# US 11,444,406 B2 · Weldable poka-yoke connector

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- Number: US 11,444,406 B2
- Document ID: US11444406B2
- Status: Granted
- Kind: B2
- Application number: 17/020,029
- Filed: 2020-09-14
- Published: 2022-03-17
- Granted: 2022-09-13
- Earliest claimed: 2020-09-14
- Assignees: Steering Solutions IP Holding Corporation
- Applicants: Steering Solutions IP Holding Corporation
- Inventors: Daniel J. Klenk; Delynn Streng; Mike J. Srda
- Web page: https://patentgrep.com/patent/US11444406B2

## CPC

- H01R 4/70: Insulation of connections (end caps H01R4/22)
- H01R 13/506: assembled by snap action of the parts
- B60R 16/0207: {Wire harnesses}
- H01R 4/023: {between cables or wires and terminals}
- H01R 4/029: {Welded connections (H01R4/021 - H01R4/028 take precedence)}
- H01R 13/5045: {different pieces being assembled by press-fit}
- H01R 13/5213: {Covers}
- H01R 43/02: for soldered or welded connections
- H01R 2201/26: for vehicles
- H01R: ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- B60R: VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR

## Abstract

The present disclosure is for an electrical connector assembly for a vehicle, among other apparatuses known in the art utilizing electrical connectors. The electrical connector assembly is comprised of a connector body and a terminal coupled to the connector body. The electrical connector assembly also comprises a wire harness having a lead. A connector is coupled to the lead and to the terminal, and the connector establishes an electrical connection between the lead and the terminal. The connector and the terminal each have a portion that forms one end of a poka-yoke connection. The connector and the terminal are welded to secure and maintain the respective electrical connection.

## Claims

### Claim 1

An electrical connector assembly comprising:
a connector body;
a terminal coupled to the connector body;
a wire harness comprising a lead;
a connector coupled to the lead and to the terminal to establish an electrical connection between the lead and the terminal;
the connector and the terminal each having a portion forming one end of a poka-yoke connection; and
the connector and the terminal are welded to secure and maintain the respective electrical connection, wherein a key is disposed about the terminal and the key forms an end of the poka-yoke connection, wherein the key is further defined as a first terminal key extending from the connector body and disposed about the terminal.

### Claim 2 (depends on 1)

The electrical connector assembly of claim 1, further comprising a cover coupled to the lead and the connector body to seal the electrical connection between connector and the terminal from an external environment.

### Claim 3 (depends on 1)

The electrical connector assembly of claim 1, wherein a portion of the connector forming another end of the poka-yoke connection comprises projections arranged to be received by the key and form a pressure-fit between the connector and terminal.

### Claim 4 (depends on 1)

The electrical connector assembly of claim 1, wherein the key is further defined by a recess.

### Claim 5

An electrical connector assembly comprising:
a connector body;
a terminal coupled to the connector body;
a wire harness comprising a lead;
a connector coupled to the lead and to the terminal to establish an electrical connection between the lead and the terminal;
the connector and the terminal each having a portion forming one end of a poka-yoke connection; and
the connector and the terminal are welded to secure and maintain the respective electrical connection, wherein a key is disposed about the terminal and the key forms an end of the poka-yoke connection, wherein the key is further defined as being recessed in the connector body and disposed about the terminal.

### Claim 6 (depends on 5)

The electrical connector assembly of claim 5, further comprising a cover coupled to the lead and the connector body to seal the electrical connection between connector and the terminal from an external environment.

### Claim 7 (depends on 5)

The electrical connector assembly of claim 5, wherein a portion of the connector forming another end of the poka-yoke connection comprises projections arranged to be received by the key and form a pressure-fit between the connector and terminal.

### Claim 8 (depends on 5)

The electrical connector assembly of claim 5, wherein the key is further defined by a recess.

### Claim 9

An electrical connector assembly comprising:
a connector body;
a terminal coupled to the connector body;
a wire harness comprising a lead;
a connector coupled to the lead and to the terminal to establish an electrical connection between the lead and the terminal;
the connector and the terminal each having a portion forming one end of a poka-yoke connection; and
the connector and the terminal are welded to secure and maintain the respective electrical connection, wherein a key is disposed about the terminal and the key forms an end of the poka-yoke connection, wherein a portion of the connector comprises fingers forming a second end of the poka-yoke connection and the fingers form a pressure-fit between the connector and terminal, wherein one of the fingers comprises a hook end and a projection having a shelf extends from the connector body and the hook end forms a snap-lock with the shelf.

### Claim 10 (depends on 9)

The electrical connector assembly of claim 9, wherein one of the fingers comprises a hook end and engages the shelf to form a snap-lock between the fingers and the connector body.

### Claim 11 (depends on 9)

The electrical connector assembly of claim 9, further comprising a cover coupled to the lead and the connector body to seal the electrical connection between connector and the terminal from an external environment.

### Claim 12 (depends on 9)

The electrical connector assembly of claim 9, wherein a portion of the connector forming another end of the poka-yoke connection comprises projections arranged to be received by the key and form a pressure-fit between the connector and terminal.

### Claim 13 (depends on 9)

The electrical connector assembly of claim 9, wherein the key is further defined by a recess.