Bolt position assurance device for power harness connector

Abstract

To provide a robust and highly reliable power connector system for an electric vehicle or the like.SOLUTION: The power harness connector 200 includes a housing including a chamber and a hub having a hole 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 received in the hub and passing through the hole and the opening of the power contact, the threaded bolt configured to be threadably coupled to a mating threaded connector of the mating harness connector 400. The power harness connector includes a bolt position assurance device 340 coupled to the hub and movable between a pre-staged position and an assurance position. The bolt position assurance device, when in the assurance position, assures positioning of the threaded bolt on the hub in the tightened position.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] This application claims the benefit of U.S. Application No. 63 / 678,190, filed August 1, 2024, the entire subject matter of which is incorporated herein by reference.

[0002] The subject matter herein relates generally to electrical power connectors. [Background technology]

[0003] Power connectors are used to electrically connect various electrical components, for example, to transmit power from one component to another. For example, in electric vehicles, power connectors may be used to electrically connect a vehicle's battery to another component, such as the vehicle's electric motor. Some known systems use power cables or bus bars for high-voltage power transmission. However, connecting power cables can be challenging. For example, when used in electric vehicles, connections are susceptible to vibration and environmental degradation, such as moisture and debris. Additionally, connectors often contain many components, making assembly time consuming and increasing the risk of components being misplaced or lost during assembly or mating. Some power connectors may be connected using bolted connections. The bolts must be tightened to a predetermined torque to ensure a proper connection. Undertightening can lead to a poor connection or the bolts can loosen over time due to factors such as vibration. Summary of the Invention [Problem to be solved by the invention]

[0004] There remains a need for robust and reliable power connector systems, such as for electric vehicles. [Means for solving the problem]

[0005] In one embodiment, a power harness connector is provided, the power harness connector including a housing having a chamber extending between a terminal 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 extending therethrough. The power harness connector includes power conductors extending from the chamber at the terminal end. The power harness connector includes power contacts received in the chamber. The power contacts have terminal ends terminated to the power conductors and mating ends aligned with the holes at the mating end of the housing. The power contacts include 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 coupled to a mating threaded connector of a mating harness connector to a fastened position. The power harness connector includes a bolt position assurance device coupled to the hub and movable between a pre-stage position and an assured position. The bolt position assurance device ensures positioning of the threaded bolt on the hub in the fastened position when in the assured position.

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

[0007] [Figure 1] FIG. 1 is a top perspective view of a power system having a power harness showing assembled components according to an exemplary embodiment; [Figure 2] 1 is a top perspective view of a power system showing components of a power harness in a pre-assembled state and ready to be coupled together in accordance with an exemplary embodiment; FIG. [Figure 3] 1 is a cross-sectional view of a power harness in accordance with an exemplary embodiment; [Figure 4] 1 is a cross-sectional view of an electrical power system showing a first harness connector initially mated with a second harness connector in a pre-stage position showing the threaded connectors in an unmated state. FIG. [Figure 5]1 is a cross-sectional view of an electrical power system showing a first harness connector mated with a second harness connector, showing the threaded connectors in a mated state and showing a bolt position assurance device in a preliminary position according to an exemplary embodiment. [Figure 6] 1 is a cross-sectional view of an electrical power system showing a first harness connector mated with a second harness connector, showing the threaded connectors in a mated state and showing a bolt position assurance device in an assurance position according to an exemplary embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0008] Figure 1 is a top perspective view of an electrical power system 100 having a power harness 102, showing the components in an assembled state, according to an exemplary embodiment. Figure 2 is a top perspective view of the electrical power system 100, showing the components of the power harness in a pre-assembled state, ready to be coupled together. The power harness 102 includes power connectors used to electrically connect 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.

[0009] The first harness connector 200 is a cable connector provided at the end of one or more power cables 202 (e.g., two power cables 202 in the embodiment shown in FIGS. 1 and 2). Additionally or alternatively, the second harness connector 400 may be provided at the end of a power cable (not shown). For example, the second harness connector 400 may be a cable connector provided at the end of one or more power cables 402 (e.g., two power cables 402 in the embodiment shown in FIGS. 1 and 2). In alternative embodiments, the second harness connector 400 may be connected to a different type of power conductor, such as a bus bar or a power terminal, associated with the second component 106.

[0010] 1 and 2, the second harness connector 400 is a header connector configured to be attached to a component, such as directly to the electrical component 106 or to a chassis, frame, wall, panel, or other support structure. The first harness connector 200 is a plug connector configured to be attached to the second harness connector 400 (e.g., a header connector) to electrically connect the component 104 and the component 106. The harness connector 200 and the harness connector 400 provide a separable interface for the power transmission line between the first component 104 and the second component 106.

[0011] In various embodiments, power system 100 may be part of a vehicle, such as an electric vehicle. First component 104 may be a vehicle battery, and second component 106 may be a vehicle power device, such as a vehicle inverter or motor, or a vehicle subsystem, such as a charging inlet, heater, compressor, or another vehicle subsystem. In alternative embodiments, power system 100 may be used in applications other than electric vehicles.

[0012] In the exemplary embodiment, the first harness connector 200 and the second harness connector 400 are mechanically connected using threaded parts, such as threaded bolts received in threaded inserts, to connect the first harness connector 200 and the second harness connector 400. In the exemplary embodiment, the harness connectors 200, 400 are compact or low profile, such as occupying less space (e.g., height and / or width and / or length) than the corresponding power cables 202.

[0013] In the exemplary embodiment, harness connectors 200, 400 are sealed connectors that form a sealed interface therebetween. First harness connector 200 is sealed to power cable 202. Second harness connector 400 may also seal to power cable 402. Second harness connector 400 may also seal to an attachment structure, such as component 106. Harness connectors 200 and 400 seal to each other using an environmental seal at the mating interface. Threaded fasteners may also be sealed within harness connectors 200, 400.

[0014] In an exemplary embodiment, the harness connectors 200, 400 are touch-safe, with all energized elements insulated to prevent short circuits, sparks, arcing, or injury from touching the energized elements. The harness connectors 200, 400 are touch-safe in both the mated and unmated states.

[0015] In the exemplary embodiment, the harness connectors 200, 400 are vibration-resistant to maintain a reliable electrical connection along the power transmission line. For example, the first harness connector 200 and / or the second harness connector 400 may include a position assurance device for the corresponding threaded connector. For example, the first harness connector 200 may include a bolt position assurance device 340 configured to provide position assurance for a threaded bolt (e.g., ensuring that the bolt is in a tightened position). The bolt position assurance device 340 may be configured to ensure that the bolt is at a predetermined torque. For example, the bolt position assurance device 340 may be movable to the assured position only when the threaded bolt is in a predetermined position corresponding to the predetermined torque (e.g., tightened a predetermined amount against the mating threaded insert).

[0016] In exemplary embodiments, harness connectors 200 and 400 may be mated with one another in various orientations. For example, power cable 202 may extend away from the connection at various angles, such as 180 degrees, 90 degrees, or other angles. While a single interface is shown in Figures 1 and 2, harness connectors 200, 400 may have multiple interfaces.

[0017] Figure 3 is a cross-sectional view of a power harness 102 according to an exemplary embodiment. Figure 3 shows a first harness connector 200 and a second harness connector in an unmated state. The first harness connector 200 includes a power conductor 204, a housing 230, power contacts 270, a threaded bolt 300, and a bolt position assurance device 340. In the embodiment shown in Figure 3, the power conductor 204 is a power cable 202. However, in alternative embodiments, the power conductor 204 may be a bus bar, a power terminal, or another type of power conductor.

[0018] Housing 230 receives power cable 202, power contacts 270, threaded bolt 300, and bolt position assurance device 340. Housing 230 is configured to mate with second harness connector 400 (shown in FIG. 1 ). Threaded bolt 300 is used to mechanically connect first harness connector 200 to second harness connector 400. Power contacts 270 are used to electrically connect power cable 202 to second harness connector 400. Bolt position assurance device 340 is configured to provide position assurance for threaded bolt 300 (e.g., ensuring that threaded bolt 300 is in a tightened position during assembly).

[0019] In the exemplary embodiment, power cable 202 is a shielded and jacketed cable. Power cable 202 may be a single-core cable or a stranded or braided cable. Power cable 202 includes a central power conductor 204 and an insulator or jacket 206 surrounding conductor 204. Power cable 202 may include a cable shield and / or an outer jacket surrounding insulator 206. Insulator 206 is formed from a dielectric or other insulating material to make power cable 202 touch-safe. Power conductor 204 may be fabricated from aluminum, copper, or an alloy thereof. Power conductor 204 is exposed at the end of power cable 202 for connection with power contacts 270. In the embodiment shown in FIG. 3, power cable 202 is a round power cable. However, in alternative embodiments, power cable 202 may be generally rectangular in cross section, such as having generally planar top and bottom surfaces. In alternative embodiments, power conductor 204 may be a bus bar, metal plate, terminal, or other structure rather than a power cable.

[0020] In the exemplary embodiment, a cable seal 212 is provided to surround power cable 202. Cable seal 212 may seal cable jacket 210. Cable seal 212 is configured to be sealed to housing 230. In various embodiments, cable seal 212 may be a rubber material. Optionally, multiple cable seals 212 may be used to seal to various components.

[0021] In the exemplary embodiment, cable seal retainer 214 is provided on an end of power cable 202 and is configured to be coupled to housing 230. Cable seal retainer 214 may be secured to housing 230 by a latch, clip, fastener, or other fastening element. Cable seal retainer 214 may provide strain relief for power cable 202. Cable seal retainer 214 may hold or support cable seal 212. Cable seal retainer 214 covers the opening of housing 230 from moisture impingement, such as from a high-pressure spray.

[0022] The housing 230 is fabricated from 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-part housing. For example, the housing 230 may have an inner housing and an outer housing. The housing 230 may be a clamshell housing having an upper housing and a lower housing.

[0023] Housing 230 includes walls that form a chamber 232 that receives power cable 202, power contacts 270, and threaded bolt 300. In the exemplary embodiment, housing 230 includes a top 234 and a bottom 236. Housing 230 includes sides 238 extending between a front portion 240 and a rear portion 242. Housing 230 includes a cable opening 244 at rear portion 242 that provides access to chamber 232. Power cable 202 is received in cable opening 244. In various embodiments, cable opening 244 may be oriented generally horizontally. Cable seal retainer 214 may be inserted into cable opening 244 and coupled to housing 230 at rear portion 242. Cable seal 212 may seal the inner surface of housing 230 at cable opening 244.

[0024] In the exemplary embodiment, the housing 230 includes contact channels 246 in the chamber 232 that receive the power contacts 270. The contact channels 246 are aligned with the cable opening 244 to receive the power contacts 270 with the power cable 202 from the cable opening 244. When the power contacts 270 are loaded into the housing 230 from the rear 242, the contact channels 246 can receive the power contacts 270 in a rear-to-front loading direction. In the embodiment shown in FIG. 3 , the contact channels 246 are located in the front 240. The housing 230 includes walls 248 that define the contact channels 246. The walls 248 may form slots that define the contact channels 246, such as one or more horizontal slots and / or one or more vertical slots.

[0025] In the exemplary embodiment, housing 230 includes hub 250 having bore 252 extending therethrough. Bore 252 opens into and partially defines chamber 232. In the embodiment shown in FIG. 3 , hub 250 is located at front portion 240 of housing 230. Hub 250 is aligned with contact channel 246 and power contacts 270. Bolt position assurance device 340 is configured to be coupled to hub 250. In various embodiments, hub 250 is generally cylindrical. However, in alternative embodiments, hub 250 may have other shapes. Bore 252 extends through housing 230, for example, along a vertical axis between top portion 234 and bottom portion 236. In the exemplary embodiment, power contact 270 is positioned in housing 230 in alignment with bore 252, e.g., along the vertical axis, to receive threaded bolt 300. Bore 252 includes upper opening 254 and lower opening 256. Threaded bolt 300 is received in hub 250 and passes through bore 252. For example, threaded bolt 300 may pass through upper opening 254 and / or lower opening 256. In the exemplary embodiment, contact channel 246 is aligned with hub 250. Power contact 270 is received in hub 250 when loaded into contact channel 246.

[0026] The power contacts 270 are metallic conductors, such as aluminum or copper conductors. In various embodiments, the power contacts 270 may be extruded metal contacts. Alternatively, the power contacts 270 may be hot forged or stamped. In various embodiments, the power contacts 270 may be plated or coated. The power contacts 270 may include textured or knurled surfaces at the mating interface to improve electrical contact.

[0027] The power contact 270 extends between a termination 272 and a mating end 274. The termination 272 is configured to be terminated to the power conductor 204 of the power cable 202. The mating end 274 is configured to electrically connect to a corresponding power contact of the second harness connector 400, for example, via a terminal. In the exemplary embodiment, the power contact 270 includes a weld pad 276 at the termination 272. The power conductor 204 is welded to the weld pad 276 at the termination 272. In alternative embodiments, other types of terminations may be used, such as a crimp barrel that is crimped onto the power conductor 204. The power contact 270 may be a multi-piece configuration, such as where the termination 272 is separate from and coupled to the mating end 274. For example, the pieces may be press-fit or welded together.

[0028] The power contact 270 includes a base plate 280 at the mating end 274. The base plate 280 may be planar. In various embodiments, the base plate 280 may be oriented horizontally. The base plate 280 includes an opening 282 therethrough, which may be located approximately centrally between the front and rear of the base plate 280 and / or between opposing sides of the base plate 280. The base plate 280 may define a weld pad 276 for welding a cable to the bottom of the base plate 280, e.g., resistance welding the cable to the base plate 280. The opening 282 may be drilled to pass through the base plate 280 and the conductor of the cable.

[0029] In the exemplary embodiment, the power contacts 270 include terminals 290 extending from the base plate 280. The terminals 290 are aligned with the openings 282 to receive, for example, the threaded bolts 300. The terminals 290 may be cylindrical and may surround the threaded connector 500 and / or the threaded bolts 300. The terminals 290 may be press-fit into the openings 282 and / or welded to the base plate 280. The terminals 290 are configured to couple to corresponding terminals or base plates of the second harness connector 400 to form an electrical path between the first harness connector 200 and the second harness connector 400. The surface area of ​​the edges of the terminals 290 can control the amount of power or current-carrying capacity of the power contacts 270.

[0030] Threaded bolt 300 is a threaded connector configured to be threadedly coupled to a corresponding threaded connector of second harness connector 400. Threaded bolt 300 includes a head 302 and a threaded shank 304 extending from head 302. Threaded shank 304 includes threads at a distal end 308 of threaded shank 304. In an exemplary embodiment, threaded bolt 300 is touch-safe. For example, threaded bolt 300 includes an insulating cover 310 on head 302 and an insulating cap 320 extending from a distal end 309 of threaded shank 304.

[0031] The insulating cover 310 may be overmolded onto the head 302. Alternatively, the insulating cover 310 may be pre-molded and snap-fit, press-fit, glued, or otherwise secured onto the head 302. The insulating cover 310 covers the head 302 to prevent contact with the metal or conductive portions of the threaded bolt 300. In an exemplary embodiment, the insulating cover 310 includes a drive mechanism 312 for driving or rotating the threaded bolt 300. For example, the drive mechanism 312 may be a flat surface on the top of the insulating cover 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 harness connector 400. In alternative embodiments, other types of drive mechanisms may be used, such as one or more slots for receiving a screwdriver or other type of tool to tighten or loosen the threaded bolt 300.

[0032] The insulating cap 320 may be overmolded onto the threaded shank 304. Alternatively, the insulating cap 320 may be pre-molded and snap-fit, press-fit, glued, or otherwise secured to the distal end 308 of the threaded shank 304. The insulating cap 320 covers the threaded shank 304 to prevent contact with metallic or conductive portions of the threaded bolt 300.

[0033] In the exemplary embodiment, the first harness connector 200 includes a bolt seal 330 for sealing between the threaded bolt 300 and the housing 230. In the embodiment shown in FIG. 3 , the bolt seal 330 is coupled to the insulating cover 310 at the head 302 of the threaded bolt 300. The outer surface of the bolt seal 330 is configured to seal against the housing 230, e.g., 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.

[0034] In the exemplary embodiment, bolt position assurance device 340 is coupled to hub 250, for example, at the top. Bolt position assurance device 340 is located above head 302 of threaded bolt 300. Bolt position assurance device 340 may define a bolt retainer for holding threaded bolt 300 to hub 250 of housing 230. Bolt position assurance device 340 is coupled to housing 230 outside of threaded bolt 300, such as above head 302 and insulating cover 310.

[0035] Bolt position assurance device 340 includes a latch element 342 configured to latchably couple to hub 250 to secure bolt position assurance device 340 to hub 250. For example, hub 250 includes a latch element 262 configured to connect with latch element 342 to hold bolt position assurance device 340 in one or more predetermined positions (e.g., a pre-stage position and an assurance position). Latch element 342 may be a deflectable latch, a catch, a detent, or other type of latch element. In the exemplary embodiment, bolt position assurance device 340 includes an opening 344 providing access to threaded bolt 300, for example, to engage drive mechanism 312 to rotate threaded bolt 300. However, in alternative embodiments, bolt position assurance device 340 may be closed to prevent access to threaded bolt 300.

[0036] In the exemplary embodiment, bolt position assurance device 340 includes an inner wall 350 and an outer wall 352, with a pocket 354 between inner wall 350 and outer wall 352. Inner wall 350 and outer wall 352 may be peripheral walls extending around bolt position assurance device 340. Pocket 354 may be a circumferential groove located between inner wall 350 and outer wall 352. Inner wall 350 extends along the inside of hub 250. Outer wall 352 extends along the outside of hub 250. In the exemplary embodiment, outer wall 352 includes a latch element 342 that connects with a latch element 262 on hub 250 to position bolt position assurance device 340 on hub 250. Latch element 262 may be a deflectable latch, a catch, a detent, or some other type of latch element.

[0037] In the exemplary embodiment, inner wall 350 includes a bottom edge 356 that faces threaded bolt 300. Bottom edge 356 is configured to connect with the threaded bolt. For example, threaded bolt 300 may press upward against bottom edge 356 and / or bottom edge 356 may press downward against threaded bolt 300. In the exemplary embodiment, bottom edge 356 defines a retention mechanism for retaining threaded bolt 300 in housing 230. Bottom edge 356 is configured to seat above head 302 and insulating cover 310 to prevent threaded bolt 300 from slipping out of opening 344. In alternative embodiments, other types of retention mechanisms may be used.

[0038] In the exemplary embodiment, the first harness connector 200 includes a mating seal 360 coupled to the housing 230 at the mating end 260 of the housing 230. In the embodiment shown in FIG. 3 , the mating end 260 is located at the bottom 236. The mating end 260 is located at the lower opening 256 of the hub 250. The mating end 260 is configured to mate with the second harness connector 400. In the exemplary embodiment, the housing 230 includes a groove 258 in the bottom 236 surrounding the lower opening 256. The mating seal 360 is located in the groove 258. Optionally, the groove 258 may receive a portion of the housing of the second harness connector 400 to seal the mating seal 360 in the groove 258. In an alternative embodiment, the mating seal 360 may be located at the bottom and face downward to connect with the housing of the second harness connector 400.

[0039] The second 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 harness connector 400 may include a pair of power contacts 470 and a corresponding threaded connector 500 held within the same housing 430. In alternative embodiments, more or fewer power contacts 470 and threaded connectors 500 may be provided. In the exemplary embodiment, the power conductor 404 is a power cable 402. However, in alternative embodiments, the power conductor 204 may be a bus bar, a power terminal, or another type of power conductor.

[0040] In the exemplary embodiment, the power cable 402 is a shielded and jacketed cable. The power cable 402 may be a single-core cable or a stranded or braided cable. The power cable 402 includes a central power conductor 404 and an insulation or jacket 406 surrounding the conductor 404. The power cable 402 may include a cable shield surrounding the insulation and an outer jacket surrounding the insulation 406. The insulation 406 is formed from a dielectric or other insulating material to make the power cable 402 touch-safe. The power conductor 404 may be fabricated from aluminum, copper, or an alloy thereof. The power conductor 404 is exposed at the end of the power cable 402 for connection with a power contact 470. 3, the power cable 402 is a round power cable. However, in alternative embodiments, the power cable 402 may have a generally rectangular cross-section, such as one with generally planar top and bottom surfaces. In alternative embodiments, the power conductor 404 may be a bus bar, metal plate, terminal, or other structure rather than a power cable.

[0041] In the exemplary embodiment, a cable seal 412 is provided to surround the power cable 402. The cable seal 412 may seal against the cable jacket 410. The cable seal 412 is configured to seal against the housing 430. In various embodiments, the cable seal 412 may be a rubber material. Optionally, multiple cable seals 412 may be used to seal various components.

[0042] In the exemplary embodiment, a cable seal retainer 414 is provided on an end of power cable 202 and is configured to be coupled to housing 430. Cable seal retainer 414 may be secured to housing 430 by a latch, clip, fastener, or other fastening element. Cable seal retainer 414 may provide strain relief for power cable 402. Cable seal retainer 414 may hold or support cable seal 412. Cable seal retainer 414 covers the opening of housing 430 from moisture impingement, such as from a high-pressure spray.

[0043] The housing 430 receives the power cable 402, the power contacts 470, and the threaded connector 500. The housing 430 is configured to mate with the first harness connector 200 (shown in FIG. 2 ). The threaded connector 500 is used to mechanically connect the second harness connector 400 to the first harness connector 200. For example, the threaded connector 500 may be threadedly coupled to the threaded bolt 300. The power contacts 470 are used to electrically connect the power cable 402 to the first harness connector 200.

[0044] The housing 430 is fabricated from 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-part housing. For example, the housing 430 may be a clamshell housing having an upper housing and a lower housing.

[0045] The housing 430 includes a shroud wall 434 that forms a chamber 432 that receives the power contacts 470 and the threaded connector 500. The chamber 432 may receive the power conductor 402. In the exemplary embodiment, the housing 430 includes a top 436 and a bottom 438. The housing 430 includes sides extending between a front portion 440 and a rear portion 442. The housing 430 includes a cable opening 444 at the rear portion 442 that provides access to the chamber 432. The power cable 402 is received in the cable opening 444. In various embodiments, the cable opening 444 may be oriented generally horizontally. The cable seal retainer 414 may be inserted into the cable opening 444 and coupled to the housing 230 at the rear portion 442. The cable seal 412 may seal the inner surface of the housing 430 at the cable opening 444.

[0046] In the exemplary embodiment, the housing 430 includes a contact channel 446 in the chamber 432 that receives the power contacts 470. The contact channel 446 is aligned with the cable opening 444 to receive the power contacts 470 with the power cable 402 through the cable opening 444. When the power contacts 470 are loaded into the housing 430 from the rear 442, the contact channel 446 can receive the power contacts 470 in a rear-to-front loading direction. In the embodiment shown in FIG. 3 , the contact channel 446 is located in the front 440. The housing 430 includes a wall 448 that defines the contact channel 446. The wall 448 may form a slot that defines the contact channel 446, such as one or more horizontal slots and / or one or more vertical slots.

[0047] In the exemplary embodiment, housing 430 includes a hub 450 having a hole 452 therethrough that receives a corresponding threaded connector 500. Hole 452 passes through housing 430, for example, along a vertical axis between top 436 and bottom 438. In the exemplary embodiment, power contacts 470 are positioned in housing 430 in alignment with hole 452, for example, along the vertical axis, to receive threaded connector 500 and / or threaded bolt 300.

[0048] The power contacts 470 are metallic conductors, such as aluminum or copper conductors. In various embodiments, the power contacts 470 may be extruded metallic contacts. Alternatively, the power contacts 470 may be hot forged or stamped. In various embodiments, the power contacts 470 may be plated or coated.

[0049] The power contacts 470 extend between a termination 472 and a mating end 474. The termination 472 is configured to be terminated to the power conductors 404. The mating end 474 is configured to be electrically connected to corresponding power contacts 270 of the first harness connector 200, for example, via a terminal between the power contacts 270. The power contacts 470 include weld pads 476 at the termination 472. The power conductors 404 are welded to the weld pads 476 at the termination 472. In alternative embodiments, other types of terminations may be used, such as a crimp barrel.

[0050] The power contacts 470 include a base plate 480 at the mating end 474. The base plate 480 may be planar. In various embodiments, the base plate 480 may be oriented horizontally. The base plate 480 includes an opening (not shown) therethrough, which may be located approximately midway between the front and rear of the base plate 480 and / or between opposing sides of the base plate 480.

[0051] In the exemplary embodiment, the power contacts 470 include terminals 490 extending from the base plate 480. The terminals 490 are aligned with the openings 482 to receive, for example, the threaded connector 500. The terminals 490 may be cylindrical and may surround the threaded connector 500 and / or the threaded bolt 300. The terminals 490 may be press-fit into the openings 482 and / or welded to the base plate 480. The terminals 490 are configured to couple to the terminals 290 to form an electrical path between the first harness connector 200 and the second harness connector 400. The surface area of ​​the edges of the terminals 490 can control the amount of power or current-carrying capacity of the power contacts 470.

[0052] In the exemplary embodiment, threaded connector 500 is a threaded insert. Threaded connector 500 includes a base portion 502 at the bottom of threaded connector 500. Base portion 502 is configured to be coupled to power contact 470, e.g., base plate 480. Threaded connector 500 includes a threaded barrel 504. Threaded barrel 504 includes internal threads within a hollow bore of threaded barrel 504. Threaded barrel 504 extends to a distal end 508. In the exemplary embodiment, threaded connector 500 is touch-safe. For example, threaded connector 500 includes an insulating cap 520 at the distal end 508 of threaded barrel 504. Insulating cap 520 may be overmolded onto threaded barrel 504. Alternatively, insulating cap 520 may be pre-formed and snap-fit, press-fit, glued, or otherwise secured to distal end 508 of threaded barrel 504. In alternative embodiments, insulating cap 520 may be coupled to housing 430, such as by being received in hub 450. Insulating cap 520 may be threadedly coupled to hub 450 or secured with an adhesive. Insulating cap 520 covers threaded barrel 504 to prevent contact with metallic or conductive portions of threaded connector 500.

[0053] FIG. 4 is a cross-sectional view of the power system 100 showing the first harness connector 200 initially mated with the second harness connector 400 in a preliminary position showing the threaded connectors in an unmated state. FIG. 5 is a cross-sectional view of the power system 100 showing the first harness connector 200 mated with the second harness connector 400, showing the threaded connectors in a mated state and showing the bolt position assurance device 340 in a preliminary position. FIG. 6 is a cross-sectional view of the power system 100 showing the first harness connector 200 mated with the second harness connector 400, showing the threaded connectors in a mated state and showing the bolt position assurance device 340 in an assurance position. The first harness connector 200 and the second harness connector 400 mate in a mating direction along a mating axis, which may be a vertical axis.

[0054] During mating, the housing 230 and the housing 430 are aligned with each other. When the first harness connector 200 mates with the second harness connector 400, the shroud wall 434 is aligned with and inserted into the groove 258. The shroud 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 on the end of the threaded bolt 300 is inserted into the hollow hole of the threaded barrel 504. When the threaded shaft 304 connects with the threaded barrel 504, the threaded bolt 300 is rotated to tighten the threaded bolt 300 against the threaded connector 500.

[0055] When mated, the power system 100 is touch-safe. An insulating cover 310 covers the top of the threaded bolt 300 to prevent the metal or conductive portions of the threaded bolt 300 from being touched from outside the first harness connector 200. The housing 230, 430 covers or surrounds the power contacts 270, 470 and terminals 290, 490 to prevent the metal or conductive portions of the power contacts 270, 470 or terminals 290, 490 from being touched from outside the harness connector 200, 400. In the exemplary embodiment, the insulating cover 310 covers the top end of the threaded bolt 300, making the first harness connector 200 touch-safe. The portion of the threaded bolt 300 exposed outside the housing 230 is an insulating cap 320. No metal or conductive portions of the threaded bolt 300 are exposed. Therefore, the first harness connector 200 is touch-safe in the unmated state. In the embodiment shown in FIGS. 4-6, the ends of the threaded connector 500 may be recessed below the top or outside of the hub 450 to prevent inadvertent contact with the exposed metal. Alternatively, a dielectric cap may be provided on the ends to make them touch-safe. No metal or conductive portions of the threaded connector 500 are exposed. Therefore, the second harness connector 400 is touch-safe in the unmated state.

[0056] During mating, an upper portion of the housing 430 of the second harness connector 400 is inserted into a lower portion of the housing 230 of the first harness connector 200. During mating, the power system 100 is sealed from the external environment. In the embodiment shown in FIGS. 4-6 , the first harness connector 200 carries a mating seal 360 that interfaces with the shroud wall 434 of the second harness connector 400 during mating, thereby providing a sealed interface between the first harness connector 200 and the second harness connector 400. In the exemplary embodiment, for example, the bolt seal 330 seals other openings in the housings 230, 430. In the exemplary embodiment, a component seal 560 is provided at the bottom 438 of the housing 430. The component seal 560 is configured to seal against the second component 106.

[0057] The threaded bolt 300 and the threaded connector 500 are used to mechanically connect the first harness connector 200 to the second harness connector 400. For example, the threaded shank 304 of the threaded bolt 300 is received in a hole in the threaded barrel 504 of the threaded connector 500. The threaded bolt 300 is rotated to tighten the threaded shank 304 within the threaded barrel 504. When the threaded bolt 300 is tightened, the first harness connector 200 is electrically connected to the second harness connector 400. For example, the threaded connection between the threaded bolt 300 and the threaded connector 500 compresses the power contact 270 into electrical connection with the power contact 470. For example, terminal 290 is pressed into terminal 490, causing terminal 290 and terminal 490 to mate at their edges, electrically connecting power contact 270 and power contact 470. Threaded connectors 300, 500 maintain electrical connections between terminal 290 and terminal 490 and between power contact 270 and power contact 470. This provides an efficient power transmission path between first harness connector 200 and second harness connector 400. A compact, robust, sealed, vibration-resistant, and touch-safe electrical connection is provided between first harness connector 200 and second harness connector 400.

[0058] During mating, when the first harness connector 200 and the second harness connector 400 are initially mated (e.g., in the pre-mating position shown in FIG. 4 ), the threaded bolt 300 is pushed up to a raised position by the threaded connector 500. The threaded bolt 300 may be pressed against the bolt position assurance device 340. The bolt position assurance device 340 holds the threaded bolt 300 in the hub 250 and prevents the threaded bolt 300 from disengaging from the chamber 232. The bolt position assurance device 340 is secured in the pre-mating position by latching elements 262, 342. For example, latch element 262 may include a pre-stage latch element 264 adjacent the top of hub 250, and latch element 342 may include a pre-stage latch element 346 adjacent the bottom of outer wall 352 of hub 340 (FIG. 2 shows pre-stage latch elements 264, 346 engaged with one another). Pre-stage latch element 264 and pre-stage latch element 346 connect to one another to hold bolt position assurance device 340 in the pre-stage position.

[0059] During assembly, threaded bolt 300 is tightened to a mated or clamped position ( FIG. 5 ). For example, threaded bolt 300 may be tightened to a predetermined torque to physically press terminals 290 and 490 together in a mated state and electrically connect first harness connector 200 and second harness connector 400. As threaded bolt 300 is tightened, it is drawn downward toward threaded connector 500, for example, away from bolt position assurance device 340. Bolt position assurance device 340 remains in the pre-stage position ( FIG. 5 ) due to the interaction of pre-stage latch element 264 and pre-stage latch element 346. Assembly is not complete at this point because bolt position assurance device 340 must be actuated to the assurance position ( FIG. 6 ).

[0060] The bolt position assurance device 340 serves as a visual indicator to the installer that the power harness 102 is properly assembled. For example, the installer can confirm proper assembly when the bolt position assurance device 340 is properly positioned in the assurance position ( FIG. 6 ). Once the threaded bolt 300 is tightened to a predetermined torque and seats on the bottom of the hub 250, the bolt position assurance device 340 can be moved to the assurance position. For example, the installer can press the bolt position assurance device 340 downward toward the threaded bolt 300. The pre-stage latch element 346 of the bolt position assurance device 340 is released from the pre-stage latch element 264 of the hub 250, thereby moving the bolt position assurance device 340 to the assurance position. The bolt position assurance device 340 may be pressed downward until the bottom edge 356 of the inner wall 350 abuts the threaded bolt 300 (e.g., the insulating cover 310). In the exemplary embodiment, latch elements 262, 342 include security latch elements 266, 348 (shown in FIGS. 1 and 2) that are different from pre-stage latch elements 264, 346 (FIG. 1 shows security latch elements 266, 348 engaged with one another). Security latch element 266 may be located closer to the bottom of hub 250 (e.g., farther from the top edge of the hub than pre-stage latch element 264). Bolt position assurance device 340 includes security latch element 348 closer to the bottom of outer wall 352 of hub 340. Security latch element 266 and security latch element 348 connect to each other to hold bolt position assurance device 340 in the security position. In the security position (FIG. 6), bolt position assurance device 340 provides visual assurance to the installer that threaded bolt 300 has been properly tightened (e.g., to a predetermined torque). For example, if threaded bolt 300 is only partially tightened and therefore not fully seated and in the raised position, bolt position assurance device 340 will not be able to move fully to the assurance position and assurance latch element 266 will not engage assurance latch element 348. Bolt position assurance device 340 will become loose on hub 250 rather than being secured by assurance latch elements 266, 348. The installer will then realize the improper installation and will need to further tighten threaded bolt 300 to the predetermined torque.

Claims

1. A power harness connector (200) comprising: a housing (230) having a chamber (232) extending between a terminal end and a mating end (260) configured to mate with a mating harness connector (400), the housing including a hub (250) at the mating end having a hole (252) extending therethrough; a power conductor (204) extending from the chamber at said terminal end; a power contact (270) received in the chamber, the power contact having an end (272) terminated to the power conductor and a mating end (274) aligned with the hole in the mating end of the housing, the power 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 configured to be threadedly coupled to a mating threaded connector (500) of the mating harness connector to a tightened position; a bolt position assurance device (340) coupled to the hub and movable between a pre-stage position and an assurance position, the bolt position assurance device assuring positioning of the threaded bolt in the hub at the tightening position in the assurance position; A power harness connector (200) comprising:

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

3. 2. The power harness connector (200) of claim 1, wherein the threaded bolt (300) is tightened to a predetermined torque in the tightened position, and the bolt position assurance device (340) is movable to the assurance position only when the threaded bolt is in the tightened position.

4. 2. The power harness connector of claim 1, wherein the housing includes a pre-stage latch and an assurance latch, the bolt position assurance device being coupled to the pre-stage latch in the pre-stage position and the bolt position assurance device being coupled to the assurance latch in the assurance position.

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

6. The power harness connector (200) of claim 1, wherein the bolt position assurance device (340) presses the threaded bolt (300) in the assured position.

7. 2. The power harness connector (200) of claim 1, wherein the bolt position assurance device (340) includes an opening (344) through which the threaded bolt (300) is accessed for tightening the threaded bolt.

8. 2. The power harness connector of claim 1, wherein the bolt position assurance device includes an inner wall and an outer wall having a pocket between the inner wall and the outer wall, the inner wall extending along the inside of the hub and the outer wall extending along the outside of the hub, the inner wall including a bottom edge facing the threaded bolt.

9. 9. The power harness connector of claim 8, wherein the outer wall includes a latching element configured to connect with a latching element of the hub to position the bolt position assurance device on the hub.

10. 2. The power harness connector (200) of claim 1, further comprising a housing seal at the mating end (274) of the housing (230) configured to connect with the mating harness connector (400) to form a sealed interface with the mating harness connector.

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

12. The power harness connector (200) of claim 1, wherein the housing (230) includes contact channels (246), and the power contacts are loaded into the contact channels.

13. 2. The power harness connector of claim 1, wherein the threaded connector includes an insulating cover on the outside of the housing, the insulating cover positioned to make the threaded connector touch-safe.

14. A power harness connector (200) comprising: a housing (230) having a chamber (232) extending between a termination (272) and a mating end (274) configured to mate with a mating harness connector (400), said housing including a hub (250) at said mating end having a hole (252) extending therethrough; a power conductor extending from the chamber at the termination; a power contact received in the chamber, the power contact having an end terminated to the power conductor and a mating end aligned with the hole in the mating end of the housing, the power contact including a base plate having an opening; a threaded bolt (300) received in the hub and passing through the hole, the threaded bolt passing through the opening, the threaded bolt configured to be threadedly coupled to a mating threaded connector (500) of the mating harness connector (400), the threaded bolt being rotated between an unclamped position and a clamped position, and the threaded bolt being tightened to a predetermined torque in the clamped position; a bolt position assurance device (340) coupled to the hub and movable between a pre-stage position and an assurance position, the bolt position assurance device being movable to the assurance position only when the threaded bolt is in the tightened position, and the bolt position assurance device assures the positioning of the threaded bolt in the hub at the tightened position when in the assurance position; A power harness connector (200) comprising:

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

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

17. A power harness (102), A first harness connector (200) having a first housing (230), the first housing (230) having a first hub (250) with a first hole (252) extending therethrough, the first harness connector including a first power conductor (204), the first harness connector including a first seal sealing the first housing, the first harness connector including a threaded bolt (300) received in the first hub and passing through the first hole, the threaded bolt having an insulating cover (310) covering a head (302) and a threaded bolt (300) at a distal end (308) of a threaded shaft (304). a first harness connector (200) including an insulating cap (320) for sealing between the threaded bolt and the first housing, the first harness connector including a bolt seal (330) for sealing between the threaded bolt and the first housing, the first harness connector including a first power contact (270) received in the first hub, the first power contact having an end (272) terminated to the first power conductor and a mating end (274) aligned with the first hole, the first power contact including a first base plate (280) having a first opening (282) for receiving the threaded shank of the threaded bolt; A second harness connector (400) coupled to the first harness connector, the second harness connector including a second housing (430), the second housing (430) having a second hub (450) with a second hole (452) extending therethrough, the second harness connector including a second power conductor (404), the second harness connector including a second seal sealing the second housing, the second harness connector including a socket insert received in the second hub and passing through the second hole, a second harness connector (400), wherein the socket insert includes a threaded hole threadedly engaged with the threaded bolt of the first harness connector, the socket insert includes an insulating cap (520) at a distal end (508) of the socket insert, the second harness connector includes second power contacts (402) having ends (472) terminated to the second power conductors and mating ends (474) aligned with the second holes, the second power contacts including a second base plate having a second opening for receiving the threaded socket insert; a mating seal (360) sealing between the first housing and the second housing at a mating interface between the first harness connector and the second harness connector; a bolt position assurance device (340) coupled to the first hub and movable between a pre-stage position and an assurance position; Equipped with the threaded bolt is threadedly coupled to the threaded socket insert to a tightened position, and the bolt position assurance device assures the positioning of the threaded bolt in the first hub in the tightened position in the assured position; Power harness (102).

18. 18. The power harness of claim 17, wherein the first power conductor is a power cable terminated to the termination of the first power contact, the power cable extending from the first housing, and the second power conductor is one of a second power cable or a bus bar connected to an electrical device.

19. The electrical power harness of claim 17, wherein both the first harness connector (200) and the second harness connector (400) are touchproof both before and after mating.

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

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