Bolt position guaranteeing device for power harness connector

Abstract

A power harness connector (200) includes a housing (230) having a chamber (232) and a hub (250) having a bore (252) through the housing. The power harness connector includes a power contact received in the chamber and a power conductor extending from the power contact and the housing. The power harness connector includes a threaded bolt (300) received in the hub and passing through the aperture and an opening (282) in the power contact, the opening (282) configured to be threadably connectable to a mating threaded connector (500) of a mating harness connector (400). The power harness connector includes a bolt position assurance device (340) coupled to the hub and movable between a pre-stage position and an assurance position. When in the assurance position, the bolt position assurance device ensures that the threaded bolt is positioned to the tightening position in the hub.

Description

[0001] Cross-reference to related applications

[0002] This application claims the benefit of U.S. Application No. 63 / 678,190, filed August 1, 2024, the subject of which is incorporated herein by reference in its entirety. Technical Field

[0003] This article mainly deals with electrical connectors. Background Technology

[0004] Electrical connectors are used to electrically connect various electrical components, such as transferring power from one component to another. For example, in electric vehicles, electrical connectors can be used to connect the vehicle's battery to another component, such as the vehicle's electric motor. Some known systems use power cables or busbars for high-voltage power transmission. However, connecting power cables can be difficult. For example, when used in electric vehicles, connections are susceptible to vibration and degradation from the environment, such as moisture or debris. Additionally, connectors consist of many parts, making assembly time-consuming, and parts may be misplaced or lost during assembly or mating. Some electrical connectors can be connected by bolts. Bolts need to be tightened to a predetermined torque for a proper connection. Insufficient tightening can lead to a poor connection or cause the bolts to loosen over time, for example, due to vibration.

[0005] A robust and reliable electrical connector system is still needed, for example, for electric vehicles. Summary of the Invention

[0006] In one embodiment, a power harness connector is provided, including a housing having a chamber extending between a terminating end and a mating end configured to mate with a mating harness connector. The housing includes a hub at the mating end having a hole through the housing. The power harness connector includes a power conductor extending from the chamber at the terminating end. The power harness connector includes a power contact received in the chamber. The power contact has a terminating end terminating to the power conductor and a mating end aligned with the hole at the mating end of the housing. The power contact includes a base plate with an opening. The power harness connector includes a threaded bolt received in the hub and passing through the hole. The threaded bolt passes through the opening. The threaded bolt is configured to be threadedly engaged to a mating threaded connector of the mating harness connector to reach a tightened position. The power harness connector includes a bolt position guaranteeing device coupled to the hub and movable between a pre-stage position and a guaranteed position. The bolt position guaranteeing device guarantees that the threaded bolt is positioned in the hub in the tightened position of the guaranteed position. Attached Figure Description

[0007] The invention will now be described by way of example with reference to the accompanying drawings, in which:

[0008] Figure 1 This is a top perspective view of a power system with power harnesses according to an exemplary embodiment, showing the components in an assembled state.

[0009] Figure 2 This is a top perspective view of an electric system according to an exemplary embodiment, showing components of an electric harness in a pre-assembled state and ready to be connected together.

[0010] Figure 3 This is a cross-sectional view of a power line harness according to an exemplary embodiment.

[0011] Figure 4 It is a cross-sectional view of the power system, showing the initial mating of the first and second wire harness connectors in a pre-stage position, and showing the threaded connectors not mating.

[0012] Figure 5 This is a cross-sectional view of an electric system according to an exemplary embodiment, showing a first wire harness connector mating with a second wire harness connector, a threaded connector in a mating state, and a bolt position guarantee device in a pre-stage position.

[0013] Figure 6 This is a cross-sectional view of a power system according to an exemplary embodiment, showing a first wire harness connector that mates with a second wire harness connector, a threaded connector in a mating state, and a bolt position guarantee device in a guaranteed position. Detailed Implementation

[0014] Figure 1 This is a top perspective view of a power system 100 having a power harness 102 according to an exemplary embodiment, showing the components in an assembled state. Figure 2 This is a top perspective view of the power system 100, showing components of a power harness in a pre-assembled state, ready to be connected together. The power harness 102 includes power connectors for electrically connecting a first component 104 and a second component 106. For example, the power harness 102 includes a first harness connector 200 and a second harness connector 400.

[0015] The first wire harness connector 200 is a cable connector disposed at the end of one or more power cables 202 (e.g., two power cables 202 in the illustrated embodiment). The second wire harness connector 400 may be additionally or alternatively disposed at the end of a power cable (not shown). For example, the second wire harness connector 400 may be a cable connector disposed at the end of one or more power cables 402 (e.g., two power cables 402 in the illustrated embodiment). In alternative embodiments, the second wire harness connector 400 may be connected to different types of power conductors, such as to busbars or power terminals, for example, associated with the second component 106.

[0016] In the illustrated embodiment, the second wiring harness connector 400 is a header connector configured to be mounted to components, such as directly to electrical component 106 or to a chassis, frame, wall, panel, or other support structure. The first wiring harness connector 200 is a plug connector configured to be inserted into the second wiring harness connector 400 (e.g., a header connector) to electrically connect components 104, 106. The wiring harness connectors 200, 400 provide a separable interface in the power line between the first component 104 and the second component 106.

[0017] In various embodiments, the power system 100 may be part of a vehicle, such as an electric vehicle. The first component 104 may be the vehicle's battery, and the second component 106 may be the vehicle's power unit, such as an inverter or motor, or a vehicle subsystem, such as a charging inlet, heater, compressor, or another vehicle subsystem. In alternative embodiments, the power system 100 may be used in applications other than electric vehicles.

[0018] In an exemplary embodiment, the first wire harness connector 200 and the second wire harness connector 400 are mechanically connected using threaded components, such as bolts received in threaded inserts, to connect the first wire harness connector 200 and the second wire harness connector 400. In an exemplary embodiment, the wire harness connectors 200, 400 are compact or low-profile, for example, occupying no much more space (e.g., height and / or width and / or length) than the corresponding power cable 202.

[0019] In an exemplary embodiment, wire harness connectors 200 and 400 are sealed connectors forming a sealed interface therebetween. The first wire harness connector 200 is sealed to a power cable 202. The second wire harness connector 400 may be sealed to a power cable 402. The second wire harness connector 400 may be sealed to a mounting structure, such as to component 106. The wire harness connectors 200 and 400 are sealed to each other at their mating interfaces using environmental seals. Threaded fasteners may additionally seal within the wire harness connectors 200 and 400.

[0020] In an exemplary embodiment, wire harness connectors 200 and 400 are touch-safe, wherein any and all live conductive elements are insulated to prevent short circuits, sparks, arcs, or injury caused by touching live elements. Wire harness connectors 200 and 400 are touch-safe in both mated and unmated states.

[0021] In exemplary embodiments, wire harness connectors 200 and 400 are vibration-resistant to maintain a reliable electrical connection along the power line. For example, the first wire harness connector 200 and / or the second wire harness connector 400 may include position assurance devices for the corresponding threaded connectors. For example, the first wire harness connector 200 may include a bolt position assurance device 340 configured to provide position assurance for the threaded bolt (e.g., assurance that the bolt is in a tightened position). The bolt position assurance device 340 may be configured to ensure the bolt is at a predetermined torque. For example, the bolt position assurance device 340 may move to the assurance position only when the threaded bolt is at a predetermined position corresponding to the predetermined torque (e.g., tightened down a predetermined amount relative to the mating threaded insert).

[0022] In exemplary embodiments, wire harness connectors 200, 400 can mate relative to each other in various orientations. For example, power cable 202 can extend away from the connection at different angles (e.g., 180°, 90°, or other angles). Although in Figure 1 and Figure 2 A single interface is shown, but the wire harness connectors 200 and 400 may have multiple interfaces.

[0023] Figure 3 This is a cross-sectional view of the power line harness 102 according to an exemplary embodiment. Figure 3 A first wire harness connector 200 and a second wire harness connector are shown in an unfitted state. The first wire harness connector 200 includes a power conductor 204, a housing 230, a power contact 270, a threaded bolt 300, and a bolt position retention device 340. In the illustrated embodiment, the power conductor 204 is a power cable 202. However, in alternative embodiments, the power conductor 204 may be a busbar, a power terminal, or another type of power conductor.

[0024] Housing 230 receives power cable 202, power contact 270, threaded bolt 300, and bolt position retention device 340. Housing 230 is configured to connect with second wire harness connector 400. Figure 1(As shown in the diagram). Threaded bolt 300 is used to mechanically connect the first wire harness connector 200 to the second wire harness connector 400. Power contact 270 is used to electrically connect the power cable 202 to the second wire harness connector 400. Bolt position guarantee device 340 is configured to provide position guarantee for threaded bolt 300 (e.g., guaranteeing that threaded bolt 300 is in the tightened position during assembly).

[0025] In an exemplary embodiment, the power cable 202 is a shielded and sheathed cable. The power cable 202 may be a solid cable or a stranded or braided cable. The power cable 202 includes a central power conductor 204 and an insulation or sheath 206 surrounding the conductor 204. The power cable 202 may include a cable shield and / or an outer sheath surrounding the insulator 206. The insulator 206 is made of a dielectric or other insulating material to make the power cable 202 safe to touch. The power conductor 204 may be made of aluminum, copper, or an alloy thereof. The power conductor 204 is exposed at the termination end of the power cable 202 for connection to the power contact 270. In the illustrated embodiment, the power cable 202 is a circular power cable. However, in alternative embodiments, the cross-section of the power cable 202 may be generally rectangular, such as having a generally planar top and bottom surface. In alternative embodiments, the power conductor 204 may be a busbar, a metal plate, a terminal, or other structure instead of a power cable.

[0026] In an exemplary embodiment, a cable seal 212 is disposed around a power cable 202. The cable seal 212 may seal to a cable sheath 210. The cable seal 212 is configured to seal against a housing 230. In various embodiments, the cable seal 212 may be made of a rubber material. Optionally, multiple cable seals 212 may be used to seal to various components.

[0027] In an exemplary embodiment, a cable seal retainer 214 is disposed at the end of the power cable 202 and configured to be coupled to the housing 230. The cable seal retainer 214 can be secured to the housing 230 by latches, clips, fasteners, or other fixing elements. The cable seal retainer 214 can provide strain relief for the power cable 202. The cable seal retainer 214 can retain or support the cable seal 212. The cable seal retainer 214 covers openings in the housing 230 to prevent the impact of moisture, such as from high-pressure spray.

[0028] The housing 230 is made of a dielectric material, such as a plastic material. Optionally, the housing 230 may be an injection-molded part. In various embodiments, the housing 230 is a multi-piece housing. For example, the housing 230 may have an inner housing and an outer housing. The housing 230 may be a clamshell-type housing with an upper housing and a lower housing.

[0029] Housing 230 includes walls forming a chamber 232 that receives a power cable 202, a power contact 270, and a threaded bolt 300. In an exemplary embodiment, housing 230 includes a top 234 and a bottom 236. Housing 230 includes a side 238 extending between a front portion 240 and a rear portion 242. Housing 230 includes a cable opening 244 at the rear portion 242, providing an entrance to the chamber 232. The power cable 202 is received in the cable opening 244. In various embodiments, the cable opening 244 may be oriented generally horizontally. A cable seal retainer 214 may be inserted into the cable opening 244 and coupled to housing 230 at the rear portion 242. A cable seal 212 may seal to the inner surface of housing 230 at the cable opening 244.

[0030] In an exemplary embodiment, housing 230 includes a contact channel 246 in chamber 232 that receives an electrical contact 270. The contact channel 246 is aligned with a cable opening 244 to receive the electrical contact 270 having an electrical cable 202 from the cable opening 244. The contact channel 246 can receive the electrical contact 270 in a rear-to-forward loading direction when the electrical contact 270 is loaded from the rear portion 242 into housing 230. In the illustrated embodiment, the contact channel 246 is located at the front portion 240. Housing 230 includes a wall 248 defining the contact channel 246. The wall 248 may form slots defining the contact channel 246, such as one or more horizontal slots and / or one or more vertical slots.

[0031] In an exemplary embodiment, housing 230 includes a hub 250 having a bore 252 passing through it. The bore 252 opens into and defines a portion of chamber 232. In the illustrated embodiment, the hub 250 is located at the front portion 240 of housing 230. The hub 250 is aligned with contact channel 246 and power contact 270. A bolt position guarantee device 340 is configured to be coupled to the hub 250. In various embodiments, the hub 250 is generally cylindrical. However, in alternative embodiments, the hub 250 may have other shapes. The bore 252 passes through housing 230, for example, along a vertical axis between top 234 and bottom 236. In an exemplary embodiment, power contact 270 is positioned in housing 230 aligned with bore 252, for example, along a vertical axis, to receive threaded bolt 300. The bore 252 includes an upper opening 254 and a lower opening 256. Threaded bolt 300 is received in hub 250 and passes through bore 252. For example, a threaded bolt 300 may pass through an upper opening 254 and / or a lower opening 256. In an exemplary embodiment, a contact channel 246 is aligned with a hub 250. When loaded into the contact channel 246, an electrical contact 270 is received in the hub 250.

[0032] The power contact 270 is a metallic conductor, such as an aluminum or copper conductor. In various embodiments, the power contact 270 may be an extruded metal contact. Alternatively, the power contact 270 may be hot-forged or stamped. In various embodiments, the power contact 270 may be electroplated or coated. The power contact 270 may include a textured or knurled surface at the mating interface to improve electrical contact.

[0033] A power contact 270 extends between a termination end 272 and a mating end 274. The termination end 272 is configured to terminate to a power conductor 204 of a power cable 202. The mating end 274 is configured, for example, to be electrically connected via a terminal to a corresponding power contact of a second wiring harness connector 400. In an exemplary embodiment, the power contact 270 includes a solder pad 276 at the termination end 272. The power conductor 204 is soldered to the solder pad 276 at the termination end 272. In alternative embodiments, other types of terminals may be used, such as crimp sleeves crimped to the power conductor 204. The power contact 270 may be a multi-piece component, for example having a termination end 272 separate from and coupled to the mating end 274. For example, the components may be crimped or soldered together.

[0034] The power contact 270 includes a base plate 280 at a mating end 274. The base plate 280 may be planar. In various embodiments, the base plate 280 may be horizontally oriented. The base plate 280 includes an opening 282 therethrough, which may be substantially centered between the front and rear portions and / or between opposite sides of the base plate 280. The base plate 280 may define a solder pad 276, for example, to allow a cable to be soldered to the bottom of the base plate 280, such as through resistance welding. The opening 282 may penetrate the base plate 280 and the conductor of the cable.

[0035] In an exemplary embodiment, the power contact 270 includes a terminal 290 extending from a base plate 280. The terminal 290 is aligned with an opening 282 to receive a threaded bolt 300. The terminal 290 may be tubular and surround the threaded connector 500 and / or the threaded bolt 300. The terminal 290 may be press-fitted into the opening 282 and / or welded to the base plate 280. The terminal 290 is configured to engage with a corresponding terminal or base plate of a second wiring harness connector 400 to form an electrical path between the first wiring harness connector 200 and the second wiring harness connector 400. The surface area of ​​the edge of the terminal 290 can control the electrical charge or current carrying capacity of the power contact 270.

[0036] The threaded bolt 300 is a threaded connector configured to be threadedly connected to a corresponding threaded connector of the second wire harness connector 400. The threaded bolt 300 includes a head 302 and a threaded shaft 304 extending from the head 302. The threaded shaft 304 includes threads at its distal end 308. In an exemplary embodiment, the threaded bolt 300 is touch-safe. For example, the threaded bolt 300 includes an insulating cap 310 on the head 302 and an insulating cap 320 extending from the distal end 308 of the threaded shaft 304.

[0037] An insulating cap 310 may be molded over the head 302. Alternatively, the insulating cap 310 may be pre-formed and snap-fit, press-fit, adhered, or otherwise secured to the head 302. The insulating cap 310 covers the head 302 to prevent contact with the metal or conductive portion of the threaded bolt 300. In an exemplary embodiment, the insulating cap 310 includes a drive feature 312 for driving or rotating the threaded bolt 300. For example, the drive feature 312 may be a flat surface at the top of the insulating cap 310 that allows a socket wrench or other tool to rotate the threaded bolt 300 clockwise or counterclockwise to tighten or loosen the threaded bolt 300 during assembly with the second wiring harness connector 400. In alternative embodiments, other types of drive features may be used, such as one or more slots, to receive a screwdriver or other types of tools for tightening and loosening the threaded bolt 300.

[0038] The insulating cap 320 may be molded over the threaded shaft 304. Alternatively, the insulating cap 320 may be pre-formed and snap-fitted, press-fitted, adhered, or otherwise secured to the distal end 308 of the threaded shaft 304. The insulating cap 320 covers the threaded shaft 304 to prevent contact with the metal or conductive parts of the threaded bolt 300.

[0039] In an exemplary embodiment, the first wire harness connector 200 includes a bolt seal 330 for sealing between a threaded bolt 300 and a housing 230. In the illustrated embodiment, the bolt seal 330 is coupled to an insulating cap 310 at the head 302 of the threaded bolt 300. The outer surface of the bolt seal 330 is configured to seal to the housing 230, such as to the hub 250, when the threaded bolt 300 is received in the hub 250. For example, the bolt seal 330 may have a diameter equal to the diameter of the hub 250 at the upper opening 254.

[0040] In an exemplary embodiment, the bolt position securing device 340 is coupled to the hub 250, for example, at the top. The bolt position securing device 340 is located above the head 302 of the threaded bolt 300. The bolt position securing device 340 may define a bolt retainer to hold the threaded bolt 300 in the hub 250 of the housing 230. The bolt position securing device 340 is coupled to the housing 230 on the outside of the threaded bolt 300 (e.g., above the head 302 and the insulating cap 310).

[0041] The bolt position guarantee device 340 includes a latching element 342 configured to be latchably coupled to the hub 250 to secure the bolt position guarantee device 340 to the hub 250. For example, the hub 250 includes a latching element 262 configured to engage with the latching element 342 to hold the bolt position guarantee device 340 in one or more predetermined positions (e.g., a pre-stage position and a guaranteed position). The latching element 342 may be a deflectable latch, a catch, a pawl, or other type of latching element. In an exemplary embodiment, the bolt position guarantee device 340 includes an opening 344 to provide passage to the threaded bolt 300, for example for engaging a drive feature 312 to rotate the threaded bolt 300. However, in an alternative embodiment, the bolt position guarantee device 340 may be closed to prevent access to the threaded bolt 300.

[0042] In an exemplary embodiment, the bolt position securing device 340 includes an inner wall 350 and an outer wall 352, with a recess 354 between the inner wall 350 and the outer wall 352. The inner wall 350 and the outer wall 352 may be circumferential walls extending around the bolt position securing device 340. The recess 354 may be a circumferential groove located between the inner wall 350 and the outer wall 352. The inner wall 350 extends along the interior of the hub 250. The outer wall 352 extends along the exterior of the hub 250. In an exemplary embodiment, the outer wall 352 includes a latching element 342 to engage with a latching element 262 of the hub 250 to position the bolt position securing device 340 on the hub 250. The latching element 262 may be a deflectable latch, a catch, a pawl, or other type of latching element.

[0043] In an exemplary embodiment, the inner wall 350 includes a bottom edge 356 facing the threaded bolt 300. The bottom edge 356 is configured to abut the threaded bolt 300. For example, the threaded bolt 300 may press upward against the bottom edge 356 and / or the bottom edge 356 may press downward against the threaded bolt 300. In an exemplary embodiment, the bottom edge 356 defines a retaining feature to retain the threaded bolt 300 within the housing 230. The bottom edge 356 is configured to be positioned above the head 302 and the insulating cap 310 to prevent the threaded bolt 300 from being removed through the opening 344. Other types of retaining features may be used in alternative embodiments.

[0044] In an exemplary embodiment, the first wiring harness connector 200 includes a mating seal 360 that engages with the housing 230 at a mating end 260. In the illustrated embodiment, the mating end 260 is located at a bottom 236. The mating end 260 is located at a lower opening 256 of the hub 250. The mating end 260 is configured to mate with a second wiring harness connector 400. In an exemplary embodiment, the housing 230 includes a recess 258 surrounding the lower opening 256 at the bottom 236. The mating seal 360 is located in the recess 258. Optionally, the recess 258 may receive a portion of the housing of the second wiring harness connector 400 to seal the mating seal 360 in the recess 258. In an alternative embodiment, the mating seal 360 may be located at the bottom and face downward to abut against the housing of the second wiring harness connector 400.

[0045] The second wire harness connector 400 includes a power conductor 404, a housing 430, one or more power contacts 470, and one or more threaded connectors 500. The second wire harness connector 400 may include a pair of power contacts 470 and corresponding threaded connectors 500 held within the same housing 430. In alternative embodiments, more or fewer power contacts 470 and threaded connectors 500 may be provided. In an exemplary embodiment, the power conductor 404 is a power cable 402. However, in alternative embodiments, the power conductor 404 may be a busbar, a power terminal, or another type of power conductor.

[0046] In an exemplary embodiment, power cable 402 is a shielded and sheathed cable. Power cable 402 may be a solid cable or a stranded or braided cable. Power cable 402 includes a central power conductor 404 and an insulation or sheath 406 surrounding the conductor 404. Power cable 402 may include a cable shield surrounding the insulation and an outer sheath surrounding the insulation 406. Insulation 406 is made of a dielectric or other insulating material to make power cable 402 safe to touch. Power conductor 404 may be made of aluminum, copper, or alloys thereof. Power conductor 404 is exposed at the termination end of power cable 402 for connection to power contact 470. In the illustrated embodiment, power cable 402 is a circular power cable. However, in alternative embodiments, the cross-section of power cable 402 may be generally rectangular, such as having a generally planar top and bottom surface. In alternative embodiments, power conductor 404 may be a busbar, metal plate, terminal, or other structure instead of a power cable.

[0047] In an exemplary embodiment, a cable seal 412 is provided around a power cable 402. The cable seal 412 may seal to a cable sheath 410. The cable seal 412 is configured to seal against a housing 430. In various embodiments, the cable seal 412 may be made of rubber material. Optionally, multiple cable seals 412 may be used to seal to various components.

[0048] In an exemplary embodiment, a cable seal retainer 414 is disposed at the end of the power cable 402 and configured to be coupled to the housing 430. The cable seal retainer 414 can be secured to the housing 430 by latches, clips, fasteners, or other fixing elements. The cable seal retainer 414 can provide strain relief for the power cable 402. The cable seal retainer 414 can retain or support the cable seal 412. The cable seal retainer 414 covers an opening in the housing 430 to prevent the impact of moisture, such as from high-pressure spray.

[0049] Housing 430 receives power cable 402, power contact 470, and threaded connector 500. Housing 430 is configured to connect with first wire harness connector 200 (in... Figure 2 (As shown in the diagram) A threaded connector 500 is used to mechanically connect the second wire harness connector 400 to the first wire harness connector 200. For example, the threaded connector 500 can be threaded onto a threaded bolt 300. A power contact 470 is used to electrically connect a power cable 402 to the first wire harness connector 200.

[0050] The housing 430 is made of a dielectric material, such as a plastic material. Optionally, the housing 430 may be an injection-molded part. In various embodiments, the housing 430 is a multi-piece housing. For example, the housing 430 may be a clamshell-type housing having an upper housing and a lower housing.

[0051] Housing 430 includes a protective wall 434 forming a chamber 432 that receives an electrical contact 470 and a threaded connector 500. The chamber 432 may receive an electrical conductor 402. In an exemplary embodiment, housing 430 includes a top 436 and a bottom 438. Housing 430 includes a side extending between a front portion 440 and a rear portion 442. Housing 430 includes a cable opening 444 at the rear portion 442, which provides access to the chamber 432. An electrical cable 402 is received in the cable opening 444. In various embodiments, the cable opening 444 may be oriented generally horizontally. A cable seal retainer 414 may be inserted into the cable opening 444 and coupled to housing 430 at the rear portion 442. A cable seal 412 may seal to the inner surface of housing 430 at the cable opening 444.

[0052] In an exemplary embodiment, housing 430 includes a contact channel 446 in chamber 432 that receives an electrical contact 470. The contact channel 446 is aligned with a cable opening 444 to receive the electrical contact 470 having a power cable 402 from the cable opening 444. The contact channel 446 can receive the electrical contact 470 in a rear-to-front loading direction when the electrical contact 470 is loaded into housing 430 from the rear portion 442. In the illustrated embodiment, the contact channel 446 is located at the front portion 440. Housing 430 includes a wall 448 defining the contact channel 446. The wall 448 may form slots defining the contact channel 446, such as one or more horizontal slots and / or one or more vertical slots.

[0053] In an exemplary embodiment, housing 430 includes a hub 450 having a bore 452 passing through it, the bore 452 receiving a corresponding threaded connector 500. The bore 452 passes through housing 430, for example, along a vertical axis between a top 436 and a bottom 438. In an exemplary embodiment, an electrical contact 470 is positioned in housing 430 aligned with the bore 452, for example, along a vertical axis, to receive the threaded connector 500 and / or a threaded bolt 300.

[0054] The power contact 470 is a metallic conductor, such as an aluminum or copper conductor. In various embodiments, the power contact 470 may be an extruded metal contact. Alternatively, the power contact 470 may be hot-forged or stamped. In various embodiments, the power contact 470 may be plated or coated.

[0055] A power contact 470 extends between a termination end 472 and a mating end 474. The termination end 472 is configured to terminate to a power conductor 404. The mating end 474 is configured to electrically connect, for example, via a terminal between power contacts 270, 470, to a corresponding power contact 270 of the first wire harness connector 200. The power contact 470 includes a solder pad 476 at the termination end 472. The power conductor 404 is soldered to the solder pad 476 at the termination end 472. In alternative embodiments, other types of terminals, such as crimp sleeves, may be used.

[0056] The power contact 470 includes a base plate 480 at a mating end 474. The base plate 480 may be planar. In various embodiments, the base plate 480 may be horizontally oriented. The base plate 480 includes an opening (not shown) therethrough, which may be substantially centered between the front and rear portions and / or between opposite sides of the base plate 480.

[0057] In an exemplary embodiment, the power contact 470 includes a terminal 490 extending from a base plate 480. The terminal 490 is aligned with an opening 482, for example, to receive a threaded connector 500. The terminal 490 may be tubular and surround the threaded connector 500 and / or threaded bolt 300. The terminal 490 may be press-fitted into the opening 482 and / or welded to the base plate 480. The terminal 490 is configured to engage with a terminal 290 to form an electrical path between a first wiring harness connector 200 and a second wiring harness connector 400. The surface area of ​​the edge of the terminal 490 can control the power amount or current carrying capacity of the power contact 470.

[0058] In an exemplary embodiment, the threaded connector 500 is a threaded insert. The threaded connector 500 includes a base 502 located at the bottom of the threaded connector 500. The base 502 is configured to engage with an electrical contact 470, such as an engagement with a base plate 480. The threaded connector 500 includes a threaded tube 504. The threaded tube 504 includes internal threads located within a hollow bore of the threaded tube 504. The threaded tube 504 extends to a distal end 508. In an exemplary embodiment, the threaded connector 500 is touch-safe. For example, the threaded connector 500 includes an insulating cap 520 at the distal end 508 of the threaded tube 504. The insulating cap 520 may be overmolded onto the threaded tube 504. Alternatively, the insulating cap 520 may be pre-formed and snap-fit, press-fit, adhered, or otherwise secured to the distal end 508 of the threaded tube 504. In an alternative embodiment, the insulating cap 520 may be coupled to a housing 430, for example, received in a hub 450. The insulating cap 520 can be threaded onto the hub 450 or secured with adhesive. The insulating cap 520 covers the threaded tube 504 to prevent contact with the metal or conductive parts of the threaded connector 500.

[0059] Figure 4 This is a cross-sectional view of the power system 100, showing the first wire harness connector 200 initially mating with the second wire harness connector 400, in a pre-stage position where the threaded connector is not mated. Figure 5 This is a cross-sectional view of the power system 100, showing the first wire harness connector 200 mating with the second wire harness connector 400, the threaded connector in the mating state, and the bolt position guarantee device 340 in the pre-stage position. Figure 6 This is a cross-sectional view of the power system 100, showing a first wire harness connector 200 that mates with a second wire harness connector 400, a threaded connector in a mated state, and a bolt position guarantee device 340 in a guaranteed position. The first wire harness connector 200 and the second wire harness connector 400 mate in a mating direction along a mating axis. The mating axis can be a vertical axis.

[0060] During mating, housings 230 and 430 are aligned with each other. When the first wiring harness connector 200 mates with the second wiring harness connector 400, the protective wall 434 aligns with and inserts into the recess 258. The protective wall 434 is used to align the threaded connector 300 (e.g., a threaded bolt) with the threaded connector 500 (e.g., a threaded insert). During mating, the threaded bolt 300 is inserted into the threaded connector 500. For example, the insulating cap 320 at the end of the threaded bolt 300 is inserted into the hollow hole of the threaded tube 504. When the threaded shaft 304 abuts against the threaded tube 504, the threaded bolt 300 is rotated to fasten the threaded bolt 300 to the threaded connector 500.

[0061] When mated, the power system 100 is touch-safe. An insulating cap 310 covers the top of the threaded bolt 300, preventing the metal or conductive portion of the threaded bolt 300 from contacting the outside of the first wiring harness connector 200. Housings 230, 430 cover or surround the electrical contacts 270, 470 and terminals 290, 490, preventing the metal or conductive portions of the electrical contacts 270, 470 or terminals 290, 490 from contacting the outside of the wiring harness connectors 200, 400. In an exemplary embodiment, the insulating cap 310 covers the top of the threaded bolt 300, making the first wiring harness connector 200 touch-safe. The portion of the threaded bolt 300 exposed outside the housing 230 is an insulating cap 320. The metal or conductive portion of the threaded bolt 300 is not exposed. Thus, the first wiring harness connector 200 is touch-safe in its unmated state. In the illustrated embodiment, the end of the threaded connector 500 may be recessed below or on the outside of the hub 450 to prevent unintentional contact due to metal exposure. Alternatively, a dielectric cap can be provided at the end to make the end touch safe. The metal or conductive parts of the threaded connector 500 are not exposed. In this way, the second wire harness connector 400 is touch safe in the unmated state.

[0062] During mating, the upper portion of the housing 430 of the second wiring harness connector 400 is inserted into the lower portion of the housing 230 of the first wiring harness connector 200. When mated, the power system 100 is sealed and isolated from the external environment. In the illustrated embodiment, the first wiring harness connector 200 carries a mating seal 360 to engage with the sheath wall 434 of the second wiring harness connector 400 during mating. Thus, a sealed interface is provided between the first wiring harness connector 200 and the second wiring harness connector 400. In an exemplary embodiment, other openings in the housings 230, 430 are sealed, for example, by bolt seals 330. In an exemplary embodiment, a component seal 560 is disposed at the bottom 438 of the housing 430. The component seal 560 is configured to seal to the second component 106.

[0063] Threaded bolt 300 and threaded connector 500 are used to mechanically connect first wire harness connector 200 to second wire harness connector 400. For example, the threaded shaft 304 of threaded bolt 300 is received in the hole of threaded tube 504 of threaded connector 500. Threaded bolt 300 is rotated to secure threaded shaft 304 in threaded tube 504. With the tightening of threaded bolt 300, first wire harness connector 200 is electrically connected to second wire harness connector 400. For example, the threaded connection between threaded bolt 300 and threaded connector 500 presses electrical contact 270 into electrical connection with electrical contact 470. For example, terminal 290 is pressed into terminal 490 such that terminals 290 and 490 mate at their edges to electrically connect electrical contacts 270 and 470. Threaded connectors 300 and 500 maintain the electrical connection between terminals 290 and 490 and electrical contacts 270 and 470. Therefore, an efficient power transmission path is created between the first wire harness connector 200 and the second wire harness connector 400. A compact, robust, sealed, vibration-resistant, and touch-safe electrical connection is formed between the first wire harness connector 200 and the second wire harness connector 400.

[0064] During mating, when the first wire harness connector 200 and the second wire harness connector 400 first mate (e.g., Figure 4 When in the pre-stage mating position (as shown), the threaded connector 500 presses the threaded bolt 300 upward to the raised position. The threaded bolt 300 can press against the bolt position securing device 340. The bolt position securing device 340 holds the threaded bolt 300 in the hub 250 and prevents the threaded bolt 300 from being removed from the chamber 232. The bolt position securing device 340 is secured in the pre-stage position by latching elements 262, 342. For example, latching element 262 may include a pre-stage latching element 264 near the top of the hub 250, and latching element 342 may include a pre-stage latching element 346 near the bottom of the outer wall 352 of the hub 340. Figure 2 Pre-stage latching elements 264 and 346 are shown engaging with each other. The pre-stage latching elements 264 and 346 engage with each other to hold the bolt position guaranteeing device 340 in the pre-stage position.

[0065] During assembly, threaded bolt 300 is tightened to the mating or tightened position. Figure 5 For example, threaded bolt 300 can be tightened to a predetermined torque to physically press terminals 290, 490 together in a mated state to electrically connect first and second wire harness connectors 200, 400. When tightened, threaded bolt 300 is pulled downwards toward threaded connector 500, for example, away from bolt position retention device 340. Due to the interaction of pre-stage latching elements 264, 346, bolt position retention device 340 is held in the pre-stage position (…). Figure 5Assembly is not yet complete at this point because the bolt position guarantee device 340 needs to be actuated to the guarantee position. Figure 6 ).

[0066] The bolt position guarantee device 340 operates as a visual indicator for the installer, indicating that the power harness 102 is correctly assembled. For example, when the bolt position guarantee device 340 is correctly positioned in the guaranteed position ( Figure 6 When the bolt 300 is tightened to a predetermined torque and seated low in the hub 250, the bolt position securing device 340 can move to the securing position. For example, the installer can press the bolt position securing device 340 downward toward the threaded bolt 300. The pre-stage latching element 346 of the bolt position securing device 340 is released from the pre-stage latching element 264 of the hub 250 to move to the securing position. The bolt position securing device 340 can be pressed downward until the bottom edge 356 of the inner wall 350 touches the threaded bolt 300 (e.g., against the insulating cap 310). In an exemplary embodiment, latching elements 262, 342 include securing latching elements 266, 348 (e.g., different from the pre-stage latching elements 264, 346) that are different from the pre-stage latching elements 264, 346. Figure 1 and Figure 2 (as shown) Figure 1 The retaining latch elements 266 and 348 are shown engaging with each other. The retaining latch element 266 may be located near the bottom of the hub 250 (e.g., a distance further from the top edge of the hub than the pre-stage latch element 264). The bolt position retaining device 340 includes a retaining latch element 348 near the bottom of the outer wall 352 of the hub 340. The retaining latch elements 266 and 348 engage with each other to hold the bolt position retaining device 340 in the retaining position. In the retaining position ( Figure 6 In this configuration, the bolt position assurance device 340 provides the installer with a visual assurance that the threaded bolt 300 is properly tightened (e.g., to a predetermined torque). For example, if the threaded bolt 300 is only partially tightened and therefore not fully in place, but rather in an elevated position, the bolt position assurance device 340 will not be able to move to the assured position, and the assurance latching elements 266, 348 will not engage. The bolt position assurance device 340 will become loose on the hub 250 instead of being secured by the assurance latching elements 266, 348. The installer will then realize the incorrect installation and will need to further tighten the threaded bolt 300 to the predetermined torque.

Claims

1. A power harness connector (200), comprising: A housing (230) having a cavity (232) extending between an end-connecting end and a mating end (260), the mating end being configured to mate with a mating wire harness connector (400), the housing including a hub (250) at the mating end, the hub having a hole (252) through the housing. An electrical conductor (204) extends from the chamber at the termination end; An electrical contact (270) is received in the chamber, the electrical contact having an end (272) connected to the electrical conductor and a mating end (274) aligned with a hole at a mating end of the housing, the electrical contact including a base plate (280) having an opening (282). A threaded bolt (300), received in the hub and passing through the hole, the threaded bolt passing through the opening, the threaded bolt being configured to be threadably connected to a mating threaded connector (500) of the mating wire harness connector to a tightened position; and A bolt position guaranteeing device (340) is connected to the hub and is movable between a pre-stage position and a guaranteed position, the bolt position guaranteeing device guaranteeing that the threaded bolt is positioned in the hub at the tightened position in the guaranteed position.

2. The power harness connector (200) according to claim 1, wherein the bolt position guaranteeing device (340) is configured to move to the guaranteeing position when the threaded bolt (300) is in the tightened position.

3. The power harness connector (200) according to claim 1, wherein the threaded bolt (300) is tightened to a predetermined torque in the tightened position, and the bolt position guaranteeing device (340) is only able to move to the guaranteeing position when the threaded bolt is in the tightened position.

4. The power harness connector (200) according to claim 1, wherein the housing (230) includes a pre-stage latch and a guarantee latch, the bolt position guarantee device (340) being coupled to the pre-stage latch at the pre-stage position and the bolt position guarantee device being coupled to the guarantee latch at the guarantee position.

5. The power harness connector (200) according to claim 1, wherein when tightened to the threaded position, the threaded bolt (300) is movable toward the mating threaded connector (500) in the tightening direction, and the bolt position guaranteeing device (340) is movable from the pre-stage position to the guaranteed position in an actuation direction parallel to the tightening direction.

6. The power harness connector (200) according to claim 1, wherein the bolt position guaranteeing device (340) presses against the threaded bolt (300) at the guaranteed position.

7. The power harness connector (200) according to claim 1, wherein the bolt position guarantee device (340) includes an opening (344) through which the threaded bolt (300) is approached to tighten the threaded bolt.

8. The power harness connector (200) according to claim 1, wherein the bolt position guarantee device (340) includes an inner wall (350) and an outer wall (352) having a recess (354) between the inner wall and the outer wall, the inner wall extending along the interior of the hub (250) and the outer wall extending along the exterior of the hub, the inner wall including a bottom edge facing the threaded bolt (300).

9. The power harness connector (200) of claim 8, wherein the outer wall (352) includes a latching element (262) configured to mate with a latching element of the hub (250) to position the bolt position guarantee device (340) on the hub.

10. The power harness connector (200) according to claim 1 further includes a housing seal at the mating end (274) of the housing (230), the housing seal being configured to mate with the mating harness connector (400) to form a sealed mating with the mating harness connector.

11. The power harness connector (200) according to claim 1, wherein the threaded bolt (300) includes a bolt seal (330) configured to seal to the housing (230).

12. The power harness connector (200) according to claim 1, wherein the housing (230) includes a contact channel (246) into which the power contacts are loaded.

13. The power harness connector (200) of claim 1, wherein the threaded connector (500) includes an insulating cover (310) located outside the housing (230), the insulating cover being positioned to make the threaded connector safe to touch.

14. A power harness connector (200), comprising: A housing (230) having a chamber (232) extending between an terminating end (272) and a mating end (274), the mating end being configured to mate with a mating wire harness connector (400), the housing including a hub (250) at the mating end, the hub having a hole (252) through the housing. An electrical conductor that extends from the chamber at the termination point; An electrical contact is received in the chamber, the electrical contact having an end connected to the electrical conductor and a mating end aligned with a hole at a mating end of the housing (230), the electrical contact including a base plate (280) having an opening (282). A threaded bolt (300), received in the hub and passing through the hole, the threaded bolt passing through the opening, the threaded bolt being configured to be threadably connected to a mating threaded connector (500) of the mating harness connector (400), the threaded bolt rotating between an untightened position and a tightened position, the threaded bolt being tightened to a predetermined torque in the tightened position; and A bolt position guaranteeing device (340) is connected to the hub and is movable between a pre-stage position and a guaranteed position. The bolt position guaranteeing device can only move to the guaranteed position when the threaded bolt is in the tightened position. The bolt position guaranteeing device guarantees that the threaded bolt is positioned in the hub at the tightened position in the guaranteed position.

15. The power harness connector (200) according to claim 14, wherein the bolt position guaranteeing device (340) is configured to move to the guaranteeing position only when the threaded bolt (300) is in the tightened position.

16. The power harness connector (200) of claim 14, wherein the housing (230) includes a pre-stage latch and a guarantee latch, the bolt position guarantee device (340) being coupled to the pre-stage latch at the pre-stage position and the bolt position guarantee device being coupled to the guarantee latch at the guarantee position.

17. A power line harness (102), comprising: A first wire harness connector (200) includes a first housing (230) having a first hub (250) having a first hole (252) through the first housing, a first electrical conductor (204) including a first seal sealed to the first housing, a threaded bolt (300) received in the first hub and passing through the first hole, the threaded bolt including an insulating cap (310) covering a head (302) and an insulating cap (320) at a distal end (308) of the threaded shaft (304), a bolt seal (330) sealing between the threaded bolt and the first housing, and a first electrical contact (270) received in the first hub having an end (272) terminating to the first electrical conductor and a mating end (274) aligned with the first hole, the first electrical contact including a first base plate (280) having a first opening (282) for receiving the threaded shaft of the threaded bolt. A second wire harness connector (400) is connected to a first wire harness connector. The second wire harness connector includes a second housing (430) having a second hub (450) having a second hole (452) through the second housing. The second wire harness connector includes a second power conductor (404). The second wire harness connector includes a second seal sealed to the second housing. The second wire harness connector includes a receptacle insert received in the second hub and through the second hole. The receptacle insert includes a threaded hole threadedly connected to a threaded bolt of the first wire harness connector. The receptacle insert includes an insulating cap (520) at a distal end (508) of the receptacle insert. The second wire harness connector includes a second power contact (402) having an terminating end (472) terminated to the second power conductor and a mating end (474) aligned with the second hole. The second power contact includes a second base plate having a second opening for receiving the threaded insert. A mating seal (360) is provided to seal the interface between the first and second housings at the mating point between the first and second wiring harness connectors; and A bolt position guaranteeing device (340) is coupled to the first hub and is movable between a pre-stage position and a guaranteed position; The threaded bolt is threadedly connected to the threaded insert to the tightened position, and the bolt position guaranteeing device guarantees that the threaded bolt is positioned in the first hub at the tightened position of the guaranteed position.

18. The power harness according to claim 17, wherein the first power conductor (204) is a power cable terminated at the termination end (272) of the first power contact (270), the power cable extending from the first connector housing (230), and the second power conductor (404) is one of a second power cable or busbar connected to an electrical device.

19. The power harness of claim 17, wherein the first and second harness connectors (200, 400) are touch-proof before and after connection.

20. The power harness of claim 17, wherein the first and second harness connectors (200, 400) are completely sealed when mated.

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