensure proper positioning of the power terminal in the cavity.

12. The power socket assembly according to claim 11, wherein: The rear cover includes an inner surface from which the TPA element extends and an outer surface that is generally planar.

13. The power socket assembly according to claim 10, wherein: The rear cover extends between a first side and a second side, and the connecting strip extends from the first side and the second side.

14. The power socket assembly according to claim 10, wherein: Before the rear cover is separated from the carrier strip, the rear cover is integral with the connection strip as a single unitary structure on the carrier strip.

15. The power socket assembly of claim 10, wherein: The connecting strip is narrower than the rear cover.

16. A method of assembling a power socket assembly, the method comprising: providing a socket housing having a housing wall forming a cavity, the socket housing extending between a front portion and a rear portion, the socket housing having a front opening at the front portion, the front opening being configured to receive a mating power contact, the socket housing having a rear opening at the rear portion, the socket housing containing a power cable outlet; loading a power terminal into the cavity through the rear opening so that the socket of the power terminal faces the front opening for mating with the mating power contact and so that the crimp barrel of the power terminal faces the rear opening; Presenting a carrier strip having a plurality of rear covers connected in series by a connecting strip; severing one of the rear covers from the carrier strip by separating the rear cover from the connecting strip; as well as The detached rear cover is coupled to the rear of the socket housing to cover the rear opening, thereby retaining the power terminals in the cavity.

17. The method of claim 16, wherein: In a single step, the rear cover is separated from the connection strip and pressed onto the socket housing.

18. The method of claim 16, wherein: The rear cover is coupled to the rear of the socket housing so that a terminal position assurance (TPA) element extending from an inner surface of the rear cover is loaded into the cavity to interface with the power terminal to ensure proper positioning of the power terminal in the cavity.

19. The method of claim 16, further comprising locking the rear cover to the socket housing to secure the rear cover to the socket housing.

20. The method of claim 16, wherein: The separating the rear cover from the carrier tape includes cutting the carrier tape between the rear cover and the connecting tape.

Images