CN118020215A

CN118020215A - Headstock power connector

Info

Publication number: CN118020215A
Application number: CN202280065105.8A
Authority: CN
Inventors: A·L·F·卡瓦列里; D·J·莱茵
Original assignee: Tyco Electronics Brasil Ltda; TE Connectivity Solutions GmbH
Current assignee: TE Connectivity Brasil Industria de Eletronicos Ltda; TE Connectivity Solutions GmbH
Priority date: 2021-08-26
Filing date: 2022-08-26
Publication date: 2024-05-10

Abstract

A header power connector includes a header housing assembly including an outer housing having cavities that receive corresponding inner housings that hold terminals for electrically connecting upper and lower bus bars. The inner housing is movable relative to the outer housing to accommodate misalignment of the corresponding upper and lower bus bars. The terminals are movable in the terminal channels of the inner housing to accommodate misalignment of the corresponding upper and lower bus bars.

Description

Headstock power connector

Cross Reference to Related Applications

The present application is a continuation-in-part application of U.S. application Ser. No.17/412,917, entitled "HEADERPOWERCONNECTOR (header Power connector)" filed on 8/26 of 2021, the subject matter of which is incorporated herein by reference in its entirety.

Background

The subject matter herein relates generally to header power connectors.

Power connectors are used to transfer power between electrical components. For example, in an electric vehicle, an electrical power connector is used to electrically connect an inverter with an electric motor. Typically, power is supplied by coupling a cable mounted plug connector to a header power connector. The plug connector may be manipulated and moved into a mated position with the header power connector. The plug connector as an additional component extending between the electrical components adds to the overall cost of the system. It is desirable to directly couple electrical components to header power connectors in order to eliminate plug connectors, thereby reducing component count and system costs. However, alignment of the electrical components with the header power connector is difficult and may result in improper mating and damage to the components.

There remains a need for a header power connector having improved mating tolerances.

Disclosure of Invention

In one embodiment, a header power connector is provided and includes a header housing assembly including an outer housing having a first cavity and a second cavity. The header housing assembly includes a first inner housing received in the first cavity and a second inner housing received in the second cavity. The first inner housing includes a first terminal passageway. The second inner housing includes a second terminal passageway. The first and second inner housings are configured to receive an upper bus bar. The first and second inner housings are configured to receive a lower bus bar. The first inner housing is movable relative to the outer housing in the first cavity to accommodate misalignment of the corresponding upper and lower bus bars in the first terminal channel, and the second inner housing is movable relative to the outer housing in the second cavity to accommodate misalignment of the corresponding upper and lower bus bars in the second terminal channel. The header power connector includes a first terminal received in the first terminal passage. The first terminal includes an upper mating end having an upper socket configured to receive a corresponding upper bus bar and a lower mating end having a lower socket configured to receive a corresponding lower bus bar. The first terminals are configured to electrically connect corresponding upper and lower bus bars. The first terminals are movable in the first terminal channels to accommodate misalignment of the corresponding upper and lower bus bars in the first terminal channels. The header power connector includes a second terminal received in the second terminal passage. The second terminal includes an upper mating end having an upper socket configured to receive a corresponding upper bus bar and a lower mating end having a lower socket configured to receive a corresponding lower bus bar. The second terminals are configured to electrically connect the corresponding upper and lower bus bars. The second terminal is movable in the second terminal channel to accommodate misalignment of the corresponding upper and lower bus bars in the second terminal channel.

In another embodiment, a header power connector is provided that includes a header housing assembly including an outer housing having a first cavity and a second cavity. The header housing assembly includes a first inner housing received in the first cavity and a second inner housing received in the second cavity. The first inner housing includes a first terminal passageway. The second inner housing includes a second terminal passageway. The first and second inner housings are configured to receive an upper bus bar. The first and second inner housings are configured to receive a lower bus bar. The header power connector includes a first terminal received in the first terminal passage. The first terminal includes an upper mating end having an upper socket configured to receive a corresponding upper bus bar and a lower mating end having a lower socket configured to receive a corresponding lower bus bar. The first terminals are configured to electrically connect corresponding upper and lower bus bars. The header power connector includes a second terminal received in the second terminal passage. The second terminal includes an upper mating end having an upper socket configured to receive a corresponding upper bus bar and a lower mating end having a lower socket configured to receive a corresponding lower bus bar. The second terminals are configured to electrically connect the corresponding upper and lower bus bars. The first inner housing is movable relative to the outer housing between a positive inner housing tilt position and a negative inner housing tilt position at various tilt angles. The first inner housing is positionable at a non-tilt angle centered between the positive inner housing tilt position and the negative inner housing tilt position. The first inner housing is movable relative to the outer housing to accommodate misalignment of corresponding upper and lower bus bars in the first terminal channel. The second inner housing is movable relative to the outer housing between a positive inner housing tilt position and a negative inner housing tilt position at various tilt angles. The second inner housing is positionable at a non-tilt angle centered between the positive inner housing tilt position and the negative inner housing tilt position. The second inner housing is movable relative to the outer housing to accommodate misalignment of corresponding upper and lower bus bars in the second terminal channels. The first terminal is movable in the first terminal passage between a positive terminal tilt position and a negative terminal tilt position relative to the first inner housing at various tilt angles. The first terminal is positionable at a non-tilt angle centered between the positive terminal tilt position and the negative terminal tilt position. The first terminals are movable relative to the first inner housing to accommodate misalignment of the corresponding upper and lower bus bars in the first terminal channels. The second terminal is movable in the second terminal passageway between a positive terminal tilt position and a negative terminal tilt position at various tilt angles relative to the second inner housing. The second terminal is positionable at a non-tilt angle centered between the positive terminal tilt position and the negative terminal tilt position. The second terminal is movable relative to the second inner housing to accommodate misalignment of corresponding upper and lower bus bars in the second terminal channel.

In another embodiment, a power connector system is provided that includes a first upper bus bar and a second upper bus bar for powering a first electrical component. The first and second upper bus bars have upper bus bar edges. The power connector system includes a first lower bus bar and a second lower bus bar for powering the second electrical component. The first lower bus bar and the second lower bus bar have lower bus bar edges. The power connector system includes header power connectors for electrically connecting the first and second upper bus bars with the first and second lower bus bars. The header power connector includes a header housing assembly including an outer housing having a first cavity and a second cavity. The header housing assembly includes a first inner housing received in the first cavity and a second inner housing received in the second cavity. The first inner housing includes a first terminal passageway. The second inner housing includes a second terminal passageway. The first inner housing receives the first upper bus bar and the first lower bus bar. The second inner housing receives the second upper bus bar and the second lower bus bar. The first inner housing is movable in the first cavity relative to the outer housing to accommodate misalignment of the first upper bus bar and the first lower bus bar in the first terminal channel. The second inner housing is movable in the second cavity relative to the outer housing to accommodate misalignment of the second upper bus bar and the second lower bus bar in the second terminal channel. The header power connector includes a first terminal received in the first terminal passage. The first terminal includes an upper mating end having an upper socket configured to receive the first upper bus bar and a lower mating end having a lower socket configured to receive the first lower bus bar. The first terminal is configured to electrically connect the first upper bus bar and the first lower bus bar. The first terminal is movable in the first terminal channel to accommodate misalignment of the first upper bus bar and the first lower bus bar in the first terminal channel. The header power connector includes a second terminal received in the second terminal passage. The second terminal includes an upper mating end having an upper socket configured to receive the second upper bus bar and a lower mating end having a lower socket configured to receive the second lower bus bar. The second terminal is configured to electrically connect the second upper bus bar and the second lower bus bar. The second terminal is movable in the second terminal channel to accommodate misalignment of the second upper bus bar and the second lower bus bar in the second terminal channel.

Drawings

Fig. 1 is a schematic diagram of a header power connector according to an exemplary embodiment.

Fig. 2 is a perspective view of a header power connector according to an exemplary embodiment.

Fig. 3 is a side view of a terminal according to an exemplary embodiment.

Fig. 4 is a bottom perspective view of an outer housing according to an exemplary embodiment.

Fig. 5 is a bottom perspective view of the inner housing according to an exemplary embodiment.

Fig. 6 is a bottom perspective view of a header power connector according to an exemplary embodiment.

Fig. 7 is a bottom perspective partial cross-sectional view of a header power connector according to an exemplary embodiment.

Fig. 8 is a cross-sectional view of a header power connector according to an exemplary embodiment.

Fig. 9 is a cross-sectional view of header power connector 100 according to an exemplary embodiment.

Fig. 10 is a cross-sectional view of a header power connector 100 according to an exemplary embodiment.

Fig. 11 is a perspective view of a header power connector according to an exemplary embodiment.

Fig. 12 is an exploded view of a header power connector according to an exemplary embodiment.

Fig. 13 is a bottom perspective partial cutaway view of a header power connector according to an exemplary embodiment.

Fig. 14 is a cross-sectional view of a header power connector according to an example embodiment, showing the header power connector mated with a first bus bar and a second bus bar.

Detailed Description

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

In the exemplary embodiment, first electrical component 102 includes a first bus bar 106 and second electrical component 104 includes a second bus bar 108. The first and second bus bars 106, 108 are configured to be directly inserted into opposite ends of the header power connector 100. The header power connector 100 electrically connects the first and second bus bars 106, 108 to transfer power between the first and second electrical components 102, 104.

Fig. 2 is a perspective view of a header power connector 100 according to an exemplary embodiment. Fig. 2 shows portions of the first electrical component 102 and the second electrical component 104. Fig. 2 shows a primary bus bar 106 and a secondary bus bar 108. The first bus bar 106 is a metal plate, such as a copper plate. The second bus bar 108 is a metal plate, such as a copper plate. In the illustrated embodiment, the first electrical component 102 includes a plurality of first bus bars 106 and the second electrical component 104 includes a plurality of second bus bars 108.

The header power connector 100 is located between a first electrical component 102 and a second electrical component 104.

The bus bar 106 of the first electrical component 102 is configured to be directly inserted into the header electrical connector 100.

The bus bars 108 of the first electrical component 104 are configured to be directly inserted into the header power connector 100. Alternatively, the header power connector 100 may be initially mounted to the first electrical component 102 (or the second electrical component 104) and mated to the second electrical component 104 (or the first electrical component 102) when the first electrical component 102 is mounted to the second electrical component 104.

The header power connector 100 includes a header housing assembly 200 and one or more terminals 300 (shown in fig. 3) held by the header housing assembly 200. In the exemplary embodiment, header housing assembly 200 is a multi-piece housing assembly. For example, the header housing assembly 200 includes an outer housing 202 and an inner housing 204. The inner housing 204 holds the terminals 300. The inner housing 204 is received in a cavity 206 of the outer housing 202. In the exemplary embodiment, outer housing 202 is configured to mount to one of the electrical components, such as second electrical component 104. In the exemplary embodiment, inner housing 204 is movable relative to outer housing 202 to accommodate alignment and mating with first electrical component 102. For example, the inner housing 204 may tilt or rotate within the outer housing 202 to accommodate misalignment of the primary and secondary bus bars 106, 108. Inner housing 204 has a limited amount of restrained movement relative to outer housing 202. The outer housing 202 is shaped to control and inhibit movement of the inner housing 204 during mating. For example, the outer housing 202 may allow the inner housing 204 to rotate a predetermined amount to allow engagement with the bus bar 106 of the first electrical component 102 during engagement with the bus bar 106 of the first electrical component 102. In the exemplary embodiment, terminal 300 also has a limited amount of limited movement relative to inner housing 204 to accommodate misalignment of first bus bar 106 and second bus bar 108 during mating.

Fig. 3 is a side view of a terminal 300 according to an exemplary embodiment. Terminal 300 is a double-ended socket terminal configured to receive first and second bus bars 106, 108 (shown in fig. 1) in opposite ends of terminal 300. Other types of terminals may be used in alternative embodiments.

The terminal 300 is a press-formed terminal made of a metal material such as a copper material. The terminal 300 may have one or more plating layers, such as nickel plating and/or gold plating. The terminal 300 includes a terminal base 302, an upper mating end 304 on a first side of the terminal base 302, and a lower mating end 306 on a second side of the terminal base 302. Alternatively, the upper mating end 304 and the lower mating end 306 may be identical.

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

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

In an exemplary embodiment, the spring beams 312, 314, 322, 324 may be identical to one another. The spring beams 312, 314, 322, 324 may be deflectable when mated with the corresponding bus bar 106 or 108. For example, the spring beams 312, 314, 322, 324 may be deflected outward when mated with the bus bars 106 or 108 to bias the spring beams 312, 314, 322, 324 inward to maintain electrical contact between the spring beams 312, 314, 322, 324 and the bus bars 106 or 108.

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

The terminal base 302 is generally located at a central portion of the terminal 300, such as between an upper mating end 304 and a lower mating end 306. The terminal base 302 includes an upper end 350 and a lower end 352. The terminal base 302 includes a first side 354 and a second side 356. The upper spring beams 312, 314 extend from the upper end 350 at a first side 354 and a second side 356, respectively. The lower spring beams 322, 324 extend from the lower end 352 at a first side 354 and a second side 356, respectively. In an exemplary embodiment, the terminal base 302 includes an opening 358 therethrough. Alternatively, the opening 358 may be generally centered between the upper end 350 and the lower end 352, and may be generally centered between the first side 354 and the second side 356. The opening 358 may receive a portion of the header housing assembly 200 to position and/or retain the terminal 300 in the header housing assembly 200. For example, the shaft may extend through the opening 358. Alternatively, the terminal 300 may be rotated about the axis to shift the relative positions of the upper and lower mating ends 304, 306.

Fig. 4 is a bottom perspective view of the outer housing 202 according to an exemplary embodiment. The outer housing 202 includes an outer wall 210 surrounding the cavity 206. The outer wall 210 extends between an upper end 212 and a lower end 214 of the outer housing 202. In the exemplary embodiment, upper end 212 is configured to be mounted to first electrical component 102 such that header electrical connector 100 extends from a bottom of first electrical connector 102. In alternative embodiments, other mounting orientations are possible. For example, the header power connector 100 may be oriented such that the end 212 defines a bottom of the outer housing 202, such as when the outer housing 202 is mounted to a top of a structure (such as one of the electrical components). In other various embodiments, the outer housing 202 may be oriented such that neither end 212, 214 is at the top or bottom, but rather defines a side of the outer housing 202. The terms "upper" and "lower" are used herein to refer to the directions shown in the drawings.

The outer housing 202 includes mounting flanges 216 at opposite sides 220, 222 of the outer housing 202. The mounting flange 216 may receive fasteners to secure the outer housing 202 to the first electrical component 102. The outer housing 202 includes a front 224 and a rear 226 extending between the sides 220, 222. The cavity 206 is formed between the front 224 and the rear 226. The cavity 206 extends between a first side 220 and a second side 222. The cavity 206 is open to receive the inner housing 204 (shown in fig. 5).

The outer housing 202 includes a support wall extending from the lower end 214. The support wall 230 is used to support the inner housing 204 in the cavity 206. Optionally, the support wall 230 is discontinuous. For example, the support walls 230 may be separated by a gap. Support walls 230 are provided at the front 224 and rear 226 portions. Alternatively, the support wall 230 may be disposed at the first side 220 and the second side 222. The support wall 230 extends to an edge 232. In the illustrated embodiment, edge 232 is a bottom edge. Optionally, the edge 232 may be chamfered to guide loading of the inner housing 204 into the cavity 206. The edges 232 may be chamfered to allow the inner housing 204 to tilt in the cavity 206 relative to the outer housing 202 to accommodate misalignment of the bus bars 106, 108, as described in further detail below.

In the exemplary embodiment, outer housing 202 includes a connecting wall 234 that extends between front 224 and rear 226. The connecting wall 234 extends across the cavity 206. The connecting wall 234 may connect the support wall 230 and/or the outer wall 210 at the front 224 and rear 226. The connecting wall 234 divides the cavity 206 into recesses (pockets) 236. In the exemplary embodiment, each recess 236 receives a corresponding bus bar 106 and/or 108.

The outer housing 202 includes a latch feature 240 for securing the inner housing 204 to the outer housing 202. In the illustrated embodiment, the latch features 240 are deflectable latch tabs configured to engage corresponding latch features of the inner housing 204. The latching feature 240 may be releasable to release the inner housing 204 from the outer housing 202. In various embodiments, the latch features 240 are formed in the support wall 230. Alternatively, the latching features 240 may be separate from the support walls 230, such as interspersed within gaps between the support walls 230. In the illustrated embodiment, the latch feature 240 includes an opening 242. The openings are configured to engage corresponding latching features of the inner housing 204. In alternative embodiments, other types of latching features may be used.

Fig. 5 is a bottom perspective view of inner housing 204 according to an exemplary embodiment. The inner housing 204 includes a plurality of inner walls 250 extending between an upper end 252 and a lower end 254. The inner wall 250 forms a terminal channel 256, the terminal channel 256 being configured to receive a corresponding terminal 300 therein. The terminal channels 256 are open at the upper and lower ends 252, 254 to receive the bus bars 106, 108, respectively. For example, the inner housing 204 includes an upper opening 257 (shown in fig. 7) that receives the primary bus bar 106 and a lower opening 258 that receives the secondary bus bar 108. The inner walls 250 guide the bus bars 106, 108 into the terminal channels 256 to mate with the terminals 300. Optionally, the upper opening 257 and/or the lower opening 258 may include a chamfered lead-in surface that guides the bus bars 106, 108 into the terminal channels 256.

The inner housing 204 includes a first side 260 and a second side 262 opposite the first side 260. The inner housing 204 includes a front 264 and a rear 266 extending between the sides 260, 262. In the exemplary embodiment, inner housing 204 includes a latch feature 268 that extends from front 264 and/or rear 266. Latch feature 268 is configured to interface with latch feature 240 (shown in fig. 4) of outer housing 202 to secure inner housing 204 in cavity 206 of outer housing 202. In the illustrated embodiment, the latching features 268 include latches, each having a ramped surface at a top of the latch and a catch surface at a bottom of the latch. In alternative embodiments, other types of latching features may be provided.

In the exemplary embodiment, inner housing 204 includes a slot 270 that is open at upper end 252. The slots 270 are configured to receive corresponding connection walls 234 (shown in fig. 4) of the outer housing 202 when the inner housing 204 is loaded into the cavity 206 of the outer housing 202. The slots 270 are used to position the inner housing 204 relative to the outer housing 202 and control the side-to-side positioning of the inner housing 204 relative to the outer housing 202.

In the exemplary embodiment, inner housing 204 includes a locating rib 272 that extends from front 264 and/or rear 266. The positioning ribs 272 are configured to position the inner housing 204 relative to the outer housing 202. In the exemplary embodiment, support walls 230 and latch features 240 (both shown in fig. 4) of outer housing 202 are received in spaces between positioning ribs 272. In the exemplary embodiment, positioning ribs 272 are configured to position inner housing 204 to mate with second electrical component 104. For example, the locating rib 272 may engage a portion of the second electrical component 104 to locate the header housing assembly 200 relative to the second electrical component 104.

Fig. 6 is a bottom perspective view of the header power connector 100 according to an exemplary embodiment. Fig. 6 shows the terminal 300 loaded in the terminal passage 256. Fig. 6 shows an inner housing 204 coupled to an outer housing 202. The inner housing 204 is loaded into the cavity 206 of the outer housing 202. The latching features 240 of the outer housing 202 engage the latching features 268 of the inner housing 204 to secure the inner housing 204 in the outer housing 202. For example, latch feature 268 is received in opening 242 of latch feature 240. The positioning ribs 272 are used to position the inner housing 204 relative to the outer housing 202. The locating rib 272 is received in the slot 238 between the support wall 230 and the latching feature 240.

In the exemplary embodiment, support wall 230 is relatively short compared to the overall height of inner wall 250. For example, the support wall 230 may extend less than half the height of the inner wall 250. In this way, the inner housing 204 can tilt or rotate within the cavity 206 relative to the support wall 230 to accommodate misalignment of the first and second bus bars 106, 108 (both shown in fig. 1). The chamfered surface at the edge 232 of the support wall 230 allows the inner housing 204 to pivot relative to the outer housing 202 to insert the second bus bar 108 into the lower opening 258 of the inner housing 204.

Fig. 7 is a bottom perspective partial cutaway view of the header power connector 100 according to an exemplary embodiment. Fig. 7 shows the terminals 300 loaded in the terminal channels 256. In the exemplary embodiment, a plurality of terminals 300 are stacked together in a terminal stack 308. Each terminal channel 256 of the inner housing 204 receives a corresponding terminal stack 308 of the terminals 300. Terminals 300 are arranged side by side in a terminal stack 308. Terminal 300 serves as a single terminal assembly within terminal stack 308. However, the terminals 300 may be independently movable with respect to each other. The terminals 300 may be stamped and formed from thin metal sheets, but stacked together to increase the overall current carrying capacity of the terminal assembly.

When assembled, the outer housing 202 and the inner housing 204 cooperate to form a recess 208 that receives a corresponding terminal stack 308. The inner case 204 holds the terminal 300 from below, from the side, from the front and from the rear, while the outer case 202 holds the terminal 300 from above, thereby closing the recess 208. In the exemplary embodiment, inner housing 204 includes a lip 274 that extends inward from front 264 and rear 266 at lower end 254. Lips 274 are provided on opposite sides of the lower opening 258. The lip 274 supports the terminal 300 in the recess 208. For example, lip 274 supports first lower spring beam 322 and second lower spring beam 324. The lower opening 258 is aligned with the lower socket 320 to receive the second bus bar 108. In the exemplary embodiment, outer housing 202 includes an opening 244 that is aligned with an upper opening 257 of inner housing 204. The opening 244 is aligned with the upper socket 310 to receive the primary bus bar 106. For example, the primary bus bar 106 passes through the opening 244 and through the upper opening 257 of the inner housing 204 into the terminal channel 256 to interface with the terminal 300.

In an exemplary embodiment, the terminal channels 256 are oversized relative to the terminals 300 to allow a limited amount of restricted movement of the terminals 300 within the terminal channels 256. For example, the terminals 300 may be displaced from front to back and/or side to side and/or rotated or pivoted from top to bottom to mate with the primary and secondary bus bars 106, 108. For example, when the first and second bus bars 106, 108 are offset from one another, the terminal 300 may shift or move within the terminal channel 256 to accommodate misalignment. Similarly, the cavity 206 of the outer housing 202 is oversized relative to the inner housing 204 to allow a limited amount of restricted movement of the inner housing 204 within the cavity 206. For example, the inner housing 204 may be displaced from front to back and/or side to side and/or rotated or pivoted from top to bottom to mate with the primary and secondary bus bars 106, 108. For example, when the primary and secondary bus bars 106, 108 are offset from one another, the inner housing 204 may move or translate within the cavity 206 to accommodate misalignment.

Fig. 8 is a cross-sectional view of the header power connector 100, showing the header power connector 100 mated with the first and second bus bars 106, 108 when the first and second bus bars 106, 108 are aligned, according to an example embodiment. Fig. 9 is a cross-sectional view of header power connector 100 according to an exemplary embodiment, showing header power connector 100 mated with first bus bar 106 and second bus bar 108, where second bus bar 108 is offset in a first (right) direction. Fig. 10 is a cross-sectional view of header power connector 100 according to an example embodiment, showing header power connector 100 mated with first bus bar 106 and second bus bar 108, where second bus bar 108 is offset in a second (left) direction.

The primary bus bar 106 includes a primary bus bar edge 120, the primary bus bar edge 120 configured to be inserted into the header power connector 100. First bus bar 106 includes a first side 122 and a second side 124. The primary bus bar 106 extends along a primary bus bar axis 126. The primary bus bar axis 126 is centered between the first side 122 and the second side 124. In the illustrated embodiment, the primary bus bar axis 126 is oriented vertically; however, the primary bus bar axis 126 may be oriented at an oblique angle other than vertical. In alternative embodiments, the header power connector 100 may be oriented such that the primary bus bars 106 mate in a different orientation (e.g., a horizontal orientation).

The second bus bar 108 includes a second bus bar edge 130, the second bus bar edge 130 configured to be inserted into the header power connector 100. The second bus bar 108 includes a first side 132 and a second side 134. Alternatively, the width of the second bus bar 108 between the first side 132 and the second side 134 may be equal to the width of the first bus bar 106. The secondary bus bar 106 extends along a secondary bus bar axis 136. The second bus bar axis 136 is centered between the first side 132 and the second side 134. In the illustrated embodiment, the second bus bar axis 136 is oriented vertically; however, the secondary bus bar axis 136 may be oriented at an oblique angle other than vertical. In alternative embodiments, the header power connector 100 may be oriented such that the second bus bars 108 mate in a different orientation (e.g., a horizontal orientation).

When first bus bar 106 and second bus bar 108 are aligned (fig. 8) (e.g., first bus bar axis 126 is parallel to second bus bar axis 136 and coincides with second bus bar axis 136), first bus bar 106 and second bus bar 108 may be inserted directly into terminal channel 256 to mate with terminal 300.

Tolerances are built into header power connector 100 to accommodate insertion of primary and secondary bus bars 106, 108 into terminal channels 256. For example, tolerances are built into the outer housing 202 and the inner housing 204, and tolerances are built into the terminal 300 and the terminal channels 256 of the inner housing 204. In various embodiments, the cavity 206 is oversized relative to the inner housing 204 such that a gap is formed between the inner surface 280 of the outer wall 210 and the outer surface 282 of the inner wall 250. For example, a first cavity gap 284 may be provided between a first outer wall 225 at the front 224 of the outer housing 202 and a first inner wall 265 at the front 264 of the inner housing 204, and a second cavity gap 286 may be provided between a second outer wall 227 at the rear 226 of the outer housing 202 and a second inner wall 267 at the rear 266 of the inner housing 204. The cavity gaps 284, 286 are narrow compared to the overall width of the header housing assembly 200, but provide some play and movement between the inner housing 204 and the outer housing 202. In various embodiments, terminal channels 256 are oversized relative to terminals 300 such that a gap is formed between inner surface 290 of inner housing 204 and the sides of terminals 300. For example, a first channel gap 294 may be disposed between a first inner wall 265 at the front 264 of the inner housing 204 and the first side 354 of the terminal 300, and a second channel gap 296 may be disposed between a second inner wall 267 at the rear 266 of the inner housing 204 and the second side 356 of the terminal 300. The channel gaps 294, 296 are relatively narrow compared to the total width of the terminal channels 256, but provide some play and movement between the terminals 300 and the inner housing 204.

When first bus bar 106 and second bus bar 108 are offset in a first direction (fig. 9) (e.g., first bus bar axis 126 is offset from second bus bar axis 136), inner housing 204 may be moved relative to outer housing 202 to accommodate the misalignment and/or terminal 300 may be moved relative to inner housing 204 to accommodate the misalignment.

In various embodiments, the inner housing 204 may be rotated such that the lower end 254 is displaced to the right and the upper end 252 is displaced to the left. The size of the cavity 206 relative to the inner housing 204 allows for a limited amount of restricted movement (e.g., rotation) of the inner housing 204 within the cavity 206. The cavity gaps 284, 286 accommodate movement of the inner housing 204 relative to the outer housing 202. The size of the cavity gaps 284, 286 may vary as the inner housing 204 moves relative to the outer housing 202. For example, as the inner housing 204 rotates from the non-tilted position (fig. 8) to the tilted position (fig. 9), the first cavity gap 284 may narrow at the upper end 252 and widen at the lower end 254. Conversely, the second cavity gap 286 may widen at the upper end 252 and narrow at the lower end 254. The inner housing 204 may be rotated until the inner housing 204 bottoms out against the outer housing 202 (bottomout). In this way, the outer housing 202 limits the amount of rotation of the inner housing 204. For example, the front 264 of the inner housing 204 bottoms out against the outer housing 202 at one side of the cavity 206, while the rear 266 of the inner housing 204 bottoms out against the outer housing 202 at the opposite side of the cavity 206. The inner housing 204 may be tilted at any angle between a non-tilted position and a maximally tilted position in which the inner housing 204 bottoms out against the outer housing 202.

During mating, the terminal base 302 may be moved (e.g., rotated and/or laterally displaced) relative to the inner housing 204 between a first position (non-tilted) and a second position (tilted) to accommodate misalignment of the first and second bus bars 106, 108 in the terminal channels 256. The terminal base 302 rotates within the terminal channel 256 to move the relative positions of the upper and lower mating ends 304, 306 to accommodate the misalignment.

In various embodiments, the terminal 300 may be rotated relative to the inner housing 204 such that the lower mating end 306 is displaced to the right and the upper mating end 304 is displaced to the left. The size of the terminal channels 256 relative to the terminals 300 allows for a limited amount of limited movement (e.g., rotation) of the terminals 300 within the terminal channels 256. The channel gaps 294, 296 accommodate movement of the terminal 300 relative to the inner housing 204. The dimensions of the channel gaps 294, 296 may vary as the terminal 300 moves relative to the inner housing 204. For example, as the terminal 300 rotates from the non-tilted position (fig. 8) to the tilted position (fig. 9), the first channel gap 294 may narrow at the upper end 252 and widen at the lower end 254. Conversely, the second channel gap 296 may widen at the upper end 252 and narrow at the lower end 254. The terminal 300 may be rotated until the terminal 300 bottoms out against the inner housing 204. In this way, the inner housing 204 limits the rotation amount of the terminal 300. For example, a first side of terminal 300 bottoms out at first inner wall 265 and a second side of terminal 300 bottoms out at second inner wall 267. The terminal 300 may be tilted at any angle between a non-tilted position and a maximally tilted position in which the terminal 300 bottoms out against the inner housing 204. In the exemplary embodiment, in the tilted position, first upper spring beam 312 is closer to first inner wall 265 than first lower spring beam 322. Similarly, in the tilted position, the second lower spring beam 324 is closer to the second inner wall 267 than the second upper spring beam 314.

In the exemplary embodiment, cavity 206 extends along a cavity axis. The cavity axis extends between an upper end 212 and a lower end 214 of the outer housing 202. In various embodiments, the cavity axis extends substantially vertically. In the exemplary embodiment, terminal channels 256 extend along a channel axis. The passage axis extends between an upper opening 257 at the upper end 252 and a lower opening 258 of the lower end 254 of the inner housing 204. In various embodiments, the channel axis extends substantially vertically. However, to accommodate misalignment of the bus bars 106, 108, the inner housing 204 may be pivoted such that the channel axis is at an oblique angle non-parallel to the cavity axis. In the exemplary embodiment, terminal 300 extends along terminal axis 140 between upper socket 310 and lower socket 320. To accommodate misalignment of the bus bars 106, 108, the terminal 300 may be pivoted such that the terminal axis 140 is at an oblique angle that is not parallel to the channel axis.

When first bus bar 106 and second bus bar 108 are offset in the second direction (fig. 10) (e.g., first bus bar axis 126 is offset from second bus bar axis 136), inner housing 204 may move relative to outer housing 202 to accommodate the misalignment and/or terminal 300 may move relative to inner housing 204 to accommodate the misalignment.

In various embodiments, the inner housing 204 may be rotated such that the lower end 254 is displaced to the left and the upper end 252 is displaced to the right. The size of the cavity 206 relative to the inner housing 204 allows for a limited amount of restricted movement (e.g., rotation) of the inner housing 204 within the cavity 206. The size of the cavity gaps 284, 286 may vary as the inner housing 204 moves relative to the outer housing 202. For example, the second cavity gap 286 may narrow at the upper end 252 and widen at the lower end 254. Conversely, the first cavity gap 284 may be widened at the upper end 252 and narrowed at the lower end 254. The inner housing 204 may be rotated until the inner housing 204 bottoms out against the outer housing 202. The inner housing 204 may be tilted at any angle between a non-tilted position (fig. 8) and a maximally tilted position (fig. 10) in which the inner housing 204 bottoms out against the outer housing 202. To accommodate misalignment of the bus bars 106, 108, the inner housing 204 may be pivoted such that the channel axis is at an oblique angle non-parallel to the cavity axis.

In various embodiments, the terminal 300 may be rotated relative to the inner housing 204 such that the lower mating end 306 is displaced to the left and the upper mating end 304 is displaced to the right. The size of the terminal channels 256 relative to the terminals 300 allows for a limited amount of limited movement (e.g., rotation) of the terminals 300 within the terminal channels 256. The channel gaps 294, 296 accommodate movement of the terminal 300 relative to the inner housing 204. The dimensions of the channel gaps 294, 296 may vary as the terminal 300 moves relative to the inner housing 204. For example, the first channel gap 294 may widen at the upper end 252 and narrow at the lower end 254. Conversely, the second channel gap 296 may narrow at the upper end 252 and widen at the lower end 254. The terminal 300 may be rotated until the terminal 300 bottoms out against the inner housing 204. The terminal 300 may be tilted at any angle between a non-tilted position (fig. 8) and a maximally tilted position (fig. 10) in which the terminal 300 bottoms out against the inner housing 204. In the exemplary embodiment, in the tilted position, first lower spring beam 322 is closer to first inner wall 265 than first upper spring beam 312. Similarly, in the tilted position, the second upper spring beam 314 is closer to the second inner wall 267 than the second lower spring beam 324. To accommodate misalignment of the bus bars 106, 108, the terminal 300 may be pivoted such that the terminal axis 140 is at an oblique angle that is not parallel to the channel axis.

Fig. 11 is a perspective view of a header power connector 150 according to an exemplary embodiment. The header power connector 150 is similar to the header connector 100 (shown in fig. 2). The header power connector 150 is used to electrically connect a first electrical component 152 and a second electrical component 154 (both shown schematically in fig. 11). In various embodiments, the first and second electrical components 152, 154 may be part of an electric vehicle. For example, the first electrical component 152 may be an inverter and the second electrical component 154 may be an electric motor. In alternative embodiments, the header power connector 150 may be used to electrically connect other types of electrical components. In the illustrated embodiment, the first electrical component 152 is located above the header electrical connector 150 (hereinafter may be referred to as the upper electrical component 152) and the second electrical component 154 is located below the header electrical connector 150 (hereinafter may be referred to as the lower electrical component 154). Alternatively, the header power connector 150 may be initially mounted to the first electrical component 152 (or the second electrical component 154) and mated to the second electrical component 154 (or the first electrical component 152) when the first electrical component 152 is mounted to the second electrical component 154.

In the exemplary embodiment, first electrical component 152 includes a plurality of first bus bars 156 and second electrical component 154 includes a plurality of second bus bars 158. The first bus bar 156 may be hereinafter referred to as an upper bus bar 156, and the second bus bar 158 may be hereinafter referred to as a lower bus bar 158. The first and second bus bars 156, 158 are configured to be directly inserted into opposite ends of the header power connector 150. The header power connector 150 electrically connects the first and second bus bars 156, 158 to transfer power between the first and second electrical components 152, 154. In an exemplary embodiment, the bus bars 156, 158 of the electrical components 152, 154 are oriented parallel and non-coplanar with each other, as opposed to the header power connector 150, which header power connector 150 orients the bus bars 156, 158 parallel and coplanar with each other. However, in alternative embodiments, other orientations of the bus bars 156, 158 are possible.

The header power connector 150 includes a header housing assembly 400 for holding the terminals 300 (shown in fig. 3). In an exemplary embodiment, the header housing assembly 400 is a multi-piece housing assembly. For example, the header housing assembly 400 includes an outer housing 402 and a plurality of inner housings 404 coupled to the outer housing 402. The inner housing 404 holds the terminal 300. The inner housing 404 is received in a corresponding outer housing cavity 406 of the outer housing 402. In the exemplary embodiment, outer housing 402 is configured to mount to one of the electrical components, such as second electrical component 154.

In an exemplary embodiment, the inner housing 404 is movable relative to the outer housing 402 to accommodate alignment and mating with the first electrical component 152. For example, each inner housing 404 may be tilted or rotated within outer housing 402 to accommodate misalignment of primary and secondary bus bars 156, 158. The inner housing 404 has a limited amount of restrained movement relative to the outer housing 402. The outer housing 402 is shaped to control and inhibit movement of the inner housing 404 during mating. For example, the outer housing 402 may allow the inner housing 404 to rotate or tilt (side-to-side and/or front-to-back) a predetermined amount to allow engagement with the bus bars 156 of the first electrical component 152 during engagement with the bus bars 156 of the first electrical component 152. The inner housing 404 is independently movable relative to each other within the outer housing 402. For example, the inner housing 404 may be tilted or moved to different angles relative to the outer housing 402. In an exemplary embodiment, the terminal 300 also has a limited amount of limited movement relative to the corresponding inner housing 404 to accommodate misalignment of the first and second bus bars 156, 158 during mating.

Fig. 12 is an exploded view of header power connector 150 according to an exemplary embodiment. Header power connector 150 includes an outer housing 402, an inner housing 404, and terminals 300. The terminals 300 are arranged in groups, such as side-by-side in a terminal stack 308. The terminals 300 within the terminal stack 308 function as a single terminal assembly. However, the terminals 300 within the terminal stack 308 may move independently relative to each other. In the illustrated embodiment, each terminal 300 is a double-ended socket terminal configured to receive the first and second bus bars 156, 158 (shown in fig. 1) in opposite ends of the terminal 300. Other types of terminals may be used in alternative embodiments.

In the exemplary embodiment, outer housing 402 is a multi-piece housing. For example, outer housing 402 includes mounting member 407 and clip 408 that is separate from mounting member 407 and coupled to mounting member 407. The mounting 407 is used to mount the header power connector 150 to either the first electrical component 152 or the second electrical component 154. The clamp 408 is used to secure the inner housing 404 to the mount 407. The mounting member 407 and/or the clamping member 408 form an outer housing cavity 406 that receives the inner housing 404.

Mounting member 407 of outer housing 402 includes a base 409 and a mounting flange 416 extending from base 409. In various embodiments, the header power connector 150 is oriented such that the base 409 extends from the bottom of the mounting flange 416. The mounting flange 416 may receive fasteners to secure the outer housing 402 to the first electrical component 152. In the exemplary embodiment, mount 407 includes a perimeter seal 411 around base 409. In the illustrated embodiment, the peripheral seal 411 is coupled to a mounting flange 416. The perimeter seal 411 may seal to the first electrical component 152 and/or the second electrical component 154.

The base 409 of the outer housing 402 comprises an outer wall 410 surrounding a base cavity 413, the base cavity 413 defining a portion of the corresponding outer housing cavity 406. The outer wall 410 extends between an upper end 412 and a lower end 414. The terms "upper" and "lower" are used herein with reference to the orientations shown in the drawings; however, in alternative embodiments, other orientations are possible. The clip 408 is configured to be coupled to a lower end 414, such as to a latch feature 415 on the base 409. In the illustrated embodiment, the latch feature 415 is a latch tab or catch extending from the base 409. In alternative embodiments, other types of securing features may be used to secure the clip 408 to the base 409. In the exemplary embodiment, base 409 includes opposite sides 420, 422 and front 424 and rear 426 extending between sides 420, 422. Base cavity 413 is formed between sides 420, 422 and between front 424 and rear 426. The base cavity 413 is open at a lower end 414 to receive the inner housing 404. In various embodiments, base 409 includes a connecting wall 428 that extends across base cavity 413. The connecting wall 428 divides the base cavity 413 into separate recesses or subchambers that receive the corresponding inner housing 404.

In the exemplary embodiment, outer housing 402 includes a bus bar seal 417 received in cavity 406, bus bar seal 417 being sealed to outer housing 402. Bus bar seal 417 is configured to seal to bus bar 156. For example, the bus bars 156 may pass through openings in the bus bar seals 417 to provide a sealed interface to the corresponding bus bars 156. In the exemplary embodiment, outer housing 402 includes a cap 418 that is received within cavity 406. The caps 418 may be located between corresponding connecting walls 428. Cap 418 may be used to retain bus bar seal 417 in outer housing 402. The cap 418 may be used to retain the terminal 300 in the inner housing 404. In the exemplary embodiment, each cap 418 includes an opening 419 that receives a corresponding bus bar 156. The bus bar 156 passes through the opening 419 to interface with the terminal 300.

The clamp 408 of the outer housing 402 includes a support wall 430 surrounding one or more clamp cavities 431, the clamp cavities 431 forming part of the outer housing cavity 406. The support wall 430 is used to support the inner housing 404 in the clamp chamber 431. Support wall 430 extends to edge 432. In the illustrated embodiment, edge 432 is a bottom edge. Optionally, edge 432 may be chamfered to guide loading of inner housing 404 into base cavity 413. The edges 432 may be chamfered to allow the inner housing 404 to tilt in the cavity 406 relative to the outer housing 402 to accommodate misalignment of the bus bars 156, 158, as described in further detail below.

The clamp 408 includes a latching feature 434 for securing the clamp 408 to the mount 407. For example, the latching features 434 interface with latching features 415 of the base 409 to secure the clip 408 to the base 409. In the illustrated embodiment, the latch feature 434 is a deflectable latch configured to latchably couple to the latch tab. The latching feature 434 may be releasable to release the clip 408 from the base 409. Latch features 434 may be provided at the front and rear of the clamp 408. In alternative embodiments, other locations are possible. In alternative embodiments, other types of securing features may be used.

The clamp 408 includes a latching feature 440 for securing the inner housing 404 to the outer housing 402. In the illustrated embodiment, the latching feature 440 is an opening that receives the latching feature of the inner housing 404. In various embodiments, the latching features 440 are formed in the support wall 430. In alternative embodiments, other types of latching features may be used.

Each inner housing 404 includes a plurality of inner walls 450 extending between an upper end 452 and a lower end 454. The inner wall 450 forms a terminal passage 456, the terminal passage 256 being configured to receive a corresponding terminal 300 therein. The terminal channels 456 open at the upper end 452 and the lower end 454 to receive the bus bars 156, 158, respectively. For example, the inner housing 404 includes an upper opening that receives a corresponding first bus bar 156 and a lower opening that receives a corresponding second bus bar 158. The inner wall 450 guides the bus bars 156, 158 into the terminal channels 456 to mate with the terminals 300. Optionally, the upper and/or lower openings may include chamfered lead-in surfaces that guide the bus bars 156, 158 into the terminal channels 456.

The inner housing 404 includes a first side 460 and a second side 462 opposite the first side 460. The inner housing 404 includes a front 464 and a rear 466 extending between the sides 460, 462. In the exemplary embodiment, inner housing 404 includes a latch feature 468 that extends from front 464 and/or rear 466. The latch features 468 are configured to interface with the latch features 440 of the outer housing 402 to secure the inner housing 404 in the cavity 406 of the outer housing 402. In the illustrated embodiment, the latch features 468 include latches, each having a ramp surface at a top of the latch and a catch surface at a bottom of the latch. In alternative embodiments, other types of latching features may be provided.

In the exemplary embodiment, support wall 430 is relatively short compared to the overall height of inner wall 450. For example, the support wall 430 may extend less than half the height of the inner wall 450. In this way, the inner housing 404 can tilt or rotate within the cavity 406 relative to the support wall 430 to accommodate misalignment of the primary and secondary bus bars 156, 158. The chamfered surface at edge 432 of support wall 430 allows inner housing 404 to pivot relative to outer housing 402 to insert second bus bar 158 into lower opening 458 of inner housing 404.

Fig. 13 is a bottom perspective partial cutaway view of a header power connector 150 according to an exemplary embodiment. Fig. 13 shows the terminals 300 loaded in the terminal channels 456 of the respective inner housings 404. The inner housing 404 is loaded into a cavity 406 of the outer housing 402.

In the exemplary embodiment, terminals 300 are stacked together in corresponding terminal stacks 308. Each terminal passage 456 of the inner housing 404 receives a corresponding terminal stack 308 of the terminals 300. Terminals 300 are arranged side by side in a terminal stack 308. Terminal 300 serves as a single terminal assembly within terminal stack 308. However, the terminals 300 may be independently movable with respect to each other. The terminals 300 may be stamped and formed from thin metal sheets, but stacked together to increase the overall current carrying capacity of the terminal assembly.

When assembled, the outer housing 402 and the inner housing 404 cooperate to form a pocket 405 that accommodates the corresponding terminal stack 308. The inner housing 404 holds the terminal 300 from below, from the side, from the front and from the rear, while the outer housing 402 (e.g., cap 418) holds the terminal 300 from above, thereby closing the pocket 405. In the exemplary embodiment, inner housing 404 includes a lip 474 that extends inwardly from front 464 and rear 466 at lower end 454. Lips 474 are disposed on opposite sides of the lower opening. The lip 474 supports the terminal 300 in the recess 405. The lower opening is aligned with the lower socket 320 to receive the second bus bar 158. In the exemplary embodiment, an opening 419 in cap 418 is aligned with an upper opening of inner housing 404. The openings 419 align with the upper sockets 310 to receive the primary bus bars 156. For example, the primary bus bar 156 passes through the opening 419 and through the upper opening of the inner housing 404 into the terminal passage 456 to interface with the terminal 300.

In an exemplary embodiment, the terminal channels 456 are oversized relative to the terminals 300 to allow a limited amount of restricted movement of the terminals 300 within the terminal channels 456. For example, a gap may be provided between the wall of the inner housing 404 and the terminal 300 to allow the inner housing 404 to move relative to the clamp 408. The terminals 300 may be displaced from front to back and/or side to side and/or top to bottom to mate with the primary and secondary bus bars 156, 158. For example, when the primary and secondary bus bars 156, 158 are offset from one another, the terminal 300 may shift or move within the terminal channel 456 to accommodate misalignment.

In the exemplary embodiment, cavity 406 of outer housing 402 is oversized relative to inner housing 404 to allow a limited amount of restricted movement of inner housing 404 within cavity 406. For example, a gap may be provided between the inner housing 404 and the support wall 430 of the clamp 408 to allow the inner housing 404 to move relative to the clamp 408. A gap may be provided between the inner housing 404 and a wall of the base 409, such as the outer wall 410 and/or the connecting wall 428, to allow movement of the inner housing 404 relative to the base 409. In the exemplary embodiment, inner housings 404 are separated from each other to allow for relative and independent movement of each inner housing 404, for example, to align inner housing 404 with respective bus bars 156, 158. For example, each inner housing 404 may be displaced from front to back and/or side to side and/or rotated or pivoted from top to bottom to mate with the primary and secondary bus bars 156, 158. For example, when the primary and secondary bus bars 156, 158 are offset from one another, the inner housing 404 may move or translate within the cavity 406 to accommodate misalignment.

Fig. 14 is a cross-sectional view of the header power connector 150, showing the header power connector 150 mated with the first and second bus bars 156, 158, according to an exemplary embodiment. Fig. 14 illustrates at least some of the primary and secondary bus bars 156, 158 being offset or misaligned. The inner housing 404 moves relative to the outer housing 402 to accommodate misalignment. The terminal 300 moves relative to the inner housing 404 to accommodate misalignment.

Each first (upper) bus bar 156 includes a first bus bar edge 160, the first bus bar edge 160 configured to be inserted into the header power connector 150. The primary bus bar 156 includes a first side 162 and a second side 164. The primary bus bar 156 extends along a primary bus bar axis 166. The primary bus bar axis 166 is centered between the first side 162 and the second side 164. In the illustrated embodiment, the primary bus bar axis 166 is oriented vertically; however, the primary bus bar axis 166 may be oriented at an oblique angle other than vertical. In alternative embodiments, the header power connector 150 may be oriented such that the primary bus bars 156 mate in a different orientation (e.g., a horizontal orientation).

Each second (lower) bus bar 158 includes a second bus bar edge 170, the second bus bar edges 170 configured to be inserted into the header power connector 150. The second bus bar 158 includes a first side 172 and a second side 174. Alternatively, the width of the second bus bar 158 between the first side 172 and the second side 174 may be equal to the width of the first bus bar 156. The secondary bus bar 158 extends along a secondary bus bar axis 176. The second bus bar axis 176 is centered between the first side 172 and the second side 174. In the illustrated embodiment, the secondary bus bar axis 176 is oriented vertically; however, the secondary bus bar axis 176 may be oriented at an oblique angle other than vertical. In alternative embodiments, the header power connector 150 may be oriented such that the second bus bars 158 mate in a different orientation (e.g., a horizontal orientation).

When first bus bar 156 and second bus bar 158 are aligned (e.g., first bus bar axis 166 is parallel to second bus bar axis 176 and coincides with second bus bar axis 176), first bus bar 156 and second bus bar 158 may be inserted directly into terminal channel 456 to mate with terminal 300. However, due to manufacturing tolerances, the primary and secondary bus bars 156, 158 may be offset or misaligned (e.g., non-parallel and/or displaced forward or backward and/or displaced rightward or leftward).

Tolerances are established in the header power connector 150 to accommodate insertion of the first and second bus bars 156, 158 into the terminal channels 456. For example, tolerances are built into the outer housing 402 and the inner housing 404, and tolerances are built into the terminal 300 and the terminal channels 456 of the inner housing 404. In various embodiments, the cavity 406 is oversized relative to the inner housing 404 such that a cavity gap 484 is formed between the outer surface 482 of the inner wall 450 and the inner surfaces 480, 481 of the walls of the outer housing 402 (e.g., the outer wall 410 and the connecting wall 428) and the inner housing 404 (e.g., the support wall 430). The cavity gap 484 is narrow compared to the overall width of the header housing assembly 400, but provides some play and movement between the inner housing 404 and the outer housing 402. In various embodiments, the terminal passages 456 are oversized relative to the terminals 300 such that a terminal gap 494 is formed between the inner surface 480 of the inner housing 404 and the sides of the terminals 300. The terminal gap 494 is narrower than the total width of the terminal passage 456, but provides some play and movement between the terminal 300 and the inner housing 404.

When the first and second bus bars 156, 158 are offset (e.g., the first bus bar axis 166 is offset from the second bus bar axis 176), the corresponding inner housing 404 may move relative to the outer housing 402 to accommodate misalignment and/or the terminal 300 may move relative to the inner housing 404 to accommodate misalignment.

In various embodiments, the inner housing 404 may be rotated (arrow a) such that the lower end 454 is displaced to the right and the upper end 452 is displaced to the left. The size of the cavity 406 relative to the inner housing 404 allows a limited amount of restricted movement (e.g., rotation) of the inner housing 404 within the cavity 406. The cavity gap 484 accommodates movement of the inner housing 404 relative to the outer housing 402. The size of the cavity gap 484 may vary as the inner housing 404 moves relative to the outer housing 402. For example, as the inner housing 404 rotates from the non-tilted position to the tilted position, the cavity gap 484 may narrow at one end and widen at the other end. The inner housing 404 may be rotated until the inner housing 404 bottoms out against the outer housing 402. In this way, the outer housing 402 limits the amount of rotation of the inner housing 404. For example, a front 464 of inner housing 404 bottoms out against outer housing 402 at one side of cavity 406, and a rear 466 of inner housing 404 bottoms out against outer housing 402 at an opposite side of cavity 406. The inner housing 404 may be tilted at any angle between a non-tilted position and a maximally tilted position in which the inner housing 404 bottoms out against the outer housing 402.

During mating, the terminal base 302 may be moved (e.g., laterally rotated and/or displaced) relative to the inner housing 404 between a first position (non-tilted) and a second position (tilted) to accommodate misalignment of the first and second bus bars 156, 158 in the terminal channels 456. The terminal base 302 rotates (arrow B) in the terminal passage 456 to move the relative positions of the upper and lower mating ends 304, 306 to accommodate the misalignment. The movement of the terminal 300 is independent of the movement of the inner housing 404.

In various embodiments, the terminal 300 may be rotated relative to the inner housing 404 such that the lower mating end 306 is displaced to the right and the upper mating end 304 is displaced to the left. The size of the terminal passage 456 relative to the terminal 300 allows a limited amount of limited movement (e.g., rotation) of the terminal 300 within the terminal passage 456. The terminal gap 494 accommodates movement of the terminal 300 relative to the inner housing 404. The size of the terminal gap 494 may vary as the terminal 300 moves relative to the inner housing 404. For example, the terminal gap 494 may narrow at one end and widen at the opposite end as the terminal 300 is rotated from the non-inclined position to the inclined position. The terminal 300 may be rotated until the terminal 300 bottoms out against the inner housing 404. In this way, the inner housing 404 limits the rotation amount of the terminal 300. The terminal 300 may be tilted at any angle between a non-tilted position and a maximally tilted position in which the terminal 300 bottoms out against the inner housing 404.

In the exemplary embodiment, cavity 406 extends along a cavity axis. The cavity axis extends between an upper end 412 and a lower end 414 of the outer housing 402. In various embodiments, the cavity axis extends substantially vertically. In the exemplary embodiment, terminal channels 456 extend along a channel axis. The channel axis extends between an upper end 452 and a lower end 454 of the inner housing 404. In various embodiments, the channel axis extends substantially vertically. However, to accommodate misalignment of the bus bars 156, 158, the inner housing 404 may be pivoted such that the channel axis is at an oblique angle that is non-parallel to the cavity axis. In the exemplary embodiment, terminal 300 extends along terminal axis 180 between upper socket 310 and lower socket 320. To accommodate misalignment of the bus bars 156, 158, the terminal 300 may be pivoted such that the terminal axis 180 is at an oblique angle that is not parallel to the channel axis.

It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. The dimensions, types of materials, orientations of the various components, and numbers and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely exemplary embodiments. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of ordinary skill in the art upon reading the foregoing description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms "including" and "in which" are used as the equivalent of the respective terms "comprising" and "in. Furthermore, in the following claims, the terms "first," "second," and "third," etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Furthermore, the limitations of the following claims are not to be written in a device-plus-function format, nor are they intended to be interpreted based on 35U.S. c. ≡112 (f), unless and until such claim limitations explicitly use the phrase "device for … …," followed by no further structural functional description.

Claims

1.A header power connector comprising:

A header housing assembly including an outer housing having a first cavity and a second cavity, the header housing assembly including a first inner housing received in the first cavity and a second inner housing received in the second cavity, the first inner housing including a first terminal channel and the second inner housing including a second terminal channel, the first inner housing and the second inner housing configured to receive an upper bus bar, the first inner housing and the second inner housing configured to receive a lower bus bar, wherein the first inner housing is movable relative to the outer housing in the first cavity to accommodate misalignment of corresponding upper and lower bus bars in the first terminal channel and the second inner housing is movable relative to the outer housing in the second cavity to accommodate misalignment of corresponding upper and lower bus bars in the second terminal channel;

A first terminal received in the first terminal channel, the first terminal including an upper mating end having an upper socket configured to receive a corresponding upper bus bar and a lower mating end having a lower socket configured to receive a corresponding lower bus bar, the first terminal configured to electrically connect the corresponding upper bus bar and lower bus bar, wherein the first terminal is movable in the first terminal channel to accommodate misalignment of the corresponding upper bus bar and lower bus bar in the first terminal channel; and

A second terminal received in the second terminal channel, the second terminal including an upper mating end and a lower mating end, the upper mating end of the second terminal having an upper socket configured to receive a corresponding upper bus bar, the lower mating end of the second terminal having a lower socket configured to receive a corresponding lower bus bar, the second terminal configured to electrically connect the corresponding upper bus bar and lower bus bar, wherein the second terminal is movable in the second terminal channel to accommodate misalignment of the corresponding upper bus bar and lower bus bar in the second terminal channel.

2. The header power connector of claim 1, wherein the first inner housing is independently movable relative to the second inner housing.

3. The header power connector of claim 1, wherein the header housing assembly includes a third inner housing received in a third cavity of the outer housing, the third inner housing including a third terminal channel configured to receive corresponding upper and lower bus bars, wherein the third inner housing is movable relative to the outer housing in the third cavity to accommodate misalignment of corresponding upper and lower bus bars, the header power connector further including a third terminal received in the third terminal channel, the third terminal including upper and lower mating ends, the upper mating end of the third terminal having an upper socket configured to receive corresponding upper bus bars, the lower mating end of the third terminal having a lower socket configured to receive corresponding lower bus bars, the third terminal configured to electrically connect corresponding upper and lower bus bars, wherein the third terminal is movable in the third terminal channel to accommodate misalignment of corresponding upper and lower bus bars in the third terminal channel.

4. The header power connector of claim 1, wherein the first terminal channel is oversized relative to the first terminal to allow the first terminal to be shifted between a first position and a second position to accommodate misalignment of corresponding upper and lower bus bars in the first terminal channel, and wherein the second terminal channel is oversized relative to the second terminal to allow the second terminal to be shifted between a second position and a second position to accommodate misalignment of corresponding upper and lower bus bars in the second terminal channel.

5. The header power connector of claim 1, wherein the outer housing includes a mounting member and a clip member separate from and coupled to the mounting member, the mounting member having a base including a chamber, the clip member including a peripheral wall surrounding the first and second cavities, the clip member including a dividing wall between the first and second cavities, the clip member including a latching feature coupled to the base to secure the clip member to the base, the first inner housing being coupled to and retained in the chamber by the clip member, the second inner housing being coupled to and retained in the chamber by the clip member, wherein the first inner housing is movable relative to the clip member and the base, and the second inner housing is movable relative to the clip member and the base.

6. The header power connector of claim 1, wherein the first terminal includes a terminal base, an upper mating end above the terminal base including the upper socket flanked by upper spring beams to engage opposite sides of a corresponding upper bus bar, and a lower mating end below the terminal base including the lower socket flanked by lower spring beams to engage opposite sides of a corresponding lower bus bar, wherein the terminal base moves relative to the first inner housing between a first position and a second position to accommodate misalignment of the first and second bus bars in the terminal channel.

7. The header power connector of claim 1, wherein the first inner housing rotates in the first cavity to move the relative positions of the first inner and outer walls to accommodate misalignment of the corresponding upper and lower bus bars in the first terminal channel, and wherein the second inner housing rotates in the second cavity to move the relative positions of the second inner and outer walls to accommodate misalignment of the corresponding upper and lower bus bars in the second terminal channel.

8. The header electrical connector of claim 1, wherein the first terminal channel extends along a first channel axis and the second terminal channel extends along a second channel axis, the first inner housing and the second inner housing being independently movable relative to the outer housing to change the relative orientation of the first channel axis and the second channel axis.

9. The header electrical connector of claim 1, wherein the first terminal channel extends along a first channel axis, the first terminal extends along a first terminal axis between the upper socket and the lower socket, the first terminal is movable within the first terminal channel to orient the first terminal axis non-parallel to the first channel axis to accommodate misalignment of corresponding upper and lower bus bars in the first terminal channel, and wherein the second terminal channel extends along a second channel axis, the second terminal extends along a second terminal axis between the upper socket and the lower socket, the second terminal is movable within the second terminal channel to orient the second terminal axis non-parallel to the second channel axis to accommodate misalignment of corresponding upper and lower bus bars in the second terminal channel.

10. A header power connector comprising:

A header housing assembly including an outer housing having a first cavity and a second cavity, the header housing assembly including a first inner housing received in the first cavity and a second inner housing received in the second cavity, the first inner housing including a first terminal channel and the second inner housing including a second terminal channel, the first inner housing and the second inner housing being configured to receive an upper bus bar, the first inner housing and the second inner housing being configured to receive a lower bus bar;

A first terminal received in the first terminal channel, the first terminal including an upper mating end and a lower mating end, the upper mating end of the first terminal having an upper socket configured to receive a corresponding upper bus bar, the lower mating end of the first terminal having a lower socket configured to receive a corresponding lower bus bar, the first terminal being configured to electrically connect the corresponding upper bus bar and lower bus bar; and

A second terminal received in the second terminal channel, the second terminal including an upper mating end and a lower mating end, the upper mating end of the second terminal having an upper socket configured to receive a corresponding upper bus bar, the lower mating end of the second terminal having a lower socket configured to receive a corresponding lower bus bar, the second terminal being configured to electrically connect the corresponding upper bus bar and lower bus bar;

Wherein the first inner housing is movable relative to the outer housing between a positive inner housing tilt position and a negative inner housing tilt position at various tilt angles, the first inner housing being positionable at a non-tilt angle centered between the positive inner housing tilt position and the negative inner housing tilt position, the first inner housing being movable relative to the outer housing to accommodate misalignment of corresponding upper and lower bus bars in the first terminal channel;

Wherein the second inner housing is movable relative to the outer housing between a positive inner housing tilt position and a negative inner housing tilt position at various tilt angles, the second inner housing being positionable at a non-tilt angle centered between the positive inner housing tilt position and the negative inner housing tilt position, the second inner housing being movable relative to the outer housing to accommodate misalignment of corresponding upper and lower bus bars in the second terminal channels;

Wherein the first terminal is movable in the first terminal channel between a positive terminal tilt position and a negative terminal tilt position at various tilt angles relative to the first inner housing, the first terminal being positionable at a non-tilt angle centered between the positive terminal tilt position and the negative terminal tilt position, the first terminal being movable relative to the first inner housing to accommodate misalignment of corresponding upper and lower bus bars in the first terminal channel; and

Wherein the second terminal is movable in the second terminal channel between a positive terminal tilt position and a negative terminal tilt position at various tilt angles relative to the second inner housing, the second terminal is positionable at a non-tilt angle centered between the positive terminal tilt position and the negative terminal tilt position, the second terminal is movable relative to the second inner housing to accommodate misalignment of corresponding upper and lower bus bars in the second terminal channel.

11. The header power connector of claim 10, wherein the first terminal channel is oversized relative to the first terminal to allow the first terminal to shift between a positive terminal tilt position and a negative terminal tilt position to accommodate misalignment of corresponding upper and lower bus bars in the first terminal channel, and wherein the second terminal channel is oversized relative to the second terminal to allow the second terminal to shift between a positive terminal tilt position and a negative terminal tilt position to accommodate misalignment of corresponding upper and lower bus bars in the second terminal channel.

12. The header power connector of claim 10, wherein the first inner housing is independently movable relative to the second inner housing.

13. The header power connector of claim 10, wherein the header housing assembly includes a third inner housing received in a third cavity of the outer housing, the third inner housing including a third terminal channel configured to receive a corresponding upper bus bar and lower bus bar, wherein the third inner housing is movable relative to the outer housing in the third cavity to accommodate misalignment of the corresponding upper bus bar and lower bus bar, the header power connector further including a third terminal received in the third terminal channel, the third terminal including an upper mating end and a lower mating end, the upper mating end of the third terminal having an upper socket configured to receive a corresponding upper bus bar, the lower mating end of the third terminal having a lower socket configured to receive a corresponding lower bus bar, the third terminal being configured to electrically connect the corresponding upper bus bar and lower bus bar, wherein the third terminal is tiltable in the third terminal channel relative to the respective tilt terminals between the third terminal and the negative terminal in a tilt-up position and a tilt-down position of the third terminal relative to the negative terminal.

14. The header power connector of claim 10, wherein the first terminal channel is oversized relative to the first terminal to allow the first terminal to shift between a positive terminal tilt position and a negative terminal tilt position to accommodate misalignment of corresponding upper and lower bus bars in the first terminal channel, and wherein the second terminal channel is oversized relative to the second terminal to allow the second terminal to shift between a positive terminal tilt position and a negative terminal tilt position to accommodate misalignment of corresponding upper and lower bus bars in the second terminal channel.

15. The header power connector of claim 10, wherein the outer housing includes a mounting member and a clip member separate from and coupled to the mounting member, the mounting member having a base including a chamber, the clip member including a peripheral wall surrounding the first and second cavities, the clip member including a dividing wall between the first and second cavities, the clip member including a latching feature coupled to the base to secure the clip member to the base, the first inner housing being coupled to and retained in the chamber by the clip member, the second inner housing being coupled to and retained in the chamber by the clip member, wherein the first inner housing is movable relative to the clip member and the base, and the second inner housing is movable relative to the clip member and the base.

16. The header power connector of claim 10, wherein the first terminal includes a terminal base, an upper mating end above the terminal base and a lower mating end below the terminal base, the upper mating end of the first terminal including the upper socket, the upper socket side receiving an upper spring beam to engage an opposite side of a corresponding upper bus bar, the lower mating end of the first terminal including the lower socket side receiving a lower spring beam to engage an opposite side of a corresponding lower bus bar, wherein the terminal base moves relative to the first inner housing between a positive terminal tilt position and a negative terminal tilt position to accommodate misalignment of the first and second bus bars in the terminal channel.

17. The header power connector of claim 10, wherein the first inner housing rotates in the first cavity to move the relative positions of the first inner and outer walls between a positive inner housing tilt position and a negative inner housing tilt position to accommodate misalignment of corresponding upper and lower bus bars in the first terminal channels, and wherein the second inner housing rotates in the second cavity to move the relative positions of the second inner and outer walls between the positive inner housing tilt position and the negative inner housing tilt position to accommodate misalignment of corresponding upper and lower bus bars in the second terminal channels.

18. The header electrical connector of claim 10, wherein the first terminal channel extends along a first channel axis and the second terminal channel extends along a second channel axis, the first inner housing and the second inner housing being independently movable relative to the outer housing between a positive inner housing tilt position and a negative inner housing tilt position to change the relative orientation of the first channel axis and the second channel axis.

19. The header electrical connector of claim 10, wherein the first terminal channel extends along a first channel axis, the first terminal extends along a first terminal axis between the upper socket and the lower socket, the first terminal is movable within the first terminal channel between a positive terminal tilt position and a negative terminal tilt position to orient the first terminal axis non-parallel to the first channel axis to accommodate misalignment of corresponding upper and lower bus bars in the first terminal channel, and wherein the second terminal channel extends along a second channel axis, the second terminal extends along a second terminal axis between the upper socket and the lower socket, the second terminal is movable within the second terminal channel between a positive terminal tilt position and a negative terminal tilt position to orient the second terminal axis non-parallel to the second channel axis to accommodate misalignment of corresponding upper and lower bus bars in the second terminal channel.

20. A power connector system, comprising:

First and second upper bus bars for powering a first electrical component, the first and second upper bus bars having upper bus bar edges;

first and second lower bus bars for powering a second electrical component, the first and second lower bus bars having lower bus bar edges; and

A header power connector for electrically connecting the first upper bus bar and the second upper bus bar with the first lower bus bar and the second lower bus bar, the header power connector comprising:

A header housing assembly including an outer housing having a first cavity and a second cavity, the header housing assembly including a first inner housing received in the first cavity and a second inner housing received in the second cavity, the first inner housing including a first terminal channel and the second inner housing including a second terminal channel, the first inner housing receiving the first upper bus bar and the first lower bus bar and the second inner housing receiving the second upper bus bar and the second lower bus bar, wherein the first inner housing is movable in the first cavity relative to the outer housing to accommodate misalignment of the first upper bus bar and the first lower bus bar in the first terminal channel and the second inner housing is movable in the second cavity relative to the outer housing to accommodate misalignment of the second upper bus bar and the second lower bus bar in the second terminal channel;

A first terminal received in the first terminal channel, the first terminal including an upper mating end and a lower mating end, the upper mating end of the first terminal having an upper socket configured to receive the first upper bus bar, the lower mating end of the first terminal having a lower socket configured to receive the first lower bus bar, the first terminal configured to electrically connect the first upper bus bar and the first lower bus bar, wherein the first terminal is movable in the first terminal channel to accommodate misalignment of the first upper bus bar and the first lower bus bar in the first terminal channel; and

A second terminal received in the second terminal channel, the second terminal including an upper mating end and a lower mating end, the upper mating end of the second terminal having an upper socket configured to receive the second upper bus bar, the lower mating end of the second terminal having a lower socket configured to receive the second lower bus bar, the second terminal configured to electrically connect the second upper bus bar and the second lower bus bar, wherein the second terminal is movable in the second terminal channel to accommodate misalignment of the second upper bus bar and the second lower bus bar in the second terminal channel.