Connector system comprising an interlock system

Abstract

A connector system configured for use in a power distribution system of an automotive vehicle and wherein the connector system includes a female housing, a female terminal assembly, and a female interlock (FIL) assembly. The female housing has an arrangement of sidewalls defining a receptacle configured to receive the female terminal assembly. The female interlock (FIL) assembly is positioned within the female terminal assembly that resides within the receptacle of the female housing to define a fully assembled female state S FAF wherein the FIL assembly is configured to be coupled to an interlock circuit that prevents current from flowing through the female terminal assembly prior to the female terminal assembly being connected to a male terminal assembly.

Description

[0001] Related applications

[0002] This application claims the benefit of U.S. Provisional Patent Application 63 / 058,061, filed July 29, 2020, the disclosure of which is incorporated herein by reference. Technical Field

[0003] This disclosure relates to a connector system, more specifically to a connector system including interlocking components, and most specifically to an innovative connector system including high-voltage interlocking components. Background Technology

[0004] Over the past few decades, the number of electrical components used in automobiles and other on-road vehicles and off-road vehicles (such as pickup trucks, commercial vans and trucks, semi-trucks, motorcycles, all-terrain vehicles, and SUVs) (collectively, "motor vehicles") has increased significantly. Electrical components are used in motor vehicles for a variety of reasons, including but not limited to monitoring vehicle performance, improving and / or controlling vehicle performance, emissions, safety, and creating comfort for vehicle occupants. Significant time, resources, and energy have been consumed in developing electrical components that meet the changing needs and complexities of the motor vehicle market; however, conventional electrical components suffer from several drawbacks.

[0005] Motor vehicles present a challenging electrical environment for both electrical components and connector assemblies due to numerous conditions, including but not limited to space constraints that make initial installation difficult, harsh operating conditions, wide ambient temperature ranges, prolonged vibration, thermal loads, and lifespan (all of which can lead to component and / or connector failure). For example, improperly installed connectors, often occurring in assembly plants, and detached connectors, often occurring in the field, are two significant failure modes for both electrical components and motor vehicles. Each of these failure modes results in substantial repair and warranty costs. For instance, the cumulative annual warranty costs for all global automakers and their direct suppliers are estimated to be between $50 billion and $150 billion. Given these challenging electrical environments, significant time, money, and effort have been devoted to developing power distribution components that meet market demands. This disclosure addresses the shortcomings of conventional power distribution components. A full discussion of the features and advantages of this disclosure is deferred to the following detailed description with reference to the accompanying drawings. Summary of the Invention

[0006] This disclosure relates to a connector system for use in aircraft, motor vehicles, military vehicles (e.g., tanks, troop carriers, heavy trucks, and troop transport vehicles), buses, locomotives, tractors, marine applications (e.g., cargo ships, tankers, yachts, submarines, and sailboats), telecommunications hardware (e.g., servers), battery packs, and 24- to 48-volt systems, for high-power applications, for high-current applications, and for high-voltage applications.

[0007] Specifically, the invention discussed herein is a connector system for electrically connecting a power source to other power distribution components or assemblies. This connector system includes an interlocking system (IL) that ensures no current is applied to the connector system before the outer male connector assembly and the intermediate female connector assembly are fully engaged. It should be understood that when the IL is used under high voltage conditions, it may be referred to as a high-voltage interlocking system (HVIL). The connector system also includes an innovative spring member with a centering device that ensures the correct relative positioning of the connector system components, including the spring member and the male terminals.

[0008] In one embodiment, the connector system is configured for use in an electrical distribution system of a motor vehicle, and wherein the connector system includes a concave housing, a concave terminal assembly, and a concave interlock (FIL) assembly. The concave housing has an arrangement defining sidewalls of a receptacle configured to receive the concave terminal assembly. The concave interlock (FIL) assembly is positioned within the concave terminal assembly residing in the receptacle of the concave housing to define a fully assembled concave state S. FAF The FIL component is configured to be connected to an interlocking circuit that prevents current from flowing through the concave terminal assembly before the concave terminal assembly is connected to the convex terminal assembly.

[0009] In another embodiment, the connector system includes a concave connector assembly having: (i) a concave housing having an arrangement defining sidewalls of a receptacle; (ii) a concave terminal assembly residing within the receptacle of the concave housing; and (iii) a concave interlocking (FIL) assembly with a receiver positioned within the concave terminal assembly residing within the receptacle of the concave housing to define a fully assembled concave state S. FAF .

[0010] In another embodiment, the connector system has an intermediate concave connector assembly, a first convex connector assembly, and a second convex connector assembly. The intermediate concave connector assembly includes: (i) a concave terminal assembly and (ii) a concave interlock (FIL) assembly, the concave interlock assembly being positioned within the concave terminal assembly to define a fully assembled concave state S. FAFThe first convex connector assembly includes a first convex terminal assembly, while the second convex connector assembly includes: (i) a second convex terminal assembly and (ii) a convex interlock (MIL) assembly positioned within the second convex terminal assembly to define a fully assembled convex state S. FAM Furthermore, the concave terminal assembly includes a socket, the size of which is designed so that in the fully connected state S FCON The lower part receives both a portion of the first convex connector assembly and a portion of the second convex connector assembly.

[0011] In another embodiment, the connector system includes a convex terminal assembly having a convex terminal body and an internal spring member. The convex terminal body includes at least one contact arm and a sidewall arrangement defining a spring receiver, while the internal spring member includes: (i) at least one spring arm having an elongated body portion with a free end, and (ii) a protrusion extending laterally from the free end of the body portion. The internal spring member resides within the spring receiver to define a fully engaged state S. FC The protrusion is located adjacent to the inner surface of the spring receiver to facilitate the alignment of the internal spring member within the spring receiver.

[0012] In another embodiment, the connector system includes a first convex terminal assembly, a second convex terminal assembly, a housing configured to surround both the first and second convex terminal assemblies, and a convex interlocking (MIL) assembly positioned within the housing and between the first and second convex terminal assemblies. The first convex terminal assembly has: (i) a first convex terminal body formed of a first material and having a contact arm and a spring receiver; and (ii) a first internal spring member formed of a second material and having a spring arm, wherein the first internal spring member is sized to reside within the spring receiver of the first convex terminal body. The second convex terminal assembly has: (i) a second convex terminal body formed of a first material and having a contact arm and a spring receiver; and (ii) a second internal spring member formed of a second material and having a spring arm, wherein the second internal spring member is sized to reside within the spring receiver of the second convex terminal body. Further structural and functional aspects and benefits of the power distribution component are disclosed in the Detailed Description section and the accompanying drawings. Attached Figure Description

[0013] The accompanying drawings, included to provide further understanding and incorporated in and forming part of this specification, illustrate embodiments of the invention disclosed and, together with the description, serve to explain the principles of the disclosed embodiments. In the drawings:

[0014] Figure 1 This is a perspective view of a first embodiment of a connector system having an inner convex connector assembly, an intermediate concave connector assembly, and an outer convex connector assembly, wherein the connector system is in an open state (S DCON );

[0015] Figure 2 yes Figure 1 Exploded view of the connector system;

[0016] Figure 3 yes Figure 1 A perspective view of the external convex connector assembly, wherein the external convex connector assembly is in a fully assembled state (S FA );

[0017] Figure 4 yes Figure 3 Front view of the external convex connector assembly;

[0018] Figure 5 yes Figure 3 An exploded view of an external convex connector assembly, wherein the external convex connector assembly has an outer housing, a convex interlocking assembly, and an external terminal assembly;

[0019] Figure 6 It is in a disengaged state (S) DC Perspective view of the external terminal assembly;

[0020] Figure 7 It is in a partially connected state (S) PC Perspective view of the external terminal assembly;

[0021] Figure 8 It is in a fully connected state (S) FC Side view of the external terminal assembly;

[0022] Figure 9 It is along Figure 8 Front view of the cross-section of the external terminal assembly, taken by line 9-9;

[0023] Figure 10 It is along Figure 8 Side view of the cross-section of the external terminal assembly, taken from line 9-9;

[0024] Figure 11 It is in a state of withdrawal (S) as disclosed in PCT / US2019 / 36010. DC Perspective view of the terminal assembly;

[0025] Figure 12 yes Figure 11 The side view of the terminal assembly shown, wherein the terminal assembly is in a fully connected state (S FC );

[0026] Figure 13 It is along Figure 12 A front view of the cross-section of the terminal assembly taken by line 13-13, wherein the spring member is correctly positioned within the receiver of the terminal body;

[0027] Figure 14 It is along Figure 12 A front view of the cross-section of the terminal assembly taken by line 13-13, wherein the spring member is not properly positioned within the receiver of the terminal body;

[0028] Figure 15 yes Figure 3 A perspective view of an external convex connector assembly, wherein the external convex connector assembly is in a first part assembly state (S PA1 );

[0029] Figure 16 yes Figure 3 A perspective view of the convex interlocking assembly;

[0030] Figure 17 yes Figure 3 Front view of the convex interlocking component;

[0031] Figure 18 yes Figure 3 Side view of the convex interlocking assembly;

[0032] Figure 19 It is along Figure 18 A sectional view of the convex interlocking assembly taken from line 19-19;

[0033] Figure 20 yes Figure 3 A perspective view of a convex connector assembly, wherein the outer convex connector assembly is in the second part assembly state (S). PA2 );

[0034] Figure 21 yes Figure 3 A perspective view of the external convex connector assembly, wherein the external convex connector assembly is in the third part assembly state (S). PA3 );

[0035] Figure 22 yes Figure 3 A perspective view of the external convex connector assembly, wherein the external convex connector assembly is in the fourth part assembly state (S). PA4 );

[0036] Figure 23 yes Figure 3 A perspective view of the external convex connector assembly, wherein the external convex connector assembly is in the fifth part assembly state (S). PA5 );

[0037] Figure 24 yes Figure 3 A side view of an external convex connector assembly, wherein the external convex connector assembly is in a fully assembled state (S FA );

[0038] Figure 25 It is along Figure 24 A cross-sectional view of the external convex connector assembly taken from line 25-25;

[0039] Figure 26 yes Figure 3 A front view of the external convex connector assembly, wherein the external convex connector assembly is in a fully assembled state (S FA );

[0040] Figure 27 It is along Figure 15 A cross-sectional view of the external convex connector assembly taken from line 27-27;

[0041] Figure 28 yes Figure 1 A perspective view of an internal convex connector assembly, wherein the internal convex connector assembly is in a fully assembled state (S FA );

[0042] Figure 29 yes Figure 28 Front view of the internal convex connector assembly;

[0043] Figure 30 yes Figure 28 An exploded view of an internal convex connector assembly, wherein the internal convex connector assembly has an internal housing and an internal terminal assembly;

[0044] Figure 31 yes Figure 28 A perspective view of an internal convex connector assembly, wherein the internal convex connector assembly is in a first part assembly state (S PA1 );

[0045] Figure 32 yes Figure 28 A perspective view of an internal convex connector assembly, wherein the internal convex connector assembly is in a second part assembly state (S). PA2 );

[0046] Figure 33 yes Figure 28 A perspective view of an internal convex connector assembly, wherein the internal convex connector assembly is in a third-part assembly state (S). PA3 );

[0047] Figure 34 yes Figure 28 A side view of the internal convex connector assembly, wherein the internal convex connector assembly is in a fully assembled state (S FA );

[0048] Figure 35 It is along Figure 34 A cross-sectional view of the internal convex connector assembly taken from line 35-35;

[0049] Figure 36 yes Figure 28 A front view of an internal convex connector assembly, wherein the internal convex connector assembly is in a fully assembled state (S FA );

[0050] Figure 37 It is along Figure 36 A cross-sectional view of the internal convex connector assembly taken from line 37-37;

[0051] Figure 38 yes Figure 1 A side view of the central concave connector assembly, wherein the central concave connector assembly is in a fully assembled state (S FA );

[0052] Figure 39 yes Figure 38 A perspective view of the central concave connector assembly;

[0053] Figure 40 yes Figure 38 Front view of the central concave connector assembly;

[0054] Figure 41 yes Figure 38 An exploded view of a central concave connector assembly, wherein the central concave connector assembly has a central housing, a concave interlocking assembly, and a central terminal assembly;

[0055] Figure 42 yes Figure 38 A perspective view of a recessed connector assembly, wherein the recessed connector assembly is in a first part assembly state (S PA1 );

[0056] Figure 43 yes Figure 38 A perspective view of the concave connector assembly, wherein the concave connector assembly is in the second part assembly state (S PA2 );

[0057] Figure 44 yes Figure 38 A perspective view of the concave connector assembly, wherein the concave connector assembly is in the third part assembly state (S). PA3 );

[0058] Figure 45 yes Figure 38 A perspective view of the concave connector assembly, wherein the concave connector assembly is in the fourth part assembly state (S). PA4 );

[0059] Figure 46 yes Figure 39 A front view of the central concave connector assembly, wherein the central concave connector assembly is in a fully assembled state (S FA );

[0060] Figure 47 It is along Figure 46 A cross-sectional view of the intermediate concave connector assembly taken from line 47-47;

[0061] Figure 48 It is in the disconnected state (S) DCON Side view of the connector system;

[0062] Figure 49 It is along Figure 48 A cross-sectional view of the connector system taken from line 49-49;

[0063] Figure 50 It is in the disconnected state (S) DCON Rear view of the connector system;

[0064] Figure 51 It is along Figure 50 A cross-sectional view of the connector system taken from line 51-51;

[0065] Figure 52 It is in the first part of the connection state (S) PCON1 Side view of the connector system;

[0066] Figure 53 It is along Figure 52 A cross-sectional view of the connector system taken from line 53-53;

[0067] Figure 54 It is in the first part of the connection state (S) PCON1 Rear view of the connector system;

[0068] Figure 55 It is along Figure 54 A cross-sectional view of the connector system taken from line 55-55;

[0069] Figure 56 It is in the second part of the connection state (S) PCONN2 Side view of the connector system;

[0070] Figure 57 It is along Figure 56A cross-sectional view of the connector system taken from line 57-57;

[0071] Figure 58 It is in the second part of the connection state (S) PCON2 Rear view of the connector system;

[0072] Figure 59 It is along Figure 58 A cross-sectional view of the connector system taken from line 59-59;

[0073] Figure 60 It is in the third part of the connection state (S) PCON3 Side view of the connector system;

[0074] Figure 61 It is along Figure 60 A cross-sectional view of the connector system taken from line 61-61;

[0075] Figure 62 It is in the third part of the connection state (S) PCON3 Rear view of the connector system;

[0076] Figure 63 It is along Figure 62 A cross-sectional view of the connector system taken from line 63-63;

[0077] Figure 64 It is in a fully connected state (S FCON Side view of the connector system;

[0078] Figure 65 It is along Figure 64 A cross-sectional view of the connector system taken from line 65-65;

[0079] Figure 66 It is in a fully connected state (S FCON Rear view of the connector system;

[0080] Figure 67 It is along Figure 66 A cross-sectional view of the connector system taken from line 67-67;

[0081] Figure 68 It is in an ready-to-use state (S) R Side view of the connector system;

[0082] Figure 69 It is along Figure 68 A cross-sectional view of the connector system taken from line 58-58;

[0083] Figure 70 It is in an ready-to-use state (S) R Rear view of the connector system;

[0084] Figure 71 It is along Figure 70 A cross-sectional view of the connector system taken from line 60-60;

[0085] Figure 72 yes Figure 1 A side view of the extent of the middle concave connector assembly and the extent of the outer convex connector assembly of the connector system, wherein the assembly is in a fully connected state (S FCON );

[0086] Figure 73 It is along Figure 72 A cross-sectional view of the middle concave connector assembly and the outer convex connector assembly taken from line 73-73;

[0087] Figure 74A This is a block diagram illustrating a construction of a first embodiment in which a connector system can be utilized;

[0088] Figure 74B It is a timing diagram of three signals contained within the connector system;

[0089] Figure 75 It is a perspective view of a vehicle skateboard with a battery pack, wherein the vehicle skateboard includes a first embodiment of a connector system;

[0090] Figure 76 It is a perspective view of a vehicle with a battery pack, wherein the vehicle includes a first embodiment of a connector system;

[0091] Figure 77 This is a block diagram showing the components of the connector system;

[0092] Figure 78 This is a block diagram showing the components of the outer housing assembly;

[0093] Figure 79 This is a block diagram showing the components of the external shielding assembly;

[0094] Figure 80 This is a block diagram showing the component with the convex terminal;

[0095] Figure 81 This is a block diagram showing the components of a spring assembly;

[0096] Figure 82 This is a block diagram showing the components of the MIL (Mean Interlocking In-line) assembly;

[0097] Figure 83 This is a block diagram showing the components of the intermediate housing assembly;

[0098] Figure 84This is a block diagram showing the components of the FIL (Fill In-Loop) assembly;

[0099] Figure 85 This is a block diagram showing the components of the internal housing assembly;

[0100] Figure 86 This is a block diagram showing the component with the convex terminal;

[0101] Figure 87 This is a block diagram showing the components of a spring assembly;

[0102] Figure 88 This is an exploded perspective view of a second embodiment of the connector system, which has a convex connector assembly and a concave connector assembly;

[0103] Figure 89 yes Figure 88 A perspective view of a convex connector assembly, wherein the convex connector assembly is in a fully assembled state (S FA );

[0104] Figure 90 yes Figure 88 Front view of the convex connector assembly;

[0105] Figure 91 yes Figure 88 An exploded view of a convex connector assembly, wherein the convex connector assembly has a convex housing, a convex interlocking assembly, and a plurality of convex terminal assemblies;

[0106] Figure 92 is Figure 91 A perspective view of the convex interlocking assembly and multiple convex terminal assemblies;

[0107] Figure 93 This is a side view of the convex terminal assembly in Figure 92, wherein the convex terminal assembly includes a convex terminal body and a convex spring member;

[0108] Figure 94 yes Figure 93 Front view of the convex terminal assembly;

[0109] Figure 95 yes Figure 93 A top view of the convex terminal assembly;

[0110] Figure 96 yes Figure 91 A top view of the convex spring component;

[0111] Figure 97 yes Figure 91 Side view of the convex spring component;

[0112] Figure 98 yes Figure 91 Front view of the convex spring component;

[0113] Figure 99 yes Figure 88 A perspective view of a concave connector assembly, wherein the concave connector assembly is in a fully assembled state (S FA );

[0114] Figure 100 yes Figure 99 Front view of the concave connector assembly;

[0115] Figure 101 yes Figure 88 An exploded view of a concave assembly, wherein the concave connector assembly has a concave housing, a concave interlocking assembly, and a plurality of concave terminals;

[0116] Figure 102 It is in a partially connected state (S PCONN Side view of the connector system;

[0117] Figure 103 It is along Figure 102 A cross-sectional view of the connector system taken from line 103-103;

[0118] Figure 104 It is in a partially connected state (S PCONN Side view of the connector system;

[0119] Figure 105 It is along Figure 104 A cross-sectional view of the connector system taken from line 105-105;

[0120] Figure 106 It is in an ready-to-use state (S) R Side view of the connector system;

[0121] Figure 107 It is along Figure 106 A cross-sectional view of the connector system taken from line 107-107;

[0122] Figure 108 It is in an ready-to-use state (S) R A side view of the connector system; and

[0123] Figure 109 It is along Figure 108 A cross-sectional view of the connector system taken from line 109-109. Detailed Implementation

[0124] In the following detailed description, numerous specific details are illustrated by way of example in order to provide a thorough understanding of the relevant teachings. However, it should be apparent to those skilled in the art that the teachings can be practiced without such details. In other instances, well-known methods, processes, components, and / or circuits have been described at a relatively high level without detailed explanation in order to avoid unnecessarily obscuring aspects of the teachings.

[0125] While this disclosure includes many different embodiments, specific embodiments are shown in the accompanying drawings and will be described in detail herein. It is understood that this disclosure should be considered as an illustration of the principles of the disclosed methods and systems and is not intended to limit the broad aspects of the disclosed concepts to the embodiments shown. As will be achieved, the disclosed methods and systems are capable of other and different configurations, and certain details can be modified without departing from the scope of the disclosed methods and systems. For example, one or more embodiments (partial or complete) of the following embodiments can be consistently combined with the disclosed methods and systems. Therefore, the drawings and detailed descriptions should be considered illustrative in nature and not as limiting or restrictive.

[0126] The accompanying drawings illustrate two embodiments of connector systems 100 and 5100, designed to mechanically and electrically connect one device or component to another device or component within a power distribution system or environment. For example, the device or component may be a current-supplying device or component (e.g., a power source such as an alternator or battery), and the other device or component may be a current-consuming device or component (e.g., a radiator fan, heating bracket, power distribution component, or other current-consuming component). The power distribution system or environment including connector systems 100 and 5100 can be installed in aircraft, motor vehicles, military vehicles (e.g., tanks, troop carriers, heavy trucks, and troop transport vehicles), buses, locomotives, tractors, ships, submarines, battery packs, 24-volt to 48-volt systems, for high-power applications, for high-current applications, and for high-voltage applications. In these applications, the power distribution component is essential to meeting industry standards, production, and performance requirements of the power distribution system and motor vehicle. It should be understood that multiple connector systems 100 and 5100 may be used in a single application.

[0127] This document discloses various aspects of a first embodiment of a connector system 100. Specifically, the connector system 100 comprises: (i) a convex connector assembly, namely an external convex connector assembly or a second connector assembly 1000; (ii) a concave connector assembly, namely an internal concave connector assembly 2000; and (iii) a convex connector assembly, namely an internal convex connector assembly or a first connector assembly 3000.

[0128] ● Figures 3 to 10 and Figures 15 to 27 Various views and components of the external convex connector assembly 1000 are shown. The external convex connector assembly 1000 mainly consists of: (i) an external convex housing assembly 1100, (ii) an external convex shielding assembly 1200, (iii) an external convex terminal assembly 1430, (iv) a convex interlocking (MIL) assembly 1600, and (v) a strain relief assembly 1800;

[0129] ● Figures 28 to 37 Various views and components of the internal convex connector assembly 3000 are shown. The internal convex connector assembly 3000 mainly consists of: (i) an internal convex housing assembly 3100, (ii) an internal convex terminal assembly 3430, and (iii) a bus assembly 3900;

[0130] ● Figures 38 to 47 Various views and components of the recessed connector assembly 2000 are shown. The recessed connector assembly 2000 mainly comprises: (i) a recessed housing assembly 2100, (ii) a recessed shielding assembly 2200, (iii) a recessed terminal assembly 2430, and (iv) a recessed interlocking assembly (FIL) 2600; and

[0131] ● Figures 48 to 71 This shows the system 100 from the disconnected state S DCON Move to ready-to-use state S R The process.

[0132] Figure 74 to Figure 76 An exemplary application of the connector system 100 is shown, wherein the connector system 100 is used in conjunction with a battery pack 200 mounted in a vehicle slide S, wherein the vehicle slide S is mounted in a vehicle V. The battery pack 200 (see Figure 74) is configured to be positioned in the vehicle slide S (see Figure 75). Figure 75 Both the battery pack and the vehicle skid plate are configured to be positioned within the motor vehicle 700 (see...). Figure 76 In one embodiment, the connector system 100 may be designed such that a second or convex connector assembly 1000 is positioned outside the sidewall 204 of the battery pack 200, an intermediate concave connector assembly 2000 is designed to extend through the sidewall 204 of the battery pack 200, and a first or convex connector assembly 3000 is positioned inside the sidewall 204 of the battery pack 200. Other embodiments, configurations, and uses of the connector system 100 are described in this patent application and contemplated by this disclosure.

[0133] This document discloses various aspects of a second embodiment of the connector system 5100. Specifically, the connector system 5100 comprises a convex connector assembly 1000 and a concave connector assembly 2000.

[0134] ● Figures 78 to 87 Various views and components of the convex connector assembly 6000 are shown. The convex connector assembly 6000 mainly consists of: (i) a convex housing assembly 6100, (ii) a convex shielding assembly 6200, (iii) a plurality of convex terminal assemblies 6430, namely a first terminal assembly and a second terminal assembly, (iv) a convex interlocking (MIL) assembly 6600, and (v) a strain relief assembly 6800;

[0135] ● Figures 89 to 91 Various views and components of the concave connector assembly 7000 are shown. The concave connector assembly 7000 mainly comprises: (i) a concave housing assembly 7100, (ii) a concave shielding assembly 7200, (iii) a plurality of concave terminal assemblies 7430, and (iv) a concave interlocking assembly (FIL) 7600; and

[0136] ● Figures 91 to 98 This illustrates the system 5100 from a partially connected state S DCON Move to ready-to-use state S R The process.

[0137] First Implementation Plan

[0138] Such as combination Figure 2 , Figure 19 , Figure 25 , Figure 40 , Figure 41 and Figures 46 to 7 4. In more detail, the IL system 4000 is shown and discussed as comprising a convex interlocking assembly (MIL) 1600, a concave interlocking assembly (FIL) 2600, and an interlocking circuit 4010. Overall, the IL system 4000 is designed to help prevent arcing during the mating of connector assemblies 1000 and 2000, which are capable of controlling the current supply. To achieve this, the connector system is placed in a fully connected state (S... FCONPrior to this, the IL system 4000 prevents current from being applied to a portion of the connector system 100, namely the intermediate concave connector assembly 2000. Specifically, before the interaction between MIL 1600 and FIL 2600, the disconnect switch 4030 is placed in the OFF position; thus, current is prevented from flowing from the power supply 206 to the intermediate concave connector assembly 2000. Once MIL 1600 and FIL 2600 are connected, the disconnect switch 4030 is placed in the OFF position; thus, current is allowed to flow from the power supply 206 to the intermediate concave connector assembly 2000. However, it should be noted that the aforementioned interaction between the MIL and FIL 1600, 2600 does not occur until the convex terminal assembly 1430 and the concave terminal assembly 2430 are fully engaged.

[0139] Typically, the IL system 4000 is used in conjunction with high-voltage systems. Therefore, the IL system is often referred to as a high-voltage interlock, hazardous voltage interlock circuit, or HVIL. This is partly due to the fact that high-voltage connectors are more likely to be damaged when they come into contact with foreign objects than low-voltage connectors. This additional potential for damage usually justifies the increase in size, weight, and cost of the conventional IL system and connectors. In particular, the increase in size, weight, and cost is primarily due to the fact that the connector portion of a conventional IL system cannot be positioned within a conventional connector due to the construction of the conventional connector, and therefore must be positioned somewhere within the connector housing. Unlike conventional ILs, the connector portions of the IL system 4000, namely MIL, FIL 1600, and 2600, are positioned within terminals 1430 and 2100. Therefore, the size of the connector system 100 or the space required by the connector system 100 does not need to be increased. By limiting the impact of adding the IL system 4000 to a component or environment, designers can obtain the benefits of utilizing the IL system 4000 without the disadvantages traditionally associated with using IL systems. Therefore, the IL system 4000 disclosed herein can be reasonably used in additional applications that may include non-high voltage systems. Consequently, the disclosed interlocking system 4000 may be referred to as a low-voltage interlocking system (LIL), a high-voltage interlocking system (HVIL), or simply an interlocking system (IL).

[0140] 1) External convex connector assembly

[0141] The convex connector assembly, the second convex connector assembly, or the external convex connector assembly 1000 includes multiple components designed to be positioned outside the sidewall 204 of the battery pack 200 and to supply power from outside the battery pack 200 to external devices (e.g., radiator fans, heating mounts, power distribution components, or another current-consuming component). The external convex connector assembly 1000 mainly comprises: (i) an external convex housing assembly 1100, (ii) an external convex shielding assembly 1200, (iii) an external convex terminal assembly 1430, (iv) a convex interlock (MIL) assembly 1600, and (v) a strain relief assembly 1800.

[0142] The convex housing assembly, second housing assembly, or outer housing assembly 1100 encapsulates or surrounds a large range of other components housed within the outer convex connector assembly 1000. The outer housing assembly 1100 generally includes: (i) an outer housing 1104 and (ii) a connector position guarantee (“CPA”) 1170. The outer housing 1104 includes two wall arrangements, wherein: (i) a first sidewall arrangement 1106 has a cylindrical shape and is designed to receive a range of wires 1495, and (ii) a second sidewall arrangement 1108 has a cubic shape and is designed to receive a large range of the outer convex terminal assembly 1430. The first sidewall arrangement 1106 includes an outer housing coupling device 1110 designed to interact with an outer cover 1810, discussed below, and is part of the strain relief assembly 1800. The second wall arrangement 1108 includes a CPA receiver 1160 extending from one of the walls 1108a and designed to receive a range of CPA 1170. The two wall arrangements are typically formed of an insulating material designed to isolate the current flowing through the external convex connector assembly 1000 from other components. Additional details regarding the external housing assembly 1100 are described in PCT / US2019 / 36070.

[0143] The convex shielding assembly, second shielding assembly, or external shielding assembly 1200 is configured to reside within the external housing 1104 and is designed to reduce electromagnetic interference (“EMI”) noise emitted by other components of the external convex connector assembly 1000. The external shielding assembly 1200 primarily comprises: (i) a first extent 1210 of the shielding housing, (ii) a second extent 1230 of the shielding housing, and (iii) a shielding cover 1250. The first extent of the shielding housing 1210 includes an arrangement of sidewalls with a rectangular configuration, wherein one of the sidewalls 1212a has a shorter length than the other sidewalls 1212b to 1212d.

[0144] like Figure 25 and Figure 27As shown, the shielding cover 1250 is designed to receive portions of the first and second ranges of the shielding housings 1210 and 1230 to form a shielding receiver 1216. This three-part assembly 1210, 1230, and 1250 allows the external shielding assembly 1200 and the external convex terminal assembly 1430 to be inserted into the outer housing 1104. Thus, the first and second ranges of the shielding housings 1210 and 1230 are designed to be positioned between the external convex terminal assembly 1430 and the inner side of the outer housing 1104. The first range of the shielding housing 1210 primarily surrounds the conductor 1495, while the second range of the shielding housing 1230 primarily surrounds the external convex terminal assembly 1430. The external shielding assembly 1200 is formed of a conductive material (such as metal). Other available conductive materials are disclosed in PCT / US2020 / 13757.

[0145] Figure 2 , Figures 5 to 10 , Figures 15 to 22 , Figure 25 and Figure 27 Various views of a convex terminal assembly, a second convex terminal assembly, or an external convex terminal assembly 1430 for this first embodiment are provided, while other embodiments of the external convex terminal assembly are disclosed in PCT / US19 / 36010 and 63 / 058,061, both of which are incorporated herein by reference. Specifically referring to the first embodiment, the convex terminal assembly 1430 includes a spring member 1440c and a convex terminal 1470. The convex terminal 1470 includes a convex terminal body or a second convex terminal body 1472 and a convex terminal connecting member or plate 1474. The convex terminal body 1472 includes: (i) a first or front convex terminal wall 1480, (ii) arrangements of convex terminal sidewalls 1482a to 1482d, and (iii) a second or rear convex terminal wall 1484. The combination of these walls 1480, 1482a to 1482d forms a spring receiver 1486, which is designed to receive an internal spring member, a convex spring member, or a second spring member 1440c.

[0146] refer to Figure 6The internal spring member 1440c includes the arrangement of spring member sidewalls 1442a to 1442d and a rear spring wall 1444. The arrangement of the spring member sidewalls 1442a to 1442d is each configured as follows: (i) a first or arcuate spring section 1448a to 1448d, (ii) a second spring section, a base spring section, or an intermediate spring section 1450a to 1450d, (iii) a third section or spring arm 1452a to 1452h, and (iv) a fourth section or centering device 1453. The arcuate spring sections 1448a to 1448d extend between the rear spring wall 1444 and the base spring sections 1450a to 1450d, and position the base spring sections 1450a to 1450d substantially perpendicular to the rear spring wall 1444. In other words, the outer surfaces of the base spring sections 1450a to 1450d are substantially perpendicular to the outer surface of the rear spring wall 1444.

[0147] The base spring sections 1450a to 1450d are positioned between the arc-shaped sections 1448a to 1448d and the spring arms 1452a to 1452h. For example... Figure 6 As shown, the base spring sections 1450a to 1450d are not connected to each other, thus forming gaps between the base spring sections 1450a to 1450d of the spring member 1440c. These gaps facilitate the omnidirectional expansion of the spring arms 1452a to 1452h, which facilitates the mechanical connection between the convex terminal 1470 and the concave terminal assembly 2430. The spring arms 1452a to 1452h extend from the base spring sections 1450a to 1450d of the spring member 1440c, away from the rear spring wall 1444, and terminate at the free end 1446. The spring arms 1452a to 1452h are generally planar and are positioned such that the outer surfaces of the spring arms 1452a to 1452h are coplanar with the outer surfaces of the base spring sections 1450a to 1450d. (This is consistent with the description in PCT / US2018 / 019787.) Figures 4 to 8 Unlike the spring arm 31 disclosed herein, the free ends 1446 of spring arms 1452a to 1452h do not have curved components. Instead, spring arms 1452a to 1452h have substantially flat outer surfaces. This construction is advantageous because it ensures that the force associated with spring 1440c is applied substantially perpendicular to the free end 1488 of the convex terminal body 1472. In contrast, in PCT / US2018 / 019787... Figures 4 to 8 The curved component of the disclosed spring arm 31 does not apply force in this way.

[0148] Similar to the base spring sections 1450a to 1450d, the spring arms 1452a to 1452h are not connected to each other. In other words, there are spring arm openings extending between the spring arms 1452a to 1452h. This configuration allows omnidirectional movement of the spring arms 1452a to 1452h, which facilitates the mechanical connection between the convex terminal 1470 and the concave terminal assembly 2430. In other embodiments, the spring arms 1452a to 1452h may be coupled to other structures to limit their omnidirectional expansion. The number and width of the individual spring arms 1452a to 1452h and the openings may vary. Additionally, the widths of the individual spring arms 1452a to 1452h are generally equal; however, in other embodiments, one of the spring arms 1452a to 1452h may be wider than the others.

[0149] refer to Figures 11 to 14 Combined with PCT / US2019 / 36127 Figures 5 to 6 The previous design of the spring member 1440pd is disclosed in more detail. Figure 13 This illustrates how the spring member 1440pd can be perfectly aligned within the convex terminal body 1472pd of the convex terminal assembly 1430pd. However, due to manufacturing tolerances and imperfect assembly methods, during the assembly of the convex terminal assembly 1430pd, the spring member 1440pd may become misaligned or warped within the convex terminal body 1472pd. Examples of such misalignment are shown in... Figure 14 As shown, the angle θ represents this misalignment when it extends between the inner surface of the spring receiver and the outer surface of the spring member 1440pd. In some embodiments, the angle θ may be between 1 degree and 5 degrees. To help avoid this misalignment, the spring member 1440c disclosed herein includes a centering device 1453, shown as anti-rotation protrusions 1454a to 1454d. Due to the interaction between the outer surfaces of the protrusions 1454a to 1454d and the inner surfaces of the sidewall portions 1492a to 1492d of the convex terminal body 1472, the anti-rotation protrusions 1454a to 1454d help center the spring member 1440c by limiting the amount of rotation that the spring member 1440c can rotate within the convex terminal body 1472.

[0150] Properly centering the spring member 1440c within the convex terminal body 1472 provides numerous advantages compared to terminals that are not properly centered or aligned within the convex terminal assembly 1430. These advantages include: (i) ensuring that the spring member 1440c applies the correct force to the convex terminal body 1472 to provide proper connection between the convex terminal assembly 1430 and the concave terminal assembly 2430; (ii) helping to ensure that the MIL assembly 1600 is correctly positioned to contact the FIL assembly 2600 when the terminal assemblies 1430, 2430 are connected to each other; (iii) helping to improve the durability and service life of the terminal assemblies 1430, 2430; and (iv) other beneficial features disclosed herein or which can be inferred by those skilled in the art from this disclosure. In the absence of proper alignment, the spring member 1440c can twist the extent of the MIL assembly 1600. The twisting of the MIL component 1600 is sufficient to prevent the proper connection of the MIL component 1600 and the FIL component 2600, thereby rendering the connector system 100 inoperable.

[0151] It should be understood that in other embodiments, the centering or alignment device 1453 may take other forms, such as: (i) protrusions extending outward from the first and second spring arms 1452a, 1452b positioned within a single sidewall; (ii) protrusions extending outward from the first and fifth spring arms 1452a, 1452e, wherein the protrusions are positioned diagonally opposite each other; (iii) protrusions extending outward from all spring arms 1452a to 1452h, wherein the protrusions associated with 1452a, 1452b, 1452e, 1452f In contrast, the protrusions associated with 1452c, 1452d, 1452g, and 1452h have an offset positional relationship: (iv) a protrusion extending inward from the inner wall of the convex terminal body 1472; (v) a protrusion extending inward from the contact arms 1494a to 1494h toward the center of the connector; (vi) a spring retainer designed with co-dimensional dimensions; and (vii) other protrusions, tabs, grooves, recesses, or ranges designed to help ensure that the spring member 1440c is centered within the convex terminal body 1472 and cannot rotate within the spring receiver 1486. ​​For example, the protrusions may extend from the front or rear wall of the convex terminal body 1472, and they may be received by an opening formed in the spring member 1440c.

[0152] It should be further understood that instead of utilizing a mechanically based centering or alignment device 1453, the centering device 1453 can be force-based, wherein such force can be magnetic or chemical. In this example, the rear wall of the spring member 1440c can be welded to the rear wall of the convex terminal body 1472. Compared to a mechanically or force-based centering device 1453, the centering device 1453 can be a method or process for forming the convex terminal assembly 1430. For example, the centering device 1453 may not be a structure, but rather the spring member 1440c can be simultaneously printed within the convex terminal body 1472 in a manner that does not require assembly. In other words, the centering device 1453 can take many forms (e.g., mechanically, force-based, or process-based) to achieve the purpose of centering the spring member 1440c within the convex terminal body 1472.

[0153] The internal spring member 1440c is typically formed from a single piece of material (e.g., metal); therefore, the spring member 1440c is either an integral spring member 1440c or has integrally formed features. Specifically, the following features are integrally formed: (i) the bow-shaped spring sections 1448a to 1448d, (ii) the base spring sections 1450a to 1450d, (iii) the spring arms 1452a to 1452h, and (iv) the centering device 1453. To integrally form these features, a die-forming process is typically used to form the spring member 1440c. The die-forming process mechanically forces the spring member 1440c to take shape. As discussed in more detail below and in PCT / US2019 / 036010, when the spring member 1440c is formed of a flat metal sheet, mounted within the convex terminal 1472 and connected to the concave socket 2472, and subjected to elevated temperatures, the spring member 1440c applies an outward-pointing spring thermal force S to the contact arms 1494a to 1494h, partly due to the fact that the spring member 1440c attempts to return to the flat sheet. TF However, it should be understood that other types of methods for forming the spring member 1440c can be used, such as casting or using additive manufacturing processes (e.g., 3D printing). In other embodiments, the features of the spring member 1440c may not be formed from a single piece or be formed in a single piece, but rather from separate pieces welded together.

[0154] In an alternative embodiment not shown, the spring member 1440c may include a recess and associated reinforcing ribs. These variations in the construction of the spring member 1440c, as discussed in PCT / US2019 / 036010, alter the force associated with the spring 1440c. Specifically, the spring bias force S BFThis is the amount of force applied by the spring member 1440c to resist the inward deflection of the free end 1446 of the spring member 1440c when the convex terminal assembly 1430 is inserted into the concave terminal assembly 2430. Specifically, this inward deflection occurs during the insertion of the convex terminal assembly 1430 because the outer surface of the convex terminal body 1472 is slightly larger than the inner side of the concave socket 2472. Therefore, when the convex terminal assembly 1430 is inserted into the concave terminal assembly 2430, the outer surface is forced toward the center 1490 of the convex terminal 1470. This inward force on the outer surface causes the free end 1446 of the spring member 1440c to shift inward (i.e., toward the center 1490). The spring member 1440c provides a spring biasing force S. F To resist the inward shift.

[0155] Figure 2 , Figures 5 to 10 , Figure 15 , Figures 20 to 22 , Figure 25 , Figure 27 A convex terminal, a second convex terminal, and an outer convex terminal 1470 are shown, comprising a convex terminal body 1472 and a convex terminal connecting plate 1474. Specifically, the convex terminal connecting plate 1474 is coupled to the convex terminal body 1472 and configured to receive a range of structures (e.g., leads or wires) for connecting the convex terminal assembly 1430 to a device (e.g., an alternator) outside the connector system 100. Wires 1495 are typically soldered to the connecting plate 1474; however, this disclosure contemplates other methods for connecting wires 1495 to the connecting plate 1474 (e.g., forming wires 1495 as part of the connecting plate 1474).

[0156] like Figure 2 , Figures 5 to 10 , Figure 15 , Figures 20 to 22 , Figure 25 , Figure 27 As shown, the convex terminal sidewalls 1482a to 1482d are interconnected and generally form a rectangular prism. The arrangement of the convex terminal sidewalls 1482a to 1482d includes: (i) sidewall portions 1492a to 1492d, which generally have a "U-shaped" structure; (ii) contact arms 1494a to 1494h; and (iii) a plurality of contact arm openings 1496a to 1496l. Figures 8 to 10As best shown, the sidewall portions 1492a to 1492d are substantially planar and have a U-shaped configuration. The U-shaped configuration is formed by three substantially linear segments, wherein the second or intermediate segments 1500a to 1500d are coupled at one end to the first or end segments 1498a to 1498d, and at the other end to the third or opposite end segments 1502a to 1502d. Contact arms 1494a to 1494h: (i) extend from the range of the intermediate segments 1500a to 1500d of the sidewall portions 1492a to 1492d, (ii) extend away from the rear convex terminal wall 1484, (iii) extend across the range of the contact arm openings 1496a to 1496l, and (iii) terminate just before reaching the front convex terminal wall 1480. Compared to PCT / US2018 / 019787 Figures 9 to 15 , Figure 18 , Figures 21 to 31 , Figure 32 , Figures 41 to 42 , Figures 45 to 46 , Figure 48 and Figure 50 The terminal configuration shown is advantageous because it allows for: (i) a shorter overall length, meaning less metal material is required for formation and the convex terminal 1470 can be installed in a narrower, more confined space; (ii) higher current carrying capacity; (iii) easier assembly; (iv) improved structural rigidity because the contact arms 1494a to 1494h are located inside the sidewall portions 1492a to 1492d of the first convex terminal; (iv) the combined benefits disclosed in PCT / US2019 / 036010; and (v) other advantageous features disclosed herein or which may be inferred by a person skilled in the art from this disclosure.

[0157] Contact arm openings 1496a to 1496l are integrally formed with the intermediate portions 1500a to 1500d of the convex terminal sidewalls 1482a to 1482d. The contact arm openings 1496a to 1496l extend along the lateral length of the contact arms 1494a to 1494h to form a configuration that allows the contact arms 1494a to 1494h to not be laterally connected to: (i) another contact arm 1494a to 1494h or (ii) a configuration other than the range of the convex terminal sidewall portions 1492a to 1492d to which the contact arms 1494a to 1494h are connected. Additionally, the contact arm openings 1496a to 1496l are aligned with the spring arm openings. This configuration of the openings forms the same number of spring arms 1452a to 1452h as the number of contact arms 1494a to 1494h. In other words, Figures 6 to 7Eight spring arms 1452a to 1452h and eight contact arms 1494a to 1494h are shown. It should be understood that in other embodiments, the number of spring arms 1452a to 1452h may not match the number of contact arms 1494a to 1494h. For example, fewer spring arms 1452a to 1452h may be present.

[0158] Contact arms 1494a to 1494h extend outward at an angle away from the rear convex terminal wall 1484. Specifically, the outward angle may be between 0.1 degrees and 16 degrees, preferably between 5 degrees and 12 degrees, and most preferably between 7 degrees and 8 degrees, between the outer surface of the convex terminal sidewalls 1492a to 1492d and the outer surface of the first range of contact arms 1494a to 1494h. This outward angle is shown in several figures, but in conjunction with… Figure 7 and Figure 10 This configuration allows for optimal display. When the convex terminal assembly 1430 is inserted into the concave terminal assembly 2430, this configuration allows the contact arms 1494a to 1494h to be deflected or displaced inward by the concave socket 2472 toward the center 1490 of the convex terminal 1470. This inward deflection... Figure 73 As best illustrated in the diagram, this is demonstrated by gap 1550. This inward deflection helps ensure proper mechanical and electrical connection by ensuring that contact arms 1494a to 1494h are positioned to contact the concave socket 2472.

[0159] like Figure 7 As shown, when the spring member 1440c is inserted into the spring receiver 1486, the ends of the contact arms 1494a to 1494h are positioned such that: (i) within the hole formed by the U-shaped sidewall portions 1492a to 1492d, (ii) substantially parallel to the convex terminal sidewalls 1492a to 1492d, and (iii) contacting the flat outer surfaces of the spring arms 1452a to 1452h. This configuration is different from that in PCT / US2018 / 019787. Figures 3 to 8 The illustrated configuration is advantageous because the assembler of the convex terminal assembly 1430 does not need to apply significant force to deform most of the contact arms 1494a to 1494h outward to receive the spring member 1440c. Due to the tilt of the contact arm 11 and the fact that the outer surface of the spring arm 31 is adjacent to the inner surface of the contact arm 11 without forming a gap between them, this required deformation can be achieved under PCT / US2018 / 019787. Figure 6 The best example is shown in PCT / US2018 / 019787. Figures 3 to 8 In comparison, this application's Figure 7This illustrates a very small gap formed between the outer surface of the spring member 1440c and the inner surfaces of the contact arms 1494a to 1494h. Therefore, very little force is required to insert the spring member 1440c into the spring receiver 1486, as the assembler does not need to force significant deformation of the contact arms 1494a to 1494h during the insertion of the spring 1440c.

[0160] The convex terminal 1470 is typically formed from a single piece of material (e.g., metal); therefore, the convex terminal 1470 is a one-piece convex terminal 1470 and has integrally formed features. To integrally form these features, a die-cutting process is typically used to form the convex terminal 1470. However, it should be understood that other types of methods for forming the convex terminal 1470 can be utilized, such as casting or using additive manufacturing processes (e.g., 3D printing). In other embodiments, the features of the convex terminal 1470 may not be formed from a single piece or be integrally formed, but rather formed from separate pieces welded together. When forming the convex terminal 1470, it should be understood that any number (e.g., between 1 and 100) of contact arms 1494a to 1494h can be formed within the convex terminal 1470.

[0161] The positioning of the internal spring member 1440c within the convex terminal assembly 1430 occurs over multiple steps or stages. Figure 6 Provided in the outgoing state S DC A first embodiment of the convex terminal assembly 1430, Figure 7 Provided in a partially connected state S PC The first embodiment of the convex terminal assembly 1430, and Figure 8 Provided in a fully connected state S FC A first embodiment of the convex terminal assembly 1430. The first stage of assembling the convex terminal assembly 1430 is in Figure 6 As shown, the front convex terminal wall 1480 is in the open or flat position P. O Furthermore, the spring member 1440c is separated from the convex terminal 1470. In this open position P... O The front convex terminal wall 1480 and one of the convex terminal side walls 1482c are substantially coplanar. This configuration of the convex terminal 1470 exposes the spring receiver 1486 and positions the convex terminal 1470 in a state ready to receive the spring member 1440c. The second stage of assembling the convex terminal assembly 1430 is in... Figure 7 As shown, the front convex terminal wall 1480 is held in the open or horizontal position P. O Furthermore, the spring member 1440c is positioned within or inserted into the spring receiver 1486. ​​To achieve the inserted state, the insertion force F... IAn insertion force F has been applied to the spring member 1440c to insert it into the spring receiver 1486. I It is applied to the spring member 1440c until the second or rear convex terminal wall 1484 is positioned adjacent to the rear spring wall 1444, the free end 1488 of the convex terminal 1470 is substantially aligned with the free end 1446 of the spring member 1440c, and a portion of the convex terminal sidewalls 1482a to 1482d is positioned adjacent to a portion of the spring member sidewalls 1442a to 1442d.

[0162] The third stage of assembling the convex terminal assembly 1430 is in Figure 8 As shown in the figure, (i) the front convex terminal wall 1480 is closed or perpendicular to P. CL (ii) The spring member 1440c is positioned within the spring receiver 1486. ​​To close the front convex terminal wall 1480, an upward force F is applied. U An application is made to the convex terminal wall 1480 to bend it around its joint, thereby placing it adjacent to the sidewalls 1482a to 1482d. After the front convex terminal wall 1480 is in the correct position, the top edge is joined (e.g., welded) to the sidewall 1480 of the convex terminal body 1472. Here, the closed or vertical P of the front convex terminal wall 1480... CL Ensure that the spring member 800 is secured within the convex terminal 1470. It should be understood that in other embodiments, the front convex terminal wall 1480 may be omitted, may not have an anti-contact probe opening passing through it, may not extend the entire path from sidewalls 1482a to 1482d (e.g., may extend partially from either sidewall 1482a to 1482d), or may be a separate piece connecting both sidewalls 1482a to 1482d.

[0163] The MIL component 1600 of the IL system 4000 consists of multiple parts and, when used in high-voltage connectors, can be referred to as a high-voltage convex interlocking device or simply a convex HVIL. (Reference) Figures 16 to 19The MIL 1600 mainly consists of: (i) a convex IL retainer 1620 and (ii) an IL jumper 1660. The convex IL retainer 1620 is designed such that: (i) a portion is located outside the side wall portions 1492a to 1492d of the convex terminal body 1472, (ii) a portion is located outside the front convex terminal wall 1480, and (iii) a portion is located within the spring member 1440c. To achieve this positional relationship between the convex IL retainer 1620, the convex terminal body 1472, and the spring member 1440c, the convex IL retainer 1620 has: (i) an arrangement of outer side walls 1604, (ii) a front wall 1608, (iii) an arrangement of inner side walls 1612, and (iv) a rear wall 1616. The arrangement 1604 of the outer sidewalls comprises a plurality of outer sidewalls 1605a to 1605d, wherein each outer sidewall 1605a to 1605d includes a hole 1606a to 1606d formed therethrough. These holes 1606a to 1606d are designed to receive contact arms 1494a to 1494h. As shown in the figure (e.g., Figure 20 As shown, each hole 1606a to 1606d receives two contact arms 1494a to 1994h formed within a single sidewall 1482a to 1482d of the convex terminal body 1472. It should be understood that more or fewer holes 1606a to 1606d can be used. For example, each contact arm 1494a to 1494h can have its own hole, or two holes can be used, with two sets of contact arms 1494a to 1494h positioned within each of these holes.

[0164] The front wall 1608 extends from the outer wall arrangement 1604 and is designed to be positioned outside the front convex terminal wall 1480. This helps prevent accidental contact between the front convex terminal wall 1480 and foreign objects. Extending from the front wall 1608 is the inner wall arrangement 1612. Specifically, the inner wall arrangement 1612 is composed of a plurality of sidewalls 1614a to 1614d, which are configured to be positioned within the spring member 1440c. The inner sidewalls 1614a to 1614d and the outer sidewalls 1605a to 1605d for the external IL receiver 1622 are configured to receive (i) the convex terminal body 1472 and (ii) the spring member 1440c. The inner sidewalls 1614a to 1614d are configured such that they do not obstruct or interact with the spring member 1440c. In other words, sidewalls 1614a to 1614d are spaced apart, so that even in the fully connected position S FCON When the spring member 1440c is compressed by the concave terminal assembly 2430, the side wall does not contact the spring member 1440c.

[0165] Inner sidewalls 1614a to 1614d connect to rear wall 1616 to form internal IL socket 1624. Rear wall 1616 includes IL jumper connection device 1628, which is designed to connect IL jumper 1660 to rear wall 1616. Here, IL jumper connection device 1628 is formed from the area of ​​rear wall 1616 using an overlay injection molding process. In other embodiments, IL jumper connection device 1628 may have different structures or different constructions. For example, convex IL retainer 1620 and IL jumper 1660 may be printed simultaneously using a 3D printer, joined together using a mechanical locking structure or by using a chemical bonding method. Overall, IL jumper connection device 1628 and rear wall 1616 are configured to correctly position IL jumper 1660 in the correct position for mating with FIL2600.

[0166] Due to tightness tolerances, the spring member 1440c should be properly aligned within the convex terminal body 1472 to ensure that the IL jumper 1660 is correctly positioned within the external connector 1000. Alternatively, if the spring member 1440c is not aligned within the convex terminal body 1472 (for example, see...), Figure 14 If this happens, the IL jumper 1660 will likely not be in the correct position within the external connector 1000 and will not be properly positioned within the FIL 2600. This is problematic because current will not flow through the connector unless the IL jumper 1660 is properly positioned within the FIL 2600. As discussed above, this misalignment of the spring member 1440c within the terminal assembly 1600 is avoided by including the centering device 1453. This, in turn, ensures that the IL jumper is correctly positioned within the external connector 1000 and allows the IL jumper 1660 to be properly positioned within the FIL 2600. It should be understood that this disclosure contemplates alternative methods to ensure that the IL jumper 1660 is correctly positioned within the external connector 1000. For example, the convex IL retainer 1620 may be formed of a material designed to force misaligned spring members to be correctly aligned within the convex terminal body 1472. Alternatively, these components may be 3D printed in a manner that ensures their correct alignment and positioning. Overall, the placement of the IL jumper 1660 within the terminal assembly 1430 offers significant advantages over conventional connectors that include interlocking devices. As discussed above, these advantages include: (i) no increase in connector size and (ii) virtually no increase in connector weight.

[0167] The strain relief assembly 1800 includes multiple components, such as a strain relief cap 1810, designed to relieve strain applied to the connection between the convex terminal assembly 1430 and the wire 1495. Additional details regarding this strain relief assembly are disclosed in conjunction with PCT / US2019 / 36070, the contents of which are incorporated herein by reference in their entirety.

[0168] The assembly of the male connector assembly, the second male connector assembly, or the external male connector assembly 1000 is performed across multiple steps or stages. The first step in assembling the external male connector assembly 1000 is assembling the external male terminal assembly 1430, which... Figures 6 to 8 As shown and as described above, the external convex terminal assembly 1430 is in the fully connected state S. FC Subsequently, the external convex terminal assembly 1430 can be connected to the wire 1495, and the external convex connector assembly is in the first part assembly state S. PA1 ,like Figure 15 As shown. Next, the MIL 1600 can be assembled and coupled to the external convex terminal assembly 1430 to form the second part of the assembly state S. PA2 ,like Figure 20 As shown. The shielding cover 1250 is placed against the rear wall 1484 of the convex terminal assembly 1430 to form the third part of the assembly state S. PA3 , its in Figure 21 As shown in the image. Next, as... Figure 22 As shown, the first portion of the shielding assembly 1210 is positioned outside the shielding cover 1250 to form the fourth part of the assembly state S. PA4 In the fourth assembly state S PA4 Below, the wire 1495 is positioned within a socket formed by the wall of the first extent of the shielding assembly 1210, and the shielding cover 1250 is positioned between the rear wall 1484 of the convex terminal assembly 1430 and the first extent of the shielding assembly 1210. Next, as... Figure 23 As shown, the convex terminal assembly 1430 and associated components (e.g., a first portion of the shielding assembly 1210, the shielding cover 1250, and a portion of the wire 1495) are inserted into the housing 1100 to form the fifth part of the assembly state S. PA5 In forming a fully assembled connector S FA In the final step, the second range of the shielding assembly 1230 is inserted into the external convex connector assembly 1000, the strain relief assembly 1800 is coupled to the external convex connector assembly 1000, and the CPA 1170 is partially inserted into the CPA receiver 1160.

[0169] In the fully assembled S FA (See) Figure 25 and Figure 27The following describes the nesting of the following elements:

[0170] ● The IL jumper 1660 is positioned within: (i) the convex IL retainer 1620, (ii) the spring member 1440c, (iii) the convex terminal body 1472, (iv) the second range of the shielding housing 1230, and (v) the outer housing 1104. In other words, the IL jumper 1660 is positioned within: (i) the range of the MIL 1600, (ii) the outer convex terminal assembly 1430, (iii) the outer shielding assembly 1200, and (iv) the outer housing assembly 1100;

[0171] ● The convex IL retainer 1620 is positioned within the following: (i) the spring member 1440c, (ii) the convex terminal body 1472, (iii) the second range of the shielding housing 1230, and (iv) the outer housing 1104. In other words, the MIL 1600 is positioned within the following: (i) the outer convex terminal assembly 1430, (ii) the outer shielding assembly 1200, and (iii) the outer housing assembly 1100;

[0172] ● The spring member 1440c is positioned within: (i) the convex terminal body 1472, (ii) the second range of the shielding housing 1230, and (iii) the outer housing assembly 1100;

[0173] ● The convex terminal body 1472 is positioned within: (i) the second range of the shielding housing 1230 and (ii) the outer housing assembly 1100;

[0174] ● The convex terminal body 1472 is positioned within: (i) the second extent of the shielding housing 1230 and (ii) the outer housing assembly 1100; and

[0175] ●The second range of the shielding housing 1230 is located within the outer housing assembly 1100.

[0176] It should be understood that one or more of these structures may be omitted or their positions may be changed so that the structure is omitted from the nested list above. For example, the second range of the shielding housing 1230 may be omitted from the component and therefore will not be included in the list above.

[0177] 2) Internal convex connector assembly

[0178] The convex connector assembly, the first convex connector assembly, or the internal connector assembly 3000 includes multiple components designed to be positioned within the sidewall 204 of the battery pack 200. The internal connector assembly 3000 primarily comprises: (i) a first housing assembly or internal housing assembly 3100, (ii) a first convex terminal assembly or internal convex terminal assembly 3430, and (iii) a bus assembly 3900. It should be understood that, for brevity, reference numerals shown in the figures may be omitted from the specification, as similar structures have similar reference numerals. For example, the disclosure relating to spring member 1440c is not repeated herein, but it applies to spring member 3440c as if that disclosure were repeated herein. In other words, the omission of reference numerals from the functional description or specific disclosure of the structure should not limit the disclosure of this patent application. Rather, reference should be made to disclosures of similar structures that may be discussed in another part of this patent application or in other patent applications incorporated herein by reference.

[0179] like Figures 28 to 37 As shown, the convex housing assembly, the first housing assembly, or the inner convex housing assembly 3100 includes: (i) a front housing member 3110, (ii) a rear housing member 3140, and (iii) an internal locking member 3180. The front housing member 3110 is designed to: (i) receive the main portion of the inner convex terminal assembly 3430, and (ii) interact with a portion of the intermediate concave connector assembly 2000 to engage the inner convex connector assembly 3000 to the intermediate concave connector assembly 2000. The rear housing member 3140 is configured to interact with the front housing member 3110 to secure the inner convex terminal assembly 3430 within the inner housing assembly 3100. Finally, similar to CPA 1170 described above in conjunction with the outer convex connector assembly 1000, the internal locking member 3180 is designed to ensure that the inner convex connector assembly 3000 is properly connected to the intermediate concave connector assembly 2000.

[0180] The convex terminal assembly, the first terminal assembly, or the internal terminal assembly 3430 has the same construction as the external convex terminal assembly 1430; therefore, the above disclosure will not be repeated here. However, it should be understood that similar reference numerals denote similar structures in these components. For example, the disclosure associated with spring member 1440c also applies to spring member 3440c. Moreover, it should be understood that the internal convex terminal assembly 3430 may differ from the external convex terminal assembly 1430. For example, the convex terminal assembly may be any terminal assembly 1343, 3430 disclosed in the following PCT applications: (i) PCT / US2020 / 14484, (ii) PCT / US2020 / 13757, or (iii) PCT / US2019 / 36010. Additionally, there may be more than one internal convex terminal assembly 3430 coupled to a single external convex terminal assembly 1430. An example of this is shown in provisional patent application 62 / 988,972, which is incorporated herein by reference. Alternatively, a single internal convex terminal assembly 3430 may be coupled to multiple external convex terminal assemblies 1430.

[0181] While the internal convex terminal assembly 3430 can be coupled to a conductor, in some embodiments, such as those shown in the accompanying drawings, the internal convex terminal assembly 3430 can be coupled to a busbar 3900. This busbar includes (i) a busbar conductor 3910 and (i) an insulator 3980. The busbar 3900 may have any features, may be constructed in a similar manner, and / or may have the same or similar functionality as the busbars disclosed in PCT patent applications PCT / US2020 / 14484, provisional patent applications 62 / 897,962 and 63 / 051,639, all of which are incorporated herein by reference.

[0182] The assembly of the male connector assembly, the internal connector assembly, and the internal male connector assembly 3000 is performed across multiple steps or stages. The first step in assembling the internal male connector assembly 3000 is assembling the internal male terminal assembly 3430. This is done when the internal male terminal assembly 3430 is in a fully engaged state. FC Subsequently, the busbar assembly 3900 can be attached to the internal convex terminal assembly 3430; thus, the first partial assembly state S is formed. PA1 (exist Figure 31 (As shown in the image). Figure 32 As shown, the rear housing member 3140 can be positioned adjacent to the rear wall of the convex terminal assembly 3430, thereby forming a second part assembly state S. PA2 The connector. Next, as... Figure 33As shown, the internal convex terminal assembly 3430 is positioned within the front housing member 3110, and the front housing member 3110 is connected to the rear housing member to form a third-part assembly state S. PA3 The connector.

[0183] In the fully assembled S FA (See) Figure 35 and Figure 37 The following describes the nesting of the following elements:

[0184] ● The spring member 3440c is positioned within: (i) the convex terminal body 3472 and (ii) the inner housing 3100; and

[0185] ● The convex terminal body 1472 is positioned inside the inner housing 3100.

[0186] 3) Middle concave connector assembly

[0187] The concave connector assembly, intermediate connector assembly, or intermediate concave connector assembly 2000 includes multiple components designed to be positioned within the sidewall 204 of the battery pack 200. The concave or intermediate connector assembly 2000 mainly comprises: (i) a concave or intermediate housing assembly 2100, (ii) a concave or intermediate shielding assembly 2200, (iii) a concave terminal assembly 2430, and (iv) a concave interlocking assembly (FIL) 2600.

[0188] A concave housing assembly, an intermediate housing assembly, or an intermediate concave housing assembly 2100 extends through the body head or sidewall 204 of the battery pack 200. Thus, the intermediate housing assembly 2100 is designed to protect the concave terminal assembly 2430 and isolate it from the body head or sidewall 204 of the battery pack 200. To achieve this, the intermediate housing assembly 2100 receives the concave terminal assembly 2430 and includes: (i) an outer range 2110 and (ii) an inner range 2160. The outer range 2110 is primarily located within the wall 204 of the battery pack and on the exterior of the battery pack 200, while the inner range 2160 is primarily located within the battery pack 200. The outer range 2110 of the intermediate housing assembly 2100 is constructed and designed to secure the concave terminal assembly 2430 and interact with the outer convex connector assembly 1000. Figure 47As best shown, the outer extent 2110 includes a sidewall assembly 2112, which is composed of a plurality of outer sidewalls 2114a to 2114d and a plurality of inner sidewalls 2116a to 2116d. Specifically, the plurality of inner sidewalls 2116a to 2116d: (i) form a concave terminal assembly receiver 2118, which is designed to receive and secure the extent of the concave terminal assembly 2430, and (ii) are configured to facilitate mating of the concave terminal assembly 2430 with the outer terminal assembly 1430.

[0189] The concave terminal assembly 2430 is secured within the internal plurality of sidewalls 2116a to 2116d for the following reasons: (i) the concave IL retainer 2680 and (ii) the construction of the outer housing range 2110 and the inner housing range 2160. First, the concave IL retainer 2680 includes a locking member 2682 received by two internal IL locking receivers 2117a, 2117c formed in the walls of the internal plurality of sidewalls 2116a to 2116d. Second, both the outer range 2110 and the inner range 2160 include beveled or inclined walls 2134a to 2134d, 2170a to 2170d that extend rearward from the front edge of the housing 2100 and are designed to compress the contact arms 1494, 3494 of the terminal assemblies 1430, 3430. The construction and design of these beveled or inclined walls 2134a to 2134d, 2170a to 2170d are described in detail in PCT / US2019 / 36070, which is incorporated herein by reference. These beveled or inclined walls 2134a to 2134d, 2170a to 2170d have rear edges that abut the edges of the concave terminal assembly 2430. Therefore, when the inner range 2160 is coupled to the outer range 2110, the concave terminal assembly 2430 is secured between the rear edges of these beveled or inclined walls 2134a to 2134d, 2170a to 2170d. It should be understood that other constructions for securing the concave terminal assembly 2430 within the intermediate housing assembly 2100 may be used with or contemplated in this disclosure.

[0190] The configuration of the external sidewalls 2114a to 2114d and the internal sidewalls 2116a to 2116d allows the intermediate shielding assembly 2200 to be positioned within the intermediate housing assembly 2100. Specifically, the intermediate shielding assembly 2200 is positioned between the internal sidewalls 2116a to 2116d and the external sidewalls 2114a to 2114d. To secure the intermediate shielding assembly 2200 within the intermediate housing assembly 2100, the internal sidewalls 2116a to 2116d include an intermediate shielding receiver 2140. This intermediate shielding assembly 2200 will be discussed in more detail below.

[0191] Multiple external sidewalls 2114a to 2114d form an outer housing receiver 2122 and include (i) a sealing member recess 2126, (ii) multiple body head coupling receivers 2130, and (iii) an external connector connector 2135. The sealing member recess 2126 receives a range of seals 2108. Seals 2108 are designed to form a seal between the body head or sidewall 204 of the battery pack 200 and the outer housing receiver 2122. This helps ensure the durability of the battery pack 200. The multiple body head coupling receivers 2130 are receivers designed to receive a range of elongated connectors 2196a to 2196d. As shown in the embodiments disclosed herein, the elongated connectors 2196a to 2196d are screws with external threads whose dimensions are cooperating with the internal threads of the receivers formed within the body head or sidewall 204 of the battery pack 200. Other types of elongated connectors 2196a to 2196d may be used, such as 1 / 4 turn screws, bayonet connectors, pin and socket connectors, or any other type of similar removable elongated connector. Finally, the external connector 2135 is a protrusion designed to be received by the outer housing 1104 and specifically by the CPA receiver 1160. Once the intermediate housing assembly 2100 is engaged to the outer housing assembly 1100, the CPA 1170 can be engaged by the user, and the connector assembly can be moved from a fully connected state to a ready-to-use state (discussed in more detail below).

[0192] The inner portion 2160 of the intermediate housing assembly 2100 is constructed and designed to hold the concave terminal assembly 2430 and interact with the inner convex connector assembly 3000. For example... Figure 47 As best shown, the inner range 2160 includes a plurality of sidewalls 2164a to 2164d, which are designed to receive and secure the range of the recessed terminal assembly 2430, and (ii) are configured to facilitate mating of the recessed terminal assembly 2430 with the inner terminal assembly 3430. Both of these functions are achieved by inclined walls 2170a to 2170d of a ramp extending rearward from the front edge of the housing 2100 and are designed to compress the contact arm 3494 of the terminal assembly 3430.

[0193] The outer portion 2110 of the intermediate housing assembly 2100 is connected to the inner portion 2160 of the intermediate housing assembly 2100 via a housing coupling device 2102. Specifically, the inner portion 2160 includes a coupling protrusion 2104 received by a coupling socket 2106 formed within the outer portion 2110. Once the inner portion 2160 is connected to the outer portion 2110, the recessed terminal assembly 2430 is secured within the intermediate housing assembly 2100 due to the construction of the sloped or inclined walls 2134a to 2134d, 2170a to 2170d.

[0194] The concave shielding assembly, intermediate shielding assembly, or intermediate concave shielding assembly 2200 is designed to shield or reduce EMI noise associated with the connector system 100. The intermediate shielding assembly 2200 includes an intermediate shielding housing 2204 and a plurality of intermediate shielding fingers 2206. The intermediate shielding housing 2204 is configured to be positioned between a plurality of outer sidewalls 2114a to 2114d and a plurality of inner sidewalls 2116a to 2116d. Thus, when the connector system 100 is in a fully connected or ready-to-use state, the intermediate shielding housing 2204 surrounds a large portion of the concave terminal assembly 2430 and contacts a second extent of the shielding housing 1230. This configuration forms an electrical shield extending from the body head 204 through the intermediate shielding housing 2204 to the outer shielding housing 1200. This allows EMI noise generated by the connector system 100 to be transmitted into the sidewalls 204 of the battery pack 200.

[0195] The structure that connects the intermediate shielding housing 2204 to the body head or sidewall 204 of the battery pack 200 consists of a plurality of intermediate shielding fingers 2206. Specifically, these fingers 2206 are integrally formed with the intermediate shielding housing 2204 and are designed to engage within shielding recesses 2180a to 2180h formed in the outer range 2110 of the intermediate housing assembly 2100. The ends of the fingers 2206 are rolled up so that the fingers 2206 can maintain contact with the inner surface of the sidewall 204. In other words, when the battery pack 200 moves, the fingers 2206 bend and move together with the connector system 100 to ensure that the shields 1200, 2200 remain connected to the battery pack 200.

[0196] The recessed terminal assembly 2430 includes a plurality of sidewalls 2434a to 2434d that form a recessed receptacle 2472, which is designed to electrically and mechanically connect the external terminal assembly 1430 to the internal terminal assembly 3430. The cross-sectional shape of the recessed receptacle 2472 is substantially square; however, it should be understood that the cross-sectional shape of the recessed receptacle 2472 can be modified to match the external shape of the terminal assembly it mates with (e.g., circular, hexagonal, etc.).

[0197] Each of the multiple sidewalls 2434a to 2434d has features formed therein to receive and secure the concave IL assembly 2600. Specifically, the middle portion of the top wall 2434a has been removed, and each of the two sidewalls 2434b and 2424c includes cutouts 2440a and 2440b formed therein to receive a locking protrusion 2686 of the IL retainer 2680, and an opening formed therein to receive a locking member 2682 of the concave IL retainer 2680. This combination of the removed portion, cutouts, and openings allows the concave terminal assembly 2430 to receive and secure the concave IL assembly 2600.

[0198] Additional details regarding the concave terminal assembly 2430 are generally discussed in PCT applications PCT / US2020 / 13757, PCT / US2019 / 36127, PCT / US2019 / 36070, and PCT / US2019 / 36010, and therefore will not be repeated here. However, the concave terminal assembly 2430 can generally be made of a conductive material (e.g., copper) and can be stamped, pressed, drawn, molded, cast, printed, or manufactured using similar methods. This disclosure contemplates other geometries and configurations for positioning the IL receiver 2660 in the correct location.

[0199] Similar to the MIL assembly 1600, the FIL assembly 2600 comprises multiple components and, when used in high-voltage connectors, may be referred to as a high-voltage concave interlocking device or simply a concave HVIL. The concave IL assembly 2600 primarily comprises: (i) a concave IL retainer 2620, (ii) a concave IL receiver 2660, and (iii) a concave IL retainer 2680. The concave IL retainer 2620 is designed to position the concave IL receiver 2660 in the correct position to receive the convex IL jumper 1660. To achieve this positional relationship, the concave IL retainer 2620 includes: (i) an arrangement 2622 of sidewalls that receive and secure the concave IL receiver 2660, and (ii) a rear wall 2624. The rear wall 2644 has an irregular periphery designed to interact with the IL retainer 2680 and the plurality of side walls 2434a to 2434d forming the concave socket 2472. Specifically, the rear wall 2624 includes a retainer cutout 2628 designed to receive the front protrusion 2684. Next, opposite the retainer cutout 2628, the rear wall 2624 includes a bottom protrusion 2630 received by an opening formed in the bottom wall 2434c of the concave socket 2472. Finally, the rear wall 2624 includes side protrusions 2632a and 2632b received by cutouts 2440a and 2440b. This combination of the retainer cutout 2628, the bottom protrusion 2630, and the side protrusions 2632a and 2632b helps ensure that the concave IL retainer 2620 is secured in the correct position.

[0200] The concave interlock (FIL) assembly 2600 is positioned within the concave terminal assembly 2430 residing in the socket of the concave housing to define the fully assembled concave state S. FAFThe FIL assembly is configured to be coupled to an interlocking circuit 4010 that prevents current from flowing through the concave terminal assembly 2430 before it is connected to the convex terminal assembly 1430. The concave IL retainer 2680 helps to secure the concave IL holder 2620 in the correct position. Specifically, the concave IL retainer 2680 includes: (i) a locking member 2682, (ii) a front protrusion 2684, and (iii) side protrusions 2632a, 2632b. Typically, the concave IL retainer 2680 fits within and fills the openings formed therein of the plurality of sidewalls 2434a to 2434d forming the concave socket 2472. As described above, the locking member 2682 engages with the concave IL locking receivers 2117a and 2117c, the front protrusion 2684 engages within the retainer cutout 2628, and the side protrusions 2632a and 2632b are received by the cutouts 2440a and 2440b. By placing the structures interacting with the concave IL retainer 2680 on all sides of the concave socket 2472, the concave IL retainer 2680 will not be altered by the forces experienced by the concave IL retainer 2680. However, in other configurations, the concave IL retainer 2680 may be supported on only three or two sides.

[0201] The assembly of the intermediate concave connector assembly 2000 is performed across multiple steps or stages. The first step in assembling the intermediate concave connector assembly 2000 is... Figure 42 As shown, a concave IL receiver 2660 is inserted into a concave IL retainer 2620, and then the concave IL retainer is inserted into a concave socket 2472 to form a first partial assembly state S. PA1 Next, the second part of the assembly state S is formed by inserting the concave IL retainer 2680 into the concave socket 2472. PA2 (exist Figure 43 (As shown in the diagram). The concave IL assembly 2600 and the concave terminal assembly 2430 are inserted into the outer range 2110 of the intermediate housing assembly 2100 (in... Figure 44 (As shown in the diagram) to form the third part of the assembly state S PA3 Next, the combination of the intermediate housing assembly 2100, the concave IL assembly 2600, and the concave terminal assembly 2430 is placed inside the head or sidewall 204 of the battery pack 200 (in... Figure 45 (As shown in the diagram) to form the fourth assembly state S PA4 Finally, in order to achieve a fully assembled state S FA (exist Figure 47As shown in the figure, the housing assembly 2100 is secured to the sidewall 204 using elongated connectors 2196a to 2196d, the inner range 2160 of the intermediate housing assembly 2100 is connected to the outer range 2110 of the intermediate housing assembly 2100, and the intermediate shielding assembly 2200 is inserted into the range of the outer range 2110 of the intermediate housing assembly 2100 until the finger 2206 contacts the inner surface of the sidewall 204.

[0202] In the fully assembled S FA In (in) Figure 47 (As shown in the image), the following describes the nesting of the following elements:

[0203] ● The concave IL receiver 2660 is positioned within: (i) the concave IL retainer 2620, (ii) the concave socket 2472, (iii) the outer extent of the intermediate housing 2110, and (iv) the intermediate shield housing 2204. In other words, the concave IL receiver 2660 is positioned within: (i) the concave terminal assembly 2430, (ii) the intermediate housing 2100, and (iii) the intermediate shield assembly 2200;

[0204] ● The concave IL retainer 2620 is positioned within: (i) the concave socket 2472, (ii) the outer area of ​​the intermediate housing 2110, and (iii) the intermediate shielding housing 2204. In other words, the concave IL retainer 2620 is positioned within: (i) the concave terminal assembly 2430, (ii) the intermediate housing 2100, and (iii) the intermediate shielding assembly 2200;

[0205] ● The recessed socket 2472 is positioned within: (i) the outer extent of the intermediate housing 2110 and (ii) the intermediate shielding housing 2204; and

[0206] ●The outer area of ​​the intermediate housing 2110 is located within the intermediate shielding housing 2204.

[0207] It should be understood that one or more of these structures may be omitted or their positions may be changed so that the structure is omitted from the nested list above. For example, the intermediate shielding housing 2204 may be omitted from this component and therefore will not be included in the list above.

[0208] As described above, the IL system 4000 also includes an interlocking circuit 4010 that prevents current from flowing to the intermediate connector 2000 before engagement occurs between the convex terminal body 1472 and the concave receptacle 2472. Examples of circuits that may be used are shown in FIG. 74 and the following U.S. Patent Nos. 7,084,361, 7,508,097, 7,586,722, 8,466,586, 9,327,601, 9,533,639, or 9,851,387, each of which is incorporated herein by reference in its entirety. For example, the interlocking circuit 4010 may include: (i) components of a battery management system 4020 including a sensing module 4022 and a disconnect controller 4024, and (ii) a disconnect switch 4030. The sensing module 4022 is coupled to the concave IL receiver 2660 and detects when the circuit is closed by insertion of the convex IL jumper 1660. When the circuit is closed, the sensing module 4022 sends a signal to the disconnect controller 4024 to close the disconnect switch 4030. When the disconnect switch 4030 is closed, current can flow from the power supply 206 through the switch 4030 to the connector system 100. Alternatively, when the convex IL jumper 1660 is not inserted into the concave IL receiver 2660, the sensing module 4022 sends a signal to the disconnect controller 4024 to open the disconnect switch 4030. When the disconnect switch 4030 is open, current cannot flow from the power supply 206 through the switch 4030 to the connector system 100. For clarity, in Figure 74B The diagram illustrates the operation of these components. This is a design that helps prevent foreign objects from contacting connector assemblies 1000, 2000, and 3000, which are capable of releasing current to foreign objects.

[0209] Figures 48 to 71 The system 100 is shown to be able to... Figures 48 to 51 The detached state S DCON Move to Figures 68 to 71 The ready-to-use state S in R Assume the first step of connecting the intermediate concave connector assembly 2000 to the wall 204 of the battery pack 200 is as described above in conjunction with assembling the intermediate concave connector assembly 2000. However, if these steps are not completed before reaching this stage, they should be completed before the steps described in conjunction with connecting connectors 1000, 2000, and 3000 to each other.

[0210] Part 1 Connection State S PCON1 exist Figures 52 to 55As shown in these figures, the contact arms 3494a to 3494h of the inner convex connector assembly 3000 are to contact the beveled or inclined surfaces 2170a to 2170d of the intermediate concave connector assembly 2000. The beveled or inclined surfaces 2170a to 2170d gently and smoothly compress the contact arms 3494a to 3494h until they can easily slide into and contact the inner surface of the concave socket 2472. This process is described in more detail in PCT / US2019 / 36070 and is incorporated herein by reference. Once the inner convex connector assembly 3000 is fully connected to the intermediate concave connector assembly 2000, the system 100 has transitioned from the first partially connected state S. PCON1 Move to the second part of the connection state S PCON2 .

[0211] Part Two: Connection Status S PCON2 exist Figures 56 to 59 As shown in these figures, contact arms 3494a to 3494h contact the inner surface of the recessed socket 2472, forming a 360-degree compliant connection. Compression of contact arms 3494a to 3494h to fit within the recessed socket 2472 compresses the spring arms 3452a to 3452h of the spring member 3440c. This compression generates a biasing force that helps ensure contact arms 3494a to 3494h contact the recessed socket 2472. This biasing force is described in PCT / US2019 / 36070 and PCT / US2019 / 36010, both of which are incorporated herein by reference. Once system 100 is in the second part of the connection state S... PCN2 The internal convex connector assembly 3000 is fully connected to the middle concave connector assembly 2000.

[0212] Part Three: Connection State S PCON3 exist Figures 60 to 63As shown in these figures, the contact arms 1494a to 1494h of the outer convex connector assembly 1000 are to contact the beveled or inclined surfaces 2134a to 2134d of the intermediate concave connector assembly 2000. The beveled or inclined surfaces 2134a to 2134d gently and smoothly compress the contact arms 1494a to 1494h until they can easily slide into and contact the inner surface of the concave socket 2472. This process is described in more detail in PCT / US2019 / 36070 and is incorporated herein by reference. As shown in these images, the MIL 1600 is not electrically connected to the FIL 2600, or in other words, the convex IL jumper 1660 is not received by the concave IL receiver 1660. This ensures that the concave terminal assembly 2430 is not "hot" or that no current flows from the inner convex connector assembly 3000 to the intermediate concave connector assembly 2000. Once the inner convex connector assembly 1000 is fully connected to the intermediate concave connector assembly 2000, the system 100 has transitioned from the first part connection state S. PCONN3 Move to the second part of the connection state S FCON .

[0213] Fully connected state S FCON exist Figures 64 to 67 As shown in these figures, contact arms 1494a to 1494h contact the inner surface of the recessed socket 2472, forming a 360-degree compliant connection. This 360-degree compliant connection is formed by positioning one contact arm 1494a to 1494h against each sidewall of the recessed terminal assembly 2430, wherein the sidewalls of the recessed terminal assembly 2430 are arranged cooperatively and sized in a manner that the contact arms 1494a to 1494h are designed as rectangular prisms. Compressing the contact arms 1494a to 1494h to fit within the recessed socket 2472 compresses the spring arms 1452a to 1452h of the spring member 1440c. This compression generates a biasing force that helps ensure contact arms 1494a to 1494h contact the recessed socket 2472. This biasing force is described in PCT / US2019 / 36070 and PCT / US2019 / 36010, which are incorporated herein by reference. In addition to the contact arms 1494a to 1494h contacting the inner surface of the concave socket 2472, the convex IL jumper 1660 is received by the concave IL receiver 2660. By receiving the convex IL jumper 1660 by the concave IL receiver 2660, the IL system 4000 is connected and the concave terminal assembly 2430 will become “hot” or have current flowing from the inner convex connector assembly 3000 to the intermediate concave connector assembly 2000. In other words, in the fully connected state S FCONBelow, the MIL 1600 is electrically connected to the FIL2600, and allows current to flow from the inner convex connector assembly 3000 through the intermediate concave connector assembly 2000 to the outer convex connector assembly 1000.

[0214] That is, state S R exist Figures 68 to 71 As shown in these figures, force is applied to CPA 1170 to position it above the external connector assembly 2135. Once this occurs, the external convex connector assembly 1000 is locked to the intermediate concave connector assembly 2000. Finally, the installer can scan the extent of CPA 1170 visible through the opening within the housing, as described in U.S. Provisional Application No. 62 / 897,658.

[0215] In fully connected state S FCON Or ready-to-use state S R See below Figures 65 to 73 The nested description of MIL1600 and its components is as follows:

[0216] ●The IL jumper 1660 is positioned within the following: (i) the concave IL receiver 2660, (ii) the concave IL retainer 2620, (iii) the convex IL retainer 1620, (iv) the spring member 1440c, (v) the convex terminal body 1472, (vi) the concave socket 2472, (vii) the outer range of the intermediate housing 2110, (viii) the intermediate shield housing 2204, (ix) the second range of the outer shield housing 1230, and (x) the outer housing 1104. In other words, the IL jumper 1660 is positioned within the following: (i) the FIL 2600, (ii) the outer convex terminal assembly 1430, (iii) the concave terminal assembly 2430, (iv) the intermediate housing 2100, (v) the intermediate shield assembly 2200, (vi) the outer shield assembly 1200, and (vii) the outer housing assembly 1100. Furthermore, the IL jumper 1660 is positioned within the intermediate concave connector assembly 2000; and

[0217] ● The convex IL retainer 1620 is located outside (i) the concave IL receiver 2660 and (ii) the concave IL retainer 2620. The convex IL retainer 1620 is located inside: (i) the spring member 1440c, (ii) the convex terminal body 1472, (iii) the concave socket 2472, (iv) the outer range of the intermediate housing 2110, (v) the intermediate shielding housing 2204, (vi) the second range of the outer shielding housing 1230, and (vii) the outer housing 1104. In other words, the convex IL retainer 1620 is located outside the FIL 2600. The convex IL retainer 1620 is positioned within: (i) the outer convex terminal assembly 1430, (ii) the concave terminal assembly 2430, (iii) the intermediate housing 2100, (iv) the intermediate shielding assembly 2200, (v) the outer shielding assembly 1200, and (vi) the outer housing assembly 1100. Furthermore, the convex IL retainer 1620 is positioned within the intermediate concave connector assembly 2000.

[0218] In fully connected state S FCON Or ready-to-use state S R See below Figures 65 to 73 The nested description of FIL 2600 and its components is as follows:

[0219] ● The concave IL receiver 2660 is located outside the IL jumper 1660. The concave IL receiver 2660 is located within: (i) the concave IL retainer 2620, (ii) the convex IL retainer 1620, (iii) the spring member 1440c, (iv) the convex terminal body 1472, (v) the concave socket 2472, (vi) the outer range of the intermediate housing 2110, (vii) the intermediate shielding housing 2204, (viii) the second range of the outer shielding housing 1230, and (ix) the outer housing 1104. In other words, the concave IL receiver 2660 is positioned within the following: (i) MIL 1600, (ii) external convex terminal assembly 1430, (iii) concave terminal assembly 2430, (iv) intermediate housing 2100, (v) intermediate shielding assembly 2200, (vi) external shielding assembly 1200, and (vii) external housing assembly 1100. Furthermore, the concave IL receiver 2660 is positioned within the external convex connector assembly 1000; and

[0220] The concave IL retainer 2620 is positioned outside the IL jumper 1660 and the concave IL receiver 2660. The concave IL retainer 2620 is positioned within: (i) the convex IL retainer 1620, (ii) the spring member 1440c, (iii) the convex terminal body 1472, (iv) the concave socket 2472, (v) the outer range of the intermediate housing 2110, (vi) the intermediate shielding housing 2204, (vii) the second range of the outer shielding housing 1230, and (viii) the outer housing 1104. In other words, the concave IL retainer 2620 is positioned within: (i) the MIL 1600, (ii) the outer convex terminal assembly 1430, (iii) the concave terminal assembly 2430, (iv) the intermediate housing 2100, (v) the intermediate shielding assembly 2200, (vi) the outer shielding assembly 1200, and (vii) the outer housing assembly 1100. Furthermore, the concave IL receiver 2660 is positioned within the external convex connector assembly 1000.

[0221] It should be understood that one or more of these structures may be omitted or their positions may be changed so that the structure is omitted from the nested list above. For example, the second range of the intermediate shielding housing 2204 and the shielding housing 1230 may be omitted from the component and therefore will not be included in the list above.

[0222] Second Implementation Plan

[0223] like Figures 88 to 109As shown, a second embodiment of the connector system 5100 includes multiple components designed to electrically and mechanically connect one device or component to another device or component within a power distribution environment. The second embodiment of the connector system 5100 primarily comprises: (i) a convex connector assembly 6000 and (ii) a concave connector assembly 7000. The convex connector assembly 6000 includes: (i) a housing assembly 6100, (ii) a shielding assembly 6200, (iii) a convex terminal assembly 6430 including a convex terminal 6470 and a spring member 6440d, (iv) a convex interlocking assembly 6600, (v) a strain relief assembly 6800, and (v) a conductor 6495. The concave connector assembly 7000 includes: (i) a housing assembly 7100, (ii) a shielding assembly 7200, (iii) a concave terminal assembly 7430 including a concave socket 7472, and (iv) a concave interlocking assembly 7600. It should be understood that, for the sake of brevity, reference numerals shown in the figures may be omitted from the specification, as similar structures have similar reference numerals. For example, the disclosure relating to spring member 1440c is not repeated herein, but it applies to spring member 6440d as if that disclosure were repeated herein. In other words, the omission of reference numerals from the description of the functionality of the structure or the specific disclosure should not limit the disclosure of this patent application. Rather, reference should be made to disclosures of similar structures that may be discussed in another part of this patent application or in other patent applications incorporated herein by reference.

[0224] The IL system 8000 of this second embodiment of the connector system 5100 functions in the same manner as the IL system 4000 disclosed above in conjunction with the first embodiment of the connector system 100. Specifically, when system 5100 is in... Figures 102 to 105 In the partially connected state shown, no current will be applied to the concave connector assembly 7000 because the MIL 6600 is not connected to the FIL 7600. In contrast, when system 5100 is in... Figures 106 to 109 In the fully connected state shown, current will be applied to the concave connector assembly 7000 because the MIL 6600 is coupled to the FIL 7600. Additional details regarding the circuitry, operation, functionality, and installation environment of the IL system 8000 are disclosed above in conjunction with the IL system 4000 and apply to the IL system 8000. Therefore, these additional details will not be repeated here.

[0225] The main differences between the first embodiment of system 100 and the second embodiment of system 5100 include: (i) the inclusion of two convex terminal assemblies 6430 and two concave terminal assemblies 7430 within housings 6100 and 7100; (ii) the positioning of MIL and FIL1600 and 2600 from inside terminals 1430 and 2430 to outside terminals 6430 and 7430; and (iii) different constructions of the convex terminal body 6472 and the spring member 6440d. Firstly, including two terminals 6430 and 7430 within housings 6100 and 7100 allows designers to increase the current-carrying capacity of connector system 5100. However, in doing so, the design must account for current creep, and therefore the terminals 6430 and 7430 must be placed at the correct distance from each other. Second, unlike the first embodiment of system 100, this second embodiment of system 5100 positions the MIL and FIL 1600, 2600 outside the terminals 6430, 7430. This alternative arrangement is generally a disadvantage because it increases the size of connector systems 100, 5100; however, when using multiple terminals, due to the structural and positional relationship of terminals 1430, 3430, 6430, there is sufficient space to place the MIL and FIL 6600, 7600 outside the terminals 6430, 7430 without increasing the package size. However, it should be understood that the MIL and FIL 6600, 7600 can be positioned inside the terminals, as discussed above.

[0226] Third, the construction of the convex terminal body 6472 differs from previous versions, wherein the differences include: (i) the omission of the “U-shaped” sidewalls disclosed in at least PCT / US2019 / 036010 and PCT / US2020 / 049870; and (ii) the contact arm openings 6496a to 6496h having varying widths, wherein the adjacent contact arms 6494a to 6494h are coupled to the sidewall 6 compared to the opening of the adjacent free end 1488. The openings at 492a to 6492d are relatively wide; (iii) the widths of the contact arms 6494a to 6494h are not uniform across the entire arm, but rather the openings adjacent to the free end 1488 at the junction of the contact arms 6494a to 6494h with the sidewalls 6492a to 6492d are narrower; and (iv) the widths of the contact arms 6494a to 6494h do not match the widths of the spring arms 6452a to 6452h. Finally, the spring member 6440d is constructed differently from the previous version, wherein the difference includes a centering device 6453 extending from a selected number of spring arms 6452a to 6452d. In the depicted embodiment, the centering device 6453 is a "J-shaped" protrusion 6456a to 6456d that extends from the lower portion of the spring arms 6452a to 6452d and is designed to surround the outer surfaces of the contact arms 6494a to 6494h when the spring member 6440d is positioned within the spring receiver 6486. While the foregoing paragraphs describe some differences between the terminal assembly 6430 and connector system 5100 of this second embodiment and the terminal assemblies 1430, 3430 and connector system 100 of the first embodiment, it should be understood that those skilled in the art can discover and understand other differences when comparing the drawings included in this application.

[0227] Systems 100 and 5100 are T4 / V4 / S3 / D2 / M2, wherein systems 100 and 5100 meet and exceed the following conditions: (i) T4 is system 100 exposed to 150°C; (ii) V4 is severe vibration; (iii) S1 is sealed high-voltage spray; (iv) D2 is 200 km durability; and (v) M2 is a force of less than 45 Newtons required to connect the convex terminal assemblies 1430, 3430, and 6430 to the concave terminal assembly 800. In addition to conforming to T4 / V4 / S3 / D2 / M2, systems 100 and 5100 also conform to Push, Click, Drag, Scan (PCTS), with additional information on this standard disclosed in PCT / US2020 / 049870.

[0228] It should be understood that the convex terminal assemblies 1430, 3430, 6430 and concave terminal assemblies 2430, 7430 disclosed in this application can be used to replace the convex terminal assemblies and concave terminal assemblies disclosed in PCT / US2018 / 019787 or PCT / US2019 / 036010. Additionally, some of these connectors have derating of 80% of their rated values ​​at an ambient temperature rise (RoA) of 55°C or 80°C: (i) at 50mm... 2 The current is 245 amps at 75mm. 2 The current is 280 amps under the conductor, and 100 mm. 2 (ii) 330 amps under the conductor, and (ii) at 100 mm 2 The current is 335 amps at 150 mm. 2 The current is 365 amps under the conductor, and at 200mm. 2 (iii) 395 amps under the conductor, at 16 mm 2 The current is 190 amps under the conductor, at 25 mm. 2 The current is 220 amps at 35mm. 2 The current is 236 amps under the conductor, at 50 mm. 2 (iv) 245 amps under the conductor, at 100 mm 2 The conductor is 365 amps (V) in Figure 114 at 16 mm. 2 The conductor carries 185 amps, (vi) at 16mm². 2 The conductor is 88 amps, and (vii) is within 25 mm. 2 The conductor carries 225 amps. Furthermore, other performance specifications of the systems 100 and 5100 disclosed herein will be readily apparent to those skilled in the art.

[0229] Included in PCT / US2019 / 36010 Figures 5 to 10 The spring member shown can be modified to include a spring member comprising a centering device 1453. Furthermore, it should be understood that alternative configurations for connector assemblies 1000, 2000, 3000, 6000, and 7000 are possible. For example, any number of convex terminal assemblies 1430, 3430, and 6430 can be positioned within housings 1100 and 3100 (as shown in 6100). Several examples of possible configurations are given below:

[0230] ● The inner convex connector housing 3100 may be configured to accommodate a plurality of (e.g., between 2 and 30, preferably between 2 and 8, and most preferably between 2 and 4) convex terminal assemblies 1430, 3430, 6430. The intermediate concave connector assembly 2000 may be reconfigured to receive these plurality of convex terminal assemblies 1430, 3430, 6430 and connect them to a single convex terminal assembly housed within the outer convex connector assembly 1000;

[0231] ● The outer convex connector housing 1100 can be configured to include a plurality of (e.g., between 2 and 30, preferably between 2 and 8, and most preferably between 2 and 4) convex terminal assemblies 1430, 3430, 6430. The intermediate concave connector assembly 2000 can be reconfigured to receive these plurality of convex terminal assemblies 1430, 3430, 6430 and connect them to a single convex terminal assembly housed within the inner convex connector assembly 3000; and

[0232] ● Both the inner and outer convex connector housings 1100 and 3100 can be configured to accommodate a plurality (e.g., between 2 and 30, preferably between 2 and 8, and most preferably between 2 and 4) of convex terminal assemblies 1430, 3430, and 6430, as shown in any of the figures included herein. The intermediate concave connector assembly 2000 can be reconfigured to receive these plurality of convex terminal assemblies 1430, 3430, and 6430 from the inner convex connector assembly 3000 and connect them to the plurality of convex terminal assemblies 1430, 3430, and 6430 accommodated within the outer convex connector assembly 1000.

[0233] In addition, alternative configurations of connector systems 100 and 5100 are possible. For example, concave connector assemblies 2000 and 7000 can be reconfigured to receive these plurality of convex terminal assemblies 1430, 3430, and 6430 into a single concave terminal assembly 2430 and 7430.

[0234] It should be understood that if multiple convex terminal assemblies 1430, 3430, 6430 are used, multiple IL systems 4000, 9000 can also be used. For example, if current is supplied by two different power sources, where each convex terminal assembly 1430, 3430, 6430 is connected to a separate and different power source, then each assembly 1430, 3430, 6430 can have its own IL system 4000, 9000. This is desirable because each IL system 4000, 9000 is able to control the current supply to its associated assembly 1430, 3430, 6430; thus providing the desired selectivity. However, it should be understood that connectors 1000, 3000, 6000 do not need to include multiple IL systems 4000, 9000 simply because two different convex terminal assemblies 1430, 3430, 6430 are included within a single connector 1000, 3000, 6000.

[0235] It should be understood that the intermediate concave connector assembly 2000 can be replaced by an alternative housing and an alternative concave terminal assembly, wherein the alternative housing and the alternative concave terminal assembly have a structural design similar to a portion of the housing and one of the terminal assemblies disclosed in the second embodiment of the coupling system 5100. It should also be understood that the convex terminal assembly can have any number of contact arms 1494, 3494, 6494 (e.g., between 2 and 100, preferably between 2 and 50, and most preferably between 2 and 8) and any number of spring arms 1452, 3452, 6452 (e.g., between 2 and 100, preferably between 2 and 50, and most preferably between 2 and 8). As discussed above, the number of contact arms 1494, 3494, 6494 may not be equal to the number of spring arms. For example, there may be more contact arms 1494, 3494, 6494 than spring arms 1452, 3452, 6452. Alternatively, contact arms 1494, 3494, and 6494 may be fewer than spring arms 1452, 3452, and 6452.

[0236] By referencing incorporated materials and publicly available content

[0237] PCT application numbers PCT / US2021 / 033446, PCT / US2020 / 050018, PCT / US2020 / 049870, PCT / US2020 / 014484, PCT / US2020 / 013757, PCT / US2019 / 036127, PCT / US2019 / 036070, PCT / US2019 / 036010 and PCT / US2018 / 019787, U.S. Patent Application No. 1 U.S. Provisional Application Nos. 6 / 194,891 and 62 / 681,973, 62 / 792,881, 62 / 795,015, 62 / 897,658, 62 / 897,962, 62 / 988,972, 63 / 051,639, 63 / 058,061, 63 / 068,622, 63 / 109,135, 63 / 159,689, and 63 / 222,859, each of which is wholly incorporated herein by reference and forms part of this document.

[0238] SAE specifications, including J1742_201003, entitled "Connections for High Voltage On-Board Vehicle Electrical Wiring Harnesses - Test Methods and General Performance Requirements", last revised in March 2010, are all incorporated herein by reference in their entirety and form part of this document.

[0239] The ASTM specifications, including (i) D4935-18, entitled "Standard Test Method for Measuring the Electromagnetic Shielding Effectiveness of Planar Materials"; and (ii) ASTM D257, entitled "Standard Test Methods for DC Resistance or Conductance of Insulating Materials", are incorporated herein by reference in their entirety and form part of this document.

[0240] American National Standards Institute and / or EOS / ESD Association specifications, including: ANSI / ESD STM11.11 Surface Resistance Measurement of Static Dissipative Planar Materials, each of which is fully incorporated herein by reference and forms part of this document.

[0241] DIN specifications, including connectors for electronic devices - testing and measurement - Part 5-2: testing current carrying capacity; Test 5b: current temperature derating (IEC 60512-5-2:2002), each of which is incorporated herein by reference in its entirety and forms part of this document.

[0242] USCAR specifications include: (i) SAE / USCAR-2, Revision 6, last revised February 2013, ISBN: 978-0-7680-7998-2; (ii) SAE / USCAR-12, Revision 5, last revised August 2017, ISBN: 978-0-7680-8446-7; (iii) SAE / USCAR-21, Revision 3, last revised December 2014; (iv) SAE / USC AR-25, Revision 3, revised March 2016, ISBN: 978-0-7680-8319-4; (v) SAE / USCAR-37, revised August 2008, ISBN: 978-0-7680-2098-4; (vi) SAE / USCAR-38, Revision 1, revised May 2016, ISBN: 978-0-7680-8350-7, each of which is incorporated herein by reference in its entirety and forms part of this document.

[0243] Other standards, including federal testing standards 101C and 4046, are fully incorporated herein by reference and form part of this document.

[0244] Industrial applicability

[0245] While some embodiments have been described and illustrated, many modifications are conceived without obviously departing from the spirit of this disclosure; and the scope of protection is limited only by the scope of the appended claims. For example, the overall shape of the above-described component may be changed to: a triangular prism, pentagonal prism, hexagonal prism, octagonal prism, sphere, pyramid, tetrahedron, cuboid, dodecahedron, icosahedron, octahedron, ellipsoid, or any other similar shape.

[0246] It should be understood that the following terms used in this article should generally refer to the following meanings:

[0247] a. “High power” should mean: (i) a voltage between 20 volts and 600 volts, regardless of the current; or (ii) any current greater than or equal to 80 amps, regardless of the voltage.

[0248] b. “High current” should mean a current greater than or equal to 80 amps, regardless of the voltage.

[0249] c. “High voltage” should refer to a voltage between 20 volts and 600 volts, regardless of the current.

[0250] Titles and subtitles (if any) are used for convenience only and are not restrictive. The word "exemplary" is used to mean serving as an example or illustration. To the extent that terms such as "include," "have," etc., are used, they are intended to be interpreted in a manner similar to the inclusion of the terms, as when used as transitional words in the claims. Relational terms (such as "first" and "second") may be used to distinguish one entity or action from another without necessarily requiring or implying any actual such relationship or order between such entities or actions.

[0251] Phrases such as aspect, the aspect, on the other hand, some aspects, one or more aspects, implementation, the implementation, another implementation, some implementations, one or more implementations, scheme, the scheme, another implementation, some implementations, one or more implementations, configuration, the configuration, another configuration, some configurations, one or more configurations, subject matter, the disclosure, the present disclosure, other variations and similar variations thereof are used for convenience and do not imply that the disclosure associated with such phrases is essential to the present technology, nor does it imply that such disclosure applies to all configurations of the present technology. The disclosure associated with such phrases may apply to all configurations or one or more configurations. One or more examples of the disclosure associated with such phrases may be provided. Phrases (such as aspect or some aspects) may refer to one or more aspects, and vice versa, and this similarly applies to other foregoing phrases.

[0252] In view of the foregoing description, many modifications to this disclosure will be apparent to those skilled in the art. Preferred embodiments of this disclosure are described herein, including best modes known to the inventors for carrying out this disclosure. It should be understood that the illustrated embodiments are merely exemplary and should not be construed as limiting the scope of this disclosure.

Claims

1. A connector system for use in an electrical distribution system of a motor vehicle, the connector system comprising: A convex terminal assembly, the convex terminal assembly having: A conductive convex terminal body, the conductive convex terminal body including at least one integrally formed contact arm and spring receiver; An internal spring component, the internal spring component comprising: (i) at least one spring arm, the at least one spring arm having an elongated body portion with a free end; (ii) a protrusion extending laterally from the free end of the main body portion of the at least one spring arm; and The internal spring member resides within the spring receiver to define a fully engaged state (S). FC ), wherein the protrusion is located adjacent to the inner surface of the spring receiver; and A convex interlocking (MIL) assembly having a range positioned within the internal spring member to define a fully assembled convex state (S). FAM ).

2. The connector system of claim 1, further comprising a concave connector assembly, the concave connector assembly comprising: (i) A recessed terminal assembly with a socket; as well as (ii) A concave interlock (FIL) assembly, the concave interlock (FIL) assembly being positioned within the concave terminal assembly to define a fully assembled concave state (S). FAF ).

3. The connector system of claim 2 further includes a concave housing, wherein the concave terminal assembly and the concave interlock (FIL) assembly are secured in the concave housing using a concave interlock retainer.

4. The connector system of claim 2, wherein the receptacle of the concave terminal assembly is sized to receive a portion of both the convex terminal assembly and the convex interlocking (MIL) assembly to define a fully connected state (S). FCON ).

5. The connector system of claim 4, wherein the connector system is in a fully connected state (S... FCON The following conforms to the T4 / V4 / S3 / D2 / M2 standard.

6. The connector system according to claim 4, wherein the connector system is in the fully connected state (S... FCON When the internal spring member applies an outward force to the free end of at least one of the contact arms to secure the convex terminal assembly within the concave terminal assembly.

7. The connector system of claim 1, wherein when the convex terminal assembly is in the fully engaged state (S... FC When: (i) at least one of the contact arms has a free end adjacent to the outer surface of the at least one spring arm, and (ii) a gap is formed between the outer surface of the at least one spring arm and the inner surface of the at least one contact arm.

8. The connector system of claim 1, wherein the convex interlock (MIL) assembly includes a jumper wire, the jumper wire being in the fully assembled convex state (S... FAM It resides within the internal spring member of the convex terminal assembly.

9. The connector system of claim 1, wherein the convex terminal assembly is partially surrounded by a shielding component adapted to reduce electromagnetic interference noise caused by the convex terminal assembly during use of the connector system.

10. The connector system of claim 1, further comprising a convex housing configured to at least partially surround the convex terminal assembly, wherein the convex housing includes a connector position guarantee (CPA) receiver designed to accommodate the extent of a connector position guarantee (CPA) member.

11. A connector system for use in an electrical distribution system of a motor vehicle, the connector system comprising: A convex connector assembly, the convex connector assembly comprising: (i) Convex terminal assembly; (ii) A convex interlock (MIL) assembly, the convex interlock (MIL) assembly being positioned within the convex terminal assembly to define a fully assembled convex state (S). FAM ), The concave connector assembly includes: (i) A recessed terminal assembly with a socket; (ii) A concave interlock (FIL) assembly, the concave interlock (FIL) assembly being positioned within the concave terminal assembly to define a fully assembled concave state (S). FAF );and The socket of the concave terminal assembly is sized to receive a portion of both the convex terminal assembly and the convex interlock (MIL) assembly to define a fully connected state (S). FCON ); The range of the convex interlock (MIL) component is configured to be in a fully connected state (S FCON The lower part is positioned within the concave interlock (FIL) assembly.

12. The connector system of claim 11, wherein the convex terminal assembly includes an internal spring member residing within a spring receiver of the convex terminal body of the convex terminal assembly.

13. The connector system of claim 12, wherein the internal spring member comprises: (i) At least one spring arm, said at least one spring arm having an elongated body portion with a free end; (ii) a protrusion extending laterally from the free end of the main body portion; and The internal spring member resides within the spring receiver of the convex terminal body to define a fully engaged state (S). FC The protrusion is located adjacent to the inner surface of the convex terminal body to facilitate the alignment of the internal spring member with the convex terminal body.

14. The connector system of claim 12, wherein the convex interlock (MIL) assembly includes a jumper wire, the jumper wire being in the fully assembled convex state (S... FAM It resides within the internal spring member of the convex terminal assembly.

15. The connector system of claim 14, wherein the convex interlocking (MIL) assembly further comprises a retainer, the retainer being in the fully assembled convex state (S... FAM The jumper wire is then fixed within the internal spring member and the convex terminal assembly.

16. The connector system of claim 11, wherein: (i) a first range of the MIL assembly is located within the convex terminal body of the convex terminal assembly, and (ii) a second range of the MIL assembly is located outside the convex terminal body.

17. The connector system of claim 11, wherein the concave interlocking (FIL) assembly includes a receiver with at least one electrical lead for connection to an interlocking circuit housed within an electrical component in the power distribution system.

18. The connector system of claim 17, wherein the receiver of the concave interlock (FIL) assembly resides within a retainer, the retainer being in the fully assembled concave state (S... FAF The lower part is located within the concave terminal assembly.

19. The connector system of claim 11, wherein the connector system is not in the fully connected state (S FCON Under these conditions, the interlocking circuit connected to the concave interlock (FIL) assembly prevents current from flowing through the concave terminal assembly.

20. The connector system of claim 11, wherein the current is configured in the fully connected state (S... FCON The fluid flows from the concave terminal assembly to the convex terminal assembly.

21. The connector system of claim 11, wherein the connector system conforms to the PCTS standard.

22. The connector system of claim 11, wherein the connector system conforms to the T4 / V4 / S3 / D2 / M2 standard.

23. A connector system for use in an electrical distribution system of a motor vehicle, the connector system comprising: A first convex terminal assembly, the first convex terminal assembly having: (i) A first convex terminal body, the first convex terminal body being formed of a first material and having a contact arm and a spring receiver, and (ii) A first internal spring member, the first internal spring member being formed of a second material and having a spring arm, wherein the dimensions of the first internal spring member are designed to reside within the spring receiver of the first convex terminal body; The second convex terminal assembly has: (i) a second convex terminal body, the second convex terminal body being formed of the first material and having a contact arm and a spring receiver, and (ii) A second internal spring member, the second internal spring member being formed of the second material and having a spring arm, wherein the dimensions of the second internal spring member are designed to reside within the spring receiver of the second convex terminal body; A housing configured to surround the extent of both the first convex terminal assembly and the second convex terminal assembly; as well as A convex interlock (MIL) assembly, the convex interlock (MIL) assembly being positioned within the housing and between the first convex terminal assembly and the second convex terminal assembly.

24. The connector system of claim 23, further comprising a concave connector assembly, the concave connector assembly comprising: (i) A first concave terminal assembly with a first socket; (ii) A second concave terminal assembly with a second socket; as well as (iii) A concave housing configured to surround a portion of both the first concave terminal assembly and the second concave terminal assembly.

25. The connector system of claim 24, wherein the concave connector assembly includes at least one inclined wall configured to compress the extent of the first convex terminal assembly when the first convex terminal assembly is inserted into the first concave terminal assembly.

26. The connector system of claim 24 further includes a concave interlock (FIL) assembly positioned within the concave housing and between the first concave terminal assembly and the second concave terminal assembly.

27. The connector system of claim 26, wherein the concave interlocking (FIL) assembly includes a receiver with at least one electrical lead for connection to an interlocking circuit housed within an electrical component in the power distribution system.

28. The connector system of claim 26, wherein a fully connected state (S) is defined when: (i) the first receptacle of the first concave terminal assembly is sized to receive a portion of the first convex terminal assembly, (ii) the second receptacle of the second concave terminal assembly is sized to receive a portion of the second convex terminal assembly, and (iii) the concave interlock (FIL) assembly receives a portion of the convex interlock (MIL) assembly. FCON ).

29. The connector system of claim 28, wherein the first internal spring member applies an outwardly pointing force to the area of ​​the first convex terminal body, in the fully connected state (S... FCON The first convex terminal assembly is fixed inside the first concave terminal assembly.

30. The connector system of claim 29, wherein the contact arm of the first convex terminal body has a free end positioned to contact the spring arm, and wherein a portion of the outwardly pointing force exerted by the spring arm is applied to the free end of the contact arm.

31. The connector system of claim 23, wherein the spring arm of the first internal spring member includes a centering device for aligning the first internal spring member within the first convex terminal body.

32. The connector system of claim 31, wherein the spring arm has an elongated body portion, and the centering device includes a protrusion extending laterally from a free end of the body portion, and wherein the protrusion is configured to reside adjacent to the inner surface of the first convex terminal body.

33. The connector system of claim 23, wherein the connector system conforms to the PCTS standard.

34. The connector system of claim 23, wherein the connector system conforms to the T4 / V4 / S3 / D2 / M2 standard.

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