# US 12,224,537 B2 · Power connector > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,224,537 B2 - Document ID: US12224537B2 - Status: Granted - Kind: B2 - Application number: 17/849,779 - Filed: 2022-06-27 - Published: 2023-12-28 - Granted: 2025-02-11 - Earliest claimed: 2022-06-27 - Assignees: TE Connectivity Solutions GmbH - Applicants: TE Connectivity Solutions GmbH - Inventors: Michael James Horning - Web page: https://patentgrep.com/patent/US12224537B2 ## CPC - H01R 25/16: Rails or bus-bars provided with a plurality of discrete connecting locations for counterparts - H01R 25/162: {Electrical connections between or with rails or bus-bars (rails having primarily a non electrical function H01R4/64)} - H01R 13/514: composed as a modular blocks or assembly, i.e. composed of co-operating parts provided with contact members or holding contact members between them - H01R 13/629: Additional means for facilitating engagement or disengagement of coupling parts, e.g. aligning or guiding means, levers, gas pressure {electrical locking indicators, manufacturing tolerances (separate tools or apparatus H01R43/26)} - H01R 13/6471: by special arrangement of ground and signal conductors, e.g. GSGS [Ground-Signal-Ground-Signal] - H01R 27/02: for simultaneous co-operation with two or more {dissimilar} counterparts - H01R 12/714: {with contacts abutting directly the printed circuit; Button contacts therefore provided on the printed circuit} - H01R 13/113: {co-operating with pins or blades having a rectangular transverse section} - H01R: ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS ## Abstract An electrical connector includes a connector housing having a base at a rear and a plug at a front of the connector housing configured to be plugged into a busbar assembly. The plug includes a slot between a first and second plug walls that receives a busbar of the busbar assembly. The electrical connector includes power contacts received in contact channels having mating ends extending along the plug walls into the slot to mate with a busbar contacts of the busbar. The electrical connector includes a cable connector assembly coupled to the connector housing. The cable connector assembly includes a cable connector housing holding a signal contact. The signal contact is electrically connected to a signal cable of the cable connector assembly. The signal contact extending along an exterior surface of the first plug wall to interface with a signal conductor of the busbar assembly when the plug is plugged into the busbar assembly. ## Claims ### Claim 1 An electrical connector comprising: a connector housing having a base at a rear of the connector housing and a plug extending forward of the base at a front of the connector housing configured to be plugged into a busbar assembly, the plug including a slot between a first plug wall and a second plug wall, the slot configured to receive a busbar of the busbar assembly, the connector housing having contact channels through the base and extending to the slot of the plug; a first power contact received in the corresponding contact channel, the first power contact having a first mating end extending along the first plug wall into the slot to mate with a first busbar contact of the busbar, the first power contact having a first cable end configured to be terminated to a first power cable; a second power contact received in the corresponding contact channel, the second power contact having a second mating end extending along the second plug wall into the slot to mate with a second busbar contact of the busbar, the second power contact having a second cable end configured to be terminated to a second power cable; and a cable connector assembly coupled to the connector housing, the cable connector assembly including a cable connector housing holding a signal contact, the signal contact being electrically connected to a signal cable of the cable connector assembly, the signal contact extending along an exterior surface of the first plug wall to interface with a signal conductor of the busbar assembly when the plug is plugged into the busbar assembly. ### Claim 2 (depends on 1) The electrical connector of claim 1, wherein the first plug wall is located between the signal contact and the first power contact. ### Claim 3 (depends on 1) The electrical connector of claim 1, wherein the first power contact includes a spring beam at the first mating end being compressible toward an interior surface of the first plug wall, the signal contact including a spring beam being compressible toward the exterior surface of the first plug wall. ### Claim 4 (depends on 1) The electrical connector of claim 1, wherein the signal contact is a first signal contact, the cable connector assembly including a second signal contact held by the cable connector housing, the second signal contact being electrically connected to a second signal cable. ### Claim 5 (depends on 1) The electrical connector of claim 1, wherein the signal contact includes a spring beam at a mating end of the signal contact and a pin at a terminating end of the signal contact, the cable connector assembly further comprising a cable connector including a cable connector contact terminated to the signal cable, the cable connector contact including a socket coupled to the pin to electrically connect the signal contact to the signal cable. ### Claim 6 (depends on 1) The electrical connector of claim 1, wherein the signal contact includes a spring beam at a mating end of the signal contact and a solder pad at a terminating end of the signal contact, the signal cable being soldered to the solder pad. ### Claim 7 (depends on 1) The electrical connector of claim 1, wherein the connector housing includes a connector port through the base, the cable connector assembly being received in the connector port. ### Claim 8 (depends on 1) The electrical connector of claim 1, wherein the connector housing includes a flange extending from the base, the flange having a connector port passing therethrough, the cable connector assembly being received in the connector port and passing through the flange to extend along the base and along the plug. ### Claim 9 (depends on 1) The electrical connector of claim 1, wherein the cable connector assembly is removable from the connector housing. ### Claim 10 (depends on 1) The electrical connector of claim 1, further comprising a ground element coupled to the connector housing, the ground element including a ground beam extending along an exterior surface of the second plug wall to interface with a ground conductor of the busbar assembly when the plug is plugged into the busbar assembly. ### Claim 11 (depends on 1) The electrical connector of claim 1, wherein the cable connector housing includes a receptacle, the signal contact including a terminating end in the receptacle, the cable connector assembly further comprising a cable connector plugged into the receptacle, the cable connector including a cable connector contact terminated to an end of the signal cable, the cable connector contact being coupled to the terminating end of the signal contact. ### Claim 12 (depends on 1) The electrical connector of claim 1, wherein the cable connector housing includes an inner shell and an outer shell forming a receptacle therebetween, the signal contact extending into the receptacle, the receptacle configured to receive a cable connector therein. ### Claim 13 An electrical connector comprising: a connector housing having a base at a rear of the connector housing and a plug extending forward of the base at a front of the connector housing configured to be plugged into a busbar assembly, the plug including a slot between a first plug wall and a second plug wall, the slot configured to receive a busbar of the busbar assembly, the connector housing having contact channels through the base and extending to the slot of the plug; a first power contact received in the corresponding contact channel, the first power contact having a first mating end extending along the first plug wall into the slot to mate with a first busbar contact of the busbar, the first power contact having a first cable end configured to be terminated to a first power cable; a second power contact received in the corresponding contact channel, the second power contact having a second mating end extending along the second plug wall into the slot to mate with a second busbar contact of the busbar, the second power contact having a second cable end configured to be terminated to a second power cable; a ground element coupled to the connector housing, the ground element including a ground beam extending along an exterior surface of the second plug wall to interface with a ground conductor of the busbar assembly when the plug is plugged into the busbar assembly; and a cable connector assembly coupled to the connector housing, the cable connector assembly including a cable connector housing holding a signal contact, the signal contact being electrically connected to a signal cable of the cable connector assembly, the signal contact extending along an exterior surface of the first plug wall to interface with a signal conductor of the busbar assembly when the plug is plugged into the busbar assembly. ### Claim 14 (depends on 13) The electrical connector of claim 13, wherein the first plug wall is located between the signal contact and the first power contact. ### Claim 15 (depends on 13) The electrical connector of claim 13, wherein the first power contact includes a spring beam at the first mating end being compressible toward an interior surface of the first plug wall, the signal contact including a spring beam being compressible toward the exterior surface of the first plug wall. ### Claim 16 (depends on 13) The electrical connector of claim 13, wherein the signal contact is a first signal contact, the cable connector assembly including a second signal contact held by the cable connector housing, the second signal contact being electrically connected to a second signal cable. ### Claim 17 (depends on 13) The electrical connector of claim 13, wherein the connector housing includes a connector port through the base, the cable connector assembly being received in the connector port. ### Claim 18 (depends on 13) The electrical connector of claim 13, wherein the cable connector housing includes a receptacle, the signal contact including a terminating end in the receptacle, the cable connector assembly further comprising a cable connector plugged into the receptacle, the cable connector including a cable connector contact terminated to an end of the signal cable, the cable connector contact being coupled to the terminating end of the signal contact. ### Claim 19 An electrical connector system comprising: a busbar assembly including a busbar housing having a first side wall and a second side wall forming a busbar cavity, the busbar assembly including a busbar in the busbar cavity between the first and second side walls, the busbar including a first busbar contact and a second busbar contact, a first pocket defined between the first busbar contact and the first side wall, a second pocket defined between the second busbar and the second side wall, the busbar assembly including a conductive structure in the first pocket along the first side wall, the conductive structure including a signal conductor; and an electrical connector coupled to the busbar assembly, the electrical connector including: a connector housing having a base at a rear of the connector housing and a plug extending forward of the base at a front of the connector housing, the plug being plugged into the busbar cavity of the busbar housing, the plug including a slot between a first plug wall and a second plug wall, the slot receiving the busbar of the busbar assembly, the connector housing having contact channels through the base and extending to the slot of the plug; a first power contact received in the corresponding contact channel, the first power contact having a first mating end extending along the first plug wall into the slot to mate with the first busbar contact of the busbar, the first power contact having a first cable end configured to be terminated to a first power cable; a second power contact received in the corresponding contact channel, the second power contact having a second mating end extending along the second plug wall into the slot to mate with the second busbar contact of the busbar, the second power contact having a second cable end configured to be terminated to a second power cable; and a cable connector assembly coupled to the connector housing, the cable connector assembly including a cable connector housing holding a signal contact, the signal contact being electrically connected to a signal cable of the cable connector assembly, the signal contact extending along an exterior surface of the first plug wall to interface with the signal conductor of the conductive structure when the plug is plugged into the busbar cavity. ### Claim 20 (depends on 19) The electrical connector system of claim 19, wherein the busbar assembly includes a second conductive structure in the second pocket along the second side wall, the second conductive structure including a ground conductor, the electrical connector further comprising a ground element coupled to the connector housing, the ground element including a ground beam extending along an exterior surface of the second plug wall to interface with the ground conductor of the second conductive structure when the plug is plugged into the busbar assembly.