Headstock power connector

Abstract

A header power connector (100) includes a header housing assembly (700) having an outer housing (702) with an outer wall (710) forming a cavity (706) and a partition wall (711) dividing the cavity into a choke chamber (708) and a terminal chamber (709). The outer housing is configured to receive an upper bus bar (606) through the top portion (906) and a lower bus bar (608) through the bottom portion (908). An inner housing (704) is received in the terminal chamber and holds a terminal assembly (801) having terminals (800) arranged in a terminal stack, the terminals being configured to electrically connect the upper bus bar and the lower bus bar. The header power connector includes a choke (900) received in the choke chamber between the outer wall and the partition wall. The choke has a choke body (902) surrounding the terminal assembly. The choke body has an opening (904) through a receiving terminal assembly of the choke body.

Description

Technical Field

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

[0002] Power connectors are used to transmit power between electrical components. For example, in electric vehicles, power connectors are used to electrically connect the inverter to the electric motor. Typically, power is supplied by connecting a plug connector to which a cable is mounted to the header power connector. The plug connector can be manipulated and moved into a position that mates with the header power connector. The plug connector, as an additional component extending between the electrical components, increases the overall cost of the system. It is desirable to connect the electrical components directly to the header power connector in order to eliminate the plug connector, thereby reducing the number of components and the cost of the system. However, alignment of the electrical components with the header power connector is difficult and can result in incorrect mating and damage to the components.

[0003] Additionally, in header power connectors, interference between components, such as electromagnetic interference (EMI), is problematic. Adding filters, such as common mode current filters or chokes, to the header power connector can reduce EMI. However, chokes can cause damage to the header power connector over time, for example due to movement of the choke within the header power connector due to vibration, which can damage the terminals, busbars, housing, or other components of the header power connector. The choke is a heavy component that requires good stability because it can move inside the housing and contact the terminal assembly inside the cavity. The result of the mechanical movement caused by vibration and external mechanical shock is increased resistance in the terminals, overheating, and possible thermal events. The choke may restrict the movement or alignment of electrical components during mating.

[0004] There remains a need for a header power connector having improved mating tolerances. Summary of the Invention

[0005] In one embodiment, a header power connector is provided, comprising a header housing assembly including an outer housing having outer walls defining a cavity. The outer housing extends between a top portion and a bottom portion. The outer housing is configured to receive an upper bus bar in the cavity through the top portion. The outer housing is configured to receive a lower bus bar in the cavity through the bottom portion. The header housing assembly includes an inner housing received in the cavity. The inner housing includes terminal passages. The header power connector includes a terminal assembly held in the terminal passages of the inner housing. The terminal assembly is received in the cavity. The terminal assembly includes a plurality of terminals arranged in a terminal stack. Each terminal includes an upper mating end and a lower mating end. The upper mating end has an upper receptacle configured to receive the upper bus bar, and the lower mating end has a lower receptacle configured to receive the lower bus bar. The terminals are configured to electrically connect the upper and lower bus bars. The header power connector includes a choke received in the cavity. The choke has a choke body surrounding the terminal assembly. The choke body has an opening through the choke body for receiving the terminal assembly. The header power connector includes a choke locator in the cavity. The choke locator engages with the choke to position the choke relative to the outer housing. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The present invention will now be described by way of example with reference to the accompanying drawings, in which:

[0007] Figure 1 is a schematic diagram of a header power connector according to an exemplary embodiment.

[0008] Figure 2 is a perspective view of a header power connector according to an exemplary embodiment.

[0009] Figure 3 is an exploded view of a header power connector according to an exemplary embodiment.

[0010] Figure 4 is an exploded view of a header power connector according to an exemplary embodiment.

[0011] Figure 5 is a side view of one of the terminals according to an exemplary embodiment.

[0012] Figure 6 is a top perspective partial cross-sectional view of a portion of a header power connector according to an exemplary embodiment.

[0013] Figure 7 is a top perspective partial cross-sectional view of a portion of a header power connector according to an exemplary embodiment.

[0014] Figure 8 is a top perspective view of a portion of a header power connector according to an exemplary embodiment.

[0015] Figure 9is an enlarged top perspective view of a portion of a header power connector according to an exemplary embodiment.

[0016] Figure 10 is an exploded view of a header power connector according to an exemplary embodiment.

[0017] Figure 11 is an exploded view of a header power connector according to an exemplary embodiment.

[0018] Figure 12 is a perspective view of a portion of an inner housing showing a terminal assembly retainer according to an exemplary embodiment.

[0019] Figure 13 is a schematic diagram of a header power connector according to an exemplary embodiment.

[0020] Figure 14 is an exploded view of a header power connector according to an exemplary embodiment.

[0021] Figure 15 is a cross-sectional view of a portion of a header power connector showing a terminal assembly according to an exemplary embodiment.

[0022] Figure 16 is a bottom perspective view of a portion of a header power connector showing a terminal assembly according to an exemplary embodiment.

[0023] Figure 17 is a front view of a header power connector according to an exemplary embodiment.

[0024] Figure 18 is a bottom view of a header power connector according to an exemplary embodiment.

[0025] Figure 19 is a side view of a header power connector according to an exemplary embodiment.

[0026] Figure 20 is a side cross-sectional view of a header power connector according to an exemplary embodiment.

[0027] Figure 21 is an end cross-sectional view of a header power connector according to an exemplary embodiment.

[0028] Figure 22 A header power connector is shown according to an exemplary embodiment.

[0029] Figure 23 is an exploded view of a header power connector according to an exemplary embodiment.

[0030] Figure 24 is a side cross-sectional view of a header power connector according to an exemplary embodiment.

[0031] Figure 25 is an end cross-sectional view of a header power connector according to an exemplary embodiment.

[0032] Figure 26 A header power connector is shown according to an exemplary embodiment.

[0033] Figure 27 is an exploded view of a header power connector according to an exemplary embodiment. DETAILED DESCRIPTION

[0034] Figure 1 is a schematic diagram of a header power connector 100 according to an exemplary embodiment. The header power connector 100 is used to electrically connect a first electrical component 102 and a second electrical component 104. In various embodiments, the first electrical component 102 and the second electrical component 104 may be part of an electric vehicle. For example, the first electrical component 102 may be an inverter, and the second electrical component 104 may be an electric motor. In alternative embodiments, the header power connector 100 may be used to electrically connect other types of electrical components. In the exemplary embodiment, when the first electrical component 102 is coupled to the second electrical component 104, the header power connector 100 is mounted to the first electrical component 102 and engages with the second electrical component 104.

[0035] In the exemplary embodiment, first electrical component 102 includes a first bus bar 106, and second electrical component 104 includes a second bus bar 108. First bus bar 106 and second bus bar 108 are configured to be directly plugged into opposite ends of header power connector 100. Header power connector 100 electrically connects first bus bar 106 and second bus bar 108 to transmit power between first electrical component 102 and second electrical component 104.

[0036] Figure 2 is a perspective view of a header power connector 100 according to an exemplary embodiment. Figure 2 Portions of a first electrical component 102 and a second electrical component 104 are shown. Figure 2 A first bus bar 106 and a second bus bar 108 are shown. In an exemplary embodiment, the header power connector 100 is used to electrically connect a plurality of first bus bars 106 (e.g., three bus bars) to a corresponding plurality of second bus bars 108 (e.g., three bus bars). The first bus bars 106 are metal plates, such as copper plates. The second bus bars 108 are metal plates, such as copper plates.

[0037] The header power connector 100 is positioned between a first electrical component 102 and a second electrical component 104. The bus bar 106 of the first electrical component 102 is configured to be inserted directly into the header power connector 100. The bus bar 108 of the second electrical component 104 is configured to be inserted directly into the header power connector 100, such as at an opposite end of the header power connector 100. Alternatively, the header power connector 100 can be initially mounted to the first electrical component 102 (or the second electrical component 104) and mated to the second electrical component 104 (or the first electrical component 102) when the first electrical component 102 is mounted to the second electrical component 104.

[0038] The header power connector 100 includes a header housing assembly 200 and one or more terminal assemblies held by the header housing assembly 200. In an exemplary embodiment, the header housing assembly 200 is a multi-piece housing assembly. For example, the header housing assembly 200 includes an outer housing 202 and an inner housing 204. The inner housing 204 holds the terminal assemblies. The inner housing 204 is received in a cavity 206 of the outer housing 202. In an exemplary embodiment, the outer housing 202 is configured to be mounted to one of the electrical components, such as the first electrical component 102. In an exemplary embodiment, the inner housing 204 is movable relative to the outer housing 202 to accommodate alignment and mating with the first electrical component 102. For example, the inner housing 204 can tilt or rotate within the outer housing 202 to accommodate misalignment of the first bus bar 106 and the second bus bar 108. The inner housing 204 has a limited amount of contained movement relative to the outer housing 202. The outer housing 202 is shaped to control and accommodate movement of the inner housing 204 during mating. For example, the outer housing 202 may allow the inner housing 204 to rotate a predetermined amount to allow for mating with the bus bar 106 of the first electrical component 102 during mating with the bus bar 106 of the first electrical component 102. In an exemplary embodiment, the terminals of the terminal assembly also have a limited amount of contained movement relative to the inner housing 204 to accommodate misalignment of the first bus bar 106 and the second bus bar 108 during mating.

[0039] Figure 3 FIG2 is an exploded view of a header power connector 100 according to an exemplary embodiment. The header power connector 100 includes a header housing assembly 200, a plurality of terminal assemblies 301 held by the header housing assembly 200, a choke 400 held by the header housing assembly 200, and a choke retainer 500 for positioning the choke 400 within the header housing assembly 200. The choke 400 surrounds the terminal assemblies 301 to eliminate EMI and is used to suppress high-frequency electronic noise from the terminal assemblies 301. The choke 400 improves the operation of the header power connector 100.

[0040] In the exemplary embodiment, the header housing assembly 200 includes an outer housing 202, an inner housing 204, and a cover 201, which is coupled to the outer housing 202 to retain other components within the outer housing 202. In the exemplary embodiment, the inner housing 204 includes a terminal assembly retainer 205, which is configured to be coupled to the outer housing 202. In alternative embodiments, the header housing assembly 200 may include more or fewer parts. For example, the inner housing 204 may include a terminal retainer that may be positioned within a cavity of the outer housing 202. Additionally, while the parts are shown as separate and discrete components in the illustrated embodiment, in alternative embodiments, the various components may be integrated into a monolithic structure. For example, in alternative embodiments, the terminal retainer may be a unitary structure integral with the outer housing 202.

[0041] The outer shell 202 includes an outer wall 210 surrounding the cavity 206. The outer wall 210 extends between an upper end 212 and a lower end 214 of the outer shell 202. In an exemplary embodiment, the upper end 212 is configured to be mounted to the first electrical component 102 such that the header power connector 100 extends from the bottom of the first electrical connector 102. In alternative embodiments, other mounting orientations are possible. For example, the header power connector 100 can be oriented such that the end 212 defines the bottom of the outer shell 202, such as when the outer shell 202 is mounted to the top of a structure, such as one of the electrical components. In various other embodiments, the outer shell 202 can be oriented such that neither end 212, 214 is at the top or bottom, but rather defines the sides of the outer shell 202. The terms "upper" and "lower" are used herein with reference to the orientation shown in the figures.

[0042] The outer housing 202 includes mounting flanges 216 at opposite sides 220, 222 of the outer housing 202. The mounting flanges 216 can receive fasteners to secure the outer housing 202 to the first electrical component 102. The outer housing 202 includes a front portion 224 and a rear portion 226 extending between the sides 220, 222. A cavity 206 is formed between the front portion 224 and the rear portion 226. The cavity 206 extends between the first side 220 and the second side 222. The cavity 206 is open to receive the inner housing 204, the terminal assembly 301, the choke 400, and the choke retainer 500.

[0043] The outer housing 202 may include a latching feature (not shown) for securing the inner housing 204 to the outer housing 202. The latching feature may be a deflectable latch tab configured to engage a corresponding latching feature of the inner housing 204. The latching feature may be releasable to release the inner housing 204 from the outer housing 202.

[0044] The outer shell 202 may include walls or other features that form terminal channels configured to receive corresponding terminal assemblies 301 therein. The terminal channels may be open at upper and lower ends to receive bus bars 106, 108, respectively. The walls guide the bus bars 106, 108 into the terminal channels to mate with the terminal assemblies 301. Optionally, the walls may include chamfered lead-in surfaces that guide the bus bars 106, 108 into the terminal channels.

[0045] The terminal assembly holder 205 includes an end wall 270 and side walls 272, 274 extending from the end wall 270. The end wall 270 includes a slot 271 configured to receive the bus bar 106. The side walls 272, 274 include openings 276, 278 that receive latching features to secure the terminal assembly holder 205 to the outer shell 202. The side walls 272, 274 can be latchably coupled to the latching features. The side walls 272, 274 can be releasable from the latching features.

[0046] The cover 201 is configured to be coupled to the outer housing 202 after the other components are assembled in the cavity 206. The cover 201 is used to retain the components in the cavity 206. For example, the cover 201 can be used to retain the inner housing 204 and the terminal assembly 301 in the cavity 206. The cover 201 is used to retain the choke 400 and the choke retainer 500 in the cavity 206.

[0047] The cover 201 includes a cover plate 290 for covering an upper opening of the outer shell 202. In the exemplary embodiment, the cover 201 includes an opening 292 for receiving the bus bar 106. However, in alternative embodiments, the cover 201 may include multiple openings, each configured to receive a corresponding bus bar 106. The cover 201 may be removably coupled to the outer shell 202. For example, the cover 201 includes a latch 294 extending from the cover plate 290, and the latch 294 is configured to be latchably coupled to the outer shell 202.

[0048] The choke 400 is configured to be received in the cavity 206 of the outer shell 202 in a loading direction (e.g., vertically). The choke 400 is configured to surround the terminal assembly 301 when received in the cavity 206. The choke 400 includes a choke body 402 that surrounds an opening 404 passing through the choke 400. The choke body 402 can be made of a ferrite material, such as a magnesium-zinc alloy material or an iron-nickel alloy material. The choke body 402 can be made of a material having the characteristics of high magnetic permeability and / or high saturation level and / or low magnetic loss of the magnetic core. In the illustrated embodiment, the choke 400 is elliptical or racetrack-shaped, with curved ends and flat or parallel sides. In alternative embodiments, the choke 400 can have other shapes.

[0049] The choke 400 extends between a top 406 and a bottom 408. An opening 404 extends between the top 406 and the bottom 408. The opening 404 is open at the top 406 and open at the bottom 408 to receive the terminal assembly 301 and the bus bars 106, 108. The choke 400 includes a first side 410 and a second side 412 opposite the first side 410. The choke 400 includes a front portion 414 and a rear portion 416 extending between the sides 410, 412. Rounded corners may be provided between the sides 410, 412 and the front portion 414 and the rear portion 416. The front portion 414 and the rear portion 416 may be elongated and oriented parallel to each other. The choke 400 includes a sidewall 418 between the top 406 and the bottom 408. The sidewall 418 faces outward. The sidewall 418 is defined by a front portion 414 , a rear portion 416 , and the sides 410 , 412 .

[0050] The choke 400 includes an inner surface 420 and an outer surface 422. The inner surface 420 surrounds and defines the opening 404. The inner surface 420 is configured to face the inner housing 204. The outer surface 422 faces outward. The outer surface 422 is configured to face the outer wall 210 of the outer housing 202.

[0051] In the exemplary embodiment, the choke 400 includes locating ribs 430 extending from the front portion 414 and / or the rear portion 416. The locating ribs 430 protrude from the choke 400. In the illustrated embodiment, the locating ribs 430 are positioned along the outer surface 422. However, in alternative embodiments, the locating ribs 430 may extend along the inner surface 420. The locating ribs 430 serve to position the choke 400 within the cavity 206. The locating ribs 430 interface with the choke locator 500 to position the choke 400 relative to the outer shell 202. In other embodiments, the locating ribs 430 may additionally or alternatively be provided along the first side 410 and / or the second side 412. Other types of locating features may be used in alternative embodiments. For example, in alternative embodiments, the locating feature may be a channel or slot rather than a protrusion. In various other embodiments, the locating feature may be a deflectable beam, such as a spring beam in the alternative embodiment.

[0052] The choke locator 500 is configured to interface with the choke 400 to position the choke 400 relative to the terminal assembly 301. In an exemplary embodiment, a plurality of choke locators 500 are provided for positioning the choke 400 in different directions. For example, the header power connector 100 may include at least one horizontal choke locator 510 and at least one vertical choke locator 520. The vertical choke locator 520 positions the choke in a direction parallel to the loading direction. The horizontal choke locator 510 positions the choke 400 in a lateral direction perpendicular to the loading direction.

[0053] The horizontal choke locator 510 positions the choke 400 in a horizontal direction, such as side-to-side and / or front-to-back. In the illustrated embodiment, the horizontal choke locator 502 includes a channel 512 in the outer housing 202. The channel 512 extends along the inner surface of the outer wall 210. The channel 512 opens into the cavity 206. The channel 512 receives the locating rib 430. The channel 512 can be positioned along the front portion 224 and / or the rear portion 226. The channel 512 can be positioned along the first side 220 and / or the second side 222. In alternative embodiments, other types of horizontal choke locators 510 can be used. The horizontal choke locator 510 can include ribs or protrusions extending from the outer wall 210, the ribs or protrusions configured to be received in recesses or grooves in the choke 400. A horizontal choke locator 510 may additionally or alternatively be provided on the terminal retainer 203 and / or the terminal assembly retainer 205. The horizontal choke locator 510 may include a biasing element, such as a spring finger, to engage and position the choke 400. The horizontal choke locator 510 may include a compressible washer or sleeve configured to engage the choke 400.

[0054] The vertical choke positioner 520 vertically positions the choke 400, for example, up and down. In the illustrated embodiment, the vertical choke positioner 520 includes a compression ring 522. The compression ring 522 is configured to couple to the top 406 and / or bottom 408. The compression ring 522 can be received in the outer housing 202, such as at the bottom of the cavity 206, and the choke 400 can rest on the compression ring 522. The compression ring 522 can be loaded into the cavity 206 after the choke 400 and fill the space between the choke 400 and the cover 201. The compression ring 522 includes an opening 524 therethrough to receive the bus bar 106 or 108. The compression ring 522 is compressible, for example, capable of being compressed between the choke 400 and the header housing assembly 200. The compression ring 522 absorbs movement of the choke 400 in the cavity 206. The compression ring 522 constrains or limits movement of the choke 400 in the vertical direction, for example due to vibration or shock of the header power connector 100 during use (e.g., when the electric vehicle is driven). Other types of vertical choke locators 504, such as locating ribs, clips, latches, or other locating features, may be used in alternative embodiments.

[0055] In the illustrated embodiment, a plurality of terminal assemblies 301 are provided. Each terminal assembly 301 includes a plurality of terminals 300 stacked together in a terminal stack. The terminals 300 are arranged side by side in the terminal stack. The terminals 300 serve as a single terminal assembly within the terminal stack. However, the terminals 300 can move independently relative to each other and relative to the inner housing 204. The terminals 300 can be stamped and formed from thin metal sheets, but are stacked together to increase the total current carrying capacity of the terminal assembly. The terminal stack is configured to be received in the outer housing 202, for example, in corresponding terminal channels, and is retained in the outer housing 202 by a terminal assembly retainer 205. The inner housing 204 retains the terminals 300 from below, from the side, from the front, and from the back, while the terminal assembly retainer 205 retains the terminals 300 from above, thereby surrounding the terminal channels 256. The choke 400 surrounds the terminal stack, such as being located in the cavity 206, between the inner housing 204 and the outer housing 202.

[0056] Figure 4 is an exploded view of the header power connector 100 according to an exemplary embodiment. Figure 4 The header power connector 100 shown is similar to Figure 3 The header power connector 100 is similar to the header power connector 100 shown in FIG. 1 , but includes a different retaining structure for retaining the terminal assembly 301. For example, the inner housing 204 is shaped differently and / or includes different components. The header power connector 100 includes a header housing assembly 200, a terminal assembly 301 retained by the header housing assembly 200, a choke 400 retained by the header housing assembly 200, and a choke retainer 500 for positioning the choke 400 in the header housing assembly 200. The choke 400 surrounds the terminal assembly 301 to eliminate EMI and is used to suppress high-frequency electronic noise of the terminal assembly 301. The choke 400 improves the operation of the header power connector 100.

[0057] In the exemplary embodiment, the header housing assembly 200 includes an outer housing 202, an inner housing 204, and a cover 201, which is coupled to the outer housing 202 to retain other components within the outer housing 202. In the exemplary embodiment, the inner housing 204 includes a terminal retainer 203. In alternative embodiments, the header housing assembly 200 may include more or fewer parts. In addition, although the parts are shown as separate and discrete components in the illustrated embodiment, in alternative embodiments, the various parts may be integrated into a monolithic structure. For example, in alternative embodiments, the terminal retainer 203 may be a one-piece structure integral with the outer housing 202.

[0058] The outer housing 202 includes an outer wall 210 surrounding a cavity 206. The outer housing 202 includes mounting flanges 216 at opposing sides 220, 222 of the outer housing 202 to secure the outer housing 202 to the first electrical component 102. The cavity 206 is formed between a front 224 and a rear 226 of the outer housing 202 and between the first side 220 and the second side 222 of the outer housing 202. The cavity 206 is open to receive the inner housing 204, the terminal assembly 301, the choke 400, and the choke retainer 500.

[0059] The outer housing 202 may include a latching feature (not shown) for securing the inner housing 204 to the outer housing 202. The latching feature may be a deflectable latch tab configured to engage a corresponding latching feature of the inner housing 204. The latching feature may be releasable to release the inner housing 204 from the outer housing 202.

[0060] The terminal retainer 203 of the inner housing 204 includes a plurality of inner walls 250 extending between an upper end 252 and a lower end 254. The inner walls 250 form terminal channels 256 that are configured to receive corresponding terminal assemblies 301 therein. The terminal channels 256 are open at the upper end 252 and the lower end 254 to receive bus bars 106, 108, respectively. For example, the terminal retainer 203 includes an upper opening 257 for receiving the first bus bar 106 and a lower opening 258 for receiving the second bus bar 108. The inner walls 250 guide the bus bars 106, 108 into the terminal channels 256 for mating with the terminal assemblies 301. Optionally, the upper opening 257 and / or the lower opening 258 may include chamfered lead-in surfaces that guide the bus bars 106, 108 into the terminal channels 256.

[0061] The terminal retainer 203 of the inner housing 204 includes a first side 260 and a second side 262 opposite the first side 260. The terminal retainer 203 of the inner housing 204 includes a front portion 264 and a rear portion 266 extending between the sides 260, 262. In an exemplary embodiment, the terminal retainer 203 of the inner housing 204 includes a positioning rib 267 extending from the front portion 264 and / or the rear portion 266. The positioning rib 267 is configured to position the inner housing 204 relative to the outer housing 202.

[0062] In an exemplary embodiment, the terminal retainer 203 of the inner housing 204 includes a latching feature 268 extending from the front portion 264 and / or the rear portion 266. The latching feature 268 is configured to interface with the outer housing 202 to secure the terminal retainer 203 within the cavity 206 of the outer housing 202. In the illustrated embodiment, the latching feature 268 includes latches, each of which has a ramp surface at the top of the latch and a catch surface at the bottom of the latch. Other types of latching features may be provided in alternative embodiments.

[0063] The cover 201 is configured to be coupled to the outer housing 202 after the other components are assembled in the cavity 206. The cover 201 is used to retain the components in the cavity 206. For example, the cover 201 can be used to retain the inner housing 204 and the terminal assembly 301 in the cavity 206. The cover 201 is used to retain the choke 400 and the choke retainer 500 in the cavity 206.

[0064] The choke 400 is configured to be received in the cavity 206 of the outer housing 202 in a loading orientation (e.g., vertically). The choke 400 is configured to surround the terminal assembly 301 when received in the cavity 206. The choke 400 includes a choke body 402 surrounding an opening 404 that is open at a top 406 and open at a bottom 408 to receive the terminal assembly 301 and the bus bars 106, 108.

[0065] The choke locator 500 is configured to interface with the choke 400 to position the choke 400 relative to the terminal assembly 301. In an exemplary embodiment, a plurality of choke locators 500 are provided for positioning the choke 400 in different directions. For example, the header power connector 100 may include at least one horizontal choke locator 510 and at least one vertical choke locator 520. The vertical choke locator 520 may be a compressible gasket stacked above and below the choke 400. The vertical choke locator 520 positions the choke in a direction parallel to the loading direction. In the illustrated embodiment, the horizontal choke locator 510 is a locating tab located within the cavity of the outer shell 202. The horizontal choke locator 510 positions the choke 400 in a lateral direction perpendicular to the loading direction.

[0066] Figure 5 is a side view of one of the terminals 300 according to an exemplary embodiment. The terminal 300 is a double-ended receptacle terminal that is configured to receive the first bus bar 106 and the second bus bar 108 at opposite ends of the terminal 300. Other types of terminals may be used in alternative embodiments.

[0067] The terminal 300 is a stamped and formed terminal made of a metal material (e.g., copper). The terminal 300 may have one or more plating layers, such as nickel plating and / or gold plating. The terminal 300 includes a terminal base 302, an upper mating end 304 on a first side of the terminal base 302, and a lower mating end 306 on a second side of the terminal base 302. Optionally, the upper mating end 304 and the lower mating end 306 may be identical.

[0068] The terminal 300 has an upper receptacle 310 at the upper mating end 304. The terminal 300 includes a first upper spring beam 312 extending along a first side of the upper receptacle 310 and a second upper spring beam 314 extending along a second side of the upper receptacle 310.

[0069] The terminal includes a lower receptacle 320 at the lower mating end 306. The terminal 300 includes a first lower spring beam 322 extending along a first side of the lower receptacle 320 and a second lower spring beam 324 extending along a second side of the lower receptacle 310.

[0070] In an exemplary embodiment, the spring beams 312, 314, 322, 324 can be identical to one another. The spring beams 312, 314, 322, 324 can be deflectable when mated to the corresponding bus bar 106 or 108. For example, when mated to the bus bar 106 or 108, the spring beams 312, 314, 322, 324 can deflect outward, thereby generating an inward biasing force or spring force to maintain electrical contact between the spring beams 312, 314, 322, 324 and the bus bar 106 or 108.

[0071] In an exemplary embodiment, each spring beam 312, 314, 322, 324 includes a base 330 and a distal end 332 at the distal end of the spring beam. The base 330 extends from the terminal base 302. Optionally, the spring beam 312, 314, 322, 324 may be widest at the base 330. In an exemplary embodiment, the spring beam 312, 314, 322, 324 narrows from the base 330 toward the distal end 332. In an exemplary embodiment, the spring beam includes a protrusion 334 near the distal end 332. Optionally, the protrusion 334 may protrude inward. The protrusion 334 has a curved surface that defines a mating interface 336 configured to mate with the corresponding bus bar 106 or 108. The spring beam 312, 314, 322, 324 includes an inner surface 338 and an outer surface 340 opposite the inner surface 338. In various embodiments, the inner surface 338 and the outer surface 340 taper inwardly from the base 330 toward the tip 332. Alternatively, the inner surface 338 may taper inwardly at a greater angle than the outer surface 340.

[0072] The terminal base 302 is located approximately in a central portion of the terminal 300, for example, between the upper mating end 304 and the lower mating end 306. The terminal base 302 includes an upper end 350 and a lower end 352. The terminal base 302 includes a first side 354 and a second side 356. Upper spring beams 312 and 314 extend from the upper end 350 at the first side 354 and the second side 356, respectively. Lower spring beams 322 and 324 extend from the lower end 352 at the first side 354 and the second side 356, respectively. In an exemplary embodiment, the terminal base 302 includes an opening 358 therethrough. Optionally, the opening 358 may be approximately centered between the upper end 350 and the lower end 352, and may be approximately centered between the first side 354 and the second side 356. The opening 358 may receive a portion of the header housing assembly 200 to position and / or retain the terminal 300 within the header housing assembly 200. For example, the shaft may extend through the opening 358. Alternatively, the terminal 300 may be rotatable about the shaft, for example to move the relative positions of the upper mating end 304 and the lower mating end 306.

[0073] Figure 6 is a top perspective partial cross-sectional view of a portion of the header power connector 100 according to an exemplary embodiment. Figure 7 is a top perspective partial cross-sectional view of a portion of the header power connector 100 according to an exemplary embodiment. Figure 6 The header power connector 100 is shown without the choke 400 . Figure 7 The header power connector 100 is shown with the choke 400 positioned within the cavity 206 .

[0074] During assembly, the terminal assembly 301 is loaded into the terminal retainer 203 of the inner housing 204. The terminal assembly retainer 205 is coupled to the terminal retainer 203 to retain the terminal assembly 301 in the terminal channel 256. The terminal assembly 301 is configured to be coupled to the bus bars 106,108.

[0075] In an exemplary embodiment, the cavity 206 includes a choke pocket 208 defined between the outer wall 210 and the inner housing 204. The choke pocket 208 is configured to receive the choke 400. The choke pocket 208 surrounds the inner housing 204 and the terminal assembly 301. When received in the choke pocket 208, the choke 400 surrounds the terminal assembly 301. In various embodiments, the choke pocket 208 can be oversized relative to the choke 400 to allow the choke 400 to be easily positioned within the cavity 206. For example, because the choke 400 may have poor manufacturing tolerances, the choke pocket 208 can be oversized to ensure that the choke 400 can fit within the choke pocket 208. The additional space or clearance can allow the choke 400 to have freedom of movement relative to the header housing assembly 200. However, the choke retainer 500 serves to limit this freedom of movement of the choke 400 once the choke 400 is positioned in the cavity 206. For example, the choke retainer 500 may physically constrain the choke 400 and limit movement (e.g., side to side and / or front to back and / or up and down). Figure 6 One of the vertical choke retainers 520 is shown in the cavity 206, such as at the bottom of the choke pocket 208. The vertical choke retainer 520 may be compressible to occupy the space between the choke 400 and the outer housing 202. The vertical choke retainer 520 may absorb vertical movement of the choke 400 within the cavity 206.

[0076] Figure 8 is a top perspective view of a portion of the header power connector 100 according to an exemplary embodiment. Figure 9 is an enlarged top perspective view of a portion of the header power connector 100 according to an exemplary embodiment. Figure 8 and Figure 9 The header power connector 100 is shown with the choke 400 positioned within the choke cavity 206 . Figure 8 and Figure 9 The choke 400 is shown docked with a horizontal choke locator 510 to position the choke 400 within the choke pocket 208. In the illustrated embodiment, the horizontal choke locator 510 includes a channel 512 that receives the locating rib 430. The walls of the channel 512 serve to position the choke 400 relative to the terminal assembly 301. For example, the channel 512 can center the choke 400 within the choke pocket 208, and the walls of the channel 512 can limit or restrict side-to-side movement of the choke 400 within the choke pocket 208. Alternatively, a compression rib or other feature can be provided in the channel 512 to tightly retain the locating rib 430 within the channel 512. Other types of horizontal choke locators can be used in alternative embodiments.

[0077] Figure 10FIG2 is an exploded view of a header power connector 100 according to an exemplary embodiment. The header power connector 100 includes a header housing assembly 200, a plurality of terminal assemblies 301 held by the header housing assembly 200, a choke 400 held by the header housing assembly 200, and a choke retainer 500 for positioning the choke 400 within the header housing assembly 200. In the illustrated embodiment, the choke retainer 500 includes a pair of vertical choke retainers 520, such as an upper vertical choke retainer 520a and a lower vertical choke retainer 520b. The choke 400 is configured to be sandwiched between the upper vertical choke retainer 520a and the lower vertical choke retainer 520b. The vertical choke retainers 520a, 520b are compressible and configured to absorb vertical movement of the choke 400 within the header housing assembly 200, such as from vibration. The horizontal choke locator 510 is shown as receiving the channel 512 of the locating rib 430 of the choke 400. Other types of horizontal choke locators may be used in alternative embodiments.

[0078] Figure 11 is an exploded view of the header power connector 100 according to an exemplary embodiment. Figure 11 A different type of choke locator 500 is shown. For example, the choke 400 does not include the locating rib 430, and the outer housing 202 does not include a channel. Instead, in the illustrated embodiment, the horizontal choke locator 510 includes a spring beam 514 extending from the inner housing 204, such as a spring beam 514 extending from the terminal assembly retainer 205. The horizontal choke locator 510 (e.g., the spring beam 514) interfaces with the choke 400 to position the choke 400 relative to the header housing assembly 200 and the terminal assembly 301. The spring beam 514 serves to center the choke 400 within the cavity 206 of the outer housing 202. The spring beam 514 is flexible. The spring beam 514 serves to absorb movement of the choke 400, such as due to vibration. For example, the spring beam 514 limits movement in a horizontal direction (e.g., side-to-side and / or front-to-back), which reduces the risk of damage to components of the header power connector 100.

[0079] Figure 12 2 is a perspective view of a portion of the inner housing 204 according to an exemplary embodiment, illustrating the terminal assembly retainer 205. The terminal assembly retainer 205 includes a spring beam 514 that defines a horizontal choke locator 510. The spring beam 514 extends from the end wall 270. The spring beam 514 has an interface configured to engage the choke body 402 in the opening 404 of the choke 400. The spring beam 514 is flexible to accommodate movement of the choke 400 relative to the inner housing 204 and the terminal assembly 301.

[0080] In the illustrated embodiment, spring beams 514 extend along the front and rear of the terminal assembly holder 205 to absorb front-to-back movement of the choke 400 relative to the terminal assembly holder 205. In the exemplary embodiment, the spring beams 514 are provided at both ends of the terminal assembly holder 205 to absorb side-to-side movement of the choke 400 relative to the terminal assembly holder 205. In the exemplary embodiment, the spring beams 514 include at least one first spring beam 514a at a first side of the terminal assembly holder 205, at least one second spring beam 514b at a second side of the terminal assembly holder 205, at least one front spring beam 514c at the front of the terminal assembly holder 205, and at least one rear spring beam 514d at the rear of the terminal assembly holder 205. The first spring beam 514a and the second spring beam 514b control the side-to-side positioning of the choke 400 relative to the terminal assembly holder 205. The front spring beam 514c and the rear spring beam 514d control the front and rear positioning of the choke 400 relative to the terminal assembly holder 205.

[0081] The spring beams 514 are curved in the illustrated embodiment and can elastically deform (e.g., flatten) when engaging the choke 400. The spring beams 514 are configured to press outwardly against the choke 400 to position the choke 400 relative to the terminal assembly holder 205 (e.g., center or return to a nominal position).

[0082] Figure 13 is a schematic diagram of a header power connector 600 according to an exemplary embodiment. Header power connector 600 is used to electrically connect a first electrical component 602 and a second electrical component 604. In various embodiments, first electrical component 602 and second electrical component 604 may be part of an electric vehicle. For example, first electrical component 602 may be an inverter, and second electrical component 604 may be an electric motor. In alternative embodiments, header power connector 600 may be used to electrically connect other types of electrical components. In the exemplary embodiment, when first electrical component 602 is coupled to second electrical component 604, header power connector 600 is mounted to first electrical component 602 and engages with second electrical component 604.

[0083] In the exemplary embodiment, first electrical component 602 includes a first bus bar 606, and second electrical component 604 includes a second bus bar 608. First bus bar 606 and second bus bar 608 are configured to plug directly into opposite ends of header power connector 600. Header power connector 600 electrically connects first bus bar 606 and second bus bar 608 to transmit power between first electrical component 602 and second electrical component 604.

[0084] In an exemplary embodiment, the header power connector 600 is used to electrically connect a plurality of first bus bars 606 (e.g., three bus bars) to a corresponding plurality of second bus bars 608 (e.g., three bus bars). The first bus bars 606 are metal plates, such as copper plates. The second bus bars 608 are metal plates, such as copper plates.

[0085] The header power connector 600 is positioned between a first electrical component 602 and a second electrical component 604. The bus bar 606 of the first electrical component 602 is configured to be plugged directly into the header power connector 600. The bus bar 608 of the second electrical component 604 is configured to be plugged directly into the header power connector 600, such as at an opposite end of the header power connector 600. Alternatively, the header power connector 600 can be initially mounted to the first electrical component 602 (or the second electrical component 604) and mated to the second electrical component 604 (or the first electrical component 602) when the first electrical component 602 is mounted to the second electrical component 604.

[0086] The header power connector 600 includes a header housing assembly 700 and one or more terminal assemblies held by the header housing assembly 700. In an exemplary embodiment, the header housing assembly 700 is a multi-piece housing assembly. For example, the header housing assembly 700 includes an outer housing 702 and an inner housing 704 ( Figure 14 ). The inner housing 704 holds the terminal assembly. The inner housing 704 is received in the cavity 706 of the outer housing 702. In an exemplary embodiment, the outer housing 702 is configured to be mounted to one of the electrical components, such as the first electrical component 602. In an exemplary embodiment, the inner housing 704 is movable relative to the outer housing 702 to accommodate alignment and mating with the first electrical component 602. For example, the inner housing 704 can be tilted or rotated within the outer housing 702 to accommodate misalignment of the first bus bar 606 and the second bus bar 608. The inner housing 704 has a limited amount of contained movement relative to the outer housing 702. The outer housing 702 is shaped to control and accommodate movement of the inner housing 704 during mating. For example, the outer housing 702 can allow the inner housing 704 to rotate a predetermined amount to allow mating with the bus bar 606 of the first electrical component 602 during mating with the bus bar 606 of the first electrical component 602. In an exemplary embodiment, the terminals of the terminal assembly also have a limited amount of contained movement relative to the inner housing 704 to accommodate misalignment of the first bus bar 606 and the second bus bar 608 during mating.

[0087] Figure 14FIG2 is an exploded view of a header power connector 600 according to an exemplary embodiment. The header power connector 600 includes a header housing assembly 700, a plurality of terminal assemblies 801 of terminals 800 held by the header housing assembly 700, a choke 900 held by the header housing assembly 700, and a choke retainer 1000 for positioning the choke 900 within the header housing assembly 700. The choke 900 surrounds the terminal assemblies 801 to eliminate EMI and to suppress high-frequency electronic noise from the terminal assemblies 801. The choke 900 improves the operation of the header power connector 600. The header housing assembly 700 holds the choke 900 relative to the terminal assemblies 801. For example, the header housing assembly 700 separates the choke 900 from the terminal assemblies 801 to physically isolate the choke 900 from the terminal assemblies 801, for example to reduce wear or damage to the terminal assemblies 801 due to movement (e.g., vibration) of the choke 900 within the electric vehicle. The header housing assembly 700 separates the choke 900 from the terminal assembly 801 to allow the terminal assembly 801 to move within the header housing assembly 700, for example, to align the terminal assembly 801 to the bus bars 606, 608 during mating. Figure 13 ).

[0088] In the exemplary embodiment, the header housing assembly 700 includes an outer housing 702, an inner housing 704, and a cover 701, which is coupled to the outer housing 702 to retain other components within the outer housing 702. In the exemplary embodiment, the inner housing 704 includes a terminal assembly retainer 705, which is configured to be coupled to the outer housing 702. In alternative embodiments, the header housing assembly 700 may include more or fewer parts. For example, the inner housing 704 may include a terminal retainer that may be positioned within a cavity 706 of the outer housing 702. Additionally, while the parts are shown as separate and discrete components in the illustrated embodiment, in alternative embodiments, the various parts may be integrated into a unitary structure.

[0089] The outer shell 702 includes an outer wall 710 surrounding the cavity 706 and a partition wall 711 in the cavity 706 surrounded by the outer wall 710 (in the Figure 20 ). The partition wall 711 is used to separate the choke 900 from the terminal assembly 801. In an exemplary embodiment, the partition wall 711 divides the cavity 706 into the choke chamber 708 ( Figure 20 ) and terminal chamber 709( Figure 20 The choke coil chamber 708 is located between the partition wall 711 and the outer wall 710 and receives the choke coil 900. The terminal chamber 709 is located on the inner side of the partition wall 711.

[0090] The outer wall 710 extends between an upper end 712 and a lower end 714 of the outer shell 702. In an exemplary embodiment, the upper end 712 is configured to be mounted to the first electrical component 602 such that the header power connector 600 extends from the bottom of the first electrical component 602. In alternative embodiments, other mounting orientations are possible. For example, the header power connector 600 can be oriented such that the end 712 defines the bottom of the outer shell 702, such as when the outer shell 702 is mounted to the top of a structure (e.g., one of the electrical components). In various other embodiments, the outer shell 702 can be oriented such that neither end 712, 714 is at the top or bottom, but rather defines the sides of the outer shell 702. The terms "upper" and "lower" are used herein with reference to the orientation shown in the figures.

[0091] The outer housing 702 includes mounting flanges 716 at opposite sides 720, 722 of the outer housing 702. The mounting flanges 716 can receive fasteners to secure the outer housing 702 to the first electrical component 602. For example, the fasteners can be threadedly coupled to the mounting flanges 716 and can be threaded inserts retained in the mounting flanges 716. The outer housing 702 can include bus bar supports 718 to support the bus bars 606. The bus bar supports 718 can be right-angle supports including vertical supports and horizontal supports. In alternative embodiments, the bus bar supports 718 can have other shapes.

[0092] The outer housing 702 includes a front portion 724 and a rear portion 726 extending between the sides 720 and 722. A cavity 706 is formed between the front portion 724 and the rear portion 726. The cavity 706 extends between the first side 720 and the second side 722. The cavity 706 is open, for example, at the bottom, to receive the inner housing 704, the terminal assembly 801, the choke 900, and the choke retainer 1000.

[0093] The outer housing 702 may include a latching feature (not shown) for securing the inner housing 704 to the outer housing 702. The latching feature may be a deflectable latch tab configured to engage a corresponding latching feature of the inner housing 704. The latching feature may be releasable to release the inner housing 704 from the outer housing 702.

[0094] In an exemplary embodiment, the inner housing 704 includes a terminal retainer 703 for holding the terminal 800. The terminal assembly holder 705 can be coupled to the terminal retainer 703. The terminal retainer 703 of the inner housing 704 includes a plurality of inner walls 750 extending between an upper end 752 and a lower end 754. The inner walls 750 form a terminal channel 756 that is configured to receive a corresponding terminal assembly 801 therein. The terminal channel 756 is open at the upper end 752 and the lower end 754 to receive the bus bars 606, 608, respectively. For example, the terminal retainer 703 includes an upper opening 757 for receiving the first bus bar 606 and a lower opening 758 for receiving the second bus bar 608. The inner walls 750 guide the bus bars 606, 608 into the terminal channel 756 to mate with the terminal assembly 801. Optionally, the upper opening 757 and / or the lower opening 758 may include chamfered lead-in surfaces that guide the bus bars 606 , 608 into the terminal channel 756 .

[0095] The terminal retainer 703 of the inner housing 704 includes a first side 760 and a second side 762 opposite the first side 760. The terminal retainer 703 of the inner housing 704 includes a front portion 764 and a rear portion 766 extending between the sides 760, 762. In an exemplary embodiment, the terminal retainer 703 of the inner housing 704 includes a positioning rib 767 extending from the front portion 764 and / or the rear portion 766. The positioning rib 767 is configured to position the inner housing 704 relative to the outer housing 702.

[0096] In an exemplary embodiment, the terminal retainer 703 of the inner housing 704 includes a latching feature 768 extending from the front portion 764 and / or the rear portion 766. The latching feature 768 is configured to interface with the outer housing 702 to secure the terminal retainer 703 within the cavity 706 of the outer housing 702. For example, the latching feature 768 can be coupled to the dividing wall 711 to retain the terminal retainer 703 within the terminal chamber 709. In the illustrated embodiment, the latching feature 768 includes latches, each of which has a ramp surface at the top of the latch and a catch surface at the bottom of the latch. Other types of latching features may be provided in alternative embodiments.

[0097] The terminal assembly retainer 705 is coupled to the bottom of the terminal retainer 703 to retain the terminal 800 in the terminal channel 756. The terminal assembly retainer 705 includes an end wall 770 and side walls 772, 774 extending from the end wall 770. The end wall 770 includes a slot 771 configured to receive the bus bar 606. The side walls 772, 774 include openings 776, 778 that receive latch features to secure the terminal assembly retainer 705 to the inner housing 704 and / or the outer housing 702. The side walls 772, 774 can be latchably coupled to the latch features. The side walls 772, 774 can be releasable from the latch features.

[0098] The cover 701 is configured to be coupled to the outer housing 702 after other components are assembled in the cavity 706. The cover 701 is used to retain the components in the cavity 706. For example, the cover 701 is used to retain the choke 900 and the choke retainer 1000 in the cavity 706. The cover 701 can be used to retain the inner housing 704 and the terminal assembly 801 in the cavity 706. For example, the cover 701 can be coupled to the terminal assembly retainer 705 to retain the terminal assembly retainer 705 and the terminal retainer 703 in the outer housing 702.

[0099] The cover 701 includes a cover plate 790 for covering the bottom of the outer shell 702. In an exemplary embodiment, the cover 701 includes an opening 792 to receive the bus bar 606 and / or the terminal assembly 801. The cover 701 can be removably coupled to the outer shell 702. For example, the cover 701 can include a latch extending from the cover plate 790, the latch being configured to be latchably coupled to the outer shell 702.

[0100] The choke 900 is configured to be received in a cavity 706 of the outer shell 702, such as the choke chamber 708, in a loading orientation (eg, vertically). The choke 900 may be coupled to the partition wall 711 ( Figure 20 ) and / or outer wall 710. The choke 900 surrounds the partition wall 711. The choke 900 is configured to surround the terminal assembly 801 when received in the cavity 706.

[0101] The choke 900 includes a choke body 902 that surrounds an opening 904 that passes through the choke 900. The choke body 902 can be made of a ferrite material, such as a magnesium-zinc alloy material or an iron-nickel alloy material. However, other types of chokes can be used in alternative embodiments. The choke body 902 can be made of a material having the characteristics of high magnetic permeability and / or high saturation level and / or low magnetic losses of the magnetic core. In the embodiment shown, the choke 900 is oval or racetrack shaped, with curved ends and flat or parallel sides. In alternative embodiments, the choke 900 can have other shapes.

[0102] The choke 900 extends between a top 906 and a bottom 908. An opening 904 extends between the top 906 and the bottom 908. The opening 904 is open at the top 906 and open at the bottom 908 to receive the terminal assembly 801 and the bus bars 606, 608. The choke 900 includes a first side 910 and a second side 912 opposite the first side 910. The choke 900 includes a front portion 914 and a rear portion 916 extending between the sides 910, 912. Rounded corners may be provided between the sides 910, 912 and the front portion 914 and the rear portion 916. The front portion 914 and the rear portion 916 may be elongated and oriented parallel to each other. The choke 900 includes a sidewall 918 between the top 906 and the bottom 908. The sidewall 918 faces outward. The sidewall 918 is defined by a front 914 , a rear 916 , and sides 910 , 912 .

[0103] The choke 900 includes an inner surface 920 and an outer surface 922. The inner surface 920 surrounds and defines the opening 904. The inner surface 920 is configured to face the partition wall 711. The outer surface 922 faces outward. The outer surface 922 is configured to face the outer wall 710 of the outer shell 702.

[0104] In the exemplary embodiment, the choke 900 includes locating features, such as locating ribs (not shown) extending from the front portion 914 and / or the rear portion 916. The locating ribs protrude from the choke 900. In the illustrated embodiment, the locating ribs are located along the outer surface 922. However, in alternative embodiments, the locating ribs may extend along the inner surface 920. The locating ribs serve to position the choke 900 within the cavity 706. The locating ribs interface with the choke locator 1000 to position the choke 900 relative to the outer shell 702. In other embodiments, the locating ribs may additionally or alternatively be provided along the first side 910 and / or the second side 912. Other types of locating features may be used in alternative embodiments. For example, in alternative embodiments, the locating features may be channels or grooves rather than protrusions. In various other embodiments, the locating features may be deflectable beams, such as the spring beams in the alternative embodiments. Epoxy or adhesive may be used to position the choke 900 within the cavity.

[0105] The choke locator 1000 is configured to interface with the choke 900 to position the choke 900 relative to the terminal assembly 801. In an exemplary embodiment, a plurality of choke locators 1000 are provided for positioning the choke 900 in different directions. For example, the header power connector 600 may include at least one horizontal choke locator and at least one vertical choke locator. The vertical choke locator positions the choke in a direction parallel to the loading direction. The vertical choke locator positions the choke 900 vertically, such as up and down. The horizontal choke locator positions the choke 900 in a lateral direction perpendicular to the loading direction. The horizontal choke locator positions the choke 900 in a horizontal direction, such as side to side and / or front to back.

[0106] In the illustrated embodiment, the choke positioner 1000 includes a compression ring 1022. The compression ring 1022 is configured to couple to the top 906 and / or bottom 908. The compression ring 1022 can be received in the outer housing 702, such as at the bottom of the cavity 706, and the choke 900 can rest on the compression ring 1022. The choke 900 can be loaded into the cavity 706 after the compression ring 1022 and fill the space between the choke 900 and the outer housing 702. The compression ring 1022 is compressible, for example, between the choke 900 and the header housing assembly 700. The compression ring 1022 absorbs movement of the choke 900 within the cavity 706. The compression ring 1022 constrains or limits movement of the choke 900, for example, in a vertical direction, for example, due to vibration or shock to the header power connector 600 during use (e.g., when the electric vehicle is driven). Other types of choke locators 1000 may be used in alternative embodiments, such as locating ribs, clips, latches, epoxy, adhesives, or other locating features.

[0107] In the illustrated embodiment, a plurality of terminal assemblies 801 are provided. Each terminal assembly 801 includes a plurality of terminals 800 stacked together in a terminal stack. The terminals 800 are arranged side by side in the terminal stack. The terminals 800 serve as a single terminal assembly within the terminal stack. However, the terminals 800 can be independently movable relative to each other and relative to the inner housing 704. The terminals 800 can be stamped and formed from thin metal sheets, but are stacked together to increase the total current carrying capacity of the terminal assembly. The choke coil 900 surrounds the terminal stack, such as in the cavity 706 between the inner housing 704 and the outer housing 702.

[0108] Figure 15 is a cross-sectional view of a portion of the header power connector 600 illustrating the terminal assembly 801 according to an exemplary embodiment. Figure 16 is a bottom perspective view of a portion of the header power connector 600 showing the terminal assembly 801 according to an exemplary embodiment. Figure 15 and Figure 16 The inner housing 704 is shown holding the terminal 800 , the terminal is shown in the terminal passage 756 in the terminal retainer 703 , and the terminal assembly retainer 705 is coupled to the terminal retainer 703 to retain the terminal 800 in the terminal passage 756 .

[0109] In an exemplary embodiment, terminal 800 is similar to Figure 5 Terminal 300 shown. Reference Figure 15 , each terminal 800 is a double-ended socket terminal that is configured to receive a first bus bar 606 and a second bus bar 608 at opposite ends of the terminal 800. Other types of terminals can be used in alternative embodiments. The terminal 800 is a stamped and formed terminal made of a metal material (such as a copper material). The terminal 800 includes a terminal base 802, an upper mating end 804 at a first side of the terminal base 802, and a lower mating end 806 at a second side of the terminal base 802. Optionally, the upper mating end 804 and the lower mating end 806 can be the same.

[0110] The terminal 800 has an upper receptacle 810 at an upper mating end 804. The terminal 800 includes a first upper spring beam 812 extending along a first side of the upper receptacle 810 and a second upper spring beam 814 extending along a second side of the upper receptacle 810.

[0111] The terminal includes a lower receptacle 820 at the lower mating end 806. The terminal 800 includes a first lower spring beam 822 extending along a first side of the lower receptacle 820 and a second lower spring beam 824 extending along a second side of the lower receptacle 810.

[0112] In the exemplary embodiment, each spring beam 812, 814, 822, 824 includes a base 830 and a distal end 832 at the distal end of the spring beam. The base 830 extends from the terminal base 802. In the exemplary embodiment, the spring beam includes a protrusion 834 near the distal end 832. Optionally, the protrusion 834 can protrude inwardly. The protrusion 834 has a curved surface that defines a mating interface 836 that is configured to mate with the corresponding bus bar 606 or 608.

[0113] Figure 17 is a front view of a header power connector 600 according to an exemplary embodiment. Figure 18 is a bottom view of a header power connector 600 according to an exemplary embodiment. Figure 19 7 is a side view of a header power connector 600 according to an exemplary embodiment. The terminal assembly 801 is retained in the header housing assembly 700, for example, by a cover 701. A seal 610 may surround the header housing assembly 700.

[0114] Figure 20is a side cross-sectional view of a header power connector 600 according to an exemplary embodiment. Figure 21 is an end cross-sectional view of a header power connector 600 according to an exemplary embodiment.

[0115] During assembly, the terminal assembly 801 is loaded into the terminal retainer 703 of the inner housing 704. The terminal assembly retainer 705 is coupled to the terminal retainer 703 to retain the terminal assembly 801 in the terminal channel 756. In an exemplary embodiment, the terminal channel 756 is oversized relative to the terminal 800 to allow the terminal 800 to move within the terminal channel 756. For example, the terminal 800 can be rotated or shifted (e.g., with a limited amount of floating movement) within the terminal channel 756 to accommodate misalignment of the bus bars 606, 608, such as when the bus bars are laterally or rotationally offset from each other.

[0116] In an exemplary embodiment, the cavity 706 of the outer housing 702 includes a choke chamber 708 and a terminal chamber 709. A partition wall 711 separates the choke chamber 708 from the terminal chamber 709. The inner housing 704 and the terminal assembly 801 are received in the terminal chamber 709. The terminal chamber 709 is located inside the partition wall 711. The partition wall 711 surrounds the inner housing 704 and the terminal assembly 801. In an exemplary embodiment, the terminal chamber 709 is oversized relative to the inner housing 704 to allow the inner housing 704 to move in the terminal chamber 709. For example, the inner housing 704 can be rotated or shifted (e.g., with a limited amount of floating movement) within the terminal chamber 709 to accommodate misalignment of the bus bars 606, 608, such as when the bus bars are laterally or rotationally offset from each other. In an exemplary embodiment, the partition wall 711 has a height similar to that of the outer wall 710. The cover 701 is coupled to the distal ends of the partition wall 711 and the outer wall 710. In an exemplary embodiment, the partition wall 711 extends at or beyond the inner housing 704. For example, the inner housing 704 is completely contained within the terminal chamber 709. The inner housing 704 is a separate housing for the terminals that protects the terminals from mechanical shock and vibration effects, such as wear, increased resistance, overheating, and thermal events, that propagate from the movement of the choke within the cavity 706. The partition wall 711 isolates the terminals 800 from the choke to protect the terminals from mechanical shock and vibration effects, such as wear, increased resistance, overheating, and thermal events, that propagate from the movement of the choke within the cavity 706. The inner housing 704 and the partition wall 711 create a stable ambient environment for the terminals 800, with consistent contact resistance and temperature. The partition wall 711 allows the inner housing 704 to move within the cavity 706 independently of the choke to align with the bus bars 606 and 608.

[0117] The choke chamber 708 is defined between the outer wall 710 and the partition wall 711. The choke 900 is received in the choke chamber 708. The choke 900 surrounds the terminal assembly 801. The cover 701 holds the choke 900 in the choke chamber 708. The partition wall 711 is used to separate the choke 900 from the terminal assembly 801. The partition wall 711 holds the choke 900 relative to the terminal assembly 801. For example, the partition wall 711 separates the choke 900 from the terminal assembly 801 to physically isolate the choke 900 from the terminal assembly 801 so as to reduce wear or damage to the terminal assembly 801 due to movement (e.g., vibration) of the choke 900 within the electric vehicle. A divider wall 711 separates the choke 900 from the terminal assembly 801 to allow the terminal assembly 801 to move within the header housing assembly 700 , such as for aligning the terminal assembly 801 with the bus bars 606 , 608 during mating without interference from the choke 900 .

[0118] In an exemplary embodiment, the choke positioner 1000 can position the choke 900 within the choke chamber 708. In various embodiments, the choke chamber 708 can be oversized relative to the choke 900 to allow the choke 900 to be easily positioned within the cavity 706. For example, because the choke 900 may have poor manufacturing tolerances, the choke chamber 708 can be oversized to ensure that the choke 900 can fit within the choke chamber 708. The additional space or gap can allow the choke 900 to have freedom of movement relative to the header housing assembly 700. However, the choke positioner 1000 is used to limit this freedom of movement of the choke 900 once the choke 900 is positioned within the cavity 706. For example, the choke positioner 1000 can physically constrain the choke 900 and limit movement (e.g., side-to-side and / or front-to-back and / or up-and-down). Figure 20 and Figure 21 The choke retainer 1000 is shown as a vertical choke retainer 1020 at the top of the choke chamber 708. The vertical choke retainer can be compressible to occupy the space between the choke 900 and the outer shell 702. The vertical choke retainer can absorb vertical movement of the choke 900 within the choke chamber 708.

[0119] Figure 22 A header power connector 600 is shown according to an exemplary embodiment. Figure 23 is an exploded view of the header power connector 100 according to an exemplary embodiment. Figure 24 is a side cross-sectional view of a header power connector 600 according to an exemplary embodiment. Figure 25 is an end cross-sectional view of a header power connector 600 according to an exemplary embodiment. Figure 22-25 The header power connector 600 shown in FIG is similar to Figure 14-21900, but includes a different retention structure for retaining the terminal assembly 801 and the choke 900. For example, the outer housing 702 is shaped differently and / or includes different components.

[0120] The header power connector 600 includes a header housing assembly 700, a terminal assembly 801 held by the header housing assembly 700, a choke 900 held by the header housing assembly 700, and a choke retainer 1000 for positioning the choke 900 within the header housing assembly 700. The choke 900 surrounds the terminal assembly 801 to eliminate EMI and to suppress high-frequency electronic noise from the terminal assembly 801. The choke 900 improves the operation of the header power connector 600. The header housing assembly 700 holds the choke 900 relative to the terminal assembly 801. For example, the header housing assembly 700 separates the choke 900 from the terminal assembly 801 to physically isolate the choke 900 from the terminal assembly 801, for example to reduce wear or damage to the terminal assembly 801 due to movement (e.g., vibration) of the choke 900 within the electric vehicle. The header housing assembly 700 separates the choke 900 from the terminal assembly 801 to allow the terminal assembly 801 to move within the header housing assembly 700 , such as for aligning the terminal assembly 801 to the bus bars 606 , 608 during mating.

[0121] In the embodiment shown, the outer wall 710 and the partition wall 711 are Figure 14-21 For example, the inner housing 704 and the terminal assembly 801 protrude beyond (e.g., below) the distal ends of the partition wall 711 and the outer wall 710. In the illustrated embodiment, the choke chamber 708 and the terminal chamber 709 are shorter.

[0122] In the illustrated embodiment, the choke locator 1000 includes a channel 1012 that receives the locating rib 930 extending from the choke 900. The walls of the channel 1012 serve to position the choke 900 within the choke chamber 708 relative to the terminal assembly 801. For example, the channel 1012 can center the choke 900 within the choke chamber 708, and the walls of the channel 1012 can limit or constrain the side-to-side and / or end-to-end movement of the choke 900 within the choke chamber 708. Optionally, a compression rib or other feature can be provided in the channel 1012 to tightly retain the locating rib 930 within the channel 1012. Other types of horizontal choke locators can be used in alternative embodiments.

[0123] Figure 26 A header power connector 600 is shown according to an exemplary embodiment. Figure 27 is an exploded view of the header power connector 100 according to an exemplary embodiment. Figures 26-27 The header power connector 600 shown in FIG is similar to Figure 22-25 , but includes a different retaining structure for holding the terminal assembly 801 and the choke 900. For example, the cover 701 is used to retain the choke 900 in the outer housing 702. In addition, a different type of choke retainer 1000 is used.

[0124] The header power connector 600 includes a header housing assembly 700, a terminal assembly 801 held by the header housing assembly 700, a choke 900 held by the header housing assembly 700, and a choke retainer 1000 for positioning the choke 900 within the header housing assembly 700. The choke 900 surrounds the terminal assembly 801 to eliminate EMI and to suppress high-frequency electronic noise from the terminal assembly 801. The choke 900 improves the operation of the header power connector 600. The header housing assembly 700 holds the choke 900 relative to the terminal assembly 801. For example, the header housing assembly 700 separates the choke 900 from the terminal assembly 801 to physically isolate the choke 900 from the terminal assembly 801, for example to reduce wear or damage to the terminal assembly 801 due to movement (e.g., vibration) of the choke 900 within the electric vehicle. The header housing assembly 700 separates the choke 900 from the terminal assembly 801 to allow the terminal assembly 801 to move within the header housing assembly 700 , such as for aligning the terminal assembly 801 to the bus bars 606 , 608 during mating.

[0125] In the illustrated embodiment, the choke positioner 1000 includes vertical choke positioners 1020 that are configured to be stacked above and below the choke 900 in the choke chamber 708 to vertically position the choke 900 in the choke chamber 708. The choke 900 is configured to be sandwiched between the upper and lower vertical choke positioners 1020. The vertical choke positioners 1020 are compressible and configured to absorb vertical movement of the choke 900 within the header housing assembly 700, such as from vibration. Other types of vertical choke positioners may be used in alternative embodiments.

[0126] CROSS-REFERENCE TO RELATED APPLICATIONS

[0127] This application is a continuation-in-part of U.S. application No. 18 / 082,704, filed on December 16, 2022, and claims the benefit of Indian application No. 202441010574, filed on February 15, 2024, the subject matter of which is incorporated herein by reference in its entirety.

Claims

1. A header power connector (100), comprising: A header housing assembly (700) includes an outer housing (702) having an outer wall (710) forming a cavity (706) and a partition wall (711) dividing the cavity into a choke chamber (708) and a terminal chamber (709), the outer housing extending between a top portion (906) and a bottom portion (908), the outer housing being configured to receive an upper bus bar (606) in the cavity through the top portion, and the outer housing being configured to receive a lower bus bar (608) in the cavity through the bottom portion, the header housing assembly including an inner housing (704) received in the terminal chamber, the inner housing including a terminal passage (756); A terminal assembly (801) is received in the terminal chamber, the terminal assembly is held in the terminal channel of the inner housing, the terminal assembly includes a plurality of terminals (800) arranged in a terminal stack, each terminal includes an upper mating end (804) and a lower mating end (806), the upper mating end has an upper socket (810) configured to receive the upper bus bar, the lower mating end has a lower socket (820) configured to receive the lower bus bar, and the terminal is configured to electrically connect the upper bus bar and the lower bus bar; and A choke (900) is received in the choke chamber between the outer wall and the partition wall, the choke having a choke body (902) surrounding the terminal assembly, the choke body having an opening (904) therethrough, the opening (904) receiving the terminal assembly.

2. The header power connector (100) according to claim 1, wherein: The partition wall (711) is located between the choke coil (900) and the inner housing (704).

3. The header power connector (100) according to claim 1, wherein: The inner housing (704) is coupled to the partition wall (711).

4. The header power connector (100) according to claim 1, wherein The partition wall (711) includes an inner surface facing the inner housing (704) and an outer surface facing the choke coil (900).

5. The header power connector (100) according to claim 1, wherein The partition wall (711) extends to a distal edge that extends beyond the ends of the terminal assembly (801) and the inner housing (704).

6. The header power connector (100) of claim 1 further comprising a choke locator (1000) in the cavity (706), the choke locator docking with the choke (900) to position the choke relative to the outer housing (702).

7. The header power connector (100) according to claim 6, wherein: The choke (900) is loaded into the cavity (706) in a loading direction, and the choke positioner (1000) positions the choke in a lateral direction perpendicular to the loading direction.

8. The header power connector (100) according to claim 6, wherein: The choke (900) includes a first side (910) and a second side (912) extending between a top (906) and a bottom (908) of the choke, and the choke positioner (1000) maintains the choke in a side-to-side position relative to the outer housing (702).

9. The header power connector (100) according to claim 6, wherein: The choke (900) includes a front portion (914) and a rear portion (916) extending between a first side portion (910) and a second side portion (912), and a contact locator maintains a front-to-rear position of the choke relative to the outer housing (702).

10. The header power connector (100) according to claim 6, wherein: The choke positioner (1000) is coupled to the top (906) of the choke (900) to vertically position the choke within the cavity (706).

11. The header power connector (100) according to claim 6, wherein: The contact locator is compressible between the choke (900) and the header housing assembly (700).

12. The header power connector (100) according to claim 1, wherein The outer shell (702) includes a channel (756) along the inner surface of the outer wall (710) and opening toward the cavity (706), the channel defining a horizontal contact locator, and the choke (900) includes a locating rib (930) received in the channel to position the choke relative to the outer wall.

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