High-voltage connector and assembling method thereof

Abstract

The invention relates to a high voltage connector and a method of assembling the same. The high voltage connector, connected to a device, is subjected to reduced electromagnetic interference, avoids electrochemical corrosion of dissimilar metals in fluid or non-fluid environments, and provides an effective electrical grounding system. The connector includes: an outer housing assembly; an inner housing mounted within the outer housing; a set of cable reinforcement retainer assemblies secured within the inner housing; a rear cover along which the cables respectively slide and cover a central opening of the outer housing through the rear cover; a braided shield covering the cable; and a clamp connecting the shield to the outer housing. When the high voltage connector is assembled, the outer housing is mounted to the device; the inner shell is fixed in the outer shell; a set of cable reinforcement retainer assemblies and associated cables are secured in the inner housing and extend from the inner housing in a substantially vertical direction; the rear cover slides along the cable and enters and covers the central opening of the outer shell; and the braided shield is mounted and connected to the outer housing by the clip.

Description

[0001] This application is a divisional application of the invention patent application with the application date of November 22, 2019, application number 201980064373.6, and invention name “High-voltage connector and assembly method thereof”.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This patent application claims priority to U.S. Provisional Patent Application No. 62 / 775,103, filed on December 4, 2018, and U.S. Provisional Patent Application No. 62 / 802,829, filed on February 8, 2019, the entire contents of which are incorporated herein by reference. Background Art

[0004] It is desirable to provide a high voltage connector for connection to a device. It is further desirable that the high voltage connector experience reduced electromagnetic interference (EMI), avoid electrochemical corrosion of dissimilar metals in either a fluid environment or a non-fluid environment, and provide an effective electrical grounding system. Summary of the Invention

[0005] The present invention provides a high-voltage connector for connecting to a device that experiences reduced EMI during operation. This is achieved by providing the connector with a braided metal shield over the transmission outer housing assembly. The connector is further provided with a metal clamp that holds the braided metal shield layer to the outer housing and provides conductive contact between the braided metal shield and the outer housing. The outer housing, preferably made of metal-injected plastic, includes an overmolded silicone seal to provide the necessary sealing and insulation to prevent galvanic corrosion between the connector and the device to which it is connected.

[0006] The metal-injected plastic outer housing with an overmolded silicone shield includes holes through which bolts are passed to secure the connector of the present invention to the device. The bolts provide the necessary grounding between the metal braided shield, the metal-injected plastic outer housing, and the device to which the connector of the present invention is to be connected. Each bolt is preferably inserted into a corresponding metal compression limiter within a corresponding one of the holes in the outer housing. By connecting the connector to the device using the bolts and the metal compression limiters, contact is established between the connector and the device, providing a grounding system for the connector of the present invention. In addition, the steel bolts are housed within the metal compression limiters, which in turn are housed within the side holes of the outer housing. An overmolded silicone seal is on the outer periphery of the base of the metal-injected outer housing, and the overmolded silicone seal, together with the above-mentioned structural arrangement composed of dissimilar metals, provides corrosion resistance.

[0007] The connector of the present invention further includes an inner housing provided within the outer housing, the inner housing further having a cable reinforcement retainer assembly securely inserted therein.

[0008] The connector of the present invention further includes a rear cover that serves as a terminal position assurance (TPA) device. During connector assembly, the cable slides through the rear cover and is secured within it. The rear cover includes an overmolded silicone seal that isolates the cable's connection interface. During connector assembly, the rear cover ensures that the inner housing is properly positioned within the outer housing.

[0009] Typically, when assembling the connector of the present invention, the transmission outer housing assembly is mounted to the associated device using bolts contained in corresponding metal compression limiters, the transmission outer housing assembly having a metal-injected plastic outer housing with an overmolded silicone seal; the inner housing is located within the outer housing and on the base of the outer housing; a rear cover and cable reinforcement retainer assembly with associated cables are installed within the outer housing and on the inner housing, and the cables are slid upward through the rear cover; a metal braided shield is mounted to the outer housing while covering the exposed cables; and a clamp is slid along the braided shield to secure it to the outer housing. BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 The present invention is generally indicated by the reference numerals 1 1 shows an exploded view of a high voltage connector showing its different elements arranged in a vertical direction ready to be mounted on an associated device.

[0011] Figure 2A is a perspective view of a fully assembled connector of the present invention without the braided shield and with the cable exposed; Figure 2B is a perspective view of a fully assembled connector of the present invention showing the braided shield fully secured to the outer housing with metal clamps.

[0012] Figure 3A is a top perspective view of the outer shell, and Figure 3B A bottom perspective view of the outer shell.

[0013] Figure 4A is a top perspective view of the outer housing surrounded at its bottom periphery by a corresponding overmolded silicone seal; Figure 4B Exploded view of an outer housing and corresponding overmolded silicone seal, with compression limiters fitting within the coincident bores of the outer housing and silicone seal.

[0014] Figure 5A is a bottom view of the base end of the outer housing assembly showing the outer housing gasket passing through the elongated slot of the base of the overmolded silicone seal; Figure 5B is a bottom view of the base end of the outer housing assembly showing another embodiment or style of a gasket of the outer housing passing through a corresponding elongated slot of another embodiment or style of the base of the overmolded silicone seal.

[0015] Figure 6 A top perspective view of the outer housing showing its inner surface through its central opening.

[0016] Figure 7A is a top perspective view of the inner housing, showing its front and top, and Figure 7B A bottom perspective view of the inner housing.

[0017] Figure 8 Shown is yet another top perspective view of the inner housing, illustrating its rear and top.

[0018] Figure 9 Shown is an exploded perspective view of a cable strength retainer assembly having a clamp (or retainer) mounted on and surrounding an end terminal.

[0019] Figure 10 Illustrated is a side view of the cable retainer assembly when the cable retainer assembly is fully assembled and the end of the end terminal of the clamp is coupled to the terminal of the cable.

[0020] Figure 11A is a front view of a first side portion of the end terminal and a first side portion of the clamp of the cable reinforcement retainer assembly, and Figure 11B A front view of a second side of the end terminal and a second side of the clamp of the cable retainer assembly.

[0021] Figure 12A A perspective view illustrating the front and bottom of the rear cover is shown, and Figure 12B A front view illustrating the bottom of the rear cover.

[0022] Figure 13A is a perspective view of the rear and top of the back cover; and Figure 13B A front view of the top of the back cover.

[0023] Figure 14A is a perspective view of a braided shield; Figure 14B A perspective view of the metal fixture.

[0024] Figure 15 A fully assembled vertical high voltage connector of the present invention is shown with a wedge (or ram) mechanism for securing a cable in an inner housing housed within an outer housing.

[0025] Figure 16A fully assembled vertical high voltage connector of the present invention is shown with a wedge (or ram) mechanism for securing a cable in an inner housing housed within an outer housing, and further showing terminals extending from a counterpart to which the connector is mounted for connection with end terminals of a cable reinforcement retainer assembly. DETAILED DESCRIPTION

[0026] like Figure 1 As shown, the high voltage connector 1 includes an outer housing assembly 3 including an outer housing 5 with an over-molded silicone seal 7. The outer housing 5 is preferably made of an injected metal shell and includes a side extension 62 of its base 32 for accommodating therein a seal for fastening the connector 1 to an associated device 210 (see Figure 15 ; For example, a corresponding bolt 12 (made of steel, etc.) of a cast automobile transmission, etc., made of aluminum, etc.

[0027] The inner housing 14 is housed in the outer housing 5 and mounted on its base 32. The connector 1 further includes a set of cable reinforcement retainer assemblies 16 (in Figure 9 、 Figure 10 、 Figure 11A and Figure 11B Specifically mentioned as reference numeral 108 in the figure, it is used to connect with the inner housing 14 and a set of cables 18. The set of cables 18 is preferably a high voltage cable (for example 25mm 2 However, the cable type is not limited to this. Figure 1 A set of three high voltage cables is shown in FIG. 1 , but the embodiment is not limited thereto. The cables 18 can be slidably received in the rear cover 20. The connector 1 further includes a metal (e.g., stainless steel) braided shield 22. When the connector 1 is as shown in FIG. Figure 2B When fully assembled as shown, the braided shield 22 forms the outer layer of the connector 1. Figure 2B Also shown, metal clamps 25 secure the braided shield 22 to the outer housing 5 when the connector 1 is fully assembled.

[0028] Figure 2A The connector 1 is shown lacking the braided shield 22 when fully assembled. Figure 2B The connector is illustrated with the braided shield 22 secured to the outer housing 5 by the metal clamp 25 when fully assembled. Figure 2A 3 further shows an outer housing assembly 3 having an outer housing 5 securely positioned on and within an overmolded silicone seal 7 through which bolts 12 are fastened using metal compression limiters 28 made of aluminum or the like. As will be discussed later, the set of cables 18 extend through an upper portion 30 of the outer housing 5.

[0029] exist Figure 2BIn FIG. 5 , the set of cables 18 is covered by a metal braided shield 22 . A metal clamp 25 ensures that a bottom portion 33 of the metal braided shield 22 is connected to an upper portion 30 of the outer housing 5 .

[0030] like Figure 3A As shown, the outer shell 5 having the base 32 stands in a vertical direction, and the horizontal ribs 34 extend from one side of the base 32 toward the central portion 36 of the outer shell 5. As for the outer shell 5, and as previously described, Figure 3A Also shown are extended sides or ribs 9 and side holes 38 for receiving corresponding bolts 12 and corresponding metal compression limiters 28 therein along with silicone seals 7. The outer housing 5 is preferably made of metal-injected plastic, while the bolts 12 are preferably made of steel or the like.

[0031] A central opening 40 extends through the central portion 36 of the outer housing 5 for completely receiving the inner housing 14 and the cable strength retainer assembly 16 therein and further partially receiving the set of cables 18. A hole 42 extends through the upper portion of the outer housing 5.

[0032] exist Figure 3B The bottom end portion 45 of the outer housing 5 is illustrated in FIG. The bottom end portion 45 is substantially flat and includes at least a pad 48 extending therefrom. The pad 48 surrounds a bottom opening or hole 50 extending through the bottom end portion 45 of the base 32 of the outer housing 5. When the outer housing 5 is mounted to the associated device 210 (see FIG. Figure 15 ), the pad 48 provides the necessary means for substantially eliminating or substantially reducing the generation of any EMI. The bottom opening or hole 50 is preferably smaller in size than the central hole 40 of the outer housing 5 and communicates therewith.

[0033] Figure 4A The outer housing assembly 3 is shown, comprising an outer housing 5 and an overmolded silicone seal 7, with the base 32 of the outer housing 5 located on and within the overmolded silicone seal 7. The overmolded silicone seal 7 provides a seal and insulating layer for electrochemical corrosion protection between the connector 1 and the device 210.

[0034] exist Figure 4B In FIG. 3 , an exploded view of the outer housing assembly 3 is shown, showing the outer housing 5 and its corresponding overmolded silicone seal 7. Figure 3A and Figure 3B As discussed with respect to the outer housing 5 shown in FIG. 1 , the outer housing 5 includes a base 32 having a bottom end 45. Figure 3B Also depicted, the base end 45 includes a pad 48 that fits through an elongated slot 51 that passes through the base 52 of the overmolded silicone seal 7 (see FIG. Figure 4B ). Figure 3BAs further described, the substantially flat bottom end portion 45 of the outer housing 5 is positioned and mounted on the base portion 52 of the overmolded silicone seal 7, as shown. Figure 4A and Figure 4B As shown. Figure 4B In the overmolded silicone seal 7 shown, the base portion 52 includes side holes 53, while the upper portion 55 of the silicone seal 7 includes side members 57, each of which has a hole 60 therethrough. Figure 4A As shown, each upper portion 55 of the silicone seal 7 is assembled to one of the side extensions 62 of the base 32 of the outer housing 5. Thus, each hole 60 of each side member 57 of the silicone seal 7 corresponds to a corresponding one of the holes 38 of the base 32 of the outer housing 5 to respectively accommodate the metal compression limiter 28 therein.

[0035] Figure 5A The bottom end 45 of the outer housing assembly 3 is illustrated, with the pad 48 of the outer housing 5 passing through the elongated slot 51 of the silicone seal 7 when the outer housing 5 is positioned and mounted on the overmolded silicone seal 7 . Figure 5B The bottom end 45 of the outer housing assembly 3 is illustrated, and when the outer housing 5 is positioned and mounted on the overmolded silicone seal 7 , the different embodiments or styles of gaskets 48 pass through the corresponding elongated slots 51 of the different embodiments or styles of silicone seal 7 .

[0036] Figure 6 FIG is a top perspective view of the outer housing 5 showing its inner surface through its central opening 40. Figure 6 As shown, as can be seen through the central opening 40 of the outer housing 5, a bottom opening or hole 50 through the bottom end 45 of the base 32 of the outer housing 5 is opposite and in communication with the central opening 40. Figure 6 As further shown, an internal shoulder 95 extends from the inner surface 97 of the outer shell 5. Although not shown in FIG. Figure 6 , but with a similar type of internal shoulder 95 extending from the opposite side of the inner surface of the outer housing 5. Figure 6 Also shown are external shoulders 98a and 98b extending from an upper portion of the outer housing 5.

[0037] Next, the inner housing 14 is described in detail. The inner housing 14 is housed within the outer housing 5 and is located on its base 32. The inner housing 14 is preferably made of nylon or the like. The inner housing 14 (preferably made of nylon or the like) provides isolation between conductive parts (e.g., the outer housing 5 made of metal-injected plastic or the like and the cable terminal 107 fixed within the inner housing 14). Figure 7AFIG. 1 is a top perspective view of the inner housing 14 showing its front portion 70 and top portion 72. The front portion 70 of the inner housing 14 has flexible members 75, 76, and 77. The top portion 72 of the inner housing 14 has a first portion 80, a second portion 82, and a third portion 84 extending from the top portion 72. Figure 7A As shown, the inner housing 14 is generally an upside-down (or inverted) basic L-shaped structure having a downward extending member 83 and a rear extending member 87 .

[0038] Figure 7B FIG is a bottom perspective view of the inner housing 14. Figure 7B The bottom end 85 of the inner housing 14 is shown in FIG. 1 and has slots 88, 89, 90 therethrough. The rear extension member 87 of the inner housing 14 is Figure 7B Similarly shown as having a bottom surface 92 .

[0039] Figure 8 Another top perspective view of the inner housing 14 is shown, illustrating the rear portion 101 and the top portion 72 of the inner housing 14. The rear portion 101 of the inner housing 14 is connected to the top portion 72 of the inner housing 14. Figure 7A 14 is opposite the front portion 70 of the inner housing 14 shown in FIG. Figure 8 1 and 2. The flexible members 75, 76, 77 are shown in the front portion 70 of the inner housing 14. Each of the flexible members 75, 76, 77 has an inclined shoulder 103. The first portion 80, the second portion 82, and the third portion 84 extend from the front portion 70 (see also FIG. Figure 7A ). Each second portion 82 extends obliquely relative to the substantially flat and horizontal first portion 80. The top 72 of the inner housing 14 is preferably similarly flat and horizontal. Between the second portion 82 and the third portion 84 is a substantially concave portion or recessed portion 105. Figure 8 Also shown are upper notches 188, 189, 190, which are respectively Figure 7B The lower notches 88, 89, 90 of the inner housing 14 shown in FIG. 1 are in communication.

[0040] Figure 9 The cable reinforcement retainer assembly 108 is shown (in Figure 1Referring to an exploded perspective view of the cable reinforcement retainer assembly 108 (also referred to as reference numeral 16 in the figure), each cable reinforcement retainer assembly 108 has a clamp (or retainer) 105 that is mounted on and surrounds a preferably flexible (although not limited to) end terminal 107. The end terminal 107 has a substantially flat end 110 that is attached to a cable terminal 113, which is attached to the cable 18. The terminal 107 includes a first side 115 and a second side 117. The first side 115 includes a plurality of preferably flexible fingers 119, and the second side 117 also includes a plurality of preferably flexible fingers 121. Although not limited to this, the flexible fingers 119 and the flexible fingers 121 are substantially symmetrical. At least an extension member 120 is attached to the second side 117, and the extension member 120 extends toward the first side 115. Each of the first and second side portions 115 , 117 of the end terminal 107 includes at least a recess or aperture 122 , 123 , respectively.

[0041] The clamp (or retainer) 105 of the cable reinforcement retainer assembly 108 includes a first side 125 and a second side 127. Each of the first side 125 and the second side 127 of the clamp 105 includes at least an inwardly projecting member 130, 132, respectively. When the end terminal 107 is received within the clamp 105 during assembly thereof, the projecting members 130, 132 enter the recesses or holes 122, 123, respectively. Figure 9 Further shown in FIG. 1 is a flexible member 133 in at least the second side 127 of the clamp 105. Although the flexible member 133 is Figure 9 A pair of flexible members 133 is shown in FIG. 1 , but is not limited thereto.

[0042] At least side 134 of terminal 107 is prevented from passing inwardly projecting members 136 at least at side 137 of clamp 105. Preferably, each of opposing sides 137 of clamp 105 includes an inwardly projecting member 136, and end terminal 107 includes opposing sides 134.

[0043] The cable reinforcement retainer assembly 108 is Figure 10 1 is shown fully assembled, with end 110 of end terminal 107 of clamp 105 coupled to terminal 113 of cable 18. Figure 10 As shown, the cable reinforcement retainer assembly 108 shows at least one end of the flexible members 121 of the second side 117 of the end terminal 107 and at least one end of the flexible members 119 of the first side 115 of the end terminal 107. See also Figure 9 .

[0044] Figure 11AFIG. 1 is a front view of the first side 115 of the end terminal 107 and the first side 125 of the clamp 105 of the cable reinforcement retainer assembly 108. The first side 125 of the clamp 105 includes at least the flexible member 135. Although not limited thereto, in Figure 11A A pair of flexible members 135 are shown with an elongated slot 138 therebetween. Figure 11A Also shown is an inwardly projecting member 132 in the first side 125 of the clamp 105, which is preferably angled to facilitate entry into the recess or hole 123 of the end terminal 107 as the end terminal 10 moves inside the clamp 105 (see FIG. Figure 9 ). Once the inwardly projecting member 132 has been received in the recess or hole 123, the end terminal 107 is retained inside the clamp 105. That is, the inwardly projecting member 132 of the clamp 105 is preferably angled to allow the terminal 107 to be inserted into the clamp 105; and once the inwardly projecting members 130, 132 have been received in the recess or hole 122, 123 of the end terminal 107, respectively, the terminal 107 is prevented from being pulled out of the clamp 105. As previously described with respect to Figure 9 As depicted, the opposite sides 134 of the end terminal 107 are retained by the inwardly projecting members 136 of the clamp 105 and prevent the retainer 107 from being pushed further forward into the clamp 105. When so assembled, the cable retainer assembly 108 causes the ends of the flexible members 119, 121 of the terminal 107 to extend outside of the clamp 105, as shown. Figure 10 、 Figure 11A and Figure 11B shown.

[0045] Figure 11B A front view of the cable retainer assembly 108 is illustrated showing the second side 117 of the end terminal 107 and the second side 127 of the clamp 105. The inwardly projecting member 130 and the pair of flexible members 133 of the clamp 105 are illustrated here, and when the cable reinforcement retainer assembly 108 is assembled as shown, the ends of the flexible members 121 of the second side 117 of the terminal 107 extend outside of the clamp 105. Figure 11B Further shown in FIG. 1 is an elongated slot 140 between the pair of flexible members 133 (here shown partially through the second side 127 of the clamp 105 ).

[0046] Figure 12AA perspective view of the front portion 142 and bottom portion 145 of the back cover 20 is illustrated. An at least substantially semicircular tubular member 148 is shown here, having a front portion 149 and extending from the bottom portion 145 of the back cover 20. For strength and stability, the semicircular tubular member 148 is coupled to a bridge (or rib) member 150, each connected to the back cover 20 and extending to a side portion 153 of the back cover 20. An opening 155 of the tubular member 148 extends toward a middle portion 160 of the back cover 20. Within the middle portion 160 are substantially circular apertures 162, each communicating with the tubular member 148. A circular silicone seal 165 is within each circular aperture 162; and an overmolded silicone seal 168 is formed on the outer periphery of the middle portion 160 of the back cover 20. The back cover 20 includes the circular silicone seal 165 for engaging the cable 18 and the overmolded silicone seal 168 for engaging the inner surface of the outer housing 5. With the cables 18 housed within the circular fitting silicone seals 165, the back cover 20 serves as a terminal position assurance (TPA) device for the high voltage connector 1 of the present invention. Shoulders 173 surround the upper portion 170 of the back cover 20; and an inclined protruding member 175 is between the shoulders 173, as shown in FIG. Figure 12A shown.

[0047] like Figure 12A The above elements of the rear cover 20 are shown in FIG. Figure 12B The bottom 145 of the rear cover 10 is similarly shown in the front view of FIG. Here, the tubular member 148 and the bridge (rib) member 150 connected to the side portion 153 are shown. Figure 12B Also shown are the respective openings 155 of the tubular member 148 communicating with the circular aperture 162 of the tubular member 148, the respective circular fitting silicone seals 165 within the circular apertures 162, and the silicone seal 168 surrounding the outer periphery of the middle portion 160 of the rear cover 20. Figure 12B The shoulder 173 is shown on the lower portion 170 of the rear cover 20 (see Figure 12A ) surrounds the upper portion 170 of the rear cover 20 on all sides, and the inclined protruding members 175 extend on opposite sides of the rear cover 20, as shown Figure 12B shown.

[0048] Figure 13A 1 is a perspective view of the rear portion 180 and top portion 182 of the rear cover 20. An angled protruding member 175 is shown on the rear portion 180. The rear portion 180 of the rear cover 20 is opposite its front portion 142. Extending from the top portion 182 is a top tubular member 185 having corresponding openings 188 that communicate with the circular apertures 162 extending through the middle portion 160 of the rear cover. Like the semicircular tubular member 148 extending from the bottom portion 145, the top tubular member 185 is similarly surrounded by a bridge (or rib) member 190. A silicone seal 168 surrounds the outer periphery of the middle portion 160.

[0049] Figure 13B is a front view of the top portion 182 of the rear cover 20 , illustrating the various openings 188 of the top tubular member 185 and the associated bridge (or rib) members 190 . Figure 13B It also shows that earlier Figure 13A A corresponding circular fitting silicone seal 165 is discussed, as well as an angled protruding member 175 located in the top 182 at an opposite side of the top 182 .

[0050] Figure 14A FIG1 is a perspective view of the braided shield 22 having an internal opening 192 extending along its entire length. The braided shield 22 is made of metal, preferably stainless steel or the like. Figure 14B 2 is a perspective view of the metal jig 25 , which is substantially annular in shape and made of stainless steel or the like.

[0051] In the high-voltage connector 1 of the present invention, the connection between the connector 1 and the associated aluminum device 210 is provided for grounding by establishing contact between the metal-infused conductive plastic outer housing 5, the aluminum compression limiter 28, the stainless steel bolt 12, and the associated aluminum device 210. EMI is significantly reduced or eliminated by the metal-infused pad 48 of the outer housing 5, in combination with the braided shield 22 extending along the path of the cable 18. The metal-infused pad 48 contacts the associated aluminum device 210. The present invention further provides electrochemical corrosion protection by shielding the metal-infused conductive plastic outer housing 5 and the associated aluminum device 210 from electrolytic fluids using the base 52 of the non-conductive overmolded silicone seal 7. Electrochemical corrosion is further prevented by shielding the metal-infused conductive plastic outer housing 5 and the aluminum compression limiter 28 from the electrolytic fluids, further shielding the stainless steel bolt 12 and the associated aluminum device 210 from the electrolytic fluids.

[0052] The method of assembling the high voltage connector of the present invention is described in detail below. The bolts 12 are respectively fixed to the compression limiters 28 in the side holes 38 of the outer housing 5, and then the outer housing 5 is installed together with the overmolded silicone seal 7 to the outer housing 5 and the device 210 to which the connector 1 will be installed (see Figure 15 ). Bolts 12 securely fasten connector 1 to device 210 and provide grounding between braided shield 22, outer housing 5, and device 210. Preferably, stainless steel bolts 12 and aluminum compression limiters 28 provide contact between connector 1 and device 210 to ground the system.

[0053] With the outer housing 5, along with the overmolded silicone seal 7, already mounted to the device, the inner housing 14 is then inserted or slid into the central opening 40 of the outer housing 5 to mount the inner housing 14 onto the bottom end 45 of the base 32 of the outer housing 5 until a click or the like is heard, which ensures that the inner housing 14 is secured within the outer housing 5. The overmolded silicone seal 7 provides a seal and insulating layer for electrochemical corrosion protection between the connector 1 and the device 210. Preferably, a plurality of preassembled cable reinforcement retainer assemblies 108 with their corresponding cables 18 are inserted into the inner housing 14 until a click or the like is heard, in which case the back cover 20 is slid along the cables 18 through the central opening 40 and into the outer housing 5 until a click or the like is heard again once the back cover 20 is secured within the outer housing 5. At this point, the partially assembled connector 1 is as shown. Figure 2A Thereafter, the braided shield 22 is mounted on the outer housing 5 , and the clamp 25 is slid downward toward the bottom of the braided shield 22 and placed on the braided shield 22 , providing conductive contact between the braided shield 22 and the outer housing 5 .

[0054] More specifically, when the inner housing 14 is inserted into the central opening 40 of the outer housing 5, the inner housing 14 is lowered toward the bottom end 45 of the base 32 of the outer housing 5, and the downward extending member 83 of the inner housing 14 enters (or slides into) the bottom opening or hole 50 of the outer housing 5. Then, the bottom surface 92 of the rear extension member 87 of the inner housing 14 is mounted to the bottom end 45 of the outer housing 5 (see Figure 3A and Figure 6 ) on. Substantially thereafter, the upper portion 201 of the flexible latch member 200 on the opposite side of the inner housing 14 (see Figure 8 ) respectively into the recessed portions 99 on the opposite inner sides of the outer shell 5 (see Figure 6 ), at which time, a click sound or the like is heard. The click sound or the like therefore indicates that the inner housing 14 is securely mounted in the outer housing 5. The inner housing 14 (preferably made of nylon or the like) provides isolation between the conductive parts (for example, the outer housing 5 made of metal-injected plastic or the like and the cable terminal 107 fixed in the inner housing 14).

[0055] Thereafter, preferably, a plurality of preassembled cable reinforcement retainer assemblies 108 (see Figure 10 ) so that its accompanying cable 18 is inserted into the corresponding circular assembly silicone seal 165 of the corresponding circular hole 162 of the back cover 20.

[0056] The preferably preassembled cable reinforcement retainer assembly 108 is then lowered toward the central opening 40 of the outer housing 5. With the first side portions 125 of the clamp 105 facing the front portion 70 of the inner housing 14, respectively, the cable reinforcement retainer assembly 108 is lowered through the central opening 40 of the outer housing 5 and subsequently through the upper notches 188, 189, 190 (see FIG. Figure 8 ), but not exceeding the notches 88, 89, 90 of the bottom end 85 of the inner shell 14 (see Figure 7B The cable reinforcement retainer assembly 108 travels downward through the upper notches 188, 189, 190 of the inner housing 14, respectively, and while traveling downward, the clamp 105 pushes the flexible members 75, 76, 77, respectively (see FIG. Figure 8 ) of the inclined shoulder 103 until each upper end 128 of each clamp 105 (see Figure 10 ) are located in the inner shell 14 (see Figure 8 ) below one of the inclined shoulders 103; immediately, a click, etc. is heard, which indicates that the clamp 105 and therefore the cable reinforcing retainer assembly 108 is securely fastened within the inner housing 14.

[0057] Thereafter, the rear cover 20 is slid downwardly along the cable 18 toward the outer housing 5 and through its central opening 40 until the inclined protruding members 175 (see FIG. Figure 13A and Figure 13B ) respectively into the holes 42 passing through the upper portion of the outer shell 5 (see Figure 3A and Figure 3B ), a click sound or the like is heard, indicating that the rear cover 20 has been securely fastened to the outer housing 5, and the cable reinforcement retainer assembly 108 is similarly completely fixed within the outer housing 5. In other words, the rear cover 20 pushes the inner housing 14 into place and ensures that the inner housing 14 is properly positioned in the outer housing 5.

[0058] like Figure 15 As shown, the vertical high-voltage connector 1 of the present invention is mounted to a device 210 (e.g., an automobile transmission, etc.) using bolts 12. The downwardly extending member 83 of the inner housing 14 is shown to have passed through the bottom opening or hole 50 of the bottom end 45 of the base 32 of the outer housing 5 and through the overmolded silicone seal 7. The pad 48 of the bottom end 45 of the base 32 of the outer housing 5 is shown to be within the elongated notch 51 of the overmolded silicone seal 7.

[0059] Figure 15 It is further illustrated that the cable reinforcement retainer assembly 108 has an associated clamp 105 located on the inner surface of the bottom end 85 of the inner housing 14 , and the bottom surface 92 of the rear extension member 87 of the inner housing is mounted to the bottom end 45 of the outer housing 5 .

[0060] exist Figure 15 Also shown is a wedge or collision mechanism A for securing the cable 18 within the inner housing 14. More specifically, as the back cover 20 slides down along the cable 18 through the central opening 40 and into the outer housing 5, the substantially semicircular tubular member 148 (see FIG. Figure 12A ) of the front portion 149 respectively squeeze or hit the side portion 111 of the end portion 110 of the end terminal 107 of the cable reinforcement retainer assembly 108 (see Figure 11B ), thereby fixing the cable 18 in the inner housing 14. Figure 16 As shown, the ends of the flexible members 119, 121 of the terminal 107 extending to the outside of the clamp 105 (see, for example, Figure 10 ) is connected to a set of terminals 220 of the associated device 210.

[0061] Thereafter, in order to shield the exposed cables 18, the braided shield 22 is lowered toward the outer housing assembly 3, whereby the lower portion of the braided shield 22 passes over the outer shoulders 98a, 98b extending from the upper portion of the outer housing 3 (see FIG. Figure 6 The clamp 25 then slides along the braided shield 22 past the external shoulders 98a, 98b and approximately below the external shoulders 98a, 98b, the clamp 25 connects the braided shield 22 to the outer housing 5 and secures the connection.

[0062] When fully assembled, the vertical high-voltage connector 1 of the present invention includes a grounding system that provides connection between the connector 1 and the associated aluminum device 210 by establishing contact between the metal-injected conductive plastic outer housing 5, the aluminum compression limiter 28, the stainless steel bolt 12, and the associated aluminum device 210. EMI is significantly reduced or eliminated by shielding the braided shield 22 along the path of the cable 18, or by diverting EMI from the braided shield 22 to the metal-injected pad 48 that contacts the associated aluminum device 210 for EMI grounding. Specifically, EMI is diverted from the stainless steel braided shield 22, which is connected to the metal-injected plastic outer housing 5 via the stainless steel clamp 25, to the metal-injected plastic outer housing 5 mounted to, for example, an aluminum automotive transmission 210. The present invention further provides galvanic corrosion protection by shielding the metal-injected conductive plastic outer housing 5 and the associated aluminum device 210 from electrolytic fluids using the base 52 of the non-conductive overmolded silicone seal 7. Electrochemical corrosion is further prevented by shielding the metal-infused conductive plastic outer housing 5 and the aluminum compression limiter 28 from the electrolytic fluid and further shielding the stainless steel bolts 12 and associated aluminum fittings 210 from the electrolytic fluid.

[0063] The present invention is not limited to the above-described embodiments; and various modifications in design, structural arrangement, etc. may be used without departing from the scope or equivalents of the present invention.

Claims

1. A high voltage connector, characterized in that: an external housing mounted to the device; an inner housing fixed within the outer housing, having a substantially L-shape and including a downward extending member and a rear extending member, wherein the downward extending member passes through a bottom opening of a bottom end portion of the outer housing, and a bottom surface of the rear extending member is mounted to the bottom end portion of the outer housing; a set of cable strength retainer assemblies fully secured within the outer housing by the inner housing, the set of cable strength retainer assemblies having respective cable terminals and cables attached to the cable terminals; a rear cover, the cables respectively sliding along and through the rear cover and covering the central opening of the outer housing, wherein the protruding members of the rear cover respectively enter the holes of the outer housing, wherein the rear cover contacts and locks to the outer housing, and wherein the outer housing locks the rear cover; a braided shield covering the cable and mounted to the outer housing; and a clamp mounted to a lower portion of the braided shield to connect the lower portion of the braided shield to the outer shell, wherein when the cable reinforcement retainer assembly is secured within the inner housing together with the corresponding cable attached thereto, the ends of the substantially semicircular tubular member extending from the lower portion of the rear cover respectively squeeze or impact the end terminals of the cable reinforcement retainer assembly, and the rear cover is configured to push the inner housing into place.

2. The high voltage connector according to claim 1, wherein: The outer housing includes an overmolded silicone seal to which the base of the outer housing is mounted.

3. The high voltage connector according to claim 1, characterized in that The inner housing includes a slot through which the set of cable strength retainer assemblies are received.

4. The high voltage connector according to claim 3, characterized in that The inner housing is generally in an inverted L-shape when secured within the outer housing.

5. The high voltage connector according to claim 1, characterized in that: Each of the cable reinforcement retainer assemblies includes a clamp or retainer mounted to and surrounding an end terminal that is attached to a cable terminal.

6. The high voltage connector according to claim 1, characterized in that The rear cover includes an aperture for receiving the cable attached to the cable reinforcement retainer assembly therein.

7. The high voltage connector according to claim 6, characterized in that: The rear cover includes an upper portion and a bottom portion, the upper portion having a tubular member extending therefrom, and the lower portion having a substantially semicircular tubular member extending therefrom, and wherein the hole of the tubular member and the hole of the substantially semicircular tubular member are communicated with the hole of the rear cover to respectively accommodate the cables therein.

8. The high voltage connector according to claim 7, characterized in that: The back cover is a terminal position assurance (TPA) device for ensuring that the cable terminal and the cable are securely positioned within the inner housing and the outer housing.

9. The high voltage connector according to claim 1, characterized in that: The outer housing is mounted to the device using steel bolts and aluminum compression limiters that each pass through a side portion extending from the base of the outer housing.

10. The high voltage connector according to claim 9, characterized in that The outer housing is made of metal-injected plastic or the like.

11. The high voltage connector according to claim 9, characterized in that The outer shell is made of nylon with stainless steel fibers.

12. The high voltage connector according to claim 9, characterized in that The inner shell is made of nylon or the like.

13. The high voltage connector according to claim 9, characterized in that The device is made of aluminum.

14. The high voltage connector according to claim 13, characterized in that: Each of the braided shield and the clamp is made of stainless steel or the like.

15. A method for assembling a high voltage connector, It is characterized by the following steps: installing the outer housing onto the device; inserting the inner housing into the outer housing, wherein the inner housing has a substantially L-shape including a downward extending member and a rear extending member, wherein the downward extending member passes through a bottom opening of a bottom end portion of the outer housing, and a bottom surface of the rear extending member is mounted to the bottom end portion of the outer housing; inserting a set of cable strength retainer assemblies into the inner housing and fully securing the set of cable strength retainer assemblies within the inner housing, the cable strength retainer assemblies having respective cables attached thereto; Sliding the back cover along the cable, the back cover enters the outer housing and covers the central opening of the outer housing, the protruding members of the back cover respectively enter the holes of the outer housing, the back cover contacts the outer housing and is locked to the outer housing, wherein the step of the back cover entering the outer housing and covering the central opening of the outer housing includes the step of locking the back cover to the outer housing; providing a braided shield to cover the cable, the braided shield being mounted to the outer housing; as well as securing the braided shield to the outer housing using a clamp, securing the connection between the braided shield and the outer housing by means of the clamp, The step of sliding the rear cover along the cable and entering and covering the central opening of the outer shell includes the following steps: causing at least a portion of a substantially semicircular tubular member extending from a lower portion of the rear cover to press or impact at least a side portion of an end terminal of at least a corresponding one of a set of cable reinforcement retainer assemblies, thereby fixing the cable terminal and the cable in the inner shell fixed in the outer shell; and pushing the inner shell into place using the rear cover.

16. The method for assembling a high voltage connector according to claim 15, wherein: The step of inserting the inner housing into the outer housing includes the steps of securing the inner housing within the outer housing by respectively entering recesses on opposite inner sides of the outer housing with flexible latch members on opposite sides of the inner housing and generating a first click sound or the like.

17. The method for assembling a high voltage connector according to claim 16, wherein: The step of inserting the set of cable strengthening retainer assemblies includes the steps of securing the cable strengthening retainer assembly within the inner housing by placing a clamp of at least one of the cable strengthening retainer assemblies under a corresponding one of the inclined shoulders of the inner housing and generating a second click, etc.

18. The method for assembling a high voltage connector according to claim 17, wherein: The step of sliding the back cover along the cable and into and covering the central opening of the outer housing includes the steps of: inclined protruding members at opposite sides of the back cover respectively entering holes through the sides of the outer housing and producing a third click sound, etc.

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