Patent Description:
It is desired that a high voltage connector connected to a device be provided. It is further desired that the high voltage connector experiences a reduced electromagnetic interference (EMI), avoids galvanic corrosion of dissimilar metals within or without a fluid environment, and provides an effective electrical ground system. <CIT> discloses a connector having the features of the preamble of claim <NUM>, namely a shielded connector formed such that two electric wire side terminals fixed to terminals of electric wires are held in a L-shaped housing and that the tips of the electric wire side terminals are projected side by side from the end face of a horizontal part. The horizontal part of the housing is fitted to a mounting port, which opens to a sidewall of a case. Each electric wire side terminal is fastened and connected, with a bolt, to the equipment-side terminal, disposed on a terminal board, and right and left side face walls of a shield shell mounted to the housing are provided with fixed plates, respectively. The respective fixed plates are fastened and fixed with bolts to mounts, provided on both sides of the mounting port. Both fastened parts of the housing to the case are located at the same height as those of the fastened parts of the electric wire side terminals with respect to the equipment-side terminals.

This invention provides such a high voltage connector for connecting to a device which, when in operation, experiences reduced EMI. This is achieved by providing the connector according to claim <NUM> and the method according to claim <NUM>. That is, the connector is provided with a metallic braided shield on top of an inverter outer housing assembly. The connector in this invention is further provided with a metallic clamp that holds the metallic braided shield above the outer housing, and provides a conductive contact between the metallic braided shield and the outer housing. The outer housing, preferably made of a metal-infused plastic, includes an over-molded silicone seal to provide the necessary sealing and insulation layer to prevent galvanic corrosion between the connector and the device to which the connector is connected.

The metal-infused plastic outer housing with the over-molded silicone shield includes apertures through which bolts pass through for fastening the connector of the invention to the device. The bolts provide the necessary grounding among the metallic braided shield, metal-infused plastic outer housing, and the device to which the connector of this invention is to be connected. Each bolt is preferably inserted into a corresponding metallic compression limiter within a respective one of the apertures of the outer housing. A ground system is provided to the connector of this invention by establishing a contact between the connector and the device, with the connection of the connector to the device, by the bolts and the metallic compression limiters. Moreover, the steel bolts are contained within the metallic compression limiters, which are in turn contained within side apertures of the outer housing. On the outer periphery of the base of the metal-infused outer housing is an over-molded silicone seal, which, along with the above-described structural arrangement composed of dissimilar metals, provides for corrosive resistant characteristics.

The connector of this invention further includes an inner housing provided within the outer housing, the inner housing further having cable reinforcement retainer assemblies securely inserted therein.

The connector of this invention further includes a back cover, which acts as a terminal position assurance (TPA) device, through which cables slide and secured thereinto, during the assembly of the connector. The back cover includes over-molded silicone seals for isolating the connecting interface of the cables. During assembly of the connector, the back cover ensures that the inner housing is properly positioned within the outer housing.

Generally, upon assembly of the connector of this invention, an inverter outer housing assembly, having the metal-infused plastic outer housing with the over-molded silicone seal, is mounted onto the associated device with the bolts accommodated within the respective metallic compression limiters; the inner housing is seated inside and onto the base of the outer housing; the back cover with its associated cables and cable reinforcement retainer assemblies are mounted inside the outer housing and onto the inner housing with the cables being slid upwards through the back cover; the metallic braided shield is mounted onto the outer housing while covering the exposed cable; and the clamp is slid along the braided shield to secure thereof onto the outer housing.

As illustrated in <FIG>, the high voltage connector <NUM> includes an outer housing assembly <NUM>, which includes an outer housing <NUM> with an accompanying over-molded silicone seal <NUM>. The outer housing <NUM> is preferably made of a metal-infused housing, and includes side extending portions <NUM> of a base <NUM> thereof for accommodating therein respective bolts <NUM> (made of stainless steel or the like) for fastening the connector <NUM> to an associated device <NUM> (see, <FIG>; e.g., an inverter or the like made of, e.g., aluminum).

Accommodated within the outer housing <NUM> and mounted onto the base <NUM> thereof is an inner housing <NUM>. The connector <NUM> further includes a set of cable reinforcement retainer assemblies <NUM> (specifically referred to as reference number <NUM> in <FIG>, <FIG>, <FIG>, and <FIG>) for coupling with the inner housing <NUM> and a set of cables <NUM>. The set of cables <NUM> is preferably high voltage cables (e.g., <NUM><NUM> cables), although the type of cables is not limited thereto. Although shown in <FIG> is a set of <NUM>-way high voltage cables, this embodiment is also not limited thereto. The cables <NUM> are slidably accommodated within a back cover <NUM>. The connector <NUM> further includes a metallic (e.g., stainless steel) braided shield <NUM>, which forms the outer layer of the connector <NUM>, when the connector <NUM> is fully assembled, as shown in <FIG>. A metallic clamp <NUM> secures the braided shield <NUM> onto the outer housing <NUM>, when the connector <NUM> is fully assembled, as also shown in <FIG>.

<FIG> illustrates the connector <NUM> when fully assembled absent the braided shield <NUM>, while <FIG> illustrates the connector <NUM> when fully assembled with the braided shield <NUM> secured onto the outer housing <NUM> by the metallic clamp <NUM>. Further shown in <FIG> is the outer housing assembly <NUM> with the outer housing <NUM> that securely sits onto and within the outer-molded silicone seal <NUM> through which the bolts <NUM> are fastened with respective metallic compression limiters <NUM>, which are made of aluminum or the like. As later discussed, the set of cables <NUM> extend through an upper portion <NUM> of the outer housing <NUM>.

In <FIG>, covered by the metallic braided shield <NUM> are the set of cables <NUM>. The metallic clamp <NUM> ensures that the bottom portion <NUM> of the metallic braided shield <NUM> is connected to the upper portion <NUM> of the outer housing <NUM>.

Extending in the horizontal direction, as illustrated in <FIG>, is the outer housing <NUM> having the base <NUM> with horizontal ribs <NUM> extending from a side of the base <NUM> towards a central portion <NUM> of the outer housing <NUM>. Also shown in <FIG>, with respect to the outer housing <NUM> and as discussed earlier, are the extending side portions or ribs <NUM> and side apertures <NUM> for accommodating therein, along with the silicone seal <NUM>, the respective bolts <NUM> and the respective metallic compression limiters <NUM>. The outer housing <NUM> is preferably made of a metal-infused plastic, while the bolts <NUM> are preferably made of stainless steel or the like.

Passing through the central portion <NUM> of the outer housing <NUM> is a central opening <NUM> for accommodating therein, in full, the inner housing <NUM> and the cable reinforcement retainer assembly <NUM>, and for further accommodating therein, in part, the set of cables <NUM>. Apertures <NUM> pass through an upper portion of the outer housing <NUM>.

Illustrated in <FIG> is the bottom end portion <NUM> of the outer housing <NUM>. The bottom end portion <NUM> is substantially flat and includes at least a pad <NUM> extending therefrom. The pad <NUM> surrounds a bottom opening or aperture <NUM> passing through the bottom end portion <NUM> of the base <NUM> of the outer housing <NUM>. When the outer housing <NUM> is mounted onto an associated device <NUM> (see, <FIG>), the pad <NUM> provides the necessary means for substantially reducing or substantially deleting any occurrence of EMI. The bottom opening or aperture <NUM> is preferably smaller in size than the central aperture <NUM> of the outer housing <NUM>, and communicates therewith.

<FIG> shows the outer housing assembly <NUM>, which comprises the outer housing <NUM> and the over-molded silicone seal <NUM>, the base <NUM> of the outer housing <NUM> sitting onto and within the over-molded silicone seal <NUM>. The over-molded silicone seal <NUM> provides a sealing and insulation layer for galvanic corrosion protection between the connector <NUM> and the device <NUM>.

In <FIG>, illustrated is an exploded view of the outer housing assembly <NUM> showing the outer housing <NUM> and its corresponding over-molded silicone seal <NUM>. As described earlier with respect to the outer housing <NUM> shown in <FIG> and <FIG>, the outer housing <NUM> includes a base <NUM> with a bottom end portion <NUM>. As also described with respect to <FIG>, the base end portion <NUM> includes the pad <NUM>, which fits and passes through elongated slits <NUM> passing through a base <NUM> of the over-molded silicone seal <NUM> (see, <FIG>). As further described with respect to <FIG>, the substantially flat bottom end portion <NUM> of the outer housing <NUM> sits and mounts onto the base portion <NUM> of the over-molded silicone seal <NUM>, as shown in <FIG> and <FIG>. In the over-molded silicone seal <NUM>, shown in <FIG>, the base portion <NUM> includes side apertures <NUM>, while an upper portion <NUM> of the silicone seal <NUM> includes side members <NUM>, each of the side member <NUM> having an aperture <NUM> passing therethrough. As shown in <FIG>, each upper portion <NUM> of the silicone seal <NUM> fits onto one of the side extending portions <NUM> of the base <NUM> of the outer housing <NUM>. Thus, each aperture <NUM> of each one of the side member <NUM> of the silicone seal <NUM> corresponds to a respective one of the apertures <NUM> of the base <NUM> of the outer housing <NUM> for respectively accommodating therein the metallic compression limiters <NUM>.

<FIG> illustrates the bottom end portion <NUM> of the outer housing assembly <NUM> with the pads <NUM> of the outer housing <NUM> passing through the elongated slits <NUM> of the silicone seal <NUM> when the outer housing <NUM> sits and mounts onto the over-molded silicone seal <NUM>. <FIG> illustrates the bottom end portion <NUM> of the outer housing assembly <NUM> with the pads <NUM> of a different embodiment or pattern passing through corresponding elongated slits <NUM> of a different embodiment or pattern of the silicone seal <NUM> when the outer housing <NUM> sits and mounts onto the over-molded silicone seal <NUM>.

<FIG> is a top perspective view of the outer housing <NUM> showing the inner surface thereof through a central opening <NUM> thereof. As can be seen through the central opening <NUM> of the outer housing <NUM>, as illustrated in <FIG>, substantially orthogonal to the central opening <NUM> and communicating therewith is a bottom opening or aperture <NUM> passing through an end portion <NUM> substantially orthogonal to the base <NUM> of the outer housing <NUM>. As further shown in <FIG>, an inner ledge <NUM> extends from an inner surface <NUM> of the outer housing <NUM>. Although not shown in <FIG>, a similar type of inner ledge <NUM> extends from the opposite side of the inner surface of the outer housing <NUM>. Also shown in <FIG> are outer ledges 98a, 98b extending from an upper portion of the outer housing <NUM>.

Next described in detail is the inner housing <NUM>, which is accommodated within the outer housing <NUM> and sits onto the base <NUM> thereof. The inner housing <NUM>. is preferably made of nylon or the like. The inner housing <NUM> (preferably made of nylon or the like) provides separation between conductive parts (e.g., the outer housing <NUM> made of metal-infused plastic or the like and the cable terminals <NUM> secured inside the inner housing <NUM>). <FIG> is a top perspective view of the inner housing <NUM> showing a back portion <NUM> and a top portion <NUM> thereof. The back portion <NUM> of the inner housing <NUM> has flexible members <NUM>, <NUM>, <NUM>. The top portion <NUM> of the inner housing <NUM> has extending therefrom first portion <NUM>, second portion <NUM>, and third portion <NUM>. The inner housing <NUM> is generally, as shown in <FIG>, an upside down (or inverted) substantially L-shaped structure with a downwardly extending member <NUM> and a front extending member <NUM>.

<FIG> is a bottom perspective view of the inner housing <NUM>. Shown in <FIG> is a bottom end portion <NUM> of the inner housing <NUM>, the bottom end portion <NUM> having slots <NUM>, <NUM>, <NUM> passing therethrough. A front extending member <NUM> of the inner housing <NUM> is similarly shown in <FIG> as having a bottom surface <NUM> thereof.

<FIG> shows yet another top perspective view of the inner housing <NUM> illustrating a front portion <NUM> and the top portion <NUM> thereof. The front portion <NUM> of the inner housing <NUM> is opposite the back portion <NUM> of the inner housing <NUM> shown in <FIG>. Similarly shown in <FIG> are the flexible members <NUM>, <NUM>, <NUM> in the back portion <NUM> of the inner housing <NUM>. Each of the flexible members <NUM>, <NUM>, <NUM> has an inclined ledge <NUM>. Extending from the back portion <NUM> are the first portion <NUM>, the second portion <NUM>, and the third portion <NUM> (see, also, <FIG>). Each second portion <NUM> extends at an incline relative to the substantially flat and substantially horizontal first portion <NUM>. The top portion <NUM> of the inner housing <NUM> is preferably similarly flat and horizontal. Between the second portion <NUM> and the third portion <NUM> is a substantially concave portion or indentation portion <NUM>. Upper slots <NUM>, <NUM>, <NUM> are also shown in <FIG>, the upper slots <NUM>, <NUM>, <NUM> communicating with the lower slots <NUM>, <NUM>, <NUM>, respectively, of the inner housing <NUM>. as shown in <FIG>.

<FIG> shows an exploded perspective view of the cable reinforcement retainer assembly <NUM> (also referred to as reference number <NUM> in <FIG>), each cable reinforcement retainer assembly <NUM> having a clamp (or retainer) <NUM> mounted onto and surrounding a preferably flexible (although not limited thereto) end terminal <NUM>. The end terminal <NUM> has a substantially flat and substantially bent end portion <NUM>, which attaches to a cable terminal <NUM> attached to a cable <NUM>. The terminal <NUM> includes a first side portion <NUM> and a second side portion <NUM>. The first side portion <NUM> includes a plurality of preferably flexible fingers <NUM>, and the second side portion <NUM> also includes a plurality of preferably flexible fingers <NUM>. Although not limited thereto, the flexible fingers <NUM> and the flexible fingers <NUM> are substantially symmetrical. Attached to the second side portion <NUM> is at least an extending member <NUM> that extends towards the first side portion <NUM>. Each of the first side portion <NUM> and the second side portion <NUM> of the end terminal <NUM> includes at least an indentation or aperture <NUM>, <NUM>, respectively.

The clamp (or retainer) <NUM> of the cable reinforcement retainer assembly <NUM> includes a first side portion <NUM> and a second side portion <NUM>. Each of the first side portion <NUM> and the second side portion <NUM> of the clamp <NUM> includes at least an inwardly protruding member <NUM>, <NUM>, respectively. The protruding members <NUM>, <NUM> enter the indentations or apertures <NUM>, <NUM>, respectively, when the end terminal <NUM> is accommodated within the clamp <NUM> during assembly thereof. Further shown in <FIG> is at least a flexible member <NUM> in the second side portion <NUM> of the clamp <NUM>. Although the flexible member <NUM> is shown in <FIG> as a pair of flexible members <NUM>, it is not limited thereto.

At least a side portion <NUM> of the terminal <NUM> is prevented from traversing pass at least an inwardly protruding member <NUM> located at a side <NUM> of the clamp <NUM>. It is preferred that each of the opposing sides <NUM> of the clamp <NUM> includes an inwardly protruding member <NUM>, and that the end terminal <NUM> includes opposing sides <NUM>.

The cable reinforcement retainer assembly <NUM> is shown in <FIG> as being fully assembled and the end portion <NUM> of the end terminal <NUM> of the clamp <NUM> being coupled to the terminal <NUM> of the cable <NUM>. The cable reinforcement retainer assembly <NUM>, as illustrated in <FIG>, shows the end portion of at least one of the flexible members <NUM> of the second side portion <NUM> of the end terminal <NUM>, and an end portion of at least one of the flexible members <NUM> of the first side portion <NUM> of the end terminal <NUM>. See, also, <FIG>.

<FIG> is an elevational view of the second side portion <NUM> of the end terminal <NUM> and the second side portion <NUM> of the clamp <NUM> of the cable reinforcement retainer assembly <NUM>. The second side portion <NUM> of the clamp <NUM> includes at least a flexible member <NUM>. Although not limited thereto, shown in <FIG>, is a pair of flexible members <NUM> with an elongated slit <NUM> therebetween. Also shown in <FIG> are the inwardly protruding members <NUM> in the second side portion <NUM> of the clamp <NUM>, which are preferably inclined for easy entry into the indentations or apertures <NUM> of the end terminal <NUM> (see, <FIG>) when the end terminal <NUM> is moved inside the clamp <NUM>. Once the inwardly protruding members <NUM> have been accommodated within the indentations or apertures <NUM>, the end terminal <NUM> is held inside the clamp <NUM>. That is, the inwardly protruding members <NUM>, <NUM> of the clamp <NUM> are preferably inclined for allowing the terminal <NUM> to be inserted into the clamp <NUM>; and once the inwardly protruding members <NUM>, <NUM> have been respectively accommodated within the indentations or apertures <NUM>, <NUM> of the end terminal <NUM>, the terminal <NUM> is prevented from being pulled out from the clamp <NUM>. As described earlier with respect to <FIG>, the opposing sides134 of the end terminal <NUM> are held by the inwardly protruding members <NUM> of the clamp <NUM>, and prevents the retainer <NUM> from being pushed further forward into the clamp <NUM>. When thus assembled, the cable retainer assembly <NUM>, as illustrated in <FIG>, <FIG>, and <FIG>, has the ends of the flexible members <NUM>, <NUM><NUM> of the terminal <NUM> extending outside of the clamp <NUM>.

Illustrated in <FIG> is an elevational view of the cable retainer assembly <NUM> showing the first side portion <NUM> of the end terminal <NUM> and the first side portion <NUM> of the clamp <NUM>. Illustrated here are the inwardly protruding members <NUM> and the pair of flexible members <NUM> of the clamp <NUM>, and the ends of the flexible members <NUM> of the first side portion <NUM> of the terminal <NUM> extending outside of the clamp <NUM> when the cable reinforcement retainer assembly <NUM> is assembled as shown.

Further shown in <FIG> is an elongated slit <NUM> (shown here as passing in its entirety through the first side portion <NUM> of the clamp <NUM> between the pair of flexible members <NUM>.

<FIG> illustrates a perspective view of a bottom portion <NUM> and a back portion <NUM> of the back cover <NUM>. Shown here is at least a substantially half-circular tubular member <NUM> having a bottom portion <NUM> and extending from the back portion <NUM> of the back cover <NUM>. For strength and stability, the half-circular tubular members <NUM> are joined to bridge (or rib) members <NUM> respectively connected to the back cover <NUM> and extending to the sides <NUM> of the back cover <NUM>. Openings <NUM> of the tubular members <NUM> extend toward a middle portion <NUM> of the back cover <NUM>. Inside the middle portion <NUM> are substantially circular apertures <NUM>, which respectively communicate with the tubular members <NUM>. Inside each of the circular apertures <NUM> is a circular fitting silicone seal <NUM>; and on the outer periphery of the middle portion <NUM> of the back cover <NUM> is an over-molded silicone seal <NUM>. The back cover <NUM> has the circular fitting silicone seal <NUM> for interface with the cable <NUM> and the over-molded silicone seal <NUM> for interface with the inner surface of the outer housing <NUM>. With the cables <NUM> being respectively accommodated within the circular fitting silicone seals <NUM>, the back cover <NUM> acts as a terminal position assurance (TPA) device for the high voltage connector <NUM> of this invention. Surrounding a lower portion <NUM> of the back cover <NUM> are ledges <NUM>; and between the ledges <NUM> are inclined protruding members <NUM>, as shown in <FIG>.

The above-described elements of the back cover <NUM>, as shown in <FIG>, are similarly shown in the elevational view of the back portion <NUM> of the back cover <NUM> illustrated in <FIG>. Shown here are the tubular members <NUM>, and bridge (rib) members <NUM> connected to the sides <NUM>. Also shown in <FIG> are the respective openings <NUM> of the tubular members <NUM>, which communicate with the circular apertures <NUM> thereof, the respective circular fitting silicone seals <NUM> being fitted inside the circular apertures <NUM>, and the silicone seal <NUM> surrounding the outer periphery of the middle portion <NUM> of the back cover <NUM>. Shown in <FIG> are the ledges <NUM> surrounding, on all sides, the lower portion <NUM> (see, <FIG>) of the back cover <NUM>, and the inclined protruding members <NUM> extending on opposing sides of the back cover <NUM>, as shown in <FIG>.

<FIG> is a perspective view of a top portion <NUM> and a front portion <NUM> of the back cover <NUM>. Shown on the top portion <NUM> are the inclined protruding members <NUM>. Opposite the top portion <NUM> of the back cover <NUM> is the bottom portion <NUM> thereof. Extending from the front portion <NUM> are top tubular members <NUM> with respective openings <NUM> that respectively communicate with the circular apertures <NUM> extending through the middle portion <NUM> of the back cover. As in the half-circular tubular members <NUM> extending from the back portion <NUM>, the top tubular members <NUM> are similarly surrounded by bridge (or rib) members <NUM>. Surrounding the outer periphery of the middle portion <NUM> is the silicone seal <NUM>.

<FIG> is an elevational view of the front portion <NUM> of the back cover <NUM> showing the respective openings <NUM> of the top tubular members <NUM> and the associated bridge (or rib) members <NUM>. Also shown in <FIG> are the respective circular fitting silicone seals <NUM>, discussed earlier with respect to <FIG>, and the inclined protruding members <NUM> located in the front portion <NUM> at opposing sides thereof.

<FIG> is a perspective view of the braided shield <NUM> having an internal opening <NUM> extending along the entire length thereof. The braided shield <NUM> is made of metal, preferably stainless steel or the like. <FIG> is a perspective view of the metallic clamp <NUM>, which is substantially ring-like in shape and is made of stainless steel or the like.

In the high voltage horizontal connector <NUM> of this invention, the ground system is provided with the connection of the connector <NUM> to the associated aluminum device <NUM> by establishing contacts among the metal-infused conductive plastic outer housing <NUM>, the aluminum compression limiters <NUM>, the stainless steel bolts <NUM>, and the associated aluminum device <NUM>. The substantial reduction or elimination of EMI is provided by the metal-infused pads <NUM> of the outer housing <NUM> in conjunction with the braided shield <NUM> extending along the paths of the cables <NUM>, the metal-infused pads <NUM> contacting the associated aluminum device <NUM>. This invention further provides a galvanic corrosion prevention with the base <NUM> of the non-conducting over-molded silicone seal <NUM> shielding the metal-infused conductive plastic outer housing <NUM> and the associated aluminum device <NUM> from electrolytic fluid to prevent galvanic corrosion. Galvanic corrosion is further prevented with the side members <NUM> of the upper portion <NUM> of the silicone seal <NUM> shielding the metal-infused conductive plastic outer housing <NUM> and the aluminum compression limiters <NUM>, and further shielding the stainless bolts <NUM> and the associated aluminum device <NUM> from electrolytic fluid to prevent galvanic corrosion.

The method for assembling the high voltage connector of this invention is hereinafter described in detail. The bolts <NUM> are respectively secured into the compression limiters <NUM>, which are inside the side apertures <NUM> of the outer housing <NUM>, thereafter mounting the outer housing <NUM>, along with the outer-molded silicone seal <NUM>, onto the device <NUM> (see, <FIG>) onto which the outer housing <NUM> and subsequently the connector <NUM> is to be mounted. The bolts <NUM> securely fasten the connector <NUM> to the device <NUM>, and provides grounding among the braided shield <NUM>, the outer housing <NUM>, and the device <NUM>. Preferably, the stainless steel bolts <NUM> and the aluminum compression limiters <NUM> provide the contact between the connector <NUM> and the device <NUM> to ground the system.

With the outer housing <NUM>, along with the outer-molded silicone seal <NUM>, having been mounted onto the device, the inner housing <NUM> is then inserted or slid into the central opening <NUM> of the outer housing <NUM> until the inner housing <NUM> is about to reach or reaches the end portion <NUM> (see, <FIG>) of the outer housing <NUM>, and the inner housing <NUM> is then inserted or slid downward into the bottom opening or aperture <NUM> (see, <FIG>) of the outer housing <NUM> so as to mount the inner housing <NUM> onto the base <NUM> of the outer housing <NUM> until a clicking sound or the like is heard, which assures that the inner housing <NUM> is secured inside the outer housing <NUM>. The over-molded silicone seal <NUM> provides a sealing and insulation layer for galvanic corrosion protection between the connector <NUM> and the device <NUM>. Preferably, a plurality of pre-assembled cable reinforcement retainer assemblies <NUM> with their respective cables <NUM> is first inserted into the central opening <NUM> of the outer housing <NUM> and then inserted downward into the inner housing <NUM> until a clicking sound or the like is heard in which case the back cover <NUM> then slides along the cables <NUM> through the central opening <NUM> and into the outer housing <NUM> until a clicking sound or the like is again heard once the back cover <NUM> is secured inside the outer housing <NUM>. At such time, the partially assembled connector <NUM> is as shown in <FIG>. Thereafter, the braided shield <NUM> is mounted onto the outer housing <NUM>, and the clamp <NUM> is slid down over the braided shield <NUM> towards the back end portion of the braided shield <NUM> and rests thereonto (see, <FIG>) and provides the conductive contact between the braided shield <NUM> and the outer housing <NUM>.

More particularly, when the inner housing <NUM> is inserted into the central opening <NUM> of the outer housing <NUM>, the inner housing <NUM> is about to reach or reaches the end portion <NUM> of the outer housing <NUM> and is then inserted into the opening or aperture <NUM> and lowered towards the base <NUM> of the outer housing <NUM>, the downwardly extending member <NUM> of the inner housing <NUM> enters (or slides) downwards into the bottom opening or aperture <NUM> of the outer housing <NUM>. Then, the bottom surface <NUM> of the front extending member <NUM> of the inner housing <NUM> mounts onto an inner side portion <NUM> (see, <FIG> and <FIG>) of the outer housing <NUM>. Substantially thereupon, the upper portion <NUM> of the flexible latch member <NUM> (see, <FIG>) on opposing sides of the inner housing <NUM> respectively enter indentations <NUM> (see, <FIG>) on opposing inner sides of the outer housing <NUM> at which time, a clicking sound or the like is heard. The clicking sound or the like thus indicates that the inner housing <NUM> is securely mounted inside the outer housing <NUM>. The inner housing <NUM> (preferably made of nylon or the like) provides separation between conductive parts (e.g., the outer housing <NUM> made of metal-infused plastic or the like and the cable terminals <NUM> secured inside the inner housing <NUM>).

Thereafter, preferably a plurality of pre-assembled cable reinforcement retainer assemblies <NUM> (see, <FIG>) with their accompanying respective cables <NUM> have their accompanying cables <NUM> inserted inside the respective circular fitting silicone seals <NUM> of the respective circular apertures <NUM> of the back cover <NUM>.

The preferably pre-assembled cable reinforcement retainer assemblies <NUM> are then inserted or slid into the central opening <NUM> of the outer housing <NUM> and lowered towards the upper slots <NUM>, <NUM>, <NUM> (see, <FIG>) of the inner housing <NUM>. More particularly, with the second side portions <NUM><NUM> of the clamps <NUM> respectively facing the front portion <NUM> of the inner housing <NUM>, the cable reinforcement retainer assemblies <NUM> are inserted or slid substantially horizontally through the central opening <NUM> of the outer housing <NUM> and subsequently lowered respectively through the upper slots <NUM>, <NUM>,<NUM>, but do not pass beyond the slots <NUM>, <NUM>, <NUM> of the bottom end portions <NUM> of the inner housing <NUM> (see, <FIG>). The cable reinforcement retainer assemblies <NUM> respectively travel downward through the upper slots <NUM>, <NUM>, <NUM> of the inner housing <NUM> and the clamps <NUM> respectively push, while traveling downward, the inclined ledges <NUM> of the flexible members <NUM>, <NUM>, <NUM> (see, <FIG>) of the inner housing <NUM> until each upper end <NUM> (see, <FIG>) of each clamp <NUM> respectively settles beneath one of the inclined ledge <NUM> of the inner housing <NUM> (see, <FIG>); thereupon, a clicking sound or the like is heard, which indicates that the clamps <NUM> and consequently the cable reinforcement retainer assemblies <NUM> are securely fastened within the inner housing <NUM>. At this time, the substantially flat and substantially bent portion <NUM> (see, <FIG>) of the end terminal <NUM> sits or is mounted onto the substantially flat and substantially horizontal first portion <NUM> of the front extending member <NUM> of the inner housing <NUM>. The second portions <NUM> of the front extending member <NUM> of the inner housing <NUM> respectively separating the substantially flat and substantially bent portions <NUM> of the end terminals <NUM>.

Thereafter, the back cover <NUM> is slid substantially horizontally, along the cables <NUM>, towards the outer housing <NUM> and through the central opening <NUM> thereof until the inclined protruding members <NUM> (see, <FIG> and <FIG>) at opposing sides of the back cover <NUM> respectively enter the apertures <NUM> (see, <FIG> and <FIG>) passing through the front portion of the outer housing <NUM> at which time a clicking sound or the like is heard to indicate that the back cover <NUM> has been securely fastened to the outer housing <NUM> with the cable reinforcement retainer assemblies <NUM> similarly fully secured inside the outer housing <NUM>. That is, the back cover <NUM> pushes the inner housing <NUM> in place and ensures that the inner housing <NUM> is properly positioned in the outer housing <NUM>.

As illustrated in <FIG>, the horizontal high voltage connector <NUM> of this invention is mounted onto a device <NUM> (e.g., an inverter or the like) with the use of the bolts <NUM>. The downwardly extending member <NUM> of the inner housing <NUM> is shown as having passed through the bottom opening or aperture <NUM> of the bottom end portion <NUM> of the base <NUM> of the outer housing <NUM> and through the over-molded silicone seal <NUM>. The pads <NUM> of the bottom end portion <NUM> of the base <NUM> of the outer housing <NUM> are shown as being inside the elongated slots <NUM> of the over-molded silicone seal <NUM>.

As further illustrated in <FIG>, the substantially flat and substantially bent portion <NUM> (see, <FIG>) of the end terminal <NUM> of the cable reinforcement retainer assembly <NUM> sits or is mounted onto the substantially flat and substantially horizontal first portion <NUM> of the front extending member <NUM> of the inner housing <NUM>. The bottom surface <NUM> of the front extending member <NUM> of the inner housing <NUM> is seated or mounted onto an inner side portion <NUM> (see, <FIG> and <FIG>) of the outer housing <NUM>.

Also illustrated in <FIG> is the wedge or impinging mechanism A for securing the cables <NUM> in the inner housing <NUM>. More particularly, when the back cover <NUM> is inserted or slid substantially horizontally, along the cables <NUM>, through the central opening <NUM> and into the outer housing <NUM>, the bottom portions <NUM> of the substantially half-circular tubular members <NUM> (see, <FIG>) of the back cover <NUM> respectively wedge or impinge against top face portions <NUM> (see, <FIG> and <FIG>) of the end portions <NUM> of the end terminals <NUM> of the cable reinforcement retainer assemblies <NUM>, thereby securing the cables <NUM> inside the inner housing <NUM>. As shown in <FIG>, the ends of the flexible members <NUM>, <NUM> of the terminal <NUM> (see, e.g., <FIG>), which extend to the outside of the clamp <NUM>, connect with a set of terminals <NUM> of the associated device <NUM>.

Thereafter, to shield the exposed cables <NUM>, the braided shield <NUM> is slid substantially horizontally towards the outer housing assembly <NUM> whereby a back portion of the braided shield <NUM> passes the outer ledges 98a, 98b (see, <FIG>), extend from a portion of the outer housing <NUM> near its central opening <NUM>. The clamp <NUM> is then slid substantially horizontally along the braided shield <NUM> pass the outer ledges 98a, 98b, and at about pass the outer ledges 98a, 98b, the clamp <NUM> connects the braided shield <NUM> to the outer housing <NUM> and assures the connection thereof.

When fully-assembled, the horizontal high voltage connector <NUM> of this invention includes a ground system that is provided with the connection of the connector <NUM> to the associated aluminum device <NUM> by establishing contacts among the metal-infused conductive plastic outer housing <NUM>, the aluminum compression limiters <NUM>, the stainless steel bolts <NUM>, and the associated aluminum device <NUM>. The substantial reduction or substantial elimination of EMI is provided by the shielding of the EMI by the braided shield <NUM> extending along the paths of the cables <NUM>, or the diversion of the EMI from the braided shield <NUM> to the metal-infused pads <NUM>, which are used for EMI grounding, contacting the associated aluminum device <NUM>. That is, the EMI is diverted to a path from the stainless steel braided shield <NUM>, which is connected to the metal-infused plastic outer housing <NUM> by the stainless steel clamp <NUM>, to the metal-infused plastic outer housing <NUM> mounted onto the, for example, aluminum inverter <NUM>. This invention further provides a galvanic corrosion prevention with the base <NUM> of the non-conducting over-molded silicone seal <NUM> shielding the metal-infused conductive plastic outer housing <NUM> and the associated aluminum inverter <NUM> from electrolytic fluid to prevent galvanic corrosion. The metal-infused pads <NUM> protruding through and bordered by the silicone seal <NUM> prevents galvanic corrosion between the metal-infused outer housing <NUM> and the aluminum inverter <NUM>. Galvanic corrosion is further prevented with the side members <NUM> of the upper portion <NUM> of the silicone seal <NUM> shielding the metal-infused conductive plastic outer housing <NUM> and the aluminum compression limiters <NUM>, and further shielding the stainless bolts <NUM> and the associated aluminum inverter <NUM> from electrolytic fluid to prevent galvanic corrosion.

Claim 1:
A high voltage connector (<NUM>), comprising:
an outer housing assembly (<NUM>) to be mounted onto a device (<NUM>), said outer housing assembly (<NUM>) including an outer housing (<NUM>) being conductive and having a central opening (<NUM>) facing a substantially horizontal direction and an inner opening (<NUM>) facing a substantially vertical direction, said central opening (<NUM>) and said inner opening (<NUM>) communicating with each other;
an inner housing (<NUM>) mounted inside said outer housing (<NUM>);
a set of cable reinforcement retainer assemblies secured inside said outer housing (<NUM>) by said inner housing (<NUM>), said set of cable reinforcement retainer assemblies (<NUM>, <NUM>) having respective cable terminals (<NUM>) and cables (<NUM>) attached thereto, said cables (<NUM>) of the high voltage connector (<NUM>) extending in the substantially horizontal direction;
a back cover (<NUM>), through which said cables (<NUM>) respectively slide through, and covers a central opening (<NUM>) of said outer housing (<NUM>);
a braided shield (<NUM>) covering said cables (<NUM>) and being mounted onto said outer housing (<NUM>); and
a clamp (<NUM>), mounted onto a lower portion of said braided shield (<NUM>), for connecting said lower portion of said braided shield (<NUM>) onto said outer housing (<NUM>),
wherein said back cover (<NUM>) includes apertures (<NUM>) for accommodating therein said cables (<NUM>) attached to said cable reinforcement retainer assemblies (<NUM>, <NUM>),
characterized in that
said back cover (<NUM>) includes a front portion (<NUM>) and a back portion (<NUM>), said front portion (<NUM>) having tubular members (<NUM>) extending therefrom and said back portion (<NUM>) having substantially half-circular tubular members (<NUM>) extending therefrom, wherein apertures (<NUM>, <NUM>) of said tubular members (<NUM>) and said substantially half-circular tubular members (<NUM>) communicate with said apertures (<NUM>) of said back cover (<NUM>) for respectively accommodating therein said cables (<NUM>).