In-line power connector for power connector system

Abstract

An inline power connector connecting first and second power cables of a power cable bundle includes a conductor terminal, a first cable conductor for electrically connecting the first power cable, and a second cable conductor for electrically connecting the second power cable. The inline power connector includes a power connector insulator surrounding the conductor terminal to insulate the conductor terminal. The inline power connector includes a power connector shield surrounding the power connector insulator. The power connector shield includes first and second shield ends. The first shield end is coupled to a first cable shield of the first power cable. The second shield end is coupled to a second cable shield of the second power cable. The inline power connector includes a power connector housing having a housing cavity receiving the power connector shield. The power connector housing is held sealed to a first seal of the first power cable at a first housing end and to a second seal of the second power cable at a second housing end.

Description

Technical Field

[0001] The main topic of this article is electrical connector systems. Background Technology

[0002] Electrical connectors are used to transfer electrical power between various components in a system. Power can be transferred between a battery and a load, or between a charging port and a battery, via electrical connectors. For example, electrical connectors in vehicles such as electric vehicles or hybrid electric vehicles can be used to supply power from the battery to another component within the vehicle, or to recharge the battery via a charging port. A typical electric vehicle includes many battery-powered devices or subsystems. It is difficult to route cable bundles between the battery and each device and subsystem. Furthermore, the numerous cable bundles increase the weight and cost of the system.

[0003] There is still a need for a power connector system with reduced weight and cost that can be assembled and operated reliably. Summary of the Invention

[0004] In one embodiment, an in-line power connector is provided for connecting a first power cable and a second power cable of a power cable bundle. The in-line power connector includes conductor terminals for electrically connecting a first cable conductor of the first power cable and a second cable conductor of the second power cable. The in-line power connector includes a power connector insulator surrounding the conductor terminals to isolate them. The in-line power connector includes a power connector shield surrounding the power connector insulator. The power connector shield includes a first shield end and a second shield end. The first shield end is configured to be coupled to a first cable shield of the first power cable. The second shield end is configured to be coupled to a second cable shield of the second power cable. The in-line power connector includes a power connector housing having a housing cavity for receiving the power connector shield, the power connector insulator, and the conductor terminals. The power connector housing holds a first seal at a first housing end, the first seal being configured to seal to the first power cable, and holds a second seal at a second housing end, the second seal being configured to seal to the second power cable. Attached Figure Description

[0005] The accompanying drawings will be described by way of example with reference to the drawings, wherein:

[0006] Figure 1 An electric vehicle with a power connector system according to an exemplary embodiment is shown.

[0007] Figure 2 A power cable bundle of a power connector system according to an exemplary embodiment is shown.

[0008] Figure 3 An exemplary embodiment is shown. Figure 2 A portion of the power cable bundle shown.

[0009] Figure 4 This is an exploded view of a power cable bundle according to an exemplary embodiment.

[0010] Figure 5 This is a partial assembly view of a power cable bundle according to an exemplary embodiment.

[0011] Figure 6 This is a partial assembly view of a power cable bundle according to an exemplary embodiment.

[0012] Figure 7 This is an assembly diagram of a power cable bundle according to an exemplary embodiment.

[0013] Figure 8 This is a cross-sectional view of an inline power connector according to an exemplary embodiment. Detailed Implementation

[0014] Figure 1 An electric vehicle with a power connector system 100 according to an exemplary embodiment is shown. The power connector system 100 is used to supply power to various components and subsystems of the electric vehicle 10. In an exemplary embodiment, the power connector system 100 is used to transfer power to or from the battery 12 of the electric vehicle 10. For example, the power connector system 100 is used to electrically connect the battery 12 to a charging inlet 14 for recharging the battery 12. The power connector system 100 uses one or more power cable bundles 102 to connect the battery 12 to various components or subsystems of the electric vehicle 10. The power connector system 100 may be a high-power connector system, for example, capable of handling high voltage and / or current intensities.

[0015] The electrical connector system 100 is used to electrically connect the battery 12 to the electric motor 16, for example, via an AC / DC inverter 18. The electric vehicle 10 may include multiple electric motors 16 and AC / DC inverters 18. The electrical connector system 100 is also used to electrically connect the battery 12 to other vehicle subsystems 20, such as an onboard AC / DC charger 22, a DC / DC converter 24, a heater 26, an AC compressor 28, etc. The electrical connector system 100 can be used to electrically connect the battery 12 to other vehicle subsystems and / or accessories.

[0016] Figure 2 A power cable bundle 102 of a power connector system 100 according to an exemplary embodiment is shown. Figure 3 It shows Figure 2 This is a portion of the power cable bundle 102 shown. The power cable bundle 102 includes components for connecting to various parts (e.g., Figure 1The charging port 14 and battery 12 shown have multiple terminals 104, 106. For example, terminal 104 may be connected to the charging port 14 or define at least a portion of the charging port 14.

[0017] In an exemplary embodiment, the power cable bundle 102 includes a main power cable 110 and a terminal power cable 120. The power cable bundle 102 includes an in-line power connector 200 between the main power cable 110 and the terminal power cable 120. The description herein refers to a single power transmission line (e.g., a positive transmission line). However, it should be appreciated that the power connector system 100 may include dual power transmission lines (e.g., a positive transmission line and a negative transmission line). For example, the harness assembly may include multiple power cable bundles 102 connected in parallel, such as a positive cable bundle and a negative cable bundle. The power cable bundles 102 may be bundled together, for example, by using a sleeve or outer sheath to keep the cables parallel for easier wiring within the electric vehicle 10.

[0018] In an exemplary embodiment, the main power cable 110 is a rigid power cable configured to maintain its shape, and the terminal power cable 120 is a flexible power cable, which is flexible to mate with corresponding components. The flexible power cable facilitates the assembly / fitting of the power cable bundle 102 within the vehicle. The rigid power cable facilitates assembly within the vehicle. For example, the rigid power cable can be shaped, such as including bends in predetermined locations, corresponding to the desired wiring layout within the vehicle. The shape of the rigid power cable allows for easy installation within the vehicle, for example, close to the vehicle's structure at a predetermined installation location along the chassis. In an exemplary embodiment, the main power cable 110 and / or the terminal power cable 120 are made of lighter or less expensive materials compared to conventional power cables used for charging inlet components. For example, the main power cable 110 and / or the terminal power cable 120 may be made of aluminum instead of copper, because aluminum is lighter and cheaper per cable length than copper.

[0019] In an exemplary embodiment, the main power cable 110 and the terminal power cable 120 are shielded cables. For example, the main power cable 110 and the terminal power cable 120 include cable shields extending the length of the main power cable 110 and the terminal power cable 120. The shielded power cable provides cable shielding along the length of the power cable bundle 102 between electrical components and may be electrically connected to or terminated to the shielding of the electrical components to provide shielding within the power connector system 100. An inline power connector 200 is electrically connected to the cable shielding of the main power cable 110 and the terminal power cable 120. The inline power connector 200 continues the shielding structure along the length of the power cable bundle 102 between the main power cable 110 and the terminal power cable 120. In an exemplary embodiment, the inline power connector 200 is sealed to the main power cable 110 and the terminal power cable 120 to prevent debris and water contamination of the terminals between the main power cable 110 and the terminal power cable 120. In an alternative embodiment, each power cable 110, 120 may be an unshielded cable. In such an embodiment, the system may include a bundled cable shield extending along the length of the power cables 110, 120, and the inline power connector 200 may be electrically connected to the bundled cable shield instead of the individual cable shields of each power cable 110, 120.

[0020] The main power cable 110 is configured to be connected to a first electrical component (e.g., charging inlet 14) via a power connector 150. The main power cable 110 is also configured to be connected to a terminal power cable 120 via an in-line power connector 200. In an exemplary embodiment, the main power cable 110 is a high-voltage shielded cable. In various embodiments, the main power cable 110 may be 200 mm². ² Shielded cable. However, in an alternative embodiment, the main power cable 110 may be a wire of a different specification. The main power cable 110 extends between a first cable end 112 and a second cable end 114. A power connector 150 is disposed at the first cable end 112, and an inline power connector 200 is disposed at the second cable end 114. The power connector 150 may be crimped or soldered to the first cable end 112. The inline power connector 200 may be crimped or soldered to the second cable end 114.

[0021] A power connector 150 is configured to be coupled to a charging port 14. In an exemplary embodiment, the power connector 150 is a plug connector configured to be removably coupled to the charging port 14. In an alternative embodiment, the power connector 150 is part of the charging port 14, such as a main power cable 110 having charging terminals (e.g., charging pins) directly terminated to the charging port 14. The power connector 150 includes a connector housing 152. The main power cable 110 extends from the connector housing 152. The main power cable 110 is configured to be coupled to power terminals (not shown) in the connector housing 152. For example, the main power cable 110 may be coupled to a charging pin of the charging port 14.

[0022] The terminal power cable 120 is configured to be coupled to a second electrical component (e.g., battery 12) via a power connector 160. In this example, the power connector 160 may define a terminal 106 configured to terminate at battery 12. The terminal power cable 120 is configured to be coupled to the main power cable 110 via an in-line power connector 200. In an exemplary embodiment, the terminal power cable 120 is a high-voltage shielded cable. In various embodiments, the terminal power cable 120 may be 120 mm. ² Shielded cable. However, in an alternative embodiment, the terminal power cable 120 may be a wire of a different specification. The terminal power cable 120 extends between a first cable end 122 and a second cable end 124. A power connector 160 is disposed at the first cable end 122, and an inline power connector 200 is disposed at the second cable end 124. The power connector 160 may be crimped or soldered to the first cable end 122. The inline power connector 200 may be crimped or soldered to the second cable end 124.

[0023] A power connector 160 is configured to connect to a charging port 14. In an exemplary embodiment, the power connector 160 is a plug connector configured to removably connect to a plug connector or receptacle connector of the battery 12. The power connector 160 includes a connector housing 162. A terminal power cable 120 extends from the connector housing 162. The terminal power cable 120 is configured to connect to power terminals (not shown) in the connector housing 162. For example, the power terminals may be blade terminals, receptacle terminals, or other types of terminals.

[0024] Figure 4This is an exploded view of a power cable bundle 102 according to an exemplary embodiment. The power cable bundle 102 includes an in-line power connector 200 between a main power cable 110 and a terminal power cable 120. The in-line power connector 200 is configured to connect to an end 114 of the main power cable 110 and is configured to connect to an end 124 of the terminal power cable 120. The in-line power connector 200 is a shielded connector that shares the cable shielding of the main power cable 110 and the terminal power cable 120. The in-line power connector 200 is a sealed connector configured to seal to the main power cable 110 and the terminal power cable 120.

[0025] The main power cable 110 includes a first cable conductor 116, a first cable insulation 117 surrounding the first cable conductor 116, and a first cable shield 118 surrounding the first cable insulation 117. The main power cable 110 may include a first cable sheath 119 surrounding the first cable shield 118. The first cable shield 118 provides shielding for the first cable conductor 116 along the length of the main power cable 110. In an exemplary embodiment, the first cable conductor 116 is a solid conductor. For example, the first cable conductor 116 may be an extruded aluminum core conductor. In the illustrated embodiment, the first cable conductor 116 has a circular cross-section. However, the first cable conductor 116 may have other shapes, such as rectangular or elliptical. The first cable conductor 116 is rigid and configured to maintain its shape.

[0026] The terminal power cable 120 includes a first cable conductor 126, a first cable insulation 127 surrounding the first cable conductor 126, and a first cable shield 128 surrounding the first cable insulation 127. The terminal power cable 120 may include a first cable sheath 129 surrounding the first cable shield 128. The first cable shield 128 provides shielding for the first cable conductor 126 along the length of the terminal power cable 120. In an exemplary embodiment, the first cable conductor 126 is a stranded core conductor. For example, the first cable conductor 126 may include a bundle of aluminum or copper wire or strands forming the core. In the illustrated embodiment, the first cable conductor 126 has a circular cross-section. However, the first cable conductor 126 may have other shapes, such as rectangular or elliptical. The first cable conductor 126 is flexible and can be manipulated or moved relative to the in-line power connector 200 and the main power cable 110, for example, for mating with corresponding electrical components.

[0027] In an exemplary embodiment, the inline power connector 200 includes conductor terminals 210, a power connector insulator 220 surrounding the conductor terminals 210, a power connector shield 250 surrounding the power connector insulator 220, and a power connector housing 280 having a housing cavity 282 that receives the power connector shield 250, the power connector insulator 220, and the conductor terminals 210.

[0028] Conductor terminal 210 is configured to electrically connect a first cable conductor 116 of a first power cable 110 and a second cable conductor 126 of a second power cable 120. In an exemplary embodiment, conductor terminal 210 includes a weld joint 212 connecting the first cable conductor 116 and the second cable conductor 126. In an exemplary embodiment, the end of the first cable conductor 116 is configured to be directly welded to the end of the second cable conductor 126 at conductor terminal 210. In other embodiments, separate welding plates may be provided at conductor terminal 210, which are welded to the first cable conductor 116 and the second cable conductor 126 respectively.

[0029] A power connector insulator 220 surrounds the conductor terminal 210 to isolate the conductor terminal 210 from the power connector shield 250. For example, the power connector insulator 220 is made of a dielectric material, such as an electrically insulating plastic material, to isolate the conductor terminal 210 from the power connector shield 250. The power connector insulator 220 is sized and shaped to receive the conductor terminal 210 and the ends of the first cable conductor 116 and the second cable conductor 126. In an exemplary embodiment, the power connector insulator 220 includes an insulator wall 222 forming an insulator cavity 224. The insulator cavity 224 receives the conductor terminal 210 and the ends of the first cable conductor 116 and the second cable conductor 126. The insulator wall 222 may include positioning features or surfaces that interface with the conductor terminal 210 and / or the first and second cable conductors 116, 126 to position the conductor terminal 210 within the insulator cavity 224.

[0030] In an exemplary embodiment, the power connector insulator 220 is a multi-piece insulator. For example, the power connector insulator 220 includes an upper insulator element 226 and a lower insulator element 228, which can be coupled together to surround the conductor terminal 210. The upper insulator element 226 and the lower insulator element 228 can be molded. In various embodiments, the upper insulator element 226 and the lower insulator element 228 are identical to each other and reversed 180° relative to each other.

[0031] In alternative embodiments, the power connector insulator 220 may be an insulating layer covering the inner surface of the power connector shield 250, or it may be an insulating layer covering the ends of the conductor terminals 210 and the cable connectors 116, 126, rather than a pre-formed insulating element. In various other embodiments, the power connector insulator 220 may be a potting material or epoxy resin filling the internal space of the power connector shield 250 to isolate the power connector shield 250 from the conductor terminals 210.

[0032] The power connector shield 250 surrounds the power connector insulator 220. The power connector shield 250 is made of a conductive material, such as aluminum, copper, stainless steel, or other metallic materials. The power connector shield 250 may be a stamped part. In various other embodiments, the power connector shield 250 may be a die-cast part. The power connector shield 250 may be defined by a layer of heat-shrinkable element (e.g., see...). Figure 8 The heat-shrinkable element 300 shown is included. The power connector shield 250 includes a shielding wall 252 forming a shielding cavity 254. The shielding cavity 254 receives the power connector insulator 220 and the ends of the conductor terminals 210 and cable connectors 116, 126. The shielding wall 252 may include positioning features or surfaces that abut against the power connector insulator 220 to position the power connector insulator 220 within the shielding cavity 254.

[0033] In an exemplary embodiment, the power connector shield 250 is a multi-piece shield. For example, the power connector shield 250 includes an upper shielding element 256 and a lower shielding element 258, which can be coupled together to surround the power connector insulator 220. The upper shielding element 256 and the lower shielding element 258 may be stamped parts. In an alternative embodiment, the upper shielding element 256 and the lower shielding element 258 may be die-cast parts. In various embodiments, the upper shielding element 256 and the lower shielding element 258 are identical to each other and are reversed 180° relative to each other.

[0034] A power connector shield 250 extends between a first shield end 260 and a second shield end 262. The first shield end 260 is configured to connect to a first cable shield 118 of a first power cable 110. The second shield end 262 is configured to connect to a second cable shield 128 of a second power cable 120. In an exemplary embodiment, the power connector shield 250 includes a first crimping element 264 at the first shield end 260, extending, for example, from an upper shield element 256 and a lower shield element 258. The first crimping element 264 is configured to crimp to the first cable shield 118 of the first power cable 110. The power connector shield 250 includes a second crimping element 266 at the second shield end 262, extending, for example, from an upper shield element 256 and a lower shield element 258. The second crimping element 266 is configured to crimp to the second cable shield 128 of the second power cable 120.

[0035] In an exemplary embodiment, the inline power connector 200 includes a first collar 270 surrounding a first power cable 110 and a second collar 272 surrounding a second power cable 120. The first collar 270 is configured to receive a first cable shield 118 between the first collar 270 and a first crimping element 264. The first collar 270 is configured to be crimped to mechanically and electrically connect a first shield end 260 of a power connector shield 250 to the first cable shield 118. The second collar 272 is configured to receive a second cable shield 128 between the second collar 272 and a second crimping element 266. The second collar 272 is configured to be crimped to mechanically and electrically connect a second shield end 262 of the power connector shield 250 to the second cable shield 128.

[0036] The power connector housing 280 includes a housing wall 284 forming a housing cavity 282. In the illustrated embodiment, the housing wall 284 forms a rectangular housing in which components of the inline power connector 200 are received. In alternative embodiments, the power connector housing 280 may have other shapes, such as a circular shape. In an exemplary embodiment, the power connector housing 280 is made of a dielectric material. For example, the power connector housing 280 may be a molded plastic component. In alternative embodiments, the power connector housing 280 may be made of other materials. For example, the power connector housing 280 may be made of a metallic material, such as a casting. Making the power connector housing 280 conductive eliminates the need for a power connector shield 250. The power connector housing 280 extends between a first housing end 286 and a second housing end 288.

[0037] In an exemplary embodiment, a power connector housing 280 is configured to hold a first seal 290 at a first housing end 286. The first seal 290 is configured to seal to a first power cable 110. The first seal 290 is configured to seal to the power connector housing 280. For example, the first seal 290 includes a sealing rib 291 at its outer periphery, configured to seal to an inner surface of the power connector housing 280. In an exemplary embodiment, a first sealing stop 292 is used to position the first seal 290 within the power connector housing 280. The first sealing stop 292 may engage other components within the power connector housing 280, such as a power connector shield 250, to position the first sealing stop 292 within the housing cavity 282. In an exemplary embodiment, a sealing cap 293 is configured to engage with the first housing end 286 of the power connector housing 280 to retain the first seal 290 within the housing cavity 282. The sealing cap 293 may be latchably engaged with the power connector housing 280. In an exemplary embodiment, the sealing cap 293 includes a cable strain relief member 294 surrounding the first power cable 110 to provide strain relief for the first power cable 110.

[0038] In an exemplary embodiment, the power connector housing 280 is configured to hold a second seal 295 at a second housing end 288. The second seal 295 is configured to seal to a second power cable 110. The second seal 295 is configured to seal to the power connector housing 280. For example, the second seal 295 includes a sealing rib 296 at its outer periphery, configured to seal to an inner surface of the power connector housing 280. In an exemplary embodiment, a second seal stop 297 is used to position the second seal 295 within the power connector housing 280. The second seal stop 297 may engage other components within the power connector housing 280, such as the power connector shield 250, to position the second seal stop 297 within a housing cavity 282. In an exemplary embodiment, a sealing cap 298 is configured to engage with the second housing end 288 of the power connector housing 280 to retain the second seal 295 within the housing cavity 282. The sealing cap 298 may be latchably engaged with the power connector housing 280. In an exemplary embodiment, the sealing cap 298 includes a cable strain relief member 299 surrounding the second power cable 110 to provide strain relief for the second power cable 110.

[0039] Figure 5This is a partial assembly view of a power cable bundle 102 according to an exemplary embodiment. The power cable bundle 102 includes an in-line power connector 200 between a main power cable 110 and a terminal power cable 120. The in-line power connector 200 is a shielded connector that is common to the cable shields 118, 128 of the main power cable 110 and the terminal power cable 120. The in-line power connector 200 is a sealed connector configured to seal to the main power cable 110 and the terminal power cable 120.

[0040] After the ends of cable conductors 116 and 126 are terminated at conductor terminals 210, the power connector insulator 220 and the power connector shield 250 are assembled. The power connector insulator 220 electrically isolates the conductor terminals 210 from the power connector shield 250. The power connector shield 250 terminates at cable shields 118 and 128 to make the cable shields 118 and 128 common potential and to provide a continuous shielding structure along the length of the power cable bundle 102. In an exemplary embodiment, the power connector shield 250 is crimped to the ends of the cable shields 118 and 128. For example, first and second collars 270 and 272 may be crimped to the first and second cable shields 118 and 128, and the first and second crimping elements 264 and 266, respectively. The crimp connection mechanically and electrically connects the power connector shield 250 to the first cable shield 118 and the second cable shield 128.

[0041] Figure 6 This is a partial assembly view of the power cable bundle 102 according to an exemplary embodiment. During assembly, after the power connector shield 250 is terminated with the first cable shield 118 and the second cable shield 128, the power connector housing 280 can be positioned above the power connector shield 250 and sealed using the first seal 290 and the second seal 295. The power connector housing 280 surrounds the power connector shield 250 and protects the internal components of the power cable bundle 102. The power connector housing 280 can provide strain relief for the conductor terminals 210 and the crimped terminals of the power connector shield 250.

[0042] Figure 7 This is an assembled view of the power cable bundle 102 according to an exemplary embodiment. During assembly, after the power connector shield 250 is connected to the first cable shield 118 and the second cable shield 128 and the power connector housing 280 is positioned above the power connector shield 250, the first seal 290 and the second seal 295 can be loaded into the end of the power connector housing 280, and sealing caps 293 and 298 are coupled to the end of the power connector housing 280. Therefore, the sealed and shielded connector is arranged in series with the main power cable 110 and the terminal power cable 120.

[0043] In an exemplary embodiment, the power connector housing 280 includes a mounting bracket 281 for mounting the inline power connector 200 to a structure such as a chassis or other component within a vehicle. Mounting the power connector housing 280 within the vehicle secures the end of the rigid main power cable 110, thereby fixing the main power cable 110 within the vehicle. The flexible end power cable 120 is movable relative to a fixed mounting point within the vehicle, for example, for mating with corresponding electrical components.

[0044] In an exemplary embodiment, the power connector housing 280 includes attachment features 283 for attaching the power connector housing 280 to the power connector housing 280 of another inline power connector 200 to bind a pair of inline power connectors 200 together. In other embodiments, more than two inline power connectors 200 may be bound together within a power cable bundle 102. Optionally, the cable shields of the bound power cables 110, 120 may be shared cable shields. For example, the first power cable 110 may share a common cable shield, and the second power cable 120 may share a common cable shield. The inline power connector 200 electrically connects the common cable shield of the first power cable 110 to the common cable shield of the second power cable 120.

[0045] Figure 8 This is a cross-sectional view of an inline power connector 200 according to an exemplary embodiment. The inline power connector 200 electrically connects a main power cable 110 and a terminal power cable 120. The inline power connector 200 electrically connects a first cable shield 118 of the first power cable 110 to a second cable shield 128 of the second power cable 120. The inline power connector 200 includes conductor terminals 210, a power connector insulator 220 surrounding the conductor terminals 210, a power connector shield 250 surrounding the power connector insulator 220, and a power connector housing 280 surrounding the power connector shield 250, the power connector insulator 220, and the conductor terminals 210.

[0046] In an exemplary embodiment, the inline power connector 200 includes a heat-shrinkable element 300. The heat-shrinkable element 300 includes a conductive layer 350 and an insulating layer 380. Heat can be applied to the main power cable 110 and the terminal power cable 120 to cause the heat-shrinkable element 300 to shrink around the ends of the main power cable 110 and the terminal power cable 120. The conductive layer 350 is disposed on the inner surface of the heat-shrinkable element 300 and defines a power connector shield 250. The conductive layer 350 is configured to be electrically connected to a first cable shield 118 of the first power cable 110 and a second cable shield 128 of the second power cable 120. The conductive layer 350 may be a film or conductive ink on the inner surface of the heat-shrinkable element 300. For example, when the heat-shrinkable element 300 is heat-shrinkably applied to power cables 110, 120, the conductive layer 350 is electrically connected to cable shields 118, 128 to form a power connector shield 250 of the inline power connector 200. An insulating layer 380 surrounds the components of the inline power connector 200 and forms a power connector housing 280 that protects the components of the inline power connector 200. In an exemplary embodiment, the insulating layer 380 is heat-shrinkably applied to cable sheaths 119, 129 of the first and second power cables 110, 120 to seal the ends of the inline power connector 200 to the ends of the first and second power cables 110, 120. In various other embodiments, the insulating layer 380 may be located inside the heat-shrinkable element 300 defining a power connector insulator 220 that electrically isolates the power connector shield 250 from the conductor terminals 210. In various other embodiments, the heat-shrinkable element 300 may include an additional insulating layer along the interior defining the power connector insulator 220.

[0047] Cross-references to related applications

[0048] This application claims priority to U.S. Application No. 63 / 931,750, filed December 5, 2025, and U.S. Application No. 63 / 774,958, filed March 20, 2025, the subject of which is incorporated herein by reference in its entirety.

Claims

1. An inline power connector (200) for connecting a first power cable (110) and a second power cable of a power cable bundle (102), the inline power connector comprising: Conductor terminal (210) for electrically connecting the first cable conductor (116) of the first power cable and the second cable conductor of the second power cable; A power connector insulator (220) surrounds the conductor terminals to isolate the conductor terminals; A power connector shield (250) surrounds the power connector insulator, the power connector shield including a first shield end (260) and a second shield end (262), the first shield end being configured to be connected to a first cable shield (128) of the first power cable, and the second shield end being configured to be connected to a second cable shield of the second power cable; and A power connector housing (152) having a housing cavity (282) receiving the power connector shield, the power connector insulator and the conductor terminals, the power connector housing holding a first seal (290) at a first housing end (286) and a second seal (295) at a second housing end (288), the first seal (290) being configured to seal to the first power cable and the second seal (295) being configured to seal to the second power cable.

2. The in-line power connector (200) according to claim 1, wherein, The conductor terminal (210) is configured to connect the solid conductor of the first power cable (110) to the stranded core conductor of the second power cable.

3. The in-line power connector (200) according to claim 1, wherein, The conductor terminal (210) includes a welded joint (212) that directly connects the first cable conductor (116) and the second cable conductor (126).

4. The in-line power connector (200) according to claim 1, wherein, The power connector insulator (220) isolates the conductor terminal (210) from the power connector shield (250) and is configured to isolate the first cable conductor (116) and the second cable conductor (126) from the power connector shield.

5. The in-line power connector (200) according to claim 1, wherein, The power connector insulator (220) includes an upper insulator element (226) and a lower insulator element (228) coupled to the upper insulator element to surround the conductor terminal (210).

6. The in-line power connector (200) according to claim 1, wherein, The power connector shield (250) includes an upper shielding element (256) and a lower shielding element (258), the lower shielding element being coupled to the upper shielding element to surround the power connector insulator (220).

7. The in-line power connector (200) according to claim 1, wherein, The power connector shield (250) includes a first crimping sleeve (264) located at the first shield and configured to crimp to the first cable shield (118) of the first power cable (110), and the power connector shield includes a second crimping sleeve (266) located at the second shield and configured to crimp to the second cable shield of the second power cable.

8. The inline power connector (200) according to claim 7 further includes a first collar (270) configured to surround an end of the first power cable (110) and a second collar (272) configured to surround an end of the second power cable, the first collar being configured to receive the first cable shield (128) between the first collar and the first crimping sleeve (264), the first collar being crimped to mechanically and electrically connect a first shield end (260) of the power connector shield (250) to the first cable shield, and the second collar being configured to receive the second cable shield between the second collar and the second crimping sleeve (266), the second collar being crimped to mechanically and electrically connect a second shield end (262) of the power connector shield to the second cable shield.

9. The in-line power connector (200) according to claim 1, wherein, The power connector housing (152) includes a first sealing cap (298) coupled to the first housing end (286) to retain the first seal (290) in the housing cavity (282), and the power connector housing (162) includes a second sealing cap coupled to the second housing end (288) to retain the second seal (295) in the housing cavity.

10. The in-line power connector (200) according to claim 9, wherein, The first sealing cap (298) includes a first cable strain relief member (294) connected to the first power cable (110), and the second sealing cap includes a second cable strain relief member (299) connected to the second power cable.

11. The in-line power connector (200) according to claim 1, wherein, The power connector housing (152) includes a mounting bracket (281) for mounting the inline power connector to a structure.

12. The in-line power connector (200) according to claim 1, wherein, The power connector housing (152) includes an attachment feature for attaching the power connector housing to the power connector housing of another inline power connector to bind the inline power connector to the other inline power connector.

13. A power cable bundle (102) for connecting electrical components of a vehicle (10), the power cable bundle comprising: A main power cable (110) extends to a first cable end (112), the main power cable having a first cable conductor (116), a first cable insulator (117) surrounding the first cable conductor, and a first cable shield (118) surrounding the first cable insulator, the first cable conductor being a solid conductor, the first cable conductor being rigid and configured to maintain its shape, wherein the opposite ends of the main power cable are configured to be electrically connected to a first electrical component in the electrical components of an electric vehicle; A terminal power cable (120) extending to a second cable end (114) having a second cable conductor (126), a second cable insulation (127) surrounding the second cable conductor, and a second cable shield (128) surrounding the second cable insulation, the second cable conductor being a stranded core conductor and flexible, wherein opposite ends of the terminal power cable are configured for electrical connection to a second electrical component in the electrical components of the electric vehicle; and An inline power connector (200) for connecting the main power cable and the terminal power cable, the inline power connector comprising: Conductor terminal (210) for electrically connecting the first cable conductor of the main power cable and the second cable conductor of the terminal power cable; A power connector insulator (220) surrounds the conductor terminals to isolate the conductor terminals; A power connector shield (250) surrounding the power connector insulator, the power connector shield including a first shielding end (260) and a second shielding end (262), the first shielding end being connected to a first cable shield of the main power cable, and the second shielding end being connected to a second cable shield of the terminal power cable; and A power connector housing (152) having a housing cavity (282) receiving the power connector shield, the power connector insulator and the conductor terminals, the power connector housing holding a first seal (290) at a first housing end (286) and a second seal (295) at a second housing end (288), the first seal (290) being configured to seal to the first power cable and the second seal (295) being configured to seal to the second power cable.

14. The power cable bundle (102) according to claim 13, wherein, The main power cable (110) has a smaller diameter than the terminal power cable (120).

15. The power cable bundle (102) according to claim 13, wherein, The length of the main power cable (110) is at least three times the length of the terminal power cable (120).

16. The power cable bundle (102) according to claim 13, wherein, The inline power connector (200) provides a sealed and shielded connection between the main power cable (110) and the terminal power cable (120).

17. The power cable bundle (102) according to claim 13, wherein, The power connector shield (250) includes a first crimping sleeve (264) located at the first shield and configured to be crimped to the first cable shield (118) of the first power cable (110), and the power connector shield includes a second crimping sleeve (266) located at the second shield and configured to be crimped to the second cable shield (128) of the second power cable.

18. The power cable bundle (102) of claim 17 further includes a first collar (270) configured to surround an end of the first power cable (110) and a second collar (272) configured to surround an end of the second power cable, the first collar being configured to receive the first cable shield (118) between the first collar and the first crimping sleeve (264), the first collar being crimped to mechanically and electrically connect a first shield end (260) of the power connector shield (250) to the first cable shield, and the second collar being configured to receive the second cable shield (128) between the second collar and the second crimping sleeve (266), the second collar being crimped to mechanically and electrically connect a second shield end (262) of the power connector shield to the second cable shield.

19. The power cable bundle (102) according to claim 13, wherein, The power connector housing (152) includes a first sealing cap (298) coupled to the first housing end (286) to retain the first seal (290) in the housing cavity (282), and the power connector housing includes a second sealing cap coupled to the second housing end (288) to retain the second seal (295) in the housing cavity.

20. A power connector system (100) for a vehicle (10), comprising: A first power connector (150) has a first power connector housing (152) for holding first power connector terminals, the first power connector terminals being configured to be electrically connected to a first electrical component of the vehicle; A second power connector (160) having a second power connector housing (162) for holding second power connector terminals configured to be electrically connected to a second electrical component of the vehicle; and Power cable bundle (102), electrically connecting the first power connector and the second power connector, the power cable bundle comprising: A main power cable (110) extends to a first cable end (112), the main power cable having a first cable conductor (116), a first cable insulator (117) surrounding the first cable conductor, and a first cable shield (118) surrounding the first cable insulator, the first cable conductor being a solid conductor, the first cable conductor being rigid and configured to maintain its shape, wherein the opposite ends of the main power cable are terminated to the first power connector terminal of the first power connector; A terminal power cable (120) extending to a second cable end (114) having a second cable conductor (126), a second cable insulator (127) surrounding the second cable conductor, and a second cable shield (128) surrounding the second cable insulator, the second cable conductor being a stranded core conductor and being flexible, wherein the opposite ends of the terminal power cable are terminated to the second power connector terminal of the second power connector; and An inline power connector (200) for connecting the main power cable and the terminal power cable, the inline power connector comprising: Conductor terminal (210) for electrically connecting the first cable conductor of the main power cable and the second cable conductor of the terminal power cable; A power connector insulator (220) surrounds the conductor terminals to isolate the conductor terminals; A power connector shield (250) surrounding the power connector insulator, the power connector shield including a first shield end (260) and a second shield end, the first shield end being connected to a first cable shield of the main power cable, and the second shield end (262) being connected to a second cable shield of the terminal power cable; and A power connector housing having a housing cavity (282) receiving the power connector shield, the power connector insulator and the conductor terminals, the power connector housing holding a first seal (290) at a first housing end (286) and a second seal (295) at a second housing end (288), the first seal being configured to seal to a first power cable and the second seal being configured to seal to a second power cable.

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