Electrical connector system having male terminal assembly with compression limiting device

Abstract

An electrical connector system having a male connector assembly and a female connector assembly is disclosed. The male connector assembly includes a male housing assembly and a male terminal assembly. The male terminal assembly has: a male terminal; a spring member having at least one contact arm having a substantially curved configuration; and an openable sheath surrounding the male terminal and a majority of the extension of the spring member. The male terminal assembly also includes a compression limiting device that prevents an external force from excessively deforming the contact arms inward. It is desirable to prevent excessive depression of the contact arm as such excessive depression may damage the contact arm and / or the spring member. The female connector assembly includes a female housing assembly designed to receive the extension of the male terminal assembly and the female terminal assembly in a connected state during operation of the electrical connector system.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to an electrical connector system, and more particularly to a relatively small connector system having a male connector assembly and a female connector assembly. The male connector assembly includes a male housing assembly and a male terminal assembly having a male terminal, a spring member with at least one contact arm with a bent section, and an openable closure shroud. The male terminal assembly further includes a compression limiting device that prevents an external force from deforming the contact arm inwardly too much. Preventing the contact arm from being depressed too much is desirable because it can damage the contact arm and / or the spring member, thereby introducing a failure mode into the male connector assembly, which can cause the entire connector system to become inoperable and unusable. BACKGROUND

[0002] The number of electrical components used in automobiles and other road and off-road vehicles (e.g., pickup trucks, commercial vans and trucks, semi-trucks, motorcycles, all-terrain vehicles, and sport utility vehicles (collectively, “motor vehicles”)) has significantly increased over the past several decades. Electrical components are used in motor vehicles for a variety of reasons, including but not limited to monitoring, improving, and / or controlling vehicle performance, emissions, safety, and providing comfort to the occupants of the motor vehicle. Considerable time, resources, and energy have been spent developing electrical distribution components that meet the various needs and complexities of the motor vehicle market; however, conventional electrical distribution components have various shortcomings.

[0003] Motor vehicles are challenging electrical environments for electrical components and connector assemblies due to several conditions, including but not limited to space constraints that make initial installation difficult, harsh operating conditions, large environmental temperature ranges, prolonged vibration, thermal loading, and life, all of which can lead to component and / or connector failure. For example, two significant failure modes for electrical components and motor vehicles are improperly installed connectors, which typically occur in the assembly plant, and dropped connectors, which typically occur in the field. Each of these failure modes results in significant repair and warranty costs. For example, the combined annual increase in warranties for all automobile manufacturers and their direct suppliers is estimated to be between $50 billion and $150 billion worldwide. Given these challenging electrical environments, considerable time, money, and energy have been spent finding electrical distribution components that meet the needs of the market. The present disclosure addresses the shortcomings of conventional electrical distribution components. A full discussion of the features and advantages of the present disclosure will be deferred to the following detailed description, which proceeds with reference to the accompanying drawings. SUMMARY

[0004] According to various implementations, an electrical connector assembly for a power distribution assembly is disclosed. The connector assembly includes a male connector assembly including a male housing assembly and a male terminal assembly. The male terminal assembly includes a male terminal body with a receiving portion and at least one contact arm having a curved portion defining a contact arm apex, a spring member with at least one spring arm configured to be positioned below the contact arm, an openable sheath, and a means for limiting over-compression of the at least one contact arm by an external force to prevent damage to the male terminal assembly. In a fully assembled state S FA (i) the spring member is positioned in the receiving portion of the male terminal body and the spring arm is positioned below the contact arm, and (ii) a majority of the male terminal body and the spring member are positioned within the sheath.

[0005] In some implementations, the openable sheath has a contact arm opening, and at least one deflection protrusion is provided on both sides of the opening.

[0006] In some implementations, in the fully assembled state S FA the contact arm apex extends above an upper edge of the deflection protrusion.

[0007] In some implementations, an outer surface of the deflection protrusion is substantially parallel to a contact surface of the contact arm.

[0008] In some implementations, the at least one spring arm includes a curved portion formed by an upwardly angled extension of the spring arm and a downwardly angled extension of the spring arm.

[0009] In some implementations, an interior angle of the curved portion of the at least one spring arm is defined between an inner surface of the upwardly angled extension and an inner surface of the downwardly angled extension, and the interior angle is between 60 degrees and 120 degrees.

[0010] In some implementations, the interior angle of the curved portion of the at least one spring arm is between 75 degrees and 105 degrees.

[0011] In some implementations, the interior angle of the curved portion of the at least one spring arm is 80 degrees.

[0012] In some implementations, the interior angle of the curved portion of the at least one spring arm is a pronounced acute angle.

[0013] In some implementations, the at least one spring arm of the spring member is a first spring arm having both a linear extension and a bent portion, the linear extension having a first width and the bent portion having a second width, and wherein the first width is greater than the second width.

[0014] In some implementations, the spring member includes a second spring arm with a bent portion having a third width, and the third width is greater than the second width of the first spring arm.

[0015] In some implementations, the male terminal body includes a wall structure with an interior spring wall with an anti-rotation protrusion, and the anti-rotation protrusion is configured to be positioned in an anti-rotation recess formed in the spring member.

[0016] In some implementations, the anti-rotation recess is formed between a pair of spring arms of the spring member.

[0017] In some implementations, when the terminal assembly is in the fully assembled state S FA , the at least one contact arm includes a free end that does not abut a planar outer surface of the spring arm.

[0018] In some implementations, when the male terminal body is in the ready-to-receive position P R , the receiving portion of the male terminal body has a first front portion dimension, and when the male terminal body is in the ready-to-use position P U , the receiving portion has a second front portion dimension, and wherein the second front portion dimension is less than the first front portion dimension.

[0019] In some implementations, the spring member includes two opposing spring arms each having a bend portion defining a spring arm apex, wherein an outer spring member dimension is defined between the spring arm apexes, and wherein the outer spring member dimension is greater than the second front portion dimension of the receiving portion of the male terminal body.

[0020] In some implementations, the male terminal body includes a base portion with an outer surface, and the at least one contact arm includes a linear extension with an outer surface that is coplanar with the outer surface of the base portion.

[0021] In some implementations, the electrical connector assembly further includes a female connector assembly including a female housing assembly and a female terminal assembly.

[0022] In some implementations, the male connector assembly and the female connector assembly are operably coupled together in the connected state S C , wherein the front portion extensions of each of the male terminal body, the spring member, and the sheath are received in the female terminal assembly.

[0023] According to other various implementations, an electrical connector assembly for a power distribution assembly in a vehicle is disclosed. The connector assembly includes a male connector assembly including a male housing assembly and a male terminal assembly. The male terminal assembly includes: a male terminal body with a receiving portion, a base portion, and at least one contact arm extending from the base portion; a spring member with at least one spring arm configured to be positioned under the contact arm; a compression limiting device configured to limit over-compression of the at least one contact arm and the at least one spring arm; an openable sheath; and a compression limiting device configured to limit over-compression of the contact arm and the spring arm. In a fully coupled state S FC , (i) the spring member is positioned in the receiving portion of the male terminal body and the spring arm is positioned under the contact arm, (ii) a majority of the male terminal body and the spring member are positioned within the sheath, and (iii) the spring member, the male terminal body, and the sheath are positioned within the male housing assembly.

[0024] In some implementations, the openable sheath has a contact arm opening, and both sides of the opening are provided with at least one deflection protrusion.

[0025] In some implementations, in a fully assembled state S FA , the contact arm apex extends above an upper edge of the deflection protrusion.

[0026] In some implementations, an outer surface of the deflection protrusion is substantially parallel to a contact surface of the contact arm.

[0027] In some implementations, the at least one spring arm includes a curved portion formed by an upwardly angled extension of the spring arm and a downwardly angled extension of the spring arm.

[0028] In some implementations, an interior angle of the curved portion of the at least one spring arm is defined between an inner surface of the upwardly angled extension and an inner surface of the downwardly angled extension, and the interior angle is between 60 degrees and 120 degrees.

[0029] In some implementations, the interior angle of the curved portion of the at least one spring arm is between 75 degrees and 105 degrees.

[0030] In some implementations, the interior angle of the curved portion of the at least one spring arm is 80 degrees.

[0031] In some implementations, the interior angle of the curved portion of the at least one spring arm is a pronounced acute angle.

[0032] In some implementations, the at least one spring arm of the spring member is a first spring arm with both a linear extension having a first width and a bent portion having a second width, and wherein the first width is greater than the second width.

[0033] In some implementations, the spring member includes a second spring arm with a bent portion having a third width, and the third width is greater than the second width of the first spring arm.

[0034] In some implementations, the male terminal body includes a wall structure with an interior spring wall with an anti-rotation protrusion, and the anti-rotation protrusion is configured to be positioned in an anti-rotation recess formed in the spring member.

[0035] In some implementations, the anti-rotation recess is formed between a pair of spring arms of the spring member.

[0036] In some implementations, when the terminal assembly is in the fully coupled state S FC , the at least one contact arm includes a free end that does not abut a planar outer surface of the spring arm.

[0037] In some implementations, when the male terminal body is in the ready to receive position P R , a receiving portion of the male terminal body has a first front portion dimension, and when the male terminal body is in the ready to use position P U , the receiving portion has a second front portion dimension, and wherein the second front portion dimension is less than the first front portion dimension.

[0038] In some implementations, the spring member includes two opposing spring arms, each spring arm having a bent portion defining a spring arm apex, wherein an outer spring member dimension is defined between the spring arm apexes, and wherein the outer spring member dimension is greater than the second front portion dimension of the receiving portion of the male terminal body.

[0039] In some implementations, the base portion includes an outer surface, and the at least one contact arm includes a linear extension having an outer surface that is coplanar with the outer surface of the base portion.

[0040] In some implementations, the electrical connector assembly further includes a female connector assembly including a female housing assembly and a female terminal assembly.

[0041] In some implementations, the male connector assembly and the female connector assembly are operably coupled together in the connected state S C , wherein the front portion extensions of each of the male terminal body, the spring member, and the sheath are received in the female terminal assembly.

[0042] In some implementations, the male terminal body includes a plurality of contact arms, and the spring member includes a plurality of spring arms, wherein the number of contact arms is equal to the number of spring arms, and wherein in the fully coupled state S FC , a single spring arm is positioned under a single contact arm.

[0043] According to other various implementations, an electrical connector assembly for a power distribution assembly is disclosed. The connector assembly includes a male connector assembly including a male housing assembly and a male terminal assembly. The male terminal assembly includes: a male terminal body with a receiving portion, a base portion, and a contact arm extending from the base portion; a spring member including: (i) a primary spring arm positioned below the contact arm and having a forward portion with an over-compression extension, and (ii) a pair of secondary spring arms positioned to the sides of the primary spring arm and having upper edges positioned at a distance from the over-compression extension of the primary spring arm. In a fully assembled state S FA , (i) the spring member is positioned in the receiving portion of the male terminal body and the primary spring arm is positioned below the contact arm, (ii) when an external force F E is applied to the contact arm, both the contact arm and the primary spring arm are compressed inwardly, and (iii) when an additional external force F E is applied to the contact arm, further inward compression of the primary spring arm is constrained by contact of the over-compression extension of the primary spring arm with the upper edges of the secondary spring arms, thereby preventing over-compression of the male terminal assembly.

[0044] In some implementations, the electrical connector assembly further includes an openable sheath, and the male terminal body and a majority of the spring member are positioned within the sheath in the fully assembled state S FA . The openable sheath has a contact arm opening, and at least one deflection protrusion is positioned on both sides of the opening.

[0045] In some implementations, the contact arm has a curved portion defining a contact arm apex, and wherein in the fully assembled state S FA , the contact arm apex extends above the upper edges of the deflection protrusions.

[0046] In some implementations, an outer surface of the deflection protrusions is substantially parallel to a contact surface of the contact arm.

[0047] In some implementations, the primary spring arm includes a curved portion formed by an upwardly angled extension of the primary spring arm and a downwardly angled extension of the primary spring arm.

[0048] In some implementations, an interior angle of the curved portion of the primary spring arm is defined between an interior surface of the upwardly angled extension and an interior surface of the downwardly angled extension, and the interior angle is between 60 degrees and 120 degrees.

[0049] In some implementations, the interior angle of the curved portion of the primary spring arm is between 75 degrees and 105 degrees.

[0050] In some implementations, the interior angle of the curved portion of the primary spring arm is 80 degrees.

[0051] In some implementations, the inner angle of the curved portion of the primary spring arm is a distinct acute angle.

[0052] In some implementations, the primary spring arm has both a linear extension having a first width and a bent portion having a second width, and the first width is greater than the second width.

[0053] In some implementations, the male terminal body includes a wall structure with an interior spring wall with an anti-rotation protrusion, and the anti-rotation protrusion is configured to be positioned in an anti-rotation recess formed in the spring member.

[0054] In some implementations, the anti-rotation recess is formed between the primary spring arm and one of the secondary spring arms of the spring member.

[0055] In some implementations, the receiving portion of the male terminal body has a first front portion dimension when the male terminal body is in the ready-to-receive position P R , and the receiving portion has a second front portion dimension when the male terminal body is in the ready-to-use position P U , and wherein the second front portion dimension is less than the first front portion dimension.

[0056] In some implementations, the spring member includes a pair of primary spring arms each having a curved portion defining a spring arm apex, wherein a primary spring member outer dimension is defined between the spring arm apexes, and wherein the primary spring member outer dimension is greater than the second front portion dimension of the receiving portion of the male terminal body.

[0057] In some implementations, each secondary spring arm has a curved portion defining a spring arm apex, wherein a secondary spring member outer dimension is defined between the spring arm apexes, and wherein the secondary spring member outer dimension is greater than the second front portion dimension of the receiving portion of the male terminal body.

[0058] In some implementations, each secondary spring arm has a curved portion defining a spring arm apex, wherein a secondary spring member outer dimension is defined between the spring arm apexes, and wherein the secondary spring member outer dimension is substantially equal to the secondary spring member outer dimension.

[0059] In some implementations, the base portion of the male terminal body has an outer surface, and wherein the contact arm of the male terminal body includes a linear extension having an outer surface that is coplanar with the outer surface of the base portion.

[0060] In some implementations, an electrical connector assembly, wherein the male terminal body includes a support rib extending from the base portion, the support rib having a length that is less than a length of the contact arm of the male terminal body.

[0061] In some implementations, the over-compression extension includes opposing flanges extending outwardly from the free end of the primary spring arm.

[0062] In some implementations, each secondary spring arm includes a protrusion extension having one of the upper edges positioned a distance from the over-compression extension of the primary spring arm, and the protrusion extension is forward of and beyond the over-compression extension of the primary spring arm.

[0063] In some implementations, the electrical connector assembly further includes an openable sheath, and in the fully assembled state S FA , the protrusion extension of the secondary spring arm of the spring member is received in an opening formed in the openable sheath.

[0064] In some implementations, the male terminal body includes a plurality of contact arms, and the spring member includes a plurality of primary spring arms and a plurality of secondary spring arms, wherein the number of contact arms is equal to the total number of primary spring arms and secondary spring arms, and wherein in the fully assembled state S FA , a single spring arm is under a single contact arm.

[0065] In some implementations, the electrical connector assembly further includes a female connector assembly including a female housing assembly and a female terminal assembly.

[0066] In some implementations, the male connector assembly and the female connector assembly are operably coupled together in the connected state S C , wherein the front extension of each of the male terminal body, the spring member, and the sheath is received in the female terminal assembly.

[0067] According to other various implementations, an electrical connector assembly for a power distribution assembly is disclosed. The connector assembly includes a male connector assembly including a male housing assembly and a male terminal assembly. The male terminal assembly includes a male terminal body with a receiving portion, a base portion, and at least one contact arm extending from the base portion, a spring member with at least one spring arm configured to be under the contact arm, wherein the at least one spring arm includes a front portion with a sheath protrusion extension, and an openable sheath with a spring arm opening. In a fully assembled state S FA , (i) the spring member is positioned in the receiving portion of the male terminal body and the primary spring arm is under the contact arm, (ii) a majority of the male terminal body and the spring member are within the sheath, (iii) when an external force F E is applied to the contact arm, both the contact arm and the primary spring arm are displaced inwardly, and (iv) when an additional external force F EFurther inward displacement of the primary spring arm when applied to the contact arm is constrained by direct contact between the inner surface of the sheath protrusion extension of the at least one spring arm and the interior compression edge of the spring arm opening, thereby preventing over-displacement of the male terminal assembly.

[0068] In some implementations, the sheath protrusion extension includes an inner surface that is in direct contact with the interior compression edge of the spring arm opening, thereby preventing damage to the male terminal assembly.

[0069] In some implementations, the sheath protrusion extension defines a forward-most portion of the spring member.

[0070] In some implementations, the at least one spring arm includes a curved portion formed by an upwardly angled extension of the primary spring arm and a downwardly angled extension of the primary spring arm.

[0071] In some implementations, an interior angle of the curved portion of the primary spring arm is defined between an inner surface of the upwardly angled extension and an inner surface of the downwardly angled extension, and the interior angle is between 60 degrees and 120 degrees.

[0072] In some implementations, the interior angle of the curved portion of the primary spring arm is between 75 degrees and 105 degrees.

[0073] In some implementations, the interior angle of the curved portion of the primary spring arm is 80 degrees.

[0074] In some implementations, the interior angle of the curved portion of the primary spring arm is a distinct acute angle.

[0075] In some implementations, the primary spring arm has both a linear extension having a first width and a bent portion having a second width, and wherein the first width is greater than the second width.

[0076] In some implementations, the male terminal body includes a wall structure with an interior spring wall with an anti-rotation protrusion, and the anti-rotation protrusion is configured to be positioned in an anti-rotation recess formed in the spring member.

[0077] In some implementations, the anti-rotation recess is formed between a pair of spring arms of the spring member.

[0078] In some implementations, the receiving portion of the male terminal body has a first forward dimension when the male terminal body is in the ready-to-receive position P R , and the receiving portion has a second forward dimension when the male terminal body is in the ready-to-use position P U , and wherein the second forward dimension is less than the first forward dimension.

[0079] In some implementations, the at least one spring arm of the spring member includes a pair of primary spring arms, each primary spring arm having a curved portion defining a spring arm apex, wherein a primary spring member outer dimension is defined between the spring arm apexes, and wherein the primary spring member outer dimension is greater than the second front portion dimension of the receiving portion of the male terminal body.

[0080] In some implementations, the at least one spring arm of the spring member further includes a pair of secondary spring arms, each secondary spring arm having a curved portion defining a spring arm apex, wherein a secondary spring member outer dimension is defined between the spring arm apexes, and wherein the secondary spring member outer dimension is greater than the second front portion dimension of the receiving portion of the male terminal body.

[0081] In some implementations, the at least one spring arm of the spring member further includes a pair of secondary spring arms, each secondary spring arm having a curved portion defining a spring arm apex, wherein a secondary spring member outer dimension is defined between the spring arm apexes, and wherein the secondary spring member outer dimension is substantially equal to the secondary spring member outer dimension.

[0082] In some implementations, the base portion of the male terminal body has an outer surface, and the contact arm of the male terminal body includes a linear extension having an outer surface that is coplanar with the outer surface of the base portion.

[0083] In some implementations, the male terminal body includes a support rib extending from the base portion, the support rib having a length that is less than a length of the contact arm of the male terminal body.

[0084] In some implementations, the at least one spring arm includes a first spring arm having a boot protrusion extension and a second spring arm having a front portion with an overcompression extension, and the first spring arm is positioned lateral to the second spring arm and has an upper edge positioned a distance from the overcompression extension.

[0085] In some implementations, the overcompression extension includes opposing flanges extending outwardly from a free end of the second spring arm.

[0086] In some implementations, the boot protrusion extension of the first spring arm is positioned forward of and beyond the overcompression extension of the second spring arm.

[0087] In some implementations, the male terminal body includes a plurality of contact arms, and the spring member includes a plurality of spring arms, wherein the number of contact arms is equal to the number of spring arms, and wherein, in the fully assembled state S FA , a single spring arm is positioned under a single contact arm.

[0088] In some implementations, the electrical connector assembly further includes a female connector assembly including a female housing assembly and a female terminal assembly.

[0089] In some implementations, the male connector assembly and the female connector assembly are operably coupled together in the connected state S C wherein the front extension of each of the male terminal body, the spring member, and the shroud is received in the female terminal assembly.

[0090] In some implementations, the at least one spring arm of the spring member includes (i) a first pair of spring arms having a front with a shroud protrusion extension, wherein the first pair of spring arms are in an opposing positional relationship, and (ii) a second pair of spring arms having a front with an over-compression extension, wherein the second pair of spring arms are in an opposing positional relationship; and wherein the first pair of spring arms are angularly oriented at 90 degrees to the second pair of spring arms.

[0091] Other aspects and advantages of the present disclosure will become apparent upon consideration of the following detailed description and accompanying drawings, in which like reference characters designate like structures throughout the several figures. BRIEF DESCRIPTION OF DRAWINGS

[0092] The accompanying drawings are included to provide a further understanding and are incorporated in and constitute a part of this specification, illustrate the disclosed embodiments and together with the description serve to explain the principles of the disclosed embodiments. In the drawings: FIG. 1A is a perspective view of a first embodiment of the connector system in a connected state S C showing the male connector assembly connected to the female connector assembly; FIG. 1B is a perspective view of the connector system of FIG. 1A in a disconnected state S DC showing the male connector assembly disconnected from the female connector assembly; FIG. 2 is an exploded view of the connector system of FIG. 1A and FIG. 1B showing the male connector assembly with the male terminal assembly and the female connector assembly with the female terminal assembly; FIG. 3 is an exploded view of the male terminal assembly of FIG. 2 showing the male terminal, the spring member, and the shroud; FIG. 4 is a perspective view of a step in the process of forming the male terminal from a blank FIG. 3 ; FIG. 5A to FIG. 5D is an enlarged view of the step shown in FIG. 4 ; FIG. 6A is a side view of the male terminal of FIG. 3 ; FIG. 6B is a perspective view of the male terminal of FIG. 3 ; FIG. 7A is a front view of the male terminal of FIG. 3 , showing the male terminal body with multiple contact arms; FIG. 7B is an enlarged view of one contact arm as shown in FIG. 7A ; FIG. 8 is a cross-sectional view of the male terminal taken along line 8-8 of FIG. 7A ; FIG. 9 is a top view of the male terminal of FIG. 6A ; FIG. 10 is a cross-sectional view of the male terminal taken along line 10-10 of FIG. 9 ; FIG. 11 is a perspective view of a step in the process of forming the spring member of FIG. 3 from a blank; FIG. 12A to FIG. 12B is an enlarged view of the step in the forming process as shown in FIG. 11 ; FIG. 13A is a perspective view of the spring member of FIG. 3 ; FIG. 13B is a front view of the spring member of FIG. 3 ; FIG. 14 is a top view of the spring member of FIG. 3 ; FIG. 15 is a cross-sectional view of the spring member taken along line 15-15 of FIG. 14 ; FIG. 16 is a perspective view of the spring member and male terminal of FIG. 3 in a disassembled state S DA ; FIG. 17 is a perspective view of the spring member and male terminal of FIG. 3 in a first partially assembled state S 1PA ; FIG. 18 is a perspective view of the spring member and male terminal of FIG. 3 in a second partially assembled state S 2PA ; FIG. 19 is a perspective view of a step in the process of forming the sheath of FIG. 3 ; FIG. 20A to FIG. 20B is an enlarged view of the step in the forming process as shown in FIG. 19 ; FIG. 21 It is shown as being in the open position P O of FIG. 3 Side view of the sheath; FIG. 22 yes FIG. 3 Rear perspective view of the sheath; FIG. 23 It is shown as being in the closed position P C of FIG. 3 Side view of the sheath; FIG. 24 It is along FIG. 23 A sectional view of the sheath taken from line 24-24; FIG. 25 It is in the third assembly state S 3PA of FIG. 3 A perspective view of the male terminal assembly; FIG. 26 It is in the fourth assembly state S 4PA of FIG. 3 A perspective view of the male terminal assembly; FIG. 27 It is in a fully assembled state S FA of FIG. 3 Front perspective view of the male terminal assembly; FIG. 28 yes FIG. 27 Rear perspective view of the male terminal assembly; FIG. 29A It is shown as being in FIG. 27 Fully assembled state S FA An enlarged view of the first part of the sheath connecting device; FIG. 29B It is shown as being in FIG. 27 Fully assembled state S FA An enlarged view of the second part of the sheath connecting device; FIG. 29C It is shown as being in FIG. 28 Fully assembled state S FA An enlarged view of the third part of the sheath connecting device; FIG. 30 Is in FIG. 27 Fully assembled state S FA Rear view of the male terminal assembly; FIG. 31 It is along FIG. 30 A perspective sectional view of the male terminal assembly taken from line 31-31; FIG. 32 yes FIG. 31 An enlarged view of the front of the male terminal assembly shown; FIG. 33 yesFIG. 31 An enlarged view of the rear of the male terminal assembly shown; FIG. 34 Is in FIG. 27 Fully assembled state S FA Front view of the male terminal assembly; FIG. 35 It is along FIG. 34 A cross-sectional view of the male terminal assembly taken from line 35-35; FIG. 36 This is shown as being in the disengaged state S. DC of FIG. 2 Side view of the male connector assembly; FIG. 37 It is along FIG. 36 A cross-sectional view of the male connector assembly taken from line 37-37; FIG. 38 This is shown as S in a partially connected state. PC of FIG. 2 Side view of the male connector assembly; FIG. 39 It is along FIG. 38 A cross-sectional view of the male connector assembly taken from line 39-39; FIG. 40 It is shown as being in FIG. 37 The state of S DC Enlarged view of the male connector assembly; FIG. 41 It is shown as being in FIG. 39 Partial connection state S PC Enlarged view of the male connector assembly; FIG. 42 This is shown as S in a fully connected state. FC of FIG. 2 A top view of the male connector assembly; FIG. 43 It is along FIG. 42 A cross-sectional view of the male connector assembly taken from line 43-43; FIG. 44 yes FIG. 43 An enlarged view of the male connector assembly shown; FIG. 45 Is in FIG. 42 Fully connected state S FC Side view of the male connector assembly; FIG. 46 It is along FIG. 45 A sectional view of the male connector assembly taken from line 46-46; FIG. 47 Is in FIG. 42 Fully connected state S FCfront view of the male connector assembly of FIG. 48 is FIG. 42 perspective view of the male connector assembly of FIG. 49 is in a fully coupled state S FIG. 43 of the sheath coupling device and the first portion of the male terminal holding device of FC FIG. 50 is FIG. 49 enlarged view of the first portion of the male terminal holding device of FIG. 51 is FIG. 49 enlarged view of the second portion of the male terminal holding device of FIG. 52 is FIG. 2 perspective view of the female terminal assembly of FIG. 53 is FIG. 52 front view of the female terminal assembly of FIG. 54 is FIG. 1B top view of the female connector assembly of FIG. 55 is a sectional view of the female connector assembly taken along line 55-55 of FIG. 54 FIG. 56 is FIG. 55 enlarged view of the first portion of the female terminal holding device of FIG. 57 is FIG. 55 enlarged view of the second portion of the female terminal holding device of FIG. 58 is a side view of the connector system of PC FIG. 1A and FIG. 1B in a partially coupled state S FIG. 59 is a sectional view of the connector system taken along line 59-59 of FIG. 58 is a side view of the connector system of C FIG. 60 and FIG. 1A in a coupled state S FIG. 1B is a sectional view of the connector system taken along line 61-61 of FIG. 61 FIG. 60 is a side view of the connector system of C and FIG. 62 in a coupled state S FIG. 1A FIG. 1B ​​​​​​​ FIG. 63 It is along FIG. 62 A cross-sectional view of the connector system taken from line 63-63; FIG. 64A This is a perspective view of a second embodiment of the male terminal assembly, showing S in a fully assembled state. FA Male terminals, spring components, and sheaths; FIG. 64B yes FIG. 64A Exploded view of the male terminal assembly; FIG. 65A yes FIG. 64A A perspective view of the spring component of the male terminal assembly; FIG. 65B yes FIG. 65A Front view of the spring component; FIG. 65C yes FIG. 65A A top view of the spring component; FIG. 66 This is a perspective view of a third embodiment of the male terminal assembly, showing S in a fully assembled state. FA Male terminals, spring components, and sheaths; FIG. 67 yes FIG. 66 Exploded view of the male terminal assembly; FIG. 68 It is formed FIG. 67 A perspective view of the steps involved in the process of constructing a spring component; FIG. 69A to FIG. 69C It is formed FIG. 68 Enlarged view of the steps in the process of the spring component shown; FIG. 70A yes FIG. 66 Front perspective view of the spring component; FIG. 70B yes FIG. 66 Rear perspective view of the spring component; FIG. 70C yes FIG. 66 Side view of the spring component; FIG. 71A It is along FIG. 70C A sectional view of the spring component taken along line 71A-71A; FIG. 71B It is along FIG. 70C A sectional view of the spring component taken from line 71B-71B; FIG. 72A It is in the first assembly state S 1PA of FIG. 67 Perspective view of the spring component and male terminal; FIG. 72B It is in the second assembly state S2PA of FIG. 67 Perspective view of the spring component and male terminal; FIG. 73 This is shown as S in a fully assembled state. FA of FIG. 66 Side view of the male terminal assembly; FIG. 74 It is along FIG. 73 A cross-sectional view of the male terminal assembly taken from line 74-74; FIG. 75A It is in a fully assembled state S FA A perspective view of a fourth embodiment of the male terminal assembly; FIG. 75B yes FIG. 75A An exploded view of the male terminal assembly shows the male terminal, spring member, and sheath; FIG. 76 yes FIG. 75B A front view of the male terminal shows the male terminal body with multiple contact arms; FIG. 77 yes FIG. 76 A perspective view of the male terminal; FIG. 78 yes FIG. 76 A side view of the male terminal shows the male terminal body; FIG. 79 It is along FIG. 78 A cross-sectional view of a portion of the male terminal taken from line 79-79; FIG. 80 yes FIG. 78 An enlarged side view of the contact arm of the male terminal; FIG. 81 yes FIG. 76 Enlarged front view of the contact arm of the male terminal; FIG. 82 yes FIG. 75B A perspective view of the spring component of the male terminal assembly; FIG. 83 yes FIG. 82 A top view of the spring component; FIG. 84 yes FIG. 82 Side view of the spring component; FIG. 85 It is along FIG. 84 A sectional view of the spring component taken from line 85-85; FIG. 86 It is in the disassembled state. DA of FIG. 75B Perspective view of the spring component and male terminal; FIG. 87 It is in the first assembly state S 1PAof FIG. 75B Front view of the spring component and male terminal; FIG. 88 It is along FIG. 87 A sectional view of the spring component and male terminal taken from line 88-88; FIG. 89 It is in the second assembly state S 2PA of FIG. 75B A perspective view of the male terminal assembly; FIG. 90 It is in a fully assembled state S FA of FIG. 75B A top view of the male terminal assembly; FIG. 91 It is along FIG. 90 A cross-sectional view of the male terminal assembly taken from line 91-91; FIG. 92 It is in a fully assembled state S FA of FIG. 75B Side view of the male terminal assembly; FIG. 93 It is along FIG. 92 A cross-sectional view of the male terminal assembly taken from line 93-93; FIG. 94 yes FIG. 91 An enlarged view of the male terminal assembly shown; FIG. 95 yes FIG. 91 An enlarged view of the first part of the sheath connection device of the male terminal assembly shown; FIG. 96 yes FIG. 93 An enlarged view of the male terminal assembly shown; FIG. 97 yes FIG. 90 A top view of the male terminal assembly shown; FIG. 98 It is along FIG. 97 A cross-sectional view of the male terminal assembly taken from line 98-98; FIG. 99 yes FIG. 90 The front view of the male terminal assembly shown; FIG. 100 It is along FIG. 99 A cross-sectional view of the male terminal assembly taken from line 100-100; FIG. 101 This is a perspective view of the fifth embodiment of the male terminal assembly, showing S in a fully assembled state. FA Male terminals, spring components, and sheaths; FIG. 102 yes FIG. 101 Front view of the male terminal assembly; FIG. 103It is along FIG. 102 A cross-sectional view of the male terminal assembly taken from line 103-103; FIG. 104 This is a perspective view of the sixth embodiment of the male terminal assembly, showing S in a fully assembled state. FA Male terminals, spring components, and sheaths; FIG. 105 It is in a fully assembled state S FA A perspective view of the seventh embodiment of the male terminal assembly; FIG. 106 yes FIG. 105 An exploded view of the male terminal assembly shows the male terminal, spring member, and sheath; FIG. 107 yes FIG. 106 Perspective view of the spring component shown; FIG. 108 yes FIG. 107 Front view of the spring component; FIG. 109 yes FIG. 107 Side view of the spring component; FIG. 110 yes FIG. 105 Front view of the male terminal assembly; FIG. 111 It is along FIG. 110 A cross-sectional view of the male terminal assembly taken from line 111-111; and FIG. 112 yes FIG. 111 An enlarged view of the front of the male terminal assembly shown.

[0093] FIG. 113 The diagram shows a vehicle, an AC charging system, and a DC charging system, wherein the AC charging system and the DC charging system have at least one charging connector and at least one receiving unit; FIG. 114 yes FIG. 113 A perspective view of a charging system, wherein the charging connectors are disconnected from the receiving unit, and wherein each charging connector includes at least one male terminal assembly and at least one female terminal assembly. FIG. 115 This is a perspective view of a battery pack with multiple connector systems for electrically connecting components of the battery pack. FIG. 116 It is with FIG. 115 A perspective view of the vehicle's chassis, including the battery pack, wheels, and tires. FIG. 117 It has FIG. 116 A perspective view of a motor vehicle with a skateboard chassis and battery pack; FIG. 118 It is in a fully assembled state SFA perspective view of an eighth embodiment of a male terminal assembly of FIG. 119 is FIG. 118 a side view of a male terminal assembly of FIG. 120 is FIG. 118 an exploded view of a male terminal assembly of FIG. 121 is FIG. 120 a side view of a male terminal of FIG. 122 is FIG. 120 a perspective view of a male terminal of FIG. 123 is FIG. 120 a front view of a male terminal of FIG. 124 is FIG. 120 a top view of a male terminal of FIG. 125 is FIG. 124 a cross-sectional view of a male terminal taken along line 125-125 of FIG. 126 is FIG. 120 a perspective view of a spring member of FIG. 127 is FIG. 120 a front view of a spring member of FIG. 128 is FIG. 120 a rear view of a spring member of FIG. 129 is FIG. 120 a side view of a spring member of FIG. 130 is FIG. 129 a cross-sectional view of a spring member taken along line 130-130 of FIG. 131 is FIG. 129 a cross-sectional view of a spring member taken along line 131-131 of FIG. 132 is FIG. 129 a cross-sectional view of a spring member taken along line 132-132 of FIG. 133 is PA a perspective view of a spring member and a male terminal of FIG. 120 in a partially assembled state S FIG. 134 is FIG. 133 a side view of a spring member and a male terminal of FIG. 135 is FIG. 133 a magnified view of a portion of a spring member and a male terminal of FIG. 136 is in a fully assembled state S FA FIG. 118 is a front view of the male terminal assembly of FIG. 137 is a cross-sectional view of the male terminal assembly taken along lines 137-137 of FIG. 136 FIG. 138 is a cross-sectional view of the male terminal assembly adjacent to the female terminal assembly according to one implementation. DETAILED DESCRIPTION

[0094] In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the relevant teachings. However, it will be apparent to one skilled in the art that the present teachings can be practiced without these details. In other instances, well-known methods, procedures, components, and / or circuitry have been described at a relatively high-level, without detail, in order to avoid unnecessarily obscuring aspects of the present teachings.

[0095] While this disclosure includes a number of different implementations of the several embodiments, it will be understood that the disclosure should be considered as an exemplification of the principles of the methods and systems disclosed, and not as a limitation of the broad aspects of the concepts disclosed. As will be appreciated, the disclosed methods and systems are capable of other and different configurations, and its several details are capable of modification in various obvious respects, without departing from the scope of the disclosed methods and systems. For example, one or more of the following embodiments can be partially or wholly combined with other disclosed methods and systems. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.

[0096] The accompanying drawings illustrate seven embodiments of a connector system 10, 1010, 2010, 3010, 4010, 5010, 6010 or components thereof, which are designed to mechanically and electrically couple one device or component within an electrical distribution system or environment to another device or component. For example, a first device or component can be removably coupled to a second device or component via the connector system 10. The first device or component can be a current supplying device or component, such as a charging coupler 2 (see FIG. 113 to FIG. 114 ), an alternator, a battery, or another power source, while the second device or component can be a current drawing device or component, such as a receiving portion 4 (see Figures 113-114 ), a radiator fan, a heating seat, an electrical distribution component, or another current drawing component. In exemplary embodiments, Figure 113 ​​Disclosed are diagrams showing a vehicle 6, an AC charging system 3a, and a DC charging system 3b, wherein the AC charging system 3a and the DC charging system 3b have at least one charging coupler 2 and at least one receiving portion 4. The charging coupler 2 and the receiving portion 4 mate with each other such that an extension of the charging coupler 2 can be received by the receiving portion 4. In Figure 114 the charging coupler 2 can include three male connector assemblies 50. Additionally, the charging coupler 2 can also include two male connector assemblies disclosed in PCT / US18 / 19787, PCT / US19 / 36010, or PCT / US21 / 43788. Meanwhile, the receiving portion 4 can include three female connector assemblies 650. Additionally, the receiving portion 4 can also include two female connector assemblies disclosed in PCT / US18 / 19787, PCT / US19 / 36010, or PCT / US21 / 43788. When the charging coupler 2 is connected to the receiving portion 4: (i) AC power can flow between the male connector assemblies 50 and the female connector assemblies 650, and (ii) DC power can flow between the male connector assemblies and the female connector assemblies disclosed in PCT / US18 / 19787, PCT / US19 / 36010, or PCT / US21 / 43788. Alternatively, one or more connector systems 10, 1010, 2010, 3010, 4010, 5010, 6010 can be used within a single device or component. A power distribution system or environment that includes the connector systems 10, 1010, 2010, 3010, 4010, 5010, 6010 can be installed within an aircraft, a vehicle skateboard 9, a motor vehicle 6, a military vehicle (e.g., a tank, a personnel carrier, a heavy truck, and a military transport truck), a bus, a locomotive, a tractor, a boat, a submarine, a battery pack 8, a 24-48 volt system, for high power applications, for high current applications, for high voltage applications.

[0097] Various aspects of the first embodiment of the connector system 10 are explained in more detail below. Generally, the connector system 10 includes: (i) a male connector assembly 50, and (ii) a female connector assembly 650. FIGS. 1-6 show various views and components of the male connector assembly 50. The first embodiment of the male connector assembly 50 primarily includes: (i) a male housing assembly 70, and (ii) a male terminal assembly 100 having a male terminal 101, a spring member 300, and a boot 400. Figure 51 Various views and components of the male connector assembly 50 are shown. The first embodiment of the male connector assembly 50 primarily includes: (i) a male housing assembly 70, and (ii) a male terminal assembly 100 having a male terminal 101, a spring member 300, and a boot 400. Figures 52-57 Various views of the first embodiment of the female connector assembly 650 are shown, which primarily includes: (i) a female housing assembly 670, and (ii) a female terminal assembly 700. Finally, Figures 58-63 The positional relationship of the male connector assembly 100 and the female connector assembly 650 and the interaction therebetween are shown.

[0098] The various seven embodiments of the connector system 10 provide a number of improvements over conventional connectors. With respect to the first embodiment, these improvements include: (i) the male terminal body 104 including a base portion 110 and at least one contact arm 180a-180d with a portion 182a-182d that is substantially coplanar with the base portion 110, (ii) the male terminal body 104 with an anti-rotation protrusion 114 configured to help prevent the spring member 300 from rotating within the receiving portion 105, (iii) the contact arms 180a-180d having a geometric bend or kink portion 178a-178d with a free end 190a-190d that does not abut the planar outer surface of the spring arm 312a-312d when the spring member 300 is positioned in the receiving portion 105, (iv) the male terminal body 104 and the spring member 300 configured such that when the contact arms 180a-180d are in the ready-to-use position P U , the spring member 300 is prevented from being inserted into the receiving portion 105 because the bent or kinked portion 320a-320d of the spring member 300 will contact and engage (e.g., hook on) the free end 190a-190d of the contact arm 180a-180d, (v) the individual spring member 300 with the geometric bend or kinked portion 320a-320d of the spring arm 312a, 312b, (vi) the male terminal assembly 100 with a means for limiting compression 314 of the contact arms 180a-180d that would result in damage to the male terminal assembly 100, (vii) the spring member 300 with two spring arms 312a-312d, wherein the width of one spring arm 312a increases between two points, e.g., along its length, and the width of the second spring arm 312b decreases between two points, e.g., along its length, (viii) the shroud 400 including spring openings 434a, 434b formed in the front shroud segment 430 configured to receive a portion of the extension of the spring member 300, (ix) the shroud 400 including an arrangement of deflection protrusions 418 configured to engage the contact arms 180a-180d, as discussed below. While the foregoing list includes some of the many improvements included in the first embodiment of the connector system 10, it should be understood that other improvements are disclosed herein and that each improvement disclosed herein is not essential or necessary to the construction, operation, or functionality of the disclosed connector system 10. In Figures 64A-74 Other similar embodiments of the connector system 10 are disclosed herein, wherein the other embodiments show alternative constructions of the spring members 1300 and 2300.

[0099] Various aspects of the fourth embodiment of the connector system 3010 are disclosed herein and shown in FIGS. 75 to Figure 100As shown in the figure. Specifically, the connector system 3010 includes: (i) a male connector assembly 3050 and (ii) a female connector assembly 3650. Figures 75A-100 Various views and components of the male connector assembly 3050 are shown. A fourth embodiment of the male connector assembly 3050 primarily includes: (i) a male housing assembly 3070 with structures and components substantially similar to those disclosed above in conjunction with the first embodiment; and (ii) a male terminal assembly 3100 having male terminals 3101, a spring member 3300, and a sheath 3400. This fourth embodiment of the male connector assembly 3050 is configured to interact with the female connector assembly 650 disclosed in the first embodiment of the coupling system 10. This fourth embodiment of the connector system 3010 provides several improvements over conventional connectors. Some of these improvements include: (i) a male terminal body 3104 comprising a base portion 3110 and at least one contact arm 3180a-3180d, the at least one contact arm having portions 3182a-3182d substantially coplanar with the base portion 3110; and (ii) contact arms 3180a-3180d having a unique bending or folding configuration that creates two contact points 3196a-3196d, 3198a with the spring member 3300. -3198d, (iii) a male terminal body 3104 with an anti-rotation protrusion 3114 configured to help prevent the spring member 3300 from rotating within the receiving portion 3105, (iv) a separate spring member 3300 with corrugations formed in at least one of the spring arms 3312a-3312d, (v) a spring member 3300 with a compression limiting device 3314, and (vi) a sheath 3400 including a deflection protrusion 3418. While the foregoing list includes some of the many improvements included in the fourth embodiment of the connector system 3010, it should be understood that other improvements are disclosed herein, and each and every improvement disclosed herein is not required or necessary for the configuration, operation, or functionality of the disclosed connector system 3010. Other similar embodiments of the connector system 3010 are described in... Figures 101-104 The disclosure shows that alternative male terminal connection members 4102 and 5102 are shown in other embodiments.

[0100] Various aspects of the seventh embodiment of the connector system 6010 are disclosed herein and Figures 105-112 As shown in the figure. Specifically, the connector system 6010 includes: (i) a male connector assembly 6050 and (ii) a female connector assembly 6650. Figures 105-112Various views and components of the male connector assembly 6050 are shown. The seventh embodiment of the male connector assembly 6050 primarily includes: (i) a male housing assembly 6070 with substantially similar structure and components as disclosed above in connection with the first embodiment, and (ii) a male terminal assembly 6100 having a male terminal 6101, a spring member 6300, and a boot 6400. This seventh embodiment of the male connector assembly 6050 is configured to interact with the female connector assembly 650 disclosed in connection with the first embodiment of the system 10. This seventh embodiment of the connector system 6010 provides a variety of improvements over conventional connectors. Some of these improvements include: (i) a male terminal body 6104 including a base portion 6110 and at least one contact arm 6180a-6180d with portions 6182a-6182d that are substantially coplanar with the base portion 6110, (ii) the contact arms 6180a-6180d have a unique curved or bent configuration that creates two contact points 6196a-6196d, 6198a-6198d with the spring member 6300, (iii) the male terminal body 6104 with an anti-rotation protrusion 6114 configured to help prevent the spring member 6300 from rotating within the receiving portion 6105, (iv) the boot 6400 including a deflection protrusion 6418. While the foregoing list includes some of the many improvements included in the seventh embodiment of the connector system 6010, it should be understood that other improvements are disclosed herein and that each and every improvement disclosed herein is not essential or necessary to the configuration, operation, or functionality of the disclosed connector system 6010.

[0101] First Embodiment

[0102] 1) Male Connector Assembly

[0103] The male connector assembly 50 includes a plurality of components designed to couple to a separate device or component (e.g., the charging coupler 2, a heat sink fan, a heating seat, a power distribution component, or another current draw component). The male connector assembly 50 primarily includes: (i) a male housing assembly 70, and (ii) a male terminal assembly 100 having a male terminal 101, a spring member 300, and a boot 400, wherein at least a substantial extension of the male terminal assembly 100 is located within the male housing assembly 70 during operation of the connector system 10.

[0104] a. Male Housing Assembly

[0105] Reference Figures 1A-2 , Figures 36-48 and Figures 60-63, the male housing assembly 70 includes: (i) an inner arrangement of side walls 72, (ii) an outer arrangement of side walls 76, (iii) a protrusion 90 with a retaining wall surface, and (iv) a male terminal retaining device 94. The inner arrangement of side walls 72 includes: (i) a plurality of side walls 73a-73d with contact arm openings 76a-76d, and (ii) a front wall 74. The plurality of side walls 73a-73d and the front wall 74 are integrally formed with one another and are arranged to define a terminal receiver 75. The terminal receiver 75 is configured to receive, in the fully coupled state S FC The female terminal assembly 100 is received within the male terminal assembly 100. In this fully coupled state S FC , (i) the contact arm openings 76a-76d receive extensions of the contact arms 180a-180d to enable mechanical and electrical connections between the contact arms and the female terminal body 710, and (ii) the front section 430 of the shroud 400 is positioned adjacent to an inner surface of the front wall 74 of the housing 70. In other words, when the connector assembly 50 is in the fully coupled state S FC , the extensions of the contact arms 180a-180d extend through the contact arm openings 76a-76d.

[0106] The outer arrangement of side walls 76 includes: (i) two opposing side walls 78a, 78b with a plurality of protrusions 80 and recesses 82, (ii) a curved bottom wall 78c extending between the opposing side walls 78a, 78b, and (iii) a deformable top wall 78d with a female receiver opening 84 formed therethrough. Each of the walls 78a-78d is spaced apart from an outer surface of the inner arrangement of side walls 72 by a housing distance D H ( Figure 46 When the system 10 is in the connected state S C ( Figure 61 , the housing distance D H is occupied by extensions of the female connector assembly 650, and more particularly, by extensions of the female housing assembly 670, (ii) the recesses 82 receive protrusions 697 formed in the side walls 672 of the female housing assembly 670, (iii) the protrusions 80 are positioned within recesses 698 formed in the side walls 672 of the female housing assembly 670, and (iv) the female receiver opening 84 receives a coupling protrusion 699.

[0107] Behind the wall plane P W ( Figure 43 , the inner arrangement of side walls 72 and the outer arrangement of side walls 80 merge into a single structure, namely, a connector arrangement of side walls 86. The connector arrangement of side walls 86 is designed to enclose the rear extensions of the male terminal assembly 100 and the wire coupled to the male terminal assembly 100. The male terminal retaining device 94 and the retaining wall surface 90 are positioned behind the wall plane P WThe male terminal assembly 100 is positioned behind and configured to secure it within the housing 70. The retaining wall surface 90 is formed by a protrusion extending inwardly from the inner surface of the connector arrangement on the sidewall 86. The male terminal retaining device 94 includes (i) a retaining body 96 and (ii) a retaining opening 95 formed in a first extension of the connector arrangement on the sidewall 86. The retaining body 96 is U-shaped and designed to be positioned adjacent to the first extension of the connector arrangement on the sidewall 86, and includes fixing protrusions 97a, 97b and retaining protrusions 98a, 98b. The fixing protrusions 97a, 97b are positioned near the ends of the legs forming the U-shape, while the retaining protrusions 98a, 98b extend from an upper transverse member extending between the legs of the U-shape.

[0108] When connector assembly 50 is in a fully connected state S FC At this time: (i) the locking tab 426 of the sheath 400 is positioned in front of the retaining wall surface 90; (ii) the retaining body 96 is positioned adjacent to a first extension of the connector arrangement of the sidewall 86, and the retaining protrusions 97a, 97b are positioned below the opposing second extension of the connector arrangement of the sidewall 86; and (iii) the retaining protrusions 98a, 98b extend into the retaining opening 95 and are positioned behind the male terminal body 104. This structure helps prevent the male terminal assembly 100 from moving rearward while securing the male terminal assembly in the housing 70. In fact, this combination ensures that a force of less than 200 Newtons will not cause the male terminal assembly 100 to move out of the housing 70. The combination of recesses 698, 82 and protrusions 80, 697 forms a system 10 with a keyed configuration, wherein the male connector assembly 50 can only mate with the female connector assembly 650 when the male connector assembly 50 is in a specific orientation relative to the female connector assembly 650.

[0109] The male housing assembly 70 is formed of non-conductive plastic and is designed to protect and isolate the conductive male terminal assembly 100 from accidental contact with foreign objects. In other embodiments, the male terminal retaining device 94 can be replaced by any structure that performs a similar function and is disclosed in any application incorporated herein by reference. Some of these structures may include other types of mechanical / structural members or bodies, magnets, springs, or other types of retaining devices that generate biasing forces on the male terminal assembly 100. In other embodiments, the housing 70 may include: (i) a connector position guarantee (CPA) assembly including readable or scannable markings conforming to USCAR specifications, including USCAR-12, USCAR-25, and USCAR-2; (ii) an EMI shield; (iii) an additional layer of non-conductive and / or conductive material; and / or (iv) a larger coverage area (e.g., charging connector 2) to receive multiple male terminal assemblies 50. Other similar male housing assemblies are disclosed in the application which is incorporated herein by reference, and features of these housing assemblies may be incorporated into the male housing assembly 70 of the male connector assembly 50 disclosed herein.

[0110] b. Male terminal assembly

[0111] Figures 3-51 and Figures 58-63 Various views of the male terminal assembly 100 are provided. Referring to a first embodiment, the male terminal assembly 100 includes a male terminal 101, a spring member 300, and a sheath 400. In addition to these main structural components 101, 300, and 400, the male terminal assembly 100 also includes a compression-limiting device 314. As described below, the compression-limiting device 314 may be formed by the interaction between the main structural components 101, 300, and 400, or may be contained within a single component 101, 300, or 400.

[0112] i. Devices for limiting compression

[0113] Unlike conventional male terminal assemblies, the male terminal assembly 100 disclosed herein includes a means 314 for limiting compression. The means 314 for limiting compression is designed to prevent external force F from... EExcessive deformation or compression of the contact arms 180a-180d and spring arms 316a-316d towards the center of connector 50 is undesirable. This is because deformation or compression can damage the contact arms 180a-180d, spring members 312a-312d, or a combination thereof, thereby damaging, rendering inoperable, and / or unusable the terminal assembly 100. Therefore, the compression-limiting device 314 reduces this potential failure mode of the terminal assembly 100. While reducing this potential failure mode is beneficial, it should be understood that the compression-limiting device 314 should not interfere with the normal or operational deformation of the contact arms 180a-180d and spring members 312a-312d. DC (See Figure 63 Interference. In this embodiment, the device 314 for limiting compression includes two separate combinations of limiting structures 315a and 315b, wherein the first combination of limiting structures 315a protects spring arms 312a and 312c and contact arms 180a and 180c, and the second combination of limiting structures 315b protects spring arms 312b and 312d and contact arms 180b and 180d. Each of these limiting structures 315a and 315b will be discussed in detail below.

[0114] ii. Male terminal

[0115] In particular, Figures 6A-10 , Figures 25-51 and Figures 58-63 The position P, ready for use, is shown. U The male terminal 101, and Figure 3 and Figures 16-17 The image shows the position P in preparation for receiving. R The male terminal. Figure 4 and Figures 5A-5DThe steps for forming the male terminal 101 from a blank of metal (e.g., copper) are shown. Specifically, this process may include multiple (e.g., 53) steps of cutting and / or bending the metal blank. Once these steps have been performed, the male terminal 101 will be formed to include the following structures: a male terminal connecting member 102 and a male terminal body 104. Specifically, the male terminal connecting member 102 is coupled to the male terminal body 104. In this embodiment, the male terminal connecting member 102 is a wire receiver 103, wherein the wire receiver 103 has a U-shaped receiving portion configured to receive an extension of an external structure (e.g., lead wire or cable) of a device (e.g., an alternator) that connects the male terminal assembly 100 to the outside of the connector system 10. The cable is typically soldered to the wire receiver 103; however, this disclosure contemplates other methods of connecting the cable to the wire receiver 103 (e.g., forming the cable as part of the wire receiver 103). In other embodiments, the male terminal connection member 102 may be a blade, a crimping member, or a circuit board connector (see [link to documentation]). Figure 104 (or any other type of connecting member 102 that mechanically and electrically connects the male terminal body 104 to an external device, part, or extension.)

[0116] Figures 3-10 The male terminal body 104 is shown to include a wall structure 106. The side wall structure 106 includes the following integrally formed walls: (i) a top wall 108a extending between S1 and S2, (ii) a first side wall 108b extending between S2 and S3, (iii) a bottom wall 108c extending between S3 and S4, (iii) a second side wall 108d extending between S4 and S5, and (iv) an inner spring wall 108e extending between S5 and S6 (see Figure 7A The combination of sidewalls 108b and 108d, top wall 108a, and bottom wall 108c forms the first reference plane P. B1 Second reference plane P B2 The cubic base or intermediate portion 110 extending between them preferably has a rectangular structure. For example... Figure 7AAs best shown, the base or intermediate portion 110 does not have a continuous perimeter. In other words, the top wall 108a is not directly connected to the second side wall 108d or the inner spring wall 108e. Additionally, the inner spring wall 108e is not directly connected to the other wall 108a-108c. However, in the case including the sheath 400, the construction of the male terminal 101 allows it to expand during operation or use of the system 10. However, in other embodiments, by forming a base or intermediate portion 101 with a continuous perimeter, by directly connecting the top wall 108a to the second side wall 108d or the inner spring wall 108e, or by directly connecting the inner spring wall 108e to the other wall 108a-108c, the potential expansion of the male terminal 101 can be mitigated.

[0117] The aforementioned internal spring wall 108e is positioned within the base or intermediate portion 110 and includes a front surface 112 configured to be positioned adjacent to the rear surface of the spring member 300 (when the spring member is positioned within the male terminal body 104). The front surface 112 of the internal spring wall 108 is not coplanar but has an interleaved configuration. In other words, the internal spring wall 108e includes recesses forming anti-rotation protrusions 114. Figure 31 , Figure 33 As best shown, when the spring member 300 is positioned in the male terminal body 104 (this occurs when the spring member 300 is positioned in the male terminal 101 and is in at least the first part of the assembly state S), 1PA When the anti-rotation protrusion 114 is configured to be positioned within the anti-rotation recess or spring arm gap 310a formed in the spring member 300. It should be understood that the combination of the anti-rotation protrusion 114 and the anti-rotation recess 310a can be replaced by different structures or combinations of structures designed to prevent the spring member 300 from rotating within the male terminal 101, or these structures can be omitted entirely. It should also be understood that the internal spring wall 108e can be replaced by different structures or combinations of structures designed to ensure that the spring member 300 is properly arranged (e.g., not pushed backward) within the male terminal 101, or this structure can be omitted entirely.

[0118] Side walls 108b, 108d, top wall 108a, and bottom wall 108c each include a portion extending from the second reference plane P. B2The following forward-extending structures / anti-structures include: (i) at least one contact arm 180a-180d with two main portions 182a-182d and 178a-178d, and preferably multiple contact arms 180a-180d; (ii) support ribs 116a-116c; and (iii) contact arm gaps or voids 120a-120g, positioned between the contact arms 180a-180d and adjacent support ribs 116a-116c, or adjacent contact arms 180a, 180d, wherein the total length of the support ribs 116a-116c is less than the total length of the contact arms 180a-180d. This configuration creates multiple structures / anti-structures within the sidewalls 108b, 108d, top wall 108a, and bottom wall 108c, wherein the structures / anti-structures may comprise seven different structures / anti-structures integrally formed with each other (i.e., not separate). For example, the bottom wall 108c includes: (i) a geometrically curved or bent portion 178c, (ii) a first, rear or linear extension 182c of the contact arm 180c, (iii) a portion of the second support rib 116b, (iv) a portion of the third support rib 116c, (v) a fourth contact arm gap or void 120d, (vi) a fifth contact arm gap or void 120e, and (vii) an extension of the base or intermediate portion 110.

[0119] Contact arm gaps 120a-120g are formed in walls 108a-108d and define contact arms 180a-180d and support ribs 116a-116c. For example, a second contact arm gap 120b is located between the first support rib 116a and the second contact arm 180b, while a third contact arm gap 120c is located between the second contact arm 180b and the second support rib 116b. The male terminal body 104 includes only three support ribs 116-116c. In other words, the male terminal body 104 does not have support ribs positioned adjacent to the top wall 108a and the second side wall 108d. Due to the construction / formation of the internal spring wall 108e, the body 104 does not have this support rib. The support ribs 116a-116c include three segments, namely a first linear segment, a curved segment, and a second linear segment. The first linear segment and the second linear segment are substantially coplanar with the associated walls 108a-108d. This construction allows the support ribs 116a-116c to extend around the corner of the male terminal body 104.

[0120] Support ribs 116a-116c from base portion 100 (second reference plane P) B2The support ribs 116a-116c extend along the first or rear extension 182a-182d of the contact arms 180a-180d, but not along the geometric bends or folds 178c of the contact arms 180a-180d. In other words, the distal ends 118a-118c of the support ribs 116a-116c are not located on the bending plane P corresponding to the bend 178c. B The distal ends 118a-118c of the support ribs 116a-116c are not connected to each other or to any other structure, as shown in the figure. Therefore, the length of the support ribs 116a-116c is determined by balancing the following: (i) if the support ribs are too long, they will not provide sufficient support for the contact arms 180a-180d and / or the sheath 400 at or near the distal ends 118a-118c of the support ribs 116a-116c; and (ii) if the support ribs are too short, they will not provide sufficient support for the contact arms 180a-180d and / or the sheath 400. However, in other embodiments, the support ribs 116a-116c may be lengthened to extend along the entire contact arms 180a-180d, or shortened to extend only along a portion of the first or rear extension 182a-182d of the contact arms 180a-180d, or additional support ribs may be added between the contact arms 180c and 180d, or they may be omitted entirely.

[0121] like Figures 6A-10 As best shown, contact arms 180a-180d are formed in the outer peripheral walls 108a-108d and extend from the base or intermediate portion 110 of the male terminal body 104. As illustrated, multiple contact arms 180a-180d are not formed in a single wall 108a-108d. In other words, there is a one-to-one relationship between the number of outer peripheral walls 108a-108d and the number of contact arms 180a-180d. This one-to-one spacing allows the contact arms 180a-180d to be spaced apart from each other along the periphery of the base portion 110, helping to ensure that other structures of the male terminal assembly 100 do not interfere with each other during use or operation of the system 10. However, in other embodiments, each of the walls 108a-108d may include multiple (e.g., 2 to 50) contact arms 180a-180d. As described above, support ribs 116a-116c are positioned in the space between the majority of the contact arms 180a-180c. The combination of support ribs 116a-116c and contact arms 180a-180c forms a spring receiver 105, the spring receiver being configured in at least a first part of the assembled state S. 1PA The middle receives the spring component 300.

[0122] For details, please refer to the following: Figure 6A , Figure 8 and Figure 10The contact arms 180a-180d have initial or rear extensions 182a-182d extending from the base or intermediate portion 110 (line C1) and geometrically bent or folded portions 178a-178d. The geometrically bent or folded portions 178a-178d include: (i) a second or upwardly inclined extension 184a-184d extending between the initial extensions 182a-182d (line C2) and the outer contact arm apexes 186a-186d (line C3) of the contact arms 180a-180d; and (ii) a third or downwardly inclined extension 188a-188d extending downward from the outer apexes 186a-186d (line C3) to the foremost extension providing the free ends 190a-190d. The geometric bend or folded portion 178a-178d of contact arm 180a-180d is superior to Figure 69 of PCT / US2019 / 036010. Figure 96 The contact arm design shown helps to reduce: (i) the insertion force due to the angled contact arm design (as opposed to the circular contact arm design), and (ii) the potential bending or breakage of the contact arms 180a-180d when the insertion of the male terminal assembly 100 is not directly in line with the female terminal assembly 700.

[0123] Unlike conventional connectors, the disclosed contact arms 180a-180d have elongated first or rear extensions 182a-182d that extend away from the base portion 110 at an angle that is not uniformly outward or substantially uniformly outward. In other words, as Figure 6A and Figure 10 As best shown, the outer surfaces 183a-183d of the first or rear extensions 182a-182d of each contact arm 180a-180d are: (i) substantially parallel to each other, and (ii) substantially aligned with the outer surface 111 of the corresponding extension of the base portion 110. Compared to conventional connectors without these elongated first or rear extensions 182a-182d, less force is required to deform or displace the contact arms 180a-180d inward or toward the center of the male terminal 101. This reduced force allows for an increase in the force required to displace the extension of the spring member 300 inward. It is advantageous to transfer the structure preventing inward displacement from the contact arms 180a-180d to the spring arms 312a-312d because the insertion force F I This can be easily modified by changing the design and / or material composition of the spring member 300 without redesigning the terminal body 104. For example, the designer can insert a stiffer spring member 300 to maintain / maximize the current carrying capacity of the system 10. Or, if a target insertion force F is set... IFor specific customer requirements, the designer can select a spring member 300 that meets those requirements without having to perform an expensive and time-consuming redesign of the male terminal body 104. This modularity and flexibility of the connector system 10 is a substantial improvement over existing technology because it reduces the number of product SKUs, increases the ability to meet customer requirements without reprocessing or redesigning the connector, and / or limits the testing and other steps required to use new / different connectors. It should be understood that the length of the first or rear extensions 182a-182d will substantially change the insertion force F required to insert the male terminal assembly 100 into the female terminal assembly 700. I Furthermore, in other embodiments, contact arms 180a-180d may extend away from base 110 at a uniform inward angle or a substantially uniform inward tilt angle. The inward tilt angle allows the male terminal assembly 100 to have an inwardly tapered design or configuration. In this alternative embodiment, the inwardly tapered design or configuration may be configured such that the outer diameter at line C2 may be 0.01% to 5% smaller than the outer diameter at line C1.

[0124] like Figure 10 As shown, the second or upwardly inclined extensions 184a-184d are positioned at an outward angle α with the laterally directed first or rearward extensions 182a-182d, wherein the angle α extends between the outer surfaces 183a-183d of the first or rearward extensions 182a-182d of the contact arms 180a-180d and the outer surfaces 185a-185d of the second or upwardly inclined extensions 184a-184d of the contact arms 180a-180d. The outward angle α is between 115 degrees and 170 degrees, preferably between 125 degrees and 145 degrees. In front of the second or upwardly inclined extensions 184a-184d, the contact arms 180a-180d have a third or downwardly inclined extension 188a-188d, which extends downward from the outer apex 186a-186d to the free end 190a-190d. An external angle θ is defined between the outer surfaces 185a-185d of the second or upwardly inclined extensions 184a-184d and the outer surfaces or contact surfaces 189a-189d of the third or downwardly inclined extensions 188a-188d. The external angle θ is between 240 degrees and 300 degrees, preferably between 255 degrees and 285 degrees. Similar to the preceding discussion, the other terminals, the disclosure of which is incorporated herein, do not have this configuration of sharp upwardly angled sections and sharp downwardly angled sections.

[0125] As discussed in more detail below, the third or downwardly inclined extensions 188a-188d, specifically contact surfaces 189a-189d, are configured to contact the extension of the female connector assembly 650 when the male terminal assembly 100 is inserted into the female terminal assembly 700. This interaction between these components causes the contact arms 180a-180d to deflect or shift inward toward the center of the male terminal assembly 100 and the spring member 700. This inward deflection of the contact arms 180a-180d causes the spring member 700 to act as a wedge to help ensure a proper mechanical and electrical connection is established between the contact arms 180a-180d and the female receiver 702.

[0126] like Figure 7BAs shown, at least a portion of the outer edge or shoulder regions 200a, 200b of the contact arms 180a-180d is pressed, beveled, or rounded 201a, 201b. The pressed, beveled, or rounded segments 201a, 201b of the outer edges 200a-200b may: (i) extend along the entire length of the contact arms 180a-180d, (ii) extend along the entire length of the second and third extensions 184a-184d, 188a-188d of the contact arms 180a-180d, and (iii) extend along a portion (e.g., half the length) of the second extension 184a-184d and a portion (e.g., half the length) of the third extension 188a-188d of the contact arms 180a-180d. Without forming pressed, beveled, or rounded sections 201a, 201b, the edges 200a, 200b of the contact arms 180a-180d can contact the inner surface 704 of the female terminal assembly 700. Due to the relationship between the linear and curved constructions of the contact arms 180a-180d and the female terminal assembly 700, adequate contact between the center of the contact arms 180a-180d and the female terminal assembly 700 can be prevented. Preventing proper contact between the center of the contact arms 180a-180d and the female terminal assembly 700 may reduce the current carrying capacity of the system 10. Furthermore, omitting the pressed, beveled, or rounded sections 201a, 201b may leave sharp edges on the contact arms 180a-180d, potentially causing the contact arms 180a-180d to be scratched or marked on the inner surface 704 of the female terminal assembly 700. Scoring reduces the number of mating cycles that system 10 can achieve without failure because it can scratch or damage the internal plating and / or surface 704 of the female terminal assembly 700. In other embodiments, the outer edges or shoulder regions 200a, 200b of the contact arms 180a-180d may not be pressed, beveled, or rounded; instead, the contact arms 180a-180d may be bent or material may be deposited on the contact arms 180a-180d to allow the outer surfaces of the contact arms 180a-180d to substantially match the curvature of the inner surface 704 of the female terminal assembly 700.

[0127] like Figures 6A-10As shown, contact arms 180a-180d are connected only to the base portion 110 of the male terminal body 104. This free-end configuration of contact arms 180a-180d allows for omnidirectional expansion of the contact arms 180a-180d. Because contact arm openings or gaps 120a-120g are distributed between each pair of contact arms 180a-180d, no support wall surrounds the entire contact arm 180a-180d. This configuration of the male terminal assembly 100 is substantially different from the configuration disclosed in PCT / US2019 / 36010. As discussed in PCT / US2019 / 36010, removing the sidewall structure surrounding the contact arms 180a-180d can increase the failure rate of the male terminal assembly 100 because the sidewall structure protects the contact arms 180a-180d. However, this increased failure rate is mitigated by including a sheath 400.

[0128] The male terminal 101 is typically formed from a single piece of material (e.g., metal); therefore, the male terminal 101 is a one-piece male terminal 101 and has integrally formed characteristics. To integrally form these features, the male terminal 101 is typically formed using a die-cutting process. However, it should be understood that other types of processes can be used to form the male terminal 101, such as casting or using additive manufacturing processes (e.g., 3D printing). In other embodiments, the features of the male terminal 101 may not be formed from a single piece or integrally, but rather from individual pieces welded together. When forming the male terminal 101, it should be understood that any number (e.g., between 1 and 100) of contact arms 180a-180d can be formed within the male terminal 101. The male terminal 101, the male terminal body 104, the contact arms 180a-180d, or extensions of the contact arms 180a-180d may be plated or coated with a second material (e.g., nickel) to help reduce corrosion, decrease insertion force, or improve conductivity. Additionally, contact arms 180a-180d or a portion thereof may have rounded or beveled edges.

[0129] iii. Spring components

[0130] Figure 11 and Figures 12A-12BThe steps for forming a spring member 300 from a metal blank (e.g., spring steel, stainless steel) are shown. Specifically, this process may include multiple (e.g., 17) steps of cutting and / or bending the metal blank. Once these steps have been performed, the spring member 300 will be formed as an arrangement including spring member sidewalls 304a-304d and a rear spring wall 306. Each spring member sidewall 304a-304d includes: (i) a first or curved spring segment 308a-308d extending from the rear wall 306 (line S1) to an initial or linear base extension 316a-316d (line S2), and (ii) spring arms 312a-312d extending forward from the first or curved spring segment 308a-308d (line S2) to free ends 330a-330d. Spring arms 312a-312d extend from the first or curved spring section 308a-308d of the spring member 300, away from the rear spring wall 306, and terminate at the front end or free end 330a-330d. Spring arms 312a-312d are not connected to each other and are separated by spring arm gaps 310a-310d. Thus, spring arm gaps 310a-310d are distributed among the spring arms 312a-312d. Spring arm gaps 310a-310d facilitate the omnidirectional expansion or contraction of the spring arms 312a-312d, which facilitates the mechanical connection between the male terminal 101 and the female terminal assembly 700.

[0131] Unlike conventional spring components, the spring component 300 disclosed herein includes spring arms 312a-312d with a geometry substantially matching that of the associated contact arms 180a-180d. In other words, the spring arms 312a-312d include geometrically bent or bent portions 320a-320d that substantially match the geometrically bent or bent portions 178a-178d of the contact arms 180a-180d. In addition to the geometrically bent or bent portions 320a-320d, the spring component 300 is unique because it includes: (i) a first pair or main pair of spring arms, including a top, main, or first spring arm 312a and a bottom or third spring arm 312c; and (ii) a second pair or auxiliary pair of spring arms, including a first side spring arm, an auxiliary spring arm, or a second spring arm 312b, and a second side spring arm or a fourth spring arm 312d. The top spring arm 312a and the bottom spring arm 312c are substantially mirror images of each other, and the first side spring arm 312b and the second side spring arm 312d are also substantially mirror images of each other. Furthermore, the geometry of the spring arms included in the first pair of spring arms (top spring arm 312a and bottom spring arm 312c) does not match the geometry of the spring arms included in the second pair of spring arms (side spring arms 312b, 312d).

[0132] The top spring arm 312a and the bottom spring arm 312c include: (i) initial or linear base extensions 316a, 316c extending from the first or curved spring section 308a, 308c (line S2) to the second or upwardly inclined extensions 322a, 322c (line S3), and (ii) geometrically curved or bent portions 320a, 320c extending forward from the initial or linear extensions 316a, 316c (line S3). The geometrically curved or bent portions 320a, 320c include: (i) a second or upwardly inclined extension 322a, 322c extending between the initial extension 316a, 316c (line S3) and the outer apexes 324a, 324c (line S4) of the spring arms 312a, 312c; (ii) a third or downwardly inclined extension 326a, 326c extending downward from the outer apexes 324a, 324c (line S4) to the overcompression extension 328a, 328c (line S5); and (iii) an overcompression extension 328a, 328c extending between the third or downwardly inclined extension 326a, 326c (line S5) and the foremost extension providing the front end 330a, 330c. The geometrically bent or folded portions 320a and 320c of the spring arms 312a and 312c are configured to complement the geometrically bent or folded portions 178a and 178c of the contact arms 180a and 180c.

[0133] like Figures 13A-15 As shown, the top spring arm 312a and the bottom spring arm 312c have: (i) a first spring arm width W 1SA (ii) the width of the transition spring arm, and (iii) the width of the second spring arm W, extending between the edges 336a and 336b of the linear extension. 2SA Extending between the contact surface edges 338a and 338b, and (iv) excessive compression or the width W of the third spring arm. 3SA Extending between the excessive compression edges 340a and 340b. The curved spring sections 308a and 308c and the linear extensions 316a and 316c of the spring member 300 have a first spring arm width W. 1SA The downwardly inclined extensions 326a and 326c of the spring member 300 have a second spring arm width W. 2SA Furthermore, the excessively compressed extensions 328a and 328c have a third spring arm width W. 3SA The upwardly inclined extensions 322a and 322c of the spring member 300 have a transition width that changes from the width W of the first spring arm when moving from line S3 to line S4. 1SA Change to the width W of the second spring arm 2SA .

[0134] This construction allows most of the bent portions 320a, 320c to have a width substantially matching the width of the bent portions 178a, 178c. It is advantageous to match the widths of the spring arms 312a, 312c and the contact arms 180a, 180c at the point where the male terminal assembly 100 is configured to contact the female terminal assembly 700, as this limits the required width of the contact arm openings 414, 470 formed in the sheath 400 and the male terminal housing 70. Furthermore, including additional material in the spring member 300 at a substantially rearward location of the bent portions 178a, 178c of the contact arms 180a, 180c allows the designer to increase the force required to deform the spring arms 312a, 312c compared to a spring member without this additional material. However, it should be understood that in other embodiments, the width of the spring arms 312a, 312c may be constant along the entire length of the arms 312a, 312c, having only two different widths, or may have more than the number of widths disclosed.

[0135] The side spring arms 312b, 312d include: (i) an initial or linear extension 316b, 316d extending from the first or curved spring section 308b, 308d (line S2) to a second or upwardly inclined extension 322b, 322d (line S3), and (ii) a geometrically curved or bent portion 320b, 320d extending forward from the initial or linear extension 316b, 316d (line S3). The geometrically curved or bent portions 320b, 320d include: (i) a second or upwardly inclined extension 322b, 322d extending between the initial extension 316b, 316d (line S3) and the outer apex 324b, 324d (line S4) of the spring arms 312b, 312d; (ii) a third or downwardly inclined extension 326b, 326d extending downward from the outer apex 324b, 324d (line S4) to a fourth extension, sheath extension or sheath protrusion extension 329b, 329d (line S6); and (iii) a sheath extension 329b, 329d extending forward from the third or downwardly inclined extension 326b, 326d (line S6) to the free end 330b, 330d. The geometrically bent or folded portions 320b and 320d of the spring arms 312b and 312d are configured to complement the geometrically bent or folded portions 178b and 178d of the contact arms 180b and 180d.

[0136] like Figures 13A-15 As shown, the side spring arms 312b and 312d have: (i) a fourth spring arm width W 4SA Extending between the edges 332a and 322b of the linear extension, (ii) the width of the transition spring arm, and (iii) the width W of the fifth spring arm. 5SAIt extends between the forward spring arm edges 334a and 324b. The curved spring sections 308b and 308d and the linear extensions 316b and 316d of the spring member 300 have a fourth spring arm width W. 4SA The downwardly inclined extensions 326b and 326d of the spring member 300 and the sheath extensions 329b and 329d have a fifth spring arm width W. 5SA The upwardly inclined extensions 322b and 322d of the spring member 300 have a transition width that, when moving from line S3 to line S4, extends from the width W of the fourth spring arm. 4SA Change to the width W of the fifth spring arm 5SA This configuration is advantageous for the same reasons discussed above regarding the combination of the top spring arm 312a and the bottom spring arm 312c.

[0137] Unlike conventional springs, the disclosed spring member includes three spring arms 312a-312d with unique or different widths. In this embodiment, the spring member 300 includes two spring arms 312a and 312b, wherein the width of one spring arm 312a increases along its length between two points (e.g., 336a-336b, 340a-340b), and the width of the second spring arm 312b decreases along its length between two points (e.g., 332a-332b, 334a-334b). Additionally, the spring member 300 has: (i) a first spring arm width W 1SA and the width W of the fourth spring arm 4SA They are equal, (ii) the width W of the second spring arm. 2SA and the width W of the fifth spring arm 5SA They are equal, (iii) the width W of the first spring arm. 1SA and the width W of the fourth spring arm 4SA Greater than the width W of the second spring arm 2SA and the width W of the fifth spring arm 5SA And (iii) the width W of the third spring arm 3SA Greater than the width W of the first spring arm 1SA The width W of the second spring arm 2SA The width W of the fourth spring arm 4SA and the width W of the fifth spring arm 5SA In other words, the width of the curved spring sections 308a-308d and the width of the linear extensions 316a-316d of the spring member 300 are substantially equal, the width of the downwardly inclined extensions 326a-326d are substantially equal, and the width of the excessively compressed extensions 328a and 328c is not equal to (i.e., greater than) the width of the sheath extensions 329b and 329d.

[0138] Unlike conventional spring members, spring member 300 includes a first portion of a compression-limiting device 314. The first portion of the compression-limiting device 314 is a first assembly of a limiting structure 315a, which includes: (i) overcompression extensions 328a, 328c, and (ii) edges of adjacent side spring arms 312b, 312d. The overcompression extensions 328a, 328c have opposing flanges extending outward and laterally from downwardly inclined extensions 326a, 326c, and define an overcompression spring arm width W greater than the widths of the other spring arms (e.g., the first, second, fourth, and fifth). 3SA In fact, excessive compression of the width W 3SA The inner surface width W extending between the inner surfaces 342a of the sheath extensions 329b and 329d of the side spring arms 312b and 312d is greater than that of the side spring arms 312b and 312d. IS Thus, the outer edges 340a and 340b of the overcompression extensions 328a and 328c are positioned outside or beyond the inner surface 342a of the side spring arms 312b and 312d. Additionally, the outer edges 340a and 340b of the overcompression extensions 328a and 328c are positioned outside or beyond the inner surface 346 of the linear extensions 316b and 316d of the side spring arms 312b and 312d. Because the front ends 330a and 330c contact the forward spring arm edges 334a and 334b ​​of the side spring arms 312b and 312d, the external force F... E The application of force to contact arms 180a and 180c will only cause contact arms 180a and 180c to deform to the maximum compression distance D. MC In this embodiment, the maximum compression distance D MC The diameter is less than 1.25 mm, preferably less than 1.0 mm, and most preferably 0.5 mm. This limits the contact arms 180a and 180c from deforming or being compressed to the maximum compression distance D. MC The degree of protection prevents contact arms 180a, 180c, spring arms 312a, 312c, and combinations thereof from being excessively deformed or compressed (e.g., greater than the maximum compression distance D) toward the center of connector 50. MC (distance). Simultaneously, the first combination of limiting structures 315a provides this beneficial feature; it should be understood that structure 315a ensures that it does not interfere with the normal or operational deformation of contact arms 312a, 312c and spring members 312a, 312c (see...). Figure 63 Constructed in the manner of ). Specifically, the normal or operational deformation distance D NC (See Figure 63 (Comparison with maximum compression distance D) MC The deformation distance D is at least 5%, preferably 20%, smaller than the normal or operational deformation distance. NCLess than 1.20 mm, preferably less than 0.95 mm, and most preferably 0.4 mm. In other words, system 10 is within the range of the maximum compression distance D. MC The compression distance at which failure occurs is the maximum compression distance D. MC Greater than system 10 when system 10 is in connected state S CN The normal or operational deformation distance D experienced during operation NC .

[0139] like Figure 15As shown, the curved spring arm portion 320a includes a second or upwardly inclined extension 322a-322d extending laterally from a first or rearward extension 316a-316d at an outward angle γ. Specifically, the angle γ extends between the outer surfaces 313a-313d of the first or rearward extension 316a-316d and the outer surfaces 323a-323d of the second or upwardly inclined extension 322a-322d. The outward angle γ is an obtuse angle, between 115 degrees and 170 degrees, preferably between 125 degrees and 145 degrees. An external angle δ is defined between the outer surfaces 323a-323d of the second or upwardly inclined extensions 322a-322d of the spring arms 312a-312d and the outer surfaces 327a-327d of the third or downwardly inclined extensions 326a-326d of the spring arms 312a-312d. The external angle δ is an anomalous angle, between 240 degrees and 300 degrees, preferably between 255 degrees and 285 degrees. An internal angle ω, complementary to the external angle δ, is defined between the inner surfaces of the second or upwardly inclined extensions 322a-322d of the spring arms 312a-312d and the inner surfaces of the third or downwardly inclined extensions 326a-326d of the spring arms 312a-312d. The internal angle ω is between 60 degrees and 120 degrees, preferably between 75 degrees and 105 degrees, and most preferably 80 degrees. In other words, the interior angle ω is a “clearly acute angle,” meaning that the angle is greater than 70 degrees but less than 90 degrees. Similar to existing discussions of conventional connectors, including those with conventional terminals and / or conventional spring members, the disclosures herein are incorporated, without this construction of sharp upward-angled segments and sharp downward-angled segments, and corresponding to the combined vertex of the exterior angle δ and the interior angle ω. Furthermore, unlike conventional spring members, the side spring arms 312b, 312d include protruding sheath extensions 329b, 329d of the spring member 300, having an inner surface 342b positioned: (i) on the outer side of the outer periphery of the rear wall 306, and (ii) on the inner side of the inner surface 346 of the linear extensions 316b, 316d of the spring arms 312b, 312d. As shown in the figure, the inner surfaces of the upwardly inclined extensions 322b, 322d and the downwardly inclined extensions 326b, 326d are positioned outside the inner surface 346 of the linear extensions 316b, 316d, so that the inner surface 342b of the protruding sheath extensions 329b, 329d is positioned inside these inner surfaces.

[0140] Spring member 300 is typically formed from a single piece of material (e.g., metal); therefore, spring member 300 has a single-piece structure with integrally formed components. Specifically, the following features are integrally formed: (i) the curved spring sections 308a-308d, and (ii) the spring arms 312a-312d. To integrally form these features, spring member 300 is typically manufactured using a die-forming process that mechanically forces spring member 300 into shape. As discussed in more detail below and in PCT / US2019 / 036010, when spring member 300 is made from a metal plate (e.g., metal... Figures 11-12B (as shown) is formed and installed in the male terminal 101 (as shown) Figures 16-18 As shown), and when subjected to elevated temperatures, the spring member 300 applies an outward-pointing spring thermal force F to the contact arms 180a-180d of the male terminal 101. ST This is partly due to the fact that the spring member 300 attempts to return to the flat plate. However, it should be understood that other methods of forming the spring member 300 can be utilized, such as casting or using additive manufacturing processes (e.g., 3D printing). In other embodiments, the features of the spring member 300 may not be formed from a single piece or integrally, but rather from individual pieces welded together.

[0141] 1. From disassembled state to partially assembled state

[0142] Positioning the spring member 300 within the male terminal 101 occurs through multiple steps or stages (see...). Figures 16-18 ). Figure 16 A spring member 300 separated from the male terminal 101 is shown, wherein the spring member 300 and the male terminal 101 are in a disassembled state. DA In this disassembled state S DA In the middle, contact arms 180a-180d are in the ready-to-receive position P. R At this receiving location P R The receiver 105 has a first front dimension D extending between the relatively free ends 190a and 190c of the contact arms 180a and 180c. 1F The external angle formed between the outer surface 111 of the male terminal body 104 and the linear extensions 182a-182d of the contact arms 180a-180d is between 90 degrees and 181 degrees (preferably between 150 degrees and 170 degrees). The assembler applies a rearward assembly force F to the spring member 300. A This is done to position the spring member 300 within the receiving portion 105 of the male terminal body 104. When positioning the spring member 300 in the receiving portion 105, the assembler must align the spring 300 with the body 104 so that the anti-rotation protrusion 114 can be inserted into the spring arm gap 310a, as shown. Figure 33As shown. Once the assembler has applied sufficient force F to spring 300... A With the rear wall 306 of the spring 300 positioned adjacent to the inner spring wall 108e, the spring member 300 and the male terminal 101 are already in the disassembled state. DA Move to the first assembly state S 1PA .

[0143] Part 1 Assembly State S 1PA exist Figure 17 As shown, the spring member 300 is positioned in the receiving portion 105 of the male terminal 101, but the contact arms 180a-180d are not positioned adjacent to the spring arms 312a-312d. To move to the next assembly stage, the assembler applies a downward contact arm force F to all contact arms 180a-180d. CA This positions arms 180a-180d adjacent to spring arms 312a-312d. The contact arm force F... CA The application of force causes contact arms 180a-180d to move from the ready-to-receive position P. R Move to the ready-to-use position P U Here we prepare to use position P. U In the middle, the receiver 105 has a second front dimension D extending between the relatively free ends 190a and 190c of the contact arms 180a and 180c. 2F And the second front dimension D 2F Smaller than the first front dimension D 1F Additionally, at position P, preparation for use U In this context, the external angle formed between the outer surface 111 of the male terminal body 104 and the linear extensions 182a-182d of the contact arms 180a-180d is approximately 170-190 degrees, preferably 180 degrees. The position of the spring member 300 and the contact arms 180a-180d are aligned with this ready-to-use position P. U The movement allows the spring member 300 and the male terminal 101 to move from the first part assembly state S 1PA Move to the second assembly state S 2PA In this second part of the assembly state S 2PA In the middle, the spring member 300 is positioned and held in the receiving part 105, and is ready for the next assembly stage. It should be understood that when the contact arms 180a-180d are in the ready-to-use position P U At this time, the spring member 300 should not be inserted into the receiving part 105 because the geometrically bent or folded portions 320a-320d of the spring member 300 will contact and engage the free ends 190a-190d of the contact arms 180a-180d. In other words, the spring member 300 has an external dimension D extending between the outer vertices 324a-324d of the opposing spring arms.E Furthermore, the external dimension D of the spring member 300 is... E Larger than the second front dimension D 2F This prevents the spring member 300 from being inserted into the receiving part 105 without causing the contact arms 180a-180d to deform outward. Thus, when the contact arms 180a-180d are in the ready-to-receive position P... R When assembling, the assembler should only attempt to insert the spring member 300 into the receiving part 105 of the male terminal body 104.

[0144] Once the male terminal 101 and the spring member 300 are in the second assembly state S 2PA Then, other unique features of this system 10 can be seen. For example, the free ends 190a-190d of the contact arms 180a-180d do not abut against the planar outer surfaces 313a-313d of the spring arms 312a-312d. Instead, the entire contact arms 180a-180d are supported by the spring arms 312a-312d, so that the system 10 does not have a significant gap formed between the outer surfaces 313a-313d of the spring arms 312a-312d and the inner surfaces of the contact arms 180a-180d. Omitting the gap between these structures and positioning the spring arms 312a-312d in this way allows most of the outer surfaces 2313a-2313d of the spring arms 312a-312d to be located below and abut against the inner surfaces of the contact arms 180a-180d. It should be understood that, since the male terminal body 104 is in the ready-to-receive position P R and prepare to use location P U The manufacturing capabilities and constraints resulting from the movement of the spring arms 312a-312d allow for the formation of minute / non-substantial gaps between the outer surfaces 313a-313d of the spring arms 312a-312d and the inner surfaces of the contact arms 180a-180d. This positional arrangement allows the disclosed system 10 to apply a spring biasing force F in the fourth, fifth, sixth, and seventh embodiments of the systems 3010, 4010, 5010, and 6010 disclosed herein. SB Applying spring bias force F in different ways SB Specifically, in these other embodiments of systems 3010, 4010, 5010, and 6010, spring members 3300, 4300, 5300, and 6300 apply a spring biasing force F in one (or possibly two) positions and in a direction substantially perpendicular to most of the outer surface of the spring member 300. SB Conversely, the disclosed spring member 300 does not: (i) apply a spring biasing force F in one (or possibly two) positions. SB Or (ii) apply a spring biasing force F in a direction substantially perpendicular to most of the outer surface of the spring member 300. SB .

[0145] iv. Sheath

[0146] Figure 19 and Figures 20A-20B The steps that can be employed to form the sheath 400 from a metal blank (e.g., spring steel, stainless steel) are shown. Specifically, this process may include multiple (e.g., 30) steps of cutting and / or bending the metal blank. Once these steps are performed, the sheath 400 will be formed with a clamshell construction designed to: (i) retain the spring member 300 in the receiver 105, and (ii) increase the durability of the terminal assembly 100. The clamshell construction of the sheath 400 is provided by connecting the front section 430 to the upper section 402 and the lower section 460 via a hinge. The hinge allows the sheath 400 to be formed in a ready-to-receive position P. R Then deform to the ready-to-use position P U As described below.

[0147] The sheath 400 is configured to surround most of the male terminal body 104 and provides an arrangement of contact arm deflection protrusions 418. The upper section 402 and lower section 460 of the sheath 400 each include wall structures 404, 462 with U-shaped configurations. Specifically, the wall structure 404 of the upper section 402 includes: (i) a top wall 406, and (ii) opposing side walls 408a, 408b. The opposing side walls 408a, 408b include: (i) a plurality of fixing features 410 designed to secure the sheath 400 to the male terminal body 102, (ii) at least one contact arm deflection protrusion 420 configured to protect the front and / or rear extensions of the contact arms 180a, 180b, 180d, (iii) contact arm recesses 424, and (iv) opposing locking tabs 426. In this embodiment, the fixing feature 410 includes a plurality of recesses 412a-412d with internal vertices 413a-413d configured to contact the sidewalls of the male terminal body 104. The contact between the upper segment 402 and the sidewalls of the male terminal body 104 ensures a proper electrical connection is formed between the sheath 400 and the male terminal body 104, thereby preventing arcing that could occur due to intermediate connections. In other embodiments, the plurality of recesses 412a-412d can be replaced by another means designed to secure the sheath 400 to the body 104 and prevent possible arcing. This means may include welding or forming the sheath as part of the male terminal body 102. The locking tab 426 is formed by an extension of the sidewalls 408a, 408b and is part of the male terminal retaining device 94. As described above, the locking tab 426 is configured to engage when the male connector assembly 50 is in the connected state S. CThe contact arm recess 424 is positioned in front of the retaining wall surface 90 of the male housing assembly 70. The contact arm recess 424 extends upward from the lower edges of the opposing sidewalls 408a, 408b and is designed to ensure that the sheath 400 does not interfere with the operation or assembly of the male terminal 100. A deflection protrusion 420 is adjacent to the contact arm recess 424, wherein the protrusion 420 is positioned between the recess 424 and the rear extension of the male terminal 101.

[0148] The top wall 406 extends between opposing side walls 408a, 408b and includes: (i) a fixing feature 410, (ii) a contact arm opening 414, and (iii) a plurality of deflection protrusions 420. The contact arm opening 414 is configured to be in the assembled state when the male terminal assembly is in the assembled state. A The contact arms 180a-180d are received at the same time. Deflection protrusions 420 are provided at the front and rear of the contact arm opening 414. The deflection protrusions 420 extend outward from the sheath 400 (more specifically, the top wall 406) at an outward angle and have an upper edge positioned below the apexes 186a-186d of the associated contact arms 180a-180d. The deflection protrusions 420 are designed to: (i) help protect the contact arms 180a-180d from external impact forces F that could damage the contact arms 180a, 180b, 180d. IEThe implementation includes (i) the influence of the contact arms 180a-180d, and (ii) ensuring that it does not interfere with the movement of the contact arms 180a-180d during operation of the connector system 10. This embodiment includes: (i) a first deflection protrusion 420 positioned (a) adjacent to the contact arm opening 414, and (b) between the front edge of the contact arm opening 414 and the front portion 430 of the sheath 400; and (ii) a second deflection protrusion 420 positioned (i) adjacent to the contact arm opening 414, and (ii) between the rear edge of the contact arm opening 414 and the rear extension of the sheath 400. The angle between the outer surface of the top wall 406 of the sheath 400 and the outer surface of the first deflection protrusion 420 is approximately equal to the angle formed between a plane parallel to the top wall 108a of the male terminal body 104 and the third or downwardly inclined extensions 188a-188d of the contact arms 180a-180d. The angle between the outer surface of the top wall 406 of the sheath 400 and the outer surface of the second deflection protrusion 420 is approximately equal to the angle formed between a plane parallel to the top wall 108a of the male terminal body 104 and the second or upwardly inclined extensions 184a-184d of the contact arms 180a-180d. It should be understood that in other embodiments, the deflection protrusion 420 may be formed in the male terminal housing 70, may be omitted, its length may be increased or decreased, or may include peripheral supports designed to support the outer edge of the deflection protrusion 420. In addition to these features, the fixing features 410 formed in the top wall 106 include: (i) an additional or top wall recess 412e, and (ii) a rear retaining tab 416 designed to wrap around the extensions of the male terminal body 104 to secure the sheath 400 to the body 104 (see [link to relevant documentation]). Figure 28 , Figure 29A ).

[0149] The front section 430 of the sheath 400 includes: (i) a front wall 432 with spring arm openings 434a, 434b formed therethrough, and (ii) a contact arm deflection protrusion 440 configured to protect the front extensions of the contact arms 180b, 180d. As will be described in more detail below, the spring arm openings 434a, 434b are configured to receive extensions of the spring member 400 (i.e., sheath extensions 329b, 329d) to help prevent excessive compression of the contact arms 180b, 180d. Similar to the upper section 402 and the lower section 462, the deflection protrusion 440 extends outward from the sheath 400 (more specifically, the extension of the front wall 432) at an outward angle and is designed to help protect the contact arms 180a-180d from external impact forces F that could damage the contact arms 180a-180d. IE The impact.

[0150] The lower section 460 of the sheath 400 includes a wall structure 462 comprising: (i) a bottom wall 466, and (ii) opposing side walls 468a, 468b. The bottom wall 466 extends between the opposing side walls 468a, 468b and includes: (i) a contact arm opening 470, (ii) a contact arm deflection protrusion 480 configured to protect the front and rear extensions of the contact arm 180c, and (iii) a fixing feature 410. The contact arm opening 470 is configured to be in the assembled state S. A The contact arms 180a-180d are received at the same time. Deflection protrusions 480 are provided at the front and rear of the contact arm opening 470. The deflection protrusions 480 extend outward at an outward angle from the sheath 400 (more specifically, the bottom wall 466) and are designed to help protect the contact arms 180a-180d from external impact forces F that could damage them. IE The influence of this. In this embodiment: (i) the first deflection protrusion 480 is positioned: (a) adjacent to the contact arm opening 470, and (b) between the front edge of the contact arm opening 470 and the front section 430 of the sheath 400, and (ii) the second deflection protrusion 480 is positioned: (i) adjacent to the contact arm opening 470, and (ii) between the rear edge of the contact arm opening 470 and the rear extension of the sheath 400. The angle between the outer surface of the bottom wall 466 of the sheath 400 and the outer surface of the first deflection protrusion 480 is approximately equal to the angle formed between the plane parallel to the top wall 108c of the male terminal body 104 and the third or downwardly inclined extensions 188a-188d of the contact arms 180a-180d. The angle between the outer surface of the bottom wall 466 of the sheath 400 and the outer surface of the second deflection protrusion 480 is approximately equal to the angle formed between the plane parallel to the bottom wall 108c of the male terminal body 104 and the second or upwardly inclined extensions 184a-184d of the contact arms 180a-180d. In addition to these deflection protrusions 480, the fixing features 410 formed in the bottom wall 106 include a plurality of peripheral retaining tabs 474 designed to wrap around the extensions of the male terminal body 104 to secure the sheath 400 to the body 104 (see...). Figure 27 and Figure 29C ).

[0151] 1. From partially assembled state to fully connected state

[0152] The male terminal assembly is assembled from the third part, state S. 3PA Move to fully connected state S FC This occurs through multiple steps or stages. First, the assembler can move the connector to the connected state S. C Previously, the male terminal assembly must be assembled from the third part, state S. 3PA Move to assembly state. Figure 25A sheath 400 separate from the male terminal 101 is shown, wherein the male terminal assembly 100 is in the third part assembly state S. 3PA In this third assembly state S 3PA In the middle, the sheath 400 is in the ready-to-receive position P. R The assembler applies a backward assembly force F on the sheath 400. A The sheath 400 is positioned above the male terminal body 104 and the spring member 300. When positioning the sheath 400 above the male terminal body 104 and the spring member 300, the assembler must align the spring arm openings 434a, 434b formed in the sheath 400 with the sheath extensions 329b, 329d of the spring member 300. Once the assembler has applied sufficient force F on the sheath 400... A (i) positioning the sheath extensions 329b, 329d of the spring member 300 in the spring arm openings 434a, 434b, and (ii) positioning the deflection protrusion 440 adjacent to the third or downwardly inclined extensions 188b, 188d of the contact arms 180b, 180d, wherein the male terminal assembly 100 has been assembled from the third part state S. 3PA Move to the fourth assembly state S 4PA .

[0153] Next, as Figure 26 As shown, the assembler applies a downward bonding force F to the upper section 402 and lower section 460 of the sheath 400. J The top wall 406 and bottom wall 466 are positioned adjacent to the top wall 108a and bottom wall 108c of the male terminal body 104. After the walls 108a, 108c, 406, and 466 are positioned adjacent to each other, the assembler must bend the retaining tabs 416 and 474 around the extension of the male terminal body 104. Once this is completed, the male terminal assembly 100 is in the assembled state. A (See Figures 27-35 In this assembly state S A In the process, the formation of the second combination of the constraint structure 315b is completed.

[0154] Unlike conventional connector assemblies, the disclosed male terminal assembly 100 includes a compression-limiting device 314. The compression-limiting device 314 further includes a second assembly of limiting structures 315b, formed by the interaction between structures contained in two separate components (i.e., the spring member 300 and the sheath 400). In other words, positioning the sheath extensions 329b, 329d of the spring member 300 in the spring arm openings 434a, 434b formed in the sheath 400 will provide the second assembly of the limiting structures 315a (see [link to original text]). Figures 31-32 Here, an external force F is applied to contact arms 180b and 180d. EIt can only deform contact arms 180b and 180d to the maximum compression distance D. MC Because the inner surface 342a of the sheath extensions 329b and 329d contacts the inner edge or inner compression edge 436a and 436b of the spring arm openings 434a and 434b, limiting the deformation of the contact arm or its compression to the maximum compression distance D. MC To prevent excessive deformation or compression (e.g., greater than the maximum compression distance D) of the contact arms 180b, 180d, spring arms 312b, 312d, and their combinations toward the center of connector 50. MC (distance).

[0155] Finally, as Figures 36-42 As shown, the assembler applies a coupling force F on the male terminal assembly 100. C This is to position the male terminal assembly 100 within the male housing assembly 70. The assembler will apply a coupling force F to the male terminal assembly 100. C Until the front wall 432 of the sheath 400 is positioned adjacent to the front wall 74 of the male housing assembly 70. Once the connector assembly 50 reaches this stage, the contact arms 180a-180d are positioned within the contact arm openings 76a-76d of the male housing assembly 70, and the locking tab 426 of the sheath 400 is positioned in front of the retaining wall surface 90. Once the male terminal assembly 100 is in this position, the assembler aligns the retaining body 96 with the retaining opening 95 and applies a downward force to the retaining body 96 to: (i) position the retaining protrusions 98a, 98b within the retaining opening 95, and (ii) position the retaining protrusions 97a, 97b below the extension of the connector arrangement on the sidewall 86. In this state, the male connector assembly 50 is in a fully connected state S. FC And is ready to engage with the female connector assembly 650.

[0156] 2) Female connector assembly

[0157] The female connector assembly 650 includes: (i) a female housing assembly 670 and (ii) a female terminal assembly 700.

[0158] a. Mother shell assembly

[0159] The female housing assembly 670 is designed to: (i) receive the female terminal assembly 700, (ii) facilitate the connection of the male terminal assembly 100 to the female terminal assembly 700, (iii) minimize the chance of accidental contact of foreign objects with the female terminal assembly 700, and (iv) meet industry standards such as the USCAR specification. The female housing assembly 670 includes a sidewall 672 having a configuration substantially matching the configuration of the female terminal assembly 700. In the embodiment shown in the figures, the female terminal assembly 700 has a cubic configuration and preferably a rectangular configuration to match the rectangle of the male terminal assembly 100. The sidewall 672 of the female housing assembly 670 also includes a plurality of protrusions 697 configured to be received by recesses 82, and protrusions 80 configured to be received by recesses 698. Finally, the female housing assembly 670 includes a coupling protrusion 699 designed to interact with the female receiver opening 84 of the male housing assembly 70. The housing assembly 670 also includes a female terminal retaining device 690, which includes: (i) a retaining body 692, (ii) a retaining opening 694 formed in the sidewall 672 of the housing assembly 670, and (iii) a terminal body protrusion receiver 961. The retaining body 692 is a U-shaped structure, including a retaining protrusion 696 extending downward from an upper transverse member extending between the legs of the U-shaped structure. When assembly 650 is in the fully engaged state S FC At that time: (i) the retaining body 692 is positioned as an extension adjacent to the sidewall 672, (ii) the retaining protrusion 696 extends into the retaining opening 694 and is positioned behind the male terminal body 104, and (iii) the terminal body protrusion 713 is positioned in the terminal body protrusion receiver 691.

[0160] The sidewall 672 of the female housing assembly 670 extends beyond the uppermost surface of the female terminal assembly 700 to allow the formation of a male compression device 674 in the extension of the sidewall 672. As shown, the male compression device 674 is an inclined or ramped surface 676 extending from the outermost edge 673 of the sidewall 672 to the uppermost edge 700a of the female terminal assembly 700. In the disclosed embodiment, the inclined or ramped surface 676 extends from each of the outermost edges 673 and has a substantially linear configuration. However, it should be understood that the inclined or ramped surface 676 may extend only from a portion of the outermost edges 673. The male compression device 674, shown as the inclined or ramped surface 676, is designed so that when the male terminal assembly 100 is in the disconnected state S DC The middle and female terminal assembly 700 are moved separately to the connected state S C When positioned within the extension of the female terminal assembly 700, the compression contact arms 180a-180d (see Figure 1 and 180d) are compressed. Figures 58-63 Thus, the distance between relative points on the outermost edge 673 is equal to the sidewall distance D. S Wherein, the sidewall distance D SGreater than the distance D between the relative points on the last edge 678 of the inclined or sloping surface 676. RE And among them, the final edge distance D RE The receiver distance D is greater than or equal to the distance between relative points extending on the inner surface 704 of the receiver portion 702 of the female terminal assembly 700. R Specifically, the sidewall distance D S The distance D from the receiver R Larger by 0.1% to 15%, and of which, the final edge distance D RE Equal to or greater than receiver distance D R The angle is between 0.1% and 3%. In other words, the inclined or ramped surface 676 is at an angle relative to the outer surface of the sidewall 672 of the female terminal assembly 700 and / or the inner surface 704 of the receiving portion 702. In particular, the interior angle χ extending between the inner surface of the inclined or ramped surface 676 and the outer surface of the sidewall 672 is between 0.1 degrees and 10 degrees.

[0161] This inclined or ramped surface 676 is made of a polymer or plastic material, thus having a lower coefficient of friction than that associated with a metallic surface. In other words, a first friction value is formed when the extension of the male terminal assembly 100 (e.g., contact arms 180a-180d) engages with the male terminal compression device 674 formed of a non-metallic material (e.g., plastic). In an alternative embodiment, a second friction value is formed if the extension of the male terminal assembly 100 (e.g., contact arms 180a-180d) engages with the male terminal compression device formed of a metallic material (e.g., copper). By comparing the friction values ​​of the disclosed embodiment with those of the alternative embodiments, it should be understood that the first or second friction value of the disclosed embodiment is less than that of the alternative embodiments.

[0162] A lower coefficient of friction reduces the force required to insert the male terminal assembly 100 into the female terminal assembly 700. This is beneficial because: (i) industry specifications, including USCAR 25, require a minimum insertion force F for Class 2 connectors. I The insertion force F must not exceed 45 Newtons, and for Class 3 connectors, the insertion force F... I (i) The force must not exceed 75 Newtons, and (ii) a larger spring bias force F must be used. SB This increases the insertion force F. I This is desirable to help ensure that the contact arm of the male terminal assembly remains in contact with the inner surface 704 of the receiving portion 702 of the female terminal assembly 700. Furthermore, this lower coefficient of friction is beneficial because the connector system 10 can transition from the disconnected state S... DC Move to connected state S CThis system meets both Category 2 and Category 3 USCAR specifications without the need for lever assistance. Eliminating lever assistance reduces the size, weight, and manufacturing cost of the connector system 10. It should be understood that, to further reduce the coefficient of friction, the inclined or ramped surface 676 can be coated with a substance that reduces this coefficient of friction, or the inclined or ramped surface 676 can be made of a material with an even lower coefficient of friction.

[0163] Due to the construction of the male connector 50 and the female connector 650, when the connector system 10 moves from the disconnected state S... DC Move to connected state S C Different levels of force are required at different times. For example, when the extension of the male terminal assembly 100 (e.g., contact arms 180a-180d) slides into contact with the male terminal compression device 674, a first force F is required. I1 To move the male terminal assembly 100, and when the extension of the male terminal assembly 100 (e.g., contact arms 180a-180d) is positioned in the female terminal receiver 702, a second force F is required. I2 Move the male terminal assembly 100. Comparing these forces, it should be understood that the second force F... I2 Less than the first force F I1 This is beneficial because it provides tactile feedback to the user, informing them that the male terminal assembly 100 is properly positioned within the female terminal assembly 700. In fact, this tactile feedback affects the user as if the male terminal assembly 100 were being pulled into the female terminal assembly 700.

[0164] To minimize the chance of the male connector assembly 50 accidentally detaching from the female connector assembly 650, the female connector assembly 650 may include an optional, non-deformable female CPA structure designed and configured to interact with the male CPA structure when the connector assemblies 50 and 650 are connected to each other. The non-deformable female CPA structure is integrally formed with the sidewall 672 of the female housing assembly 670. Additional details regarding the structure and / or function of the female CPA structure are disclosed in PCTUS2019 / 036070, PCTUS2020 / 049870, and PCTUS2021 / 033446, all of which are incorporated herein by reference.

[0165] b. Female terminal

[0166] The female terminal assembly 700 of the female connector assembly 650 includes: (i) a female terminal connecting member 701, and (ii) a female terminal body 710. Specifically, the female terminal connecting member 701 is coupled to the female terminal body 710. In this embodiment, the female terminal connecting member 701 is a wire receiver having a blade-like structure configured to receive an extension of a structure (e.g., lead or wire) of a device (e.g., an alternator) connecting the female terminal assembly 700 to the outside of the connector system 10. The wire is typically soldered to the wire receiver; however, this disclosure contemplates other methods of connecting the wire to the wire receiver (e.g., forming the wire as part of the wire receiver). In other embodiments, the female terminal connecting member 701 may be a crimp connection, a circuit board connector having a U-shaped configuration, or any other type of connecting member 102 that mechanically and electrically connects the female terminal body 710 to an external device, component, or extension.

[0167] The female terminal body 710 of the female connector assembly 650 includes a sidewall 712 having an inner surface 704, which is formed with a receiver distance D. R The cylindrical terminal receiving portion 702 extends between opposite points on the inner surface 704 of the sidewall 712. As described above, the receiver distance D R Yes: (i) less than the sidewall distance D S And (ii) equal to or greater than the last edge distance D RE Furthermore, the receiver distance is 0.1% to 15% smaller than the distance between the outermost extensions of the opposing contact arms 180a-180d. The terminal receiving portion 702, having a receiver distance smaller than the distance between the male terminal arms, ensures that the contact arms 180a-180d are compressed when the male terminal arm 100 is inserted into the female terminal arm 700. This compression of the male terminal arm 100 compresses the spring member 300. Thus, the spring member 300 applies an outwardly pointing biasing force F to the contact arms 180a-180d. SB This helps ensure that it remains in contact with the inner surface 704 of the terminal receiving portion 702, so as to facilitate electrical and mechanical connection between the male terminal assembly 100 and the female terminal assembly 700.

[0168] The female terminal assembly 700 is typically formed of metal, preferably a highly conductive metal such as copper. The female terminal assembly 700 may be plated or coated with Ni-Ag. In other embodiments, the sidewalls 712 may be made of different materials, and / or the female terminal assembly 700 may not be plated or coated with Ni-Ag. Once manufactured, the female terminal assembly 700 can be coupled to wires, parts, components, or devices via the female terminal connection member 701.

[0169] 3) Connector system

[0170] Connector system 10 can switch from disconnected state S DC Move to partial connection state S PC The male connector assembly 50's contact arms 180a-180d contact the inclined or ramped surface 676 of the female connector assembly 650. This inclined or ramped surface 676 gently and smoothly compresses the contact arms 180a-180d until they can easily slide into and contact the inner surface 704 of the female receiver 702. This process is described in more detail in PCT / US2019 / 36070 and is incorporated herein by reference. Once the male connector assembly 50 is connected to the female connector assembly 650, the connector system 10 has transitioned from a partially connected state S. PC Move to connected state S C If present, a force is applied to the CPA, causing it to interact with an extension of the external component, and the installer can scan the extension of the CPA, which is visible through an opening within the housing, as described in PCT / US2020 / 049870.

[0171] 4) Terminal properties and functionality

[0172] Figure 61 Describes the connection state S C The cross-section of the male connector assembly 50 connected to the female connector assembly 650. While the following disclosure is discussed in conjunction with a first embodiment of system 10, it should be understood that this disclosure applies with equal force to all embodiments of systems 1010, 2010, 3010, 4010, 5010, and 6010. As described above, the outermost extensions or diameters of the contact arms 180a-180d are slightly larger than the inner diameter of the female terminal body 710. Thus, when these components mate with each other, the spring member 300 is compressed. This compression of the spring member 300 produces a wedging effect or an outwardly pointing biasing force F. SB It abuts against the contact arms 180a-180d and is away from the interior of the spring member 300.

[0173] The male terminal body 104, including contact arms 180a-180d, can be formed of a first material, such as copper, a highly conductive copper alloy (e.g., C151 or C110), aluminum, and / or another suitable conductive material. The first material preferably has a conductivity greater than 80% of the IACS (International Standard for Annealed Copper, i.e., an empirically derived standard value for the conductivity of commercially available copper). For example, C151 typically has 95% of the conductivity of standard pure copper conforming to IACS. Similarly, C110 has 101% of the conductivity of IACS. C151 may be preferred in certain operating environments or technical applications due to its corrosion resistance properties desired in high-stress and / or harsh weather applications. The first material used for the male terminal body 104 is C151, and according to ASTM B747, it is reported to have an elastic modulus (Young's modulus) of approximately 115-125 gigapascals (GPa) at room temperature, and a terminal expansion coefficient (CTE) of 17.6 ppm / degree Celsius (from 20 degrees Celsius to 300 degrees Celsius) and 17.0 ppm / degree Celsius (from 20 degrees Celsius to 200 degrees Celsius).

[0174] The spring member 300 can be formed of a second material, such as spring steel, stainless steel (e.g., 301SS, 1 / 4 hardness), and / or another suitable material having greater stiffness (e.g., measured by Young's modulus) and elasticity than the first material of the male terminal body 104. The second material preferably has a lower conductivity than the first material. The second material also has a Young's modulus of approximately 193 GPa at room temperature and a coefficient of terminal expansion (CTE) of 17.8 ppm / °C (from 0°C to 315°C) and 16.9 ppm / °C (from 0°C to 100°C). In the high-voltage applications considered, the cross-sectional area of ​​the copper alloy forming the first connector is balanced with the conductivity of the selected copper alloy. For example, when a copper alloy with lower conductivity is selected, the contact arms 180a-180d formed therefrom have a larger cross-sectional area for sufficient conductivity. Similarly, choosing a first material with higher conductivity allows contact arms 180a-180d to have a relatively smaller cross-sectional area while still meeting conductivity specifications.

[0175] In an exemplary embodiment, the CTE of the second material can be greater than that of the first material; that is, the CTE of the spring member 300 is greater than that of the male terminal body 104. Therefore, when the assembly of the male terminal body 104 and the spring member 300 is subjected to the high voltage and high temperature environment typically used in electrical connectors described in this disclosure, the spring member 300 expands relatively more than the male terminal body 104. Consequently, the outward force F generated by the spring member 300 on the contact arms 180a-180d of the male terminal body 104... SBIt increases with increasing temperature, which is referred to below as the thermal spring force F. ST .

[0176] Exemplary applications of this disclosure, such as for charging connectors, are suitable for deployment in Class 5 automotive environments, such as those found in passenger cars and commercial vehicles. Class 5 environments are typically found under the hood of a vehicle, such as an alternator, and present ambient temperatures of 150 degrees Celsius, and often reach 200 degrees Celsius. When copper and / or highly conductive copper alloys are subjected to temperatures above approximately 150 degrees Celsius, the alloys become ductile and lose their mechanical elasticity, i.e., the copper material softens. However, the steel forming the spring member 300 retains its hardness and mechanical properties when subjected to similar conditions. Therefore, when both the male terminal body 104 and the spring member 300 are subjected to high temperatures, the first material of the male terminal body 104 softens, while the structural integrity of the spring member 300 formed of the second material is maintained, such that in the fully connected position S... FC In this process, the force applied by the spring member 300 to the softened contact arms 180a-180d more effectively causes the softened contact arms 180a-180d to shift outward relative to the interior of the male terminal body 104.

[0177] The male terminal body 104, spring member 300, and female terminal body 710 are configured to maintain electrical and mechanical engagement while withstanding elevated temperatures and thermal cycling. Furthermore, the male terminal body 104 and female terminal body 710 can undergo thermal expansion due to elevated temperatures and thermal cycling, which increases the outward force F exerted by the male terminal body 104 on the female terminal body 710. SB The construction of the male terminal body 104, the spring member 300, and the female terminal body 710 increases the outward connecting force between them, while the connector system 10 withstands the force exerted by the connection position P. C Thermal expansion caused by thermal cycling.

[0178] Based on the above exemplary embodiments, the Young's modulus and CTE of the spring member 300 are greater than those of the male terminal body 104. Therefore, when the male terminal body 104 is used in high-power applications, subjecting the connector system 10 to repeated thermal cycling with elevated temperatures (e.g., approximately 150 degrees Celsius), then: (i) the male terminal body 104 becomes malleable and loses some mechanical elasticity, i.e., the copper material in the male terminal body 104 softens, and (ii) the spring member 300 does not become malleable or lose as much mechanical stiffness as the male terminal body 104.

[0179] Therefore, when the spring member 300 is mechanically cold-formed (e.g., using a die-forming process) and subjected to elevated temperatures, the spring member 300 will attempt to return to at least its uncompressed state, which occurs before the male terminal assembly 100 is inserted into the female terminal assembly 700, and preferably to its initial flat state, which occurs before the formation of the spring member 300. In doing so, the spring member 300 will apply a generally outward-pointing thermal spring force F along the entire length of the contact arms 180a-180d (rather than just at discrete points). ST (like Figure 61 The middle is marked as "F" ST (As depicted by the arrow). This thermal spring force F ST Depending on the local temperature conditions of the environment in which the system 10 is installed, including high and / or low temperatures, the spring bias force F... SB and thermal spring force F ST The combination provides the synthetic bias force F RSB This ensures that the outer surface of the contact arms 180a-180d or the contact surfaces 189a-189d are forced into contact with the inner surface 704 of the female terminal body 710 when the female terminal assembly 700 is inserted into the female terminal 700 and during operation of the system 10, thereby ensuring electrical and mechanical connection. Additionally, in the event of repeated thermal cycling, the male terminal assembly 100 will maintain and / or increase the outward-pointing composite spring force S. RBF The combined spring force is applied to the female terminal assembly 700 during repeated operation of the system 10.

[0180] like Figure 61 Furthermore, as shown, in the connected state S C In the middle, the male terminal assembly 100 provides 360° compliance with the female terminal assembly 700 to ensure a sufficient amount of outward bias force F. SBThe male terminal assembly 100 applies to the female terminal assembly 700 for electrical and mechanical connectivity in all four principal directions. This property allows for the omission of keying features and / or another feature designed to ensure the desired orientation of components during connection. The 360° compliant property of system 10 also helps maintain mechanical and electrical connections under severe mechanical conditions, such as vibration. In conventional blade or fork connectors with 180° compliance, i.e., connections only on two opposite sides, vibration can generate harmonic resonances that cause the 180° compliant connector to oscillate at a specific frequency with a larger amplitude. For example, subjecting a fork connector to harmonic resonances may cause it to disconnect. Opening a fork connector during conduction is undesirable because the momentary mechanical separation of the fork connector from the associated terminals may result in arcing. Arcing can have significant negative effects on the 180° compliant terminals and the entire electrical system as a component of the 180° compliant terminal. However, the 360° compliance feature of this disclosure can prevent possible catastrophic failures caused by strong vibrations and arc discharges.

[0181] 5) Alternative implementation methods for male connector assemblies

[0182] a. Second Implementation Method

[0183] Figures 64A-65C A second embodiment of the spring member 1300 is shown, which can be used in place of the spring assembly 300 shown and described above. Because the contact structures in this embodiment of system 1010 are substantially similar to those in the first embodiment of system 10, it should be understood that, for brevity, the reference numerals shown in the drawings may be omitted from the description, as the same structures have the same reference numerals. For example, the disclosure relating to male terminal 101 is not repeated here, but it applies to male terminal 1101 as if it were repeated here. 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 application. Instead, reference should be made to the disclosure of similar structures that may be discussed in another part of this application or in other applications incorporated herein by reference.

[0184] In this second embodiment of system 1010, the extension of the compression-limiting device 314 of the first embodiment of system 10 is replaced by an alternative extension of the compression-limiting device 1314. Specifically, the second combination of the limiting structure 315b (i.e., the sheath extensions 329b and 329d of the spring member 300 and the spring arm openings 434a and 434b formed in the sheath 400) is replaced by an alternative combination of structure 1315b (i.e., contact extensions 1331b and 1331d). Here, the contact extensions 1331b and 1331d disclosed in this embodiment 1010 replace the sheath extensions 329b and 329d of the first embodiment of system 10. In this embodiment, an external force F is applied to the contact arms 1180b and 1180d. E It can only deform contact arms 1180b and 1180d, i.e., the maximum compressive distance D that can be replaced. AMC Because the front ends 1330b and 1330d are in contact with each other, the contact arms 1180b and 1180d are limited from deforming or being pressed down to the alternative maximum compression distance D. AMC The degree of protection prevents excessive deformation or downward pressure (e.g., greater than the alternative maximum compression distance D) of the contact arms 1180b, 1180d, spring arms 1312b, 1312d, and combinations thereof toward the center of the connector 1050. AMC (distance). In this embodiment, the alternative maximum compression distance D AMC It is the maximum compression distance D MC It is twice the size of F, but still small enough to reduce the impact of external forces F. E The system 1010 failure is caused by excessive compression. In other words, the compression distance of the system 1010 failure is greater than the maximum compressibility distance D. AMC The maximum compression distance D of this alternative AMC Greater than the maximum compression distance D MC The maximum compression distance D MC Greater than when system 1010 is in connected state S CN The normal or operational deformation distance experienced by system 1010. The design of this terminal assembly 1100 may be more ideal than the first embodiment of terminal assembly 100 because the means 1314 for limiting compression is entirely contained in a single structure (i.e., spring member 1300), which in turn can increase the durability and lifespan of system 1010.

[0185] b. Third implementation method

[0186] Figures 66-74A third embodiment of the spring member 2300 is shown, which can be used in place of the spring assembly 300 shown and described above. Because the contact structure in this embodiment of system 2010 is substantially similar to that of the first embodiment of contact system 10, it should be understood that, for brevity, reference numerals shown in the drawings may be omitted from the description, as the same structure has the same reference numerals. For example, the disclosure relating to male terminal 101 is not repeated here, but it applies to male terminal 2101 as if it were repeated here. In other words, the omission of reference numerals from the functional description or specific disclosure of this structure should not limit the disclosure of this application. Instead, reference should be made to disclosures of similar structures that may be discussed in another part of this application or in other applications incorporated herein by reference. In this embodiment, the geometrically bent or folded portions 320a-320d of the first embodiment of system 10 and the device 314 for limiting compression have been replaced by the contact arm support 2350 and the compression tab 2370. Specifically, the contact arm support 2350 includes: (i) forward bending extensions 2351a-2351d extending between the linear extensions 2316b, 2316d (line S3) and the vertical extensions 2353a-2353d (line S4) of the spring member 300, and (ii) vertical extensions 2353a-2353d extending forward from the forward bending extensions 2351a-2351d (line S4) and terminating at free ends 2330a-2330d.

[0187] Unlike the first two embodiments of the male terminal assemblies 100 and 1100 disclosed herein, the spring arms 2312a-2312d do not have a geometry that substantially matches the geometry of the associated contact arms 2180a-2180d. Thus, the spring arms 2312a-2312d do not have an outer surface 2313a-2313d located below and abutting the inner surface of the associated contact arms 2180a-2180d. Instead, the free ends 2330a-2330d of the spring arms 2312a-2312d are positioned below the apex 2186a-2186d of the bent or folded portions 178a-178d of the contact arms 180a-180d. This configuration forms a gap G (which has a right-angled triangular shape) between the upwardly inclined extension 233a, the vertical extensions 2353a-2353d of the spring arms 2312a-2312d, and the linear extensions 2316a-2316d of the spring arms 2312a-2312d. Similar to the first two embodiments of systems 10 and 1100, the free ends 2190a-2190d of the contact arms 2180a-2180d do not abut against the planar outer surfaces 2313a-2313d of the spring arms 2312a2-312d. Based on Figures 66-74Other structural, functional, or positional relationships may be obvious to those skilled in the art.

[0188] In this embodiment, the spring member 2300 is replaced by a structure that is entirely integrally formed within the spring member 2300, replacing the existing type of compression-limiting devices 314, 1314. Here, the compression-limiting device 2314 is formed by a combination of compression tabs 2370 and the edges 2332a-2332b, 2334a-2334b of adjacent spring arms 2312a-2312d. The compression tabs 2370 include: (i) lateral protrusions 2371a-2371b extending outward from forwardly curved extensions 2351a, 2351c (lines S5, S6) and terminating at outer surfaces 2373a-2373b; and (ii) substantially vertical wings 2375a-2375b extending outward from linear extensions 2316b, 2316d (lines S7, S8) and terminating at outer surfaces 2376a-2376b. In other words, in this embodiment, the device 2314 for limiting compression includes: (i) a first combination of limiting structures 2315a, namely, the lateral protrusions 2371a-2371b and edges 2334a-2334b of adjacent side spring arms 2312b and 2312d, and (ii) a second combination of limiting structures 2315b, namely, the substantially vertical wings 2375a-2375b and edges 2332a-2332b of adjacent side spring arms 2312a and 2312c.

[0189] The outer surfaces 2373a-2373b of the lateral protrusions 2371a-2371b are positioned outside or beyond the inner surfaces 2346 of the opposing linear extensions 2316b, 2316d. In other words, the length between the outer surfaces 2373a-2373b of the lateral protrusions 2371a-2371b is greater than the width W of the inner linear surface extending between the inner surfaces 2346 of the opposing linear extensions 2316b, 2316d. ILS An external force F is applied to contact arms 2180a and 2180c. E Only the maximum compression distance D that can deform contact arms 2180a and 2180c MC Because the inner surface 2372 of the lateral protrusions 2371a-2371b contacts the forward spring arm edges 2334a, 2334b of the side spring arms 2312b, 2312d (specifically, the edges of the forward curved extensions 2351b, 2351d of the side spring arms 2312b, 2312d). In this embodiment, the maximum compression distance D MC The diameter is less than 1.25 mm, preferably less than 1.0 mm, and most preferably 0.85 mm. This limits the contact arms 2180a and 2180c from deforming or being compressed to the maximum compression distance D. MCThe degree of compression helps prevent contact arms 2180a, 2180c, spring arms 2312a, 2312c, and combinations thereof from excessively deforming or pressing down on arms 2180a, 2180c toward the center of connector 2050 (e.g., greater than the maximum compression distance D). MC (distance).

[0190] The outer surfaces 2376a-2376b of the substantially vertical wings 2375a-2375b are positioned outside or beyond the inner surfaces 2346 of the opposing linear extensions 2316a, 2316c. In other words, the length between the outer surfaces 2376a-2376b of the substantially vertical wings 2375a-2375b is greater than the width W of the inner linear surface extending between the inner surfaces 2346 of the opposing linear extensions 2316a, 2316c. ILS An external force F is applied to contact arms 2180b and 2180d. E Only the maximum compression distance D that can deform contact arms 2180b and 2180d MC Because the inner surfaces 2374 of the substantially vertical wings 2375a-2375b contact the linear extension edges 2332a, 2332b of the top and bottom spring arms 2312a, 2312c (specifically, the edges of the linear extensions 2316a, 2316b of the side spring arms 2312b, 2312d). In this embodiment, the maximum compression distance D MC The diameter is less than 1.25 mm, preferably less than 1.0 mm, and most preferably 0.85 mm. This limits the contact arms 2180b and 2180d from deforming or being compressed to the maximum compression distance D. MC The degree of compression helps prevent contact arms 2180b, 2180d, spring arms 2312b, 2312d, and combinations thereof from excessively deforming or pressing down on arms 2180b, 2180d toward the center of connector 2050 (e.g., greater than the maximum compression distance D). MC (distance).

[0191] c. Fourth Implementation Method

[0192] 1) Male connector assembly

[0193] Figures 75A-100A fourth embodiment of the male terminal assembly 3100 is shown, comprising a male terminal 3101 and a spring member 3300, which can be used in place of the male terminal 101 and spring member 300 shown and described above. Because the structures in contact in this embodiment of system 3010 are substantially similar to those in the first embodiment of system 10, it should be understood that reference numerals shown in the drawings may be omitted from the description for brevity, as the same structures have the same reference numerals. For example, the disclosure relating to sheath 400 is not repeated herein, but it applies to sheath 3400 as if it 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 application. Instead, reference should be made to disclosures of similar structures that may be discussed in another part of this application or in other applications incorporated herein by reference. Similar to the first embodiment, this fourth embodiment of the male connector assembly 3050 includes a plurality of components designed to be coupled to individual devices or components (e.g., charging connector 2, radiator fan, heating base, power distribution component, or another current-drawing component). The male connector assembly 3050 mainly includes: (i) a male housing assembly 3070, and (ii) a male terminal assembly 3100 with a male terminal 3101, a spring member 3300 and a sheath 3400, wherein, during operation of the connector system 10, at least a considerable extension of the male terminal assembly 3100 is located within the male housing assembly.

[0194] a. Male terminal assembly

[0195] Figures 75A-100Various views of the male terminal assembly 3100 are provided. Although the structure included in the fourth embodiment of the male terminal body 3104 is largely similar to that of the first embodiment of the male terminal body 104, substantial changes have been made between the constructions of the contact arms 180a-180d and 3180a-3180d. Thus, the following disclosure will focus on this alternative construction of the contact arms 3180a-3180d. The contact arms 3180a-3180d have initial or rear extensions 3182a-3182d extending from the base or intermediate portion 3110 (line C1), and bent or folded portions 3178a-3178d. The bent or folded portions 3178a-3178d include a first layer of contact arms 3180a-3180d that directly overlaps with the second layer of contact arms 3180a-3180d, wherein: (i) a second or upwardly inclined extension 3184a-3184d extends between the initial extension 3182a-3182d (line C2) of contact arms 3180a-3180d and the outer vertex 3186a-3186d (line C3); and (ii) a third or downwardly inclined extension 3188a-3188d extends downward from the outer vertex 3186a-3186d (line C3). Extending to the foremost extension, which provides a front end or nose end 3190a-3190d (line C4) with a rounded or curved end construction, (iii) a fourth or rearward extension 3192a-3192d extending rearward and upward from the foremost extension 3190a-3190d (line C4) to the inner vertices 3193a-3193d (line C5), and (iv) a fifth or vertical extension 3194a-3194d extending inward from the inner vertices 3193a-3193d (line C5), preferably substantially perpendicular to the midpoint of the inner vertices 3193a-3193d. These extensions and apexes provide contact arms 3180a-3180d with curved or bent structures, whereby the third extension 3188a-3188d overlaps with the fourth extension 3192a-3192d, and the outer apex 3186a overlaps with the inner apex 3193a-3193d. Furthermore, the contact arms 3180a-3180d have a pleated structure forming: (i) a front spring contact section 3196a-3196d, positioned near the foremost front end or nose 3190a-3190d and within the fourth or rearwardly extending extension 3192a-3192d; and (ii) an intermediate spring contact section 3198a-3198d, which is part of the fifth or vertical extension 3194a-3194d.

[0196] The bent or folded construction of the contact arms 3180a-3180d provides the connector system 3010 with several advantages over previous designs. For example, this design includes vertical extensions 3194a-3194d that support the outer apexes 3186a-3186d of the contact arms 3180a-3180d. This added support increases the durability of the contact arms 3180a-3180d, which is superior to the contact arm 3180a-3180d design shown in PCT / US2019 / 036010, i.e., Figures 69 to... Figure 86 The design shown is advantageous due to the small size of the contact arms 3180a-3180d. Furthermore, when the male terminal assembly 3100 is inserted into the female terminal assembly 700, the front spring contact sections 3196a-3196d and the intermediate spring contact sections 3198a-3198d help distribute the compressive force F applied to the spring arms 3312a-3312d. COM Furthermore, the construction of the third or downwardly inclined extensions 3188a-3188d is as shown in Figures 69 to 68010 of PCT / US2019 / 036010. Figure 96 The contact arm design shown is beneficial because it helps to reduce: (i) the insertion force due to the angled contact arm design (compared to the circular contact arm design), and (ii) the potential bending or breakage of the contact arms 3180a-3180d when the insertion of the male terminal assembly 3100 is not directly in line with the female terminal assembly 700.

[0197] refer to Figures 77-79 Unlike conventional connectors, the disclosed contact arms 3180a-3180d have elongated initial or rear extensions 3182a-3182d that do not extend away from the base portion 3110 at a uniform or substantially uniform outward tilt angle. In other words, and as... Figure 79 As best shown, the outer surfaces 3183a-3183d of the initial or rear extensions 3182a-3182d of each contact arm 3180a-3180d are: (i) substantially parallel to each other, and (ii) substantially aligned with the outer surface 3111 of the corresponding extension of the base portion 3110. Compared to conventional connectors without such elongated initial or rear extensions 3182a-3182d, less force is required to deform or displace the contact arms 3180a-3180d inward or toward the center of the male terminal 3101. This reduced force allows for an increase in the force required to displace the extension of the spring member 3300 inward. It is advantageous to translate the structure preventing inward displacement from the contact arms 3180a-3180d to the spring arms 3312a-3312d because the insertion force F can be easily changed by altering the design and / or material composition of the spring member 3300 without redesigning the terminal body 3104. IFor example, the designer can insert a stiffer spring member 3300 to maintain / maximize the current carrying capacity of system 3010. Or if a target insertion force F is set. I For specific customer requirements, designers can select spring members 3300 that meet these requirements without having to perform an expensive and time-consuming redesign of the male terminal body 3104. This modularity and flexibility of the connector system 3010 is a substantial improvement over existing technology because it reduces the number of product SKUs, increases the ability to meet customer requirements without reprocessing or redesigning connectors, and / or limits the testing and other steps required to use new / different connectors. It should be understood that the length of the initial or rear extensions 3182a-3182d will significantly change the insertion force F required to insert the male terminal assembly 3100 into the female terminal assembly 3700. I Furthermore, in other embodiments, contact arms 3180a-3180d may extend away from base 3110 at a uniform inward angle or a substantially uniform inward tilt angle. The inward tilt angle allows male terminal assembly 3100 to have an inwardly tapered design or configuration. In this alternative embodiment, the inwardly tapered design or configuration may be configured such that the outer diameter at line C2 may be 0.01% to 5% smaller than the outer diameter at line C1.

[0198] like Figure 80 As shown, in front of the lateral initial or rearward extensions 3182a-3182d, the second or upwardly inclined extensions 3184a-3184d are positioned at an outward angle σ, which is defined between the outer surfaces 3183a-3183d of the initial or rearward extensions 3182a-3182d of the contact arms 3180a-3180d and the outer surfaces 3185a-3185d of the second or upwardly inclined extensions 3184a-3184d of the contact arms. The outward angle σ is between 115 degrees and 170 degrees, preferably between 125 degrees and 145 degrees. In front of the second or upwardly inclined extensions 3184a-3184d, the contact arms 3180a-3180d have a third or downwardly inclined extension 3188a-3188d, which extends downward from the outer apex 3186a-3186d to the foremost front end or nose 3190a-3190d. An outer angle λ is defined between the outer surfaces 3185a-3185d of the second or upwardly inclined extensions 3184a-3184d and the outer surfaces or contact surfaces 3189a-3189d of the third or downwardly inclined extensions 3188a-3188d. The outer angle λ is between 240 degrees and 300 degrees, preferably between 255 degrees and 285 degrees. Similar to the preceding discussion, the other terminals, the disclosure of which is incorporated herein, do not have this configuration of sharp upwardly angled segments and sharp downwardly angled segments, nor numerous composite apexes.

[0199] As discussed in more detail below, the third or downwardly inclined extensions 3188a-3188d, specifically contact surfaces 3189a-3189d, are configured to contact the extension of the female connector assembly 650 when the male terminal assembly 3100 is inserted into the female terminal assembly 700. This interaction between these components causes the contact arms 3180a-3180d to deflect or shift inward and toward the center of the male terminal assembly 3100 and the spring member 700. This inward deflection of the contact arms 3180a-3180d causes the spring member 700 to act as a wedge to help ensure a proper mechanical and electrical connection is established between the contact arms 3180a-3180d and the female receiver 702.

[0200] like Figure 91 and Figure 94 As shown, the front spring contact sections 3196a-3196d and the intermediate spring contact sections 3198a-3198d of the contact arms 3180a-3180d are positioned almost parallel to the inner surfaces 318a-3181d of the initial or rear extensions 3182a-3182d of the contact arms 3180a-3180d. (Reference) Figure 94 This configuration provides (i) a first gap G1 (which is generally triangular when viewed from the side) formed between the inner surfaces of the contact arms 3180a-3180d and the spring member 3300, and between the vertical extension 3194a and the rear extension 3182a of the contact arm 180a, and (ii) a second gap G2 (which is generally triangular when viewed from the side) formed between the inner surfaces of the contact arms 3180a-3180d and the spring member 3300, and between the vertical extension 3194a and the fourth extension 3192a of the contact arm 3180a or the front spring contact section 3196a-3196d. Thus, the vertical extension 3194a engages with the outer spring arm surface 3313a at a substantially vertical angle, preferably a perpendicular angle. This configuration is superior to that in PCT / US2018 / 019787. Figures 3-8 The illustrated construction is advantageous because the assembler of the male terminal assembly 3100 does not need to apply significant force to deform most of the contact arms 3180a-3180d outward to receive the spring member 3300. This required deformation is best illustrated in Figure 6 of PCT / US2018 / 019787 based on the construction of the spring arm 31 and the contact arm 11. The construction disclosed herein is advantageous because the performance of the connector system 3010 does not change over time due to material creep. Or in other words, the connector system 3010 does not have a limited shelf life because the spring member 3300 is not under constant tension before the system 3010 is used.

[0201] like Figure 81As shown, at least a portion of the outer edges or shoulder regions 3200a, 3200b of the contact arms 3180a-3180d are pressed, beveled, or rounded. The rounding of the outer edges 3200a, 3200b causes the outer surfaces of the contact arms 3180a-3180d, at least the vertices 3186a-3186d, to match the curvature of the inner surface 704 of the female terminal assembly 700. The pressed, beveled, or rounded outer edges 3200a-3200b may: (i) extend along the entire length of the contact arms 3180a-3180d, (ii) extend along the entire length of the second extensions 3184a-3184d and the third extensions 3188a-3188d of the contact arms 3180a-3180d, and (iii) extend along a portion (e.g., half the length) of the second extensions 3184a-3184d and a portion (e.g., half the length) of the third extensions 3188a-3188d of the contact arms 3180a-3180d. Without pressing, beveling, or rounding a portion of the outer edges 3200a and 3200b of the contact arms 3180a-3180d, the edges 3200a and 3200b will contact the inner surface 704 of the female terminal assembly 700. Furthermore, the relationship between the linear and curved constructions of the contact arms 3180a-3180d and the female terminal assembly 700 will prevent the center of the contact arms 3180a-3180d from making adequate contact with the female terminal assembly 700. Preventing proper contact between the center of the contact arms 3180a-3180d and the female terminal assembly 700 will undesirably reduce the current carrying capacity of the system 3010. Additionally, omitting pressing, beveling, or rounding may leave sharp edges on the contact arms 3180a-3180d, which could cause the contact arms 3180a-3180d to scratch or mark the inner surface 704 of the female terminal assembly 700. The scoring can reduce the number of mating cycles that the system 10 can achieve without failure, because the scoring can scrape or damage the internal plating and / or surface 704 of the female terminal assembly 700, which can lead to arcing or significant electrical degradation of the system 3010. In other embodiments, the outer edges or shoulder regions 3200a, 3200b of the contact arms 3180a-3180d may not be pressed, beveled, or rounded; instead, the contact arms 3180a-3180d may be bent or material may be deposited on the contact arms 3180a-3180d to allow the outer surfaces of the contact arms 3180a-3180d to substantially match the curvature of the inner surface 704 of the female terminal assembly 700.

[0202] like Figures 76-79 and Figure 88As shown, contact arms 3180a-3180d are not connected to any structure except extending from the base portion 3110. This free-end configuration of contact arms 3180a-3180d allows for omnidirectional extension of the contact arms 3180a-3180d. Because of the contact arm openings or gaps 3280a-3280d sandwiched between each pair of contact arms 3180a-3180d, there is no support wall surrounding the contact arms 3180a-3180d. This configuration of the male terminal assembly 3100 is substantially different from the configuration disclosed in PCT / US2019 / 36010. As discussed in PCT / US2019 / 36010, the removal of the sidewall structure surrounding the contact arms 3180a-3180d may increase the failure rate of the male terminal assembly 3100, since the sidewall structure protects the contact arms 3180a-3180d. However, this increased failure rate is mitigated because the sheath 3400 has been configured to replace the functionality of the support wall. The construction disclosed herein is advantageous because it replaces the expensive copper structure with a cheaper and more robust one.

[0203] The male terminal 3101 is typically formed from a single piece of material (e.g., metal); therefore, the male terminal 3101 is a one-piece male terminal 3101 and has integrally formed characteristics. To integrally form these features, the male terminal 3101 is typically formed using a die-cutting process. However, it should be understood that other types of forming of the male terminal 3101 can be utilized, such as casting or using additive manufacturing processes (e.g., 3D printing). In other embodiments, the features of the male terminal 3101 may not be formed from a single piece or integrally, but rather from individual pieces welded together. When forming the male terminal 3101, it should be understood that any number (e.g., between 1 and 100) of contact arms 3180a-3180d can be formed within the male terminal 3101. The male terminal 3101, the male terminal body 104, the contact arms 3180a-3180d, or extensions of the contact arms 3180a-3180d may be plated or coated with a second material (e.g., nickel) to help reduce corrosion, reduce insertion force, or improve conductivity. Additionally, contact arms 3180a-3180d or a portion thereof may have rounded or beveled edges.

[0204] b. Spring components

[0205] As in Figures 82-86 , Figure 88 , Figure 93 , Figure 98As best shown, the spring member 3300 includes an arrangement of spring member sidewalls 3304a-3304d and a rear spring wall 3306. Each spring member sidewall 3304a-3304d includes: (i) a first or curved spring segment 3308a-3308d, and (iii) a second segment or spring arm 3312a-3312d. The curved spring segments 3308a-3308d extend between the rear spring wall 3306 and the spring arms 3312a-3312d, and position the spring arms 3312a-3312d substantially perpendicular to the rear spring wall 3306. In other words, a large portion, if not integral, of the extension of the outer surface of the spring arms 3312a-3312d is substantially perpendicular to the outer surface of the rear spring wall 3306. As shown in Figures 12 to 1340. Figure 15 As shown, spring arms 3312a-3312d extend from the first or curved spring sections 3308a-3308d of the spring member 3300, away from the rear spring wall 3306, and terminate at free ends 3330a-3330d. Spring arms 3312a-3312d are not connected, and therefore spring arm slits 3310a-3310d are formed between the spring arms 3312a-3312d of the spring member 3300. Spring arm slits 3310a-3310d facilitate omnidirectional expansion of the spring arms 3312a-3312d to enable mechanical connection between the male terminal assembly 3100 and the female terminal assembly 4100.

[0206] The spring member 3300 disclosed in this embodiment includes a centering device 3380. The disclosed centering device 3380 does not rely on outwardly extending lateral protrusions, but rather, on corrugations 3382a-3382b formed in at least one, and preferably two, opposing spring arms 3312b, 3312d. Figure 36 As best shown, corrugations 3382a-3382b are positioned near the free ends 3330b and 3330d and extend between lines S3 and S4. These corrugations 3382a-3382b are designed to mate between the front spring contact sections 3196b and 3196d and the intermediate spring contact sections 3198a-3198d of the contact arms 3180b and 3180d. By positioning the corrugations 3382a-3382b between the contact end sections 3196a-3196d and 3198a-3198d, movement of the spring member 3300 is reduced. Reducing the movement of the spring member 3300 is desirable because it helps ensure consistent and reliable performance of the system 3010.

[0207] In this embodiment, the spring member 3300 is replaced by a structure that is entirely integrally formed into the spring member 3300, instead of the existing types of compression-limiting devices 314, 1314, and 2134. The compression-limiting device 3314 can...Figures 82-86 The most clearly visible part is the compression device 3314, which is formed by the combination of compression tabs 3370 and the edges 3332a-2332b, 3334a-3334b of the adjacent spring arms 3312a-3312d. The compression tabs 3370 include: (i) lateral protrusions 3371a-3371b extending outward from the linear extensions 3316b, 3316d (lines S5, S6) and terminating at the outer surfaces 3373a-3373b; and (ii) substantially vertical wings 3375a-3375b extending outward from the linear extensions 3316b, 3316d (lines S7, S8) and terminating at the outer surfaces 3376a-3376b. Here, the lateral protrusions 3371a-3371b are: (i) positioned in front of the substantially vertical wings 3375a-3375b, and (ii) positioned above / below the extension of the centering device 3380 (e.g., corrugations 3382a-3382b). In other words, in this embodiment, the device 3314 for limiting compression includes: (i) a first combination of limiting structures 3315a, namely, the edges 3334a-3334b of the lateral protrusions 3371a-3371b and the adjacent side spring arms 3312b, 3312d, and (ii) a second combination of limiting structures 3315b, namely, the edges 3332a-3332b of the substantially vertical wings 3375a-3375b and the adjacent side spring arms 3312a, 3312c.

[0208] The outer surfaces 3373a-3373b of the lateral protrusions 3371a-3371b are positioned outside or beyond the inner surfaces 3346 of the opposing corrugations 3382a-3382b. In other words, the length between the outer surfaces 3373a-3373b of the lateral protrusions 3371a-3371b is greater than the width W of the inner linear surface extending between the inner surfaces 3346 of the opposing corrugations 3382a-3382b. ILS An external force F is applied to contact arms 3180a and 3180c. E Only the maximum compression distance D that can deform contact arms 3180a and 3180c MC Because the inner surfaces 3372 of the lateral protrusions 3371a-3371b contact the forward spring arm edges 3334a and 3334b of the side spring arms 3312b and 3312d. In this embodiment, the maximum compression distance D MC The diameter is less than 1.25 mm, preferably less than 1.0 mm, and most preferably 0.85 mm. This limits the contact arms 3180a and 3180c from deforming or being compressed to the maximum compression distance D. MCThe degree to which contact arms 3180a, 3180c, spring arms 3312a, 3312c, and combinations thereof help prevent arms 3180a, 3180c from excessively deforming or pressing down toward the center of connector 3050 (e.g., greater than the maximum compression distance D). MC (distance).

[0209] The outer surfaces 3376a-3376b of the substantially vertical wings 3375a-3375b are positioned outside or beyond the inner surfaces 3346 of the opposing linear extensions 3316a, 3316c. In other words, the length between the outer surfaces 3376a-3376b of the substantially vertical wings 3375a-3375b is greater than the width W of the inner linear surface extending between the inner surfaces 3346 of the opposing linear extensions 3316a, 3316c. ILS An external force F is applied to contact arms 3180b and 3180d. E Only the maximum compression distance D that can deform contact arms 3180b and 3180d MC Because the inner surfaces 3374 of the substantially vertical wings 3375a-3375b contact the linear extension edges 3332a, 3332b of the top spring arm 3312a and the bottom spring arm 3312c (specifically, the linear extensions 3316a, 3316b of the side spring arms 3312b, 3312d). In this embodiment, the maximum compression distance D MC The diameter is less than 1.25 mm, preferably less than 1.0 mm, and most preferably 0.85 mm. This limits the contact arms 3180b and 3180d from deforming or being compressed to the maximum compression distance D. MC The degree to which contact arms 3180b, 3180d, spring arms 3312b, 3312d, and combinations thereof help prevent arms 3180b, 3180d from being excessively deformed or pressed down toward the center of connector 3050 (e.g., greater than the maximum compression distance D). MC (distance).

[0210] Spring arms 3312a-3312d are generally planar and positioned substantially perpendicular to the outer surface of the rear wall 3306. This configuration is advantageous over previously disclosed spring arms that extend outward at an angle because insertion force calculations are simplified, the size of the terminal assembly 3100 is reduced, alignment of the spring members is more reliable, and other benefits will be apparent to those skilled in the art based on this disclosure. (See PCT / US2018 / 019787) Figures 4-8Unlike the disclosed spring arm 31, the free ends 3330a-3330d of spring arms 3312a-3312d do not have curved end members. However, for the small corrugations 3382a-3382b, spring arms 3312a-3312d have substantially flat outer surfaces. This construction is advantageous because it ensures that the force associated with spring 3300 is applied substantially perpendicular to the end of male terminal body 3104. Conversely, in PCT / US2018 / 019787... Figures 4-8 The curved component of the disclosed spring arm 31 does not apply force in this manner.

[0211] In an alternative embodiment not shown, the spring member 3300 may include a recess and associated reinforcing ribs. As discussed in PCT / US2019 / 036010, these changes in the construction of the spring member 3300 alter the force associated with the spring 3300. Specifically, the spring biasing force S BF This is the amount of force applied by the spring member 3300 to resist the inward deflection of the free end of the spring member 3300 when the male terminal assembly 3100 is inserted into the female terminal assembly 700. Specifically, this inward deflection occurs during the insertion of the male terminal assembly 3100 because the extension of the outer surface of the male terminal body 3104 is slightly larger than the interior of the female receiving portion 704. Therefore, when the male terminal assembly 3100 is inserted into the female terminal assembly 2430, the extension of the outer surface is pushed toward the center of the male terminal 3101. This inward force on the outer surface causes the free ends 3330a-3330d of the spring member 3300 to shift inward (i.e., toward the center). The spring member 3300 provides a wedging effect or spring deflection force S. F This resists inward displacement. In other embodiments, spring arms 3312a-3312d can be coupled to other structures to limit their omnidirectional expansion or compression. The number and width of individual spring arms 3312a-3312d and openings can vary. Furthermore, the widths of individual spring arms 3312a-3312d are generally equal; however, in other embodiments, one of the spring arms 3312a-3312d may be wider than the others.

[0212] c. Fifth and Sixth Embodiments

[0213] Figures 101-104The third and fourth embodiments of male terminal connection members 4102 and 5102 are shown, which can be used in place of male terminal connection members 102, 1102, 2102, 3102, or 6102 shown and described herein. Because the contact structures in these embodiments of systems 4010 and 5010 are substantially similar to those in the fourth embodiment of contact system 3010, it should be understood that, for brevity, reference numerals shown in the drawings may be omitted from the description, as identical structures have the same reference numerals. For example, the disclosure relating to male terminal 3101 is not repeated here, but it applies to male terminals 4101 and 5101 as if it 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 application. Instead, reference should be made to disclosures of similar structures that may be discussed in another part of this application or in other applications incorporated herein by reference. In this embodiment, male terminal connection member 3102 is replaced by male terminal connection members 4102 and 5102.

[0214] d. Seventh Implementation Method

[0215] Figures 106-112 A seventh embodiment of the male terminal assembly 6100 is shown, comprising a mesh frame 6400 and a spring member 6300, which may be used in place of the sheath 3101 and spring member 3300 shown and described above. Because the structures in contact with this embodiment of system 6010 are substantially similar to those in the fourth embodiment of system 3010, it should be understood that, for brevity, reference numerals shown in the figures may be omitted from the specification due to the identical reference numerals for the same structures. For example, the disclosure relating to male terminal 101 is not repeated here, but applies to male terminal 6101 as if it were repeated here. 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 application. Instead, reference should be made to disclosures of similar structures that may be discussed in another part of this application or in other applications incorporated herein by reference. Similar to the fourth embodiment, this seventh embodiment of the male connector assembly 6050 includes a plurality of components designed to be coupled to individual devices or components (e.g., charging connector 2, radiator fan, heating base, power distribution component, or another current-drawing component). The male connector assembly 6050 mainly includes: (i) a male housing assembly 6070, and (ii) a male terminal assembly 6100 with a male terminal 6101, a spring member 6300 and a sheath 6400, wherein, during operation of the connector system 6010, at least a considerable extension of the male terminal assembly 6100 is located within the male housing assembly.

[0216] 1) Spring component

[0217] refer to Figures 107-109 The spring member 6300 includes arrangements of spring member sidewalls 6304a-6304d and a rear spring wall 6306. Each spring member sidewall 6304a-6304d includes: (i) a first or curved spring segment 6310a-6310d, and (iii) a second segment or spring arm 6312a-6312d. The curved spring segments 6310a-6310d extend between the rear spring wall 6306 and the spring arms 6312a-6312d, and position the spring arms 6312a-6312d substantially perpendicular to the rear spring wall 6306. In other words, the outer surfaces 6313a-6313d of the spring arms 6312a-6312d are substantially perpendicular to the outer surface of the rear spring wall 6306. Figure 107 and Figure 109 As shown, spring arms 6312a-6312d extend from the first or curved spring sections 6310a-6310d of the spring member 6300 away from the rear spring wall 6306 and terminate at a free end 6318. Spring arms 6312a-6312d are not connected to each other, thus forming spring arm gaps 6320a-6320d between the spring arms 6312a-6312d of the spring member 6300. Spring arm gaps 6320a-6320d facilitate omnidirectional extension of the spring arms 6312a-6312d, which facilitates the mechanical connection between the male terminal 6101 and the female terminal assembly 700.

[0218] Spring arms 6312a-6312d are generally planar and positioned such that the outer surfaces 6313a-6313d of the spring arms 6312a-6312d are substantially perpendicular to the outer surface of the rear wall 6306. (This is in accordance with PCT / US2018 / 019787.) Figures 4-8 Unlike the spring arms 31 disclosed herein, the free ends 6318 of the spring arms 6312a-6312d do not have curved components. Instead, the spring arms 6312a-6312d have substantially planar outer surfaces 6313a-6313d. This configuration is advantageous because it ensures that the force associated with the spring member 6300 is applied to the front spring contact sections 6196a-6196d and the intermediate spring contact sections 6198a-6198d of the contact arms 6180a-6180d. Conversely, in PCT / US2018 / 019787... Figures 4-8 The curved component of the disclosed spring arm 31 does not apply force in this manner.

[0219] In an alternative embodiment not shown, the spring member 6300 may include a recess and associated reinforcing ribs. These variations in the construction of the spring member 6300, as discussed in PCT / US2019 / 036010, alter the force generated or applied by the spring member 6300. Specifically, the spring biasing force F... SB This force, F, is applied by the spring member 6300 to resist the inward deflection of the free end 6318 of the spring member 6300 when the male terminal assembly 6100 is inserted into the female terminal assembly 700. Specifically, this inward deflection occurs during the insertion of the male terminal assembly 6100 because the extension of the outer surface of the male terminal body 6104 is slightly larger than the interior of the female receiving portion 702. Therefore, when the male terminal assembly 6100 is inserted into the female terminal assembly 700, the extension of the outer surface is pushed towards the center of the male terminal 6101. This compressive force F on the outer surface of the male terminal body 6104... COM This causes the free end 6318 of the spring member 6300 to shift inward (i.e., towards the center). The spring member 6300 provides an outward-pointing spring biasing force F. SB To resist this inward displacement. In other embodiments, spring arms 6312a-6312d can be coupled to other structures to limit their omnidirectional expansion. The number and width of individual spring arms 6312a-6312d and openings can vary. Furthermore, the widths of individual spring arms 6312a-6312d are generally equal to each other; however, in other embodiments, one of the spring arms 6312a-6312d may be wider than the others.

[0220] 2) Sheath

[0221] Figures 111-112 The sheath comprises: (i) an upper section 6402, a front section 6430, and a lower section 6460. Unlike other embodiments of the sheaths 400 and 3400 disclosed herein, the front section 6430 of the sheath 6400 includes a front wall 6432 with a spring arm limiter 6450. The spring arm limiter 6450 extends inward from the inner surface of the front wall 6432a and is designed to interact with the spring arms 6312a and 6312c. An external force F is applied to the contact arms 6180a and 6180c. E Only the contact arms 6180a and 6180c can deform to the maximum compression distance D. MC This is because the inner surfaces of the front extensions of the spring arms 6312a and 6312c contact the outer surfaces 6451a and 6451b of the spring arm limiter 6450. In this embodiment, the maximum compression distance D... MC The diameter is less than 1.25 mm, preferably less than 1.0 mm, and most preferably 0.5 mm. This limits the contact arms 6180a and 6180c from deforming or being compressed to the maximum compression distance D. MCThe degree of protection prevents contact arms 6180a, 6180c, spring arms 6312a, 6312c and combinations thereof from being excessively deformed or compressed toward the center of connector 6050 (e.g., greater than the maximum compression distance D). MC (distance).

[0222] e. Eighth Implementation Method

[0223] Figures 118-138 An eighth embodiment of the male terminal assembly 7100 is shown, comprising: (i) a spring member 7300, which may replace the spring assembly 300 shown and described above, and (ii) a male terminal 7101, which may replace the male terminal 101 shown and described above. Because the structures in contact in this embodiment of system 7010 are substantially similar to those described in other parts of this application, and because the same structures have the same reference numerals, it should be understood that, for brevity, [reference numerals may be used]. Figures 118-138 Reference numerals shown in the figures are omitted in the written disclosure. For example, the disclosure relating to sheath 1400 is not repeated here, but applies to sheath 7400 as if it were repeated herein. In other words, the omission of reference numerals for components in the eighth embodiment of male terminal assembly 7100 from the functional description or specific disclosure of the components in the eighth embodiment of male terminal assembly 7100 does not limit the disclosure of this application. Rather, reference can be made to disclosures of similar structures that may be discussed in another part of this application or in other applications incorporated herein by reference.

[0224] a. Public terminal

[0225] Figures 118-125 The male terminal 7101 of this eighth embodiment shown is similar to Figures 6A-10The male terminal 101 of the first embodiment is shown. However, the initial or rear extensions 182a-182d extending from the base or intermediate portion 110 (line C2) of the contact arms 180a-180d in the first embodiment have been eliminated in this eighth embodiment of the male terminal 7101. Instead, the material contained in the initial or rear extensions 182a-182d of the first embodiment has been added to the geometrically bent or folded portions 7178a-7178d of the contact arms 7180a-7180d in this eighth embodiment of the male terminal 7101. In other words, the second or upwardly inclined extensions 7184a-7184d of the contact arms 7180a-7180d have been extended (compared to the first embodiment) and are directly connected to the base or intermediate portion 7110. In other words, the contact arms 7180a-7180d do not have extensions coplanar with the extensions of the base or intermediate portion 7110. Although the first initial or rear extension 182a-182d of the contact arm 180a-180d of the first embodiment has been omitted in this eighth embodiment, the contact arm 7180a-7180d of this eighth embodiment still includes all portions contained within the geometrically curved or bent portions 178a-178d of the contact arm 180a-180d of the first embodiment.

[0226] In addition to extending the length of the geometrically curved or bent portions 7178a-7178d of the contact arms 7180a-7180d (compared to the first embodiment), the angle α extending between the outer surface of the base or intermediate portion 7110 and the outer surfaces 7185a-7185d of the upwardly inclined extensions 7184a-7184d of the contact arms 7180a-7180d is larger and has been increased compared to the first embodiment. Specifically, the angle α in the first embodiment is between 115 degrees and 170 degrees, preferably between 125 degrees and 145 degrees, while the angle α in the eighth embodiment is between 125 degrees and 179 degrees, preferably between 150 degrees and 170 degrees. Similarly, by extending the length of the upwardly inclined extensions 7184a-7184d of the contact arms 7180a-7180d, the angle α is positioned closer to the center of the male terminal 7101 compared to the first embodiment of the male terminal 101. Furthermore, the change in angle α between the first embodiment and the eighth embodiment also changes angle θ, which is defined between the outer surfaces 7185a-7185d of the upwardly inclined extensions 7184a-7184d and the outer surfaces or contact surfaces 7189a-7189d of the downwardly inclined extensions 7188a-7188d. Specifically, in the first embodiment, angle θ is between 240 degrees and 300 degrees, preferably between 255 degrees and 285 degrees, while in the eighth embodiment, angle θ is between 215 degrees and 275 degrees, preferably between 235 degrees and 255 degrees.

[0227] In this eighth embodiment of the male terminal 7101, the first initial or rear extension 182a-182d of the first male terminal embodiment of the contact arms 180a-180d is omitted, such that a gap 7107 is formed between the outer surface of the spring arms 7312a-7312d and the inner surface of the contact arms 7180a-7180d. This gap 7107 is in Figures 132-133 The best illustration is shown in the diagram. Due to the arrangement of the gap 7107, the contact arms 7180a-7180d are not supported along their entire length by the spring arms 7312a-7312d. Other modifications can be shown by comparing the embodiments included in this disclosure; however, an additional modification is that the support ribs 116a-116c and their associated structures have been omitted from this embodiment. It should be understood that this disclosure considers other modifications to the male terminal 7101. For example, support ribs may be incorporated into this embodiment.

[0228] b. Spring components

[0229] The spring member 7300 disclosed in this eighth embodiment utilizes different types of compression-limiting devices 314, 1314, 2314, and 3314. Similar to the compression-limiting device 3314, the structure of the compression-limiting device 7314 included in this embodiment is entirely integrally formed into the spring member 7300. The compression-limiting device 7314 can... Figures 124-130The best illustration shows that it is formed by a combination of compression tabs 7370 and the edges 7371 of adjacent spring arms 7312a-7312d. The compression tab 3370 includes: (i) rear protrusions 7372a-7372d extending outward from the spring arms 7312a-7312d at line S6 and terminating at end faces 7373a-7373d, wherein the rear protrusions 7372a-7372d include inner surfaces 7374a-7374d; (ii) front protrusions 7375a-7375d extending outward from the spring arms 7312a-7312d at line S5 and terminating at end faces 7376a-7376d, wherein the front protrusions 7375a-7375d include inner surfaces 7377a-7377d; and (iii) limiting protrusions 7378a-7378d extending outward from the spring arms 7312a-7312d at line S6 and terminating at end faces 7379a-7379d. Here, each spring arm 7312a-7312d includes three compression tabs 7370 (i.e., front protrusions 7375a-7375d, rear protrusions 7372a-7372d, and restraining protrusions 7378a-7378d), wherein the front protrusions 7375a-7375d are substantially aligned with the restraining protrusions 7378a-7378d, and the rear protrusions 7372a-7372d are positioned between the rear wall 7306 and the restraining protrusions 7378a-7378d. It should be understood that, in alternative embodiments, a second set of restraining protrusions may be included in the spring member 7300, aligned with the rear protrusions 7372a-7372d, to minimize potential rotation of the spring arms 7312a-7312d during compression.

[0230] The extensions of the inner surfaces 7374a-7374d and 7377a-7377d of the rear protrusions 7372a-7372d and the front protrusions 7376a-7376d extend beyond the outer surface of the adjacent spring arms 7312a-7312d. In other words, the end faces 7373a-7373d and 7376a-7376d of the rear protrusions 7372a-7372d and the front protrusions 7376a-7376d are located outside the outer surface of the outer surface of the adjacent spring arms 7312a-7312d. In other words, the W of the rear protrusions 7372a-7372d and the front protrusions 7376a-7376d (extending from lines S5 and S6 to end faces 7373a-7373d and 7376a-7376d) FP W RP The width is greater than the opening distance D of the spring arm. SRO(It extends from the side surface of the spring arms 7312a-7312d to the outer surface of the adjacent spring arms 7312a-7312d). This structural arrangement helps prevent the spring arms 7312a-7312d from being excessively deformed or pressed toward the center of the connector 7050, which would cause the connector 7050 to fail or be damaged.

[0231] An external force F is applied to the contact arms 7180a-7180d. E (When the male terminal assembly is fully assembled) or when an external force F is applied to the spring arms 7312a-7312d. E (When the spring member 7300 is separated from the male terminal 7101) the contact arms 7180a-7180d or the spring arms 7312a-7312d must not deform beyond or pass through the excessive compression distance D. OC Conversely, the external force F E It can only deform the contact arms 7180a-7180d and / or the spring arms 7312a-7312d to the stress compression distance D. SC And preferably deformed to the working compression distance D WC This is because of the external force F. E This could result in: (i) the inner surfaces 7377a-7377d of the front protrusions 7375a-7375d contacting the end faces 7379a-7379d of the limiting protrusions 7378a-7378d located on the adjacent spring arms 7312a-7312d; and (ii) the inner surfaces 7374a-7374d of the rear protrusions 7372a-7372d contacting the side edges on the adjacent spring arms 7312a-7312d. For example, an external force F applied to the spring arm 7312a. E This allows: (i) the inner surface 7377a of the front protrusion 7375a to contact the end face 7379d of the limiting protrusion 7378d, and (ii) the inner surface 7374a of the rear protrusion 7372a to contact the side edge of the spring arm 7312b. Thus, the spring arm 7312a relies on the structure associated with the spring arms 7312b and 7312d to prevent it from being compressed only. In this embodiment: (i) the over-compression distance D MC Greater than 0.8 mm, (ii) stress compression distance D SC The distance is equal to or less than 0.8 mm, preferably less than 0.7 mm, most preferably 0.6 mm, and (iii) the working compression distance D WC The distance is less than 0.5 mm, preferably less than 0.4 mm, and most preferably 0.3 mm. Therefore, this allows the connector to compress from the working distance D. WC Move to the stress compression distance D SC Previously, this embodiment of connector 7050 could withstand an external force F of up to 6 Newtons.E The design of this terminal assembly 1100 can be more ideal than the first embodiment of the terminal assembly 100 because the means 7314 for limiting compression is entirely contained in a single structure (i.e., spring member 7300), which in turn can increase the durability and lifespan of the connector 7050 and the system 7010.

[0232] Information for the system

[0233] Systems 10, 1010, 2010, 3010, 4010, 5010, 6010, and 7010 conform to T4 / V4 / D2 / M2, wherein systems 10, 1010, 2010, 3010, 4010, 5010, 6010, and 7010 meet and exceed: (i) T4 exposes the system to temperatures from 10°C to 150°C, (ii) V4 is severe vibration, (iii) D2 is 200 km durability, and (iv) M2 requires less than 45 Newtons of force to connect male terminal assemblies 100, 1100, 2100, 3100, 4100, 5100, 6100, and 7100 to female terminal assemblies 700, 1700, 2700, 3700, 4700, 5700, 6700, and 7700. In addition to conforming to T4 / V4 / D2 / M2, systems 10, 1010, 2010, 3010, 4010, 5010, 6010, and 7010 also conform to Push, Dot, Drag, Scan (PCTS), with additional information about this standard disclosed in PCT / US2020 / 049870.

[0234] It should be understood that the male terminal assemblies 100, 1100, 2100, 3100, 4100, 5100, 6100 and 7100 and the female terminal assemblies 700, 1700, 2700, 3700, 4700, 5700, 6700 and 7700 disclosed in this application have the following specifications regarding an ambient temperature rise (RoA) of 55°C or 80°C and having 80% of their rated values: (i) wherein the outer perimeter of the male terminal assemblies 100, 1100, 2100, 3100, 4100, 5100, 6100 and 7100 is 8 mm, and their rated values ​​are 16 mm. 2The wire carries 210 amperes. Additionally, system 10 meets USCAR-20 mile durability, has a contact mating force between 10 and 30 Newtons, preferably 15 Newtons, a non-mating force possibly greater than the mating force, and meets a vibration standard of 31 Gs between 10 and 30 Newtons, preferably 18 Newtons, and is ISL / TPA compliant. These significant increases in current carrying capacity offer considerable advantages over prior art connectors while meeting USCAR specifications. Connector systems 10, 1010, 2010, 3010, 4010, 5010, 6010, and 7010 also meet the applicable USCAR-38 specifications.

[0235] It should be understood that this disclosure contemplates alternative constructions for the compression limiting devices 314, 1314, 3314, 4314, 5314, 6314, and 7314. For example, in other embodiments, the compression limiting device 3314 may be: (i) a protrusion extending outward from the spring arm and received by an opening in the sheath; (ii) a structure extending from one sidewall of the sheath to the opposite sidewall of the sheath, wherein the structure is configured to interact with the inner surface of the spring member; (iii) a contact arm nose, wherein the contact arm noses are configured to interact with each other; (iv) a structure extending through a contact opening formed in the sheath and positioned in a gap formed between the spring member and the contact arm; (v) interaction between opposing spring arms or contact arms; (vi) interaction between the sheath and the spring arm or contact arm; (vii) interaction between the housing assembly and the contact arm or spring arm; or (viii) any combination of these structures. It should also be understood that these compression tabs are not designed herein as alignment devices 3380; however, the compression tabs may extend to provide alignment. Additionally, this disclosure contemplates alternative male terminal housings. For example, the housing may include any number of male terminal assemblies 100, 1100, 2100, 3100, 4100, 5100, 6100, and 7100 (e.g., between 2 and 30, preferably between 2 and 8, most preferably between 2 and 4) that can be positioned within the housing. Furthermore, alternative constructions for female terminal assemblies are also possible. For example, the housing may include any number of female terminal assemblies that can be positioned within the housing (e.g., between 2 and 30, preferably between 2 and 8, most preferably between 2 and 4). Moreover, the female connector assembly may be reconfigured to accept these multiple male terminal assemblies as a single female terminal assembly. It should also be understood that male terminal assemblies 100, 1100, 2100, 3100, 4100, 5100, 6100, and 7100 can have any number of contact arms (e.g., between 2 and 100, preferably between 2 and 50, most preferably between 2 and 8) and any number of spring arms (e.g., between 2 and 100, preferably between 2 and 50, most preferably between 2 and 8). As mentioned above, the number of contact arms may not be equal to the number of spring arms. For example, there may be more contact arms than spring arms. Alternatively, there may be fewer contact arms than spring arms.

[0236] By citing the materials and publicly available information cited herein.

[0237] PCT application numbers PCT / EP2023 / 025203, PCT / EP2023 / 025202, PCT / EP2023 / 025059, PCT / EP2022 / 025551, PCT / US2022 / 037508, PCT / IB20 22 / 057772, PCT / US2021 / 057959, PCT / US2021 / 047180, PCT / US2021 / 043788, PCT / US2021 / 043686, PCT / US2021 / 033446, PCT / U U.S. Patent Application Nos. 16 / 194,891 and U.S. Provisional Applications Nos. 63 / 286,072 and 63 / 286,080, each of which is incorporated herein by reference in its entirety and is a part thereof.

[0238] SAE specifications, including J1742_201003, last revised in March 2010, entitled “Connections for high-voltage vehicle wiring harnesses – Test methods and general performance requirements,” each of which is incorporated herein by reference in its entirety and as a part thereof.

[0239] ASTM specifications, including (i) D4935-18, entitled “Standard Test Method for Measuring the Electromagnetic Shielding Effect of Planar Materials”, and (ii) ASTM D257, entitled “Standard Test Method for DC Resistance or Conductivity of Insulating Materials”, each of which is incorporated herein by reference in its entirety and as a part thereof.

[0240] Specifications from the American National Standards Institute and / or the EOS / ESD Association, Inc., including: ANSI / ESD STM11.11 Surface Resistance Measurement of Static Dissipative Planar Materials, each of which is fully incorporated herein by reference and is a part thereof.

[0241] DIN standards, including connectors for electronic equipment – ​​testing and measurement – ​​Part 5-2: test of 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 as part thereof.

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

[0243] Other standards, including Federal Test Standards 101C and 4046, each of which is incorporated herein by reference in its entirety and is a part thereof. While some implementations have been shown and described, many modifications may be contemplated without significantly 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 aforementioned component may be changed to: a triangular prism, a pentagonal prism, a hexagonal prism, an octagonal prism, a sphere, a cone, a tetrahedron, a cuboid, a dodecahedron, an icosahedron, an octahedron, an ellipsoid, or any other similar shape.

[0244] It should be understood that the following terms used in this article should generally mean the following: a. “High power” should mean (i) a voltage between 20 volts and 600 volts, regardless of current, or (ii) any current greater than or equal to 80 amperes, regardless of voltage.

[0245] b. “High current” should mean a current greater than or equal to 80 amperes, regardless of voltage.

[0246] c. “High voltage” should mean a voltage between 20 volts and 600 volts, and has nothing to do with current.

[0247] Titles and subtitles, if any, are used for convenience only and are not restrictive. The word "exemplary" is used to indicate that it is used as an embodiment or illustration. With regard to the use of terms including, having, etc., such terms are intended to be inclusive in a manner similar to the term "comprising," as interpreted when "comprising" is used as a transition word in the claims. Relational terms such as first and second, etc., can 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.

[0248] Phrases such as "one aspect," "this aspect," "on the other hand," "some aspects," "one or more aspects," "an implementation," "this implementation," "another implementation," "some implementations," "one or more implementations," "an embodiment," "this embodiment," "another implementation," "some implementations," "one or more implementations," "a configuration," "this configuration," "another configuration," "some configurations," "one or more configurations," "the subject matter," "disclosure," "this disclosure," "other variations," etc., are for convenience and do not imply that the disclosure associated with such a phrase is necessary for the subject matter or that such disclosure applies to all configurations of the subject matter. The disclosure associated with such a phrase may apply to all configurations, or one or more configurations. The disclosure associated with such a phrase may provide one or more embodiments. Phrases such as "one aspect" or "some aspects" may refer to one or more aspects, and vice versa, and this similarly applies to other foregoing phrases.

[0249] 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 considered as limiting the scope of this disclosure.

Claims

1. An electrical connector assembly for a power distribution component, the connector assembly comprising: A male connector assembly, including a male housing assembly and a male terminal assembly, wherein the male terminal assembly includes: The male terminal body has a receiving portion and at least one contact arm, the at least one contact arm having a curved portion defining the apex of the contact arm; A spring member having at least one spring arm, the at least one spring arm being configured to be located below the contact arm; A cover that can be opened; and Device for limiting excessive compression of the at least one contact arm caused by external force to prevent damage to the male terminal assembly; Among them, in the fully assembled state S FA In the above, (i) the spring member is positioned in the receiving portion of the male terminal body, and the spring arm is located below the contact arm, and (ii) the majority of the male terminal body and the spring member are located within the sheath.

2. The electrical connector assembly according to claim 1, wherein, The openable sheath has a contact arm opening, wherein at least one deflection protrusion is provided on both sides of the opening.

3. The electrical connector assembly according to claim 2, wherein, In the fully assembled state S FA In this configuration, the apex of the contact arm extends above the upper edge of the deflection protrusion.

4. The electrical connector assembly according to claim 2, wherein, The outer surface of the deflection protrusion is substantially parallel to the contact surface of the contact arm.

5. The electrical connector assembly according to claim 1, wherein, The at least one spring arm includes a curved portion formed by an upwardly inclined extension of the spring arm and a downwardly inclined extension of the spring arm.

6. The electrical connector assembly according to claim 5, wherein, The interior angle of the bent portion of the at least one spring arm is defined between the inner surface of the upwardly inclined extension and the inner surface of the downwardly inclined extension, wherein the interior angle is between 60 degrees and 120 degrees.

7. The electrical connector assembly according to claim 6, wherein, The interior angle of the bent portion of the at least one spring arm is between 75 degrees and 105 degrees.

8. The electrical connector assembly according to claim 6, wherein, The interior angle of the bent portion of the at least one spring arm is 80 degrees.

9. The electrical connector assembly according to claim 6, wherein, The inner angle of the bent portion of the at least one spring arm is a distinct acute angle.

10. The electrical connector assembly according to claim 1, wherein, The at least one spring arm of the spring member is a first spring arm having both a linear extension and a bent portion, the linear extension having a first width, the bent portion having a second width, and wherein the first width is greater than the second width.

11. The electrical connector assembly of claim 10, wherein, The spring member includes a second spring arm with a bent portion having a third width, wherein the third width is greater than the second width of the first spring arm.

12. The electrical connector assembly according to claim 1, wherein, The male terminal body includes a wall structure having an internal spring wall with an anti-rotation protrusion, wherein the anti-rotation protrusion is configured to be positioned in an anti-rotation recess formed in the spring member.

13. The electrical connector assembly of claim 12, wherein, The anti-rotation recess is formed between a pair of spring arms of the spring member.

14. The electrical connector assembly of claim 1, wherein, When the terminal assembly is in the fully assembled state S FA When, the at least one contact arm includes a free end that does not abut against the outer surface of the spring arm.

15. The electrical connector assembly according to claim 1, wherein, When the male terminal body is in the ready-to-receive position P R When the male terminal body is in the ready-to-use position P, the receiving portion of the male terminal body has a first front dimension. U At that time, the receiving part has a second front dimension, wherein the second front dimension is smaller than the first front dimension.

16. The electrical connector assembly of claim 15, wherein, The spring member includes two opposing spring arms, each spring arm having a curved portion defining a vertex of the spring arm, wherein an external dimension of the spring member is defined between the vertices of the spring arms, and wherein the external dimension of the spring member is larger than the second front dimension of the receiving portion of the male terminal body.

17. The electrical connector assembly of claim 1, wherein, The male terminal body includes a base portion having an outer surface, and wherein the at least one contact arm includes a linear extension having an outer surface coplanar with the outer surface of the base portion.

18. The electrical connector assembly of claim 1, further comprising a female connector assembly, the female connector assembly including a female housing assembly and a female terminal assembly.

19. The electrical connector assembly of claim 18, wherein, The male connector assembly and the female connector assembly are in connection state S C They are operatively connected together, wherein the front extension of each of the male terminal body, the spring member, and the sheath is received in the female terminal assembly.

20. An electrical connector assembly for a power distribution system in a vehicle, the connector assembly comprising: A male connector assembly, including a male housing assembly and a male terminal assembly, wherein the male terminal assembly includes: The male terminal body has a receiving part, a base part, and at least one contact arm extending from the base part; A spring member having at least one spring arm, the at least one spring arm being configured to be located below the contact arm; A compression limiting device configured to limit excessive compression of the at least one contact arm and the at least one spring arm; A cover that can be opened; and A compression limiting device is configured to limit excessive compression of the contact arm and the spring arm; In the fully connected state S FC In the above, (i) the spring member is positioned in the receiving portion of the male terminal body and the spring arm is located below the contact arm, (ii) the majority of the male terminal body and the spring member are located within the sheath, and (iii) the spring member, the male terminal body and the sheath are positioned within the male housing assembly.

21. The electrical connector assembly of claim 20, wherein, The openable sheath has a contact arm opening, wherein at least one deflection protrusion is provided on both sides of the opening.

22. The electrical connector assembly of claim 21, wherein, In the fully assembled state S FA In this configuration, the apex of the contact arm extends above the upper edge of the deflection protrusion.

23. The electrical connector assembly of claim 21, wherein, The outer surface of the deflection protrusion is substantially parallel to the contact surface of the contact arm.

24. The electrical connector assembly of claim 21, wherein, The at least one spring arm includes a curved portion formed by an upwardly inclined extension of the spring arm and a downwardly inclined extension of the spring arm.

25. The electrical connector assembly of claim 24, wherein, The interior angle of the bent portion of the at least one spring arm is defined between the inner surface of the upwardly inclined extension and the inner surface of the downwardly inclined extension, wherein the interior angle is between 60 degrees and 120 degrees.

26. The electrical connector assembly of claim 25, wherein, The inner angle of the bent portion of the at least one spring arm is between 75 and 105 degrees.

27. The electrical connector assembly of claim 25, wherein, The interior angle of the bent portion of the at least one spring arm is 80 degrees.

28. The electrical connector assembly of claim 25, wherein, The inner angle of the bent portion of the at least one spring arm is a distinct acute angle.

29. The electrical connector assembly of claim 21, wherein, The at least one spring arm of the spring member is a first spring arm having both a linear extension and a bent portion, the linear extension having a first width, the bent portion having a second width, and wherein the first width is greater than the second width.

30. The electrical connector assembly of claim 29, wherein, The spring member includes a second spring arm with a bent portion having a third width, wherein the third width is greater than the second width of the first spring arm.

31. The electrical connector assembly of claim 21, wherein, The male terminal body includes a wall structure having an internal spring wall with an anti-rotation protrusion, wherein the anti-rotation protrusion is configured to be positioned in an anti-rotation recess formed in the spring member.

32. The electrical connector assembly of claim 31, wherein, The anti-rotation recess is formed between a pair of spring arms of the spring member.

33. The electrical connector assembly of claim 32, wherein, When the terminal assembly is in the fully connected state S FC When, the at least one contact arm includes a free end that does not abut against the outer surface of the spring arm.

34. The electrical connector assembly of claim 21, wherein, When the male terminal body is in the ready-to-receive position P R When the male terminal body is in the ready-to-use position P, the receiving portion of the male terminal body has a first front dimension. U At that time, the receiving part has a second front dimension, wherein the second front dimension is smaller than the first front dimension.

35. The electrical connector assembly of claim 34, wherein, The spring member includes two opposing spring arms, each spring arm having a curved portion defining a vertex of the spring arm, wherein an external dimension of the spring member is defined between the vertices of the spring arms, and wherein the external dimension of the spring member is larger than the second front dimension of the receiving portion of the male terminal body.

36. The electrical connector assembly of claim 21, wherein, The base portion includes an outer surface, and wherein the at least one contact arm includes a linear extension having an outer surface coplanar with the outer surface of the base portion.

37. The electrical connector assembly of claim 21 further includes a female connector assembly, the female connector assembly comprising a female housing assembly and a female terminal assembly.

38. The electrical connector assembly of claim 22, wherein, The male connector assembly and the female connector assembly are operatively connected together in the connected state SC, wherein the front extension of each of the male terminal body, the spring member, and the sheath is received in the female terminal assembly.

39. The electrical connector assembly of claim 20, wherein, The male terminal body includes multiple contact arms, and the spring member includes multiple spring arms, wherein the number of contact arms is equal to the number of spring arms, and wherein, in the fully connected state S FC In the middle, a single spring arm is located below a single contact arm.

40. An electrical connector assembly for a power distribution component, the connector assembly comprising: A male connector assembly, including a male housing assembly and a male terminal assembly, wherein the male terminal assembly includes: The male terminal body has a receiving part, a base part, and a contact arm extending from the base part; A spring member includes: (i) a main spring arm located below the contact arm and including a front portion having an overcompression extension; and (ii) a pair of auxiliary spring arms located on the sides of the main spring arm and having an upper edge positioned at a distance from the overcompression extension of the main spring arm. Among them, in the fully assembled state S FA In the middle, (i) the spring member is positioned in the receiving part of the male terminal body, and the main spring arm is located below the contact arm, (ii) when the external force F E When applied to the contact arm, both the contact arm and the main spring arm are compressed inward, and (iii) when the additional external force F E When applied to the contact arm, further inward compression of the main spring arm is restrained by the contact between the overcompression extension of the main spring arm and the upper edge of the secondary spring arm, thereby preventing overcompression of the male terminal assembly.

41. The electrical connector assembly of claim 40, further comprising an openable sheath; and, in, In the fully assembled state S FA In this configuration, the majority of the male terminal body and the spring member are located within the sheath. The openable sheath has a contact arm opening, and at least one deflection protrusion is provided on both sides of the opening.

42. The electrical connector assembly of claim 41, wherein, The contact arm has a curved portion defining the vertex of the contact arm, and wherein, in the fully assembled state S FA In this configuration, the apex of the contact arm extends above the upper edge of the deflection protrusion.

43. The electrical connector assembly of claim 41, wherein, The outer surface of the deflection protrusion is substantially parallel to the contact surface of the contact arm.

44. The electrical connector assembly of claim 40, wherein, The main spring arm includes a curved portion formed by an upwardly inclined extension of the main spring arm and a downwardly inclined extension of the main spring arm.

45. The electrical connector assembly of claim 44, wherein, The inner angle of the curved portion of the main spring arm is defined between the inner surface of the upwardly inclined extension and the inner surface of the downwardly inclined extension, wherein the inner angle is between 60 degrees and 120 degrees.

46. ​​The electrical connector assembly of claim 45, wherein, The inner angle of the bent portion of the main spring arm is between 75 degrees and 105 degrees.

47. The electrical connector assembly of claim 45, wherein, The inner angle of the bent portion of the main spring arm is 80 degrees.

48. The electrical connector assembly of claim 45, wherein, The inner angle of the curved portion of the main spring arm is a distinct acute angle.

49. The electrical connector assembly of claim 40, wherein, The main spring arm has both a linear extension and a bent portion, the linear extension having a first width and the bent portion having a second width, wherein the first width is greater than the second width.

50. The electrical connector assembly of claim 40, wherein, The male terminal body includes a wall structure having an internal spring wall with an anti-rotation protrusion, wherein the anti-rotation protrusion is configured to be positioned in an anti-rotation recess formed in the spring member.

51. The electrical connector assembly of claim 50, wherein, The anti-rotation recess is formed between the main spring arm and the secondary spring arm of the spring member.

52. The electrical connector assembly of claim 40, wherein, When the male terminal body is in the ready-to-receive position P R When the male terminal body is in the ready-to-use position P, the receiving portion of the male terminal body has a first front dimension. U At that time, the receiving part has a second front dimension, wherein the second front dimension is smaller than the first front dimension.

53. The electrical connector assembly according to claim 52, wherein, The spring member includes a pair of main spring arms, each main spring arm having a curved portion defining a spring arm vertex, wherein an external dimension of the main spring member is defined between the spring arm vertices, and wherein the external dimension of the main spring member is larger than the second front dimension of the receiving portion of the male terminal body.

54. The electrical connector assembly of claim 52, wherein, Each of the sub-spring arms has a curved portion defining a spring arm vertex, wherein an external dimension of the sub-spring member is defined between the spring arm vertices, and wherein the external dimension of the sub-spring member is larger than the second front dimension of the receiving portion of the male terminal body.

55. The electrical connector assembly of claim 53, wherein, Each of the sub-spring arms has a curved portion defining a spring arm vertex, wherein an external dimension of the sub-spring member is defined between the spring arm vertices, and wherein the external dimension of the sub-spring member is substantially equal to the external dimension of the sub-spring member.

56. The electrical connector assembly of claim 40, wherein, The base portion of the male terminal body has an outer surface, and wherein the contact arm of the male terminal body includes a linear extension having an outer surface coplanar with the outer surface of the base portion.

57. The electrical connector assembly of claim 40, wherein, The male terminal body includes a support rib extending from the base portion, the length of which is less than the length of the contact arm of the male terminal body.

58. The electrical connector assembly of claim 40, wherein, The overcompression extension includes opposing flanges extending outward from the free end of the main spring arm.

59. The electrical connector assembly of claim 40, wherein, Each second spring arm includes a protruding extension having one of its upper edges positioned at a distance from the overcompression extension of the main spring arm, and wherein the protruding extension is positioned in front of and beyond the overcompression extension of the main spring arm.

60. The electrical connector assembly of claim 59, further comprising an openable sheath; and, in, In the fully assembled state S FA In this case, the protruding extension of the second spring arm of the spring member is received in an opening formed in the openable sheath.

61. The electrical connector assembly of claim 40, wherein, The male terminal body includes multiple contact arms, and the spring member includes multiple main spring arms and multiple auxiliary spring arms, wherein the number of contact arms is equal to the total number of main spring arms and auxiliary spring arms, and wherein, in the fully assembled state S FA In the middle, a single spring arm is located below a single contact arm.

62. The electrical connector assembly of claim 40 further includes a female connector assembly, the female connector assembly comprising a female housing assembly and a female terminal assembly.

63. The electrical connector assembly of claim 62, wherein, The male connector assembly and the female connector assembly are in connection state S C They are operatively connected together, wherein the front extension of each of the male terminal body, the spring member, and the sheath is received in the female terminal assembly.

64. An electrical connector assembly for a power distribution system, the connector assembly comprising: A male connector assembly, including a male housing assembly and a male terminal assembly, wherein the male terminal assembly includes: The male terminal body has a receiving part, a base part, and at least one contact arm extending from the base part; A spring member having at least one spring arm configured below the contact arm, wherein the at least one spring arm includes a front portion having a sheath protrusion extension; The sheath can be opened and has a spring-loaded arm opening; and Among them, in the fully assembled state S FA In the above, (i) the spring member is positioned in the receiving portion of the male terminal body and the main spring arm is located below the contact arm; (ii) most of the male terminal body and the spring member are located within the sheath; (iii) when an external force F... E When applied to the contact arm, both the contact arm and the main spring arm shift inward, and (iv) when an additional external force F is applied... E When applied to the contact arm, further inward displacement of the main spring arm is constrained by direct contact between the inner surface of the sheath protrusion extension of the at least one spring arm and the inner compression edge of the spring arm opening, thereby preventing excessive displacement of the male terminal assembly.

65. The electrical connector assembly of claim 64, wherein, The sheath protrusion extension includes an inner surface that directly contacts the inner compression edge of the spring arm opening to prevent damage to the male terminal assembly.

66. The electrical connector assembly of claim 65, wherein, The sheath protrusion extension defines the foremost portion of the spring member.

67. The electrical connector assembly of claim 64, wherein, The at least one spring arm includes a curved portion formed by an upwardly inclined extension of the main spring arm and a downwardly inclined extension of the main spring arm.

68. The electrical connector assembly of claim 67, wherein, The inner angle of the curved portion of the main spring arm is defined between the inner surface of the upwardly inclined extension and the inner surface of the downwardly inclined extension, wherein the inner angle is between 60 degrees and 120 degrees.

69. The electrical connector assembly of claim 68, wherein, The inner angle of the bent portion of the main spring arm is between 75 degrees and 105 degrees.

70. The electrical connector assembly of claim 68, wherein, The inner angle of the bent portion of the main spring arm is 80 degrees.

71. The electrical connector assembly of claim 68, wherein, The inner angle of the curved portion of the main spring arm is a distinct acute angle.

72. The electrical connector assembly of claim 64, wherein, The main spring arm has both a linear extension and a bent portion, the linear extension having a first width and the bent portion having a second width, wherein the first width is greater than the second width.

73. The electrical connector assembly of claim 64, wherein, The male terminal body includes a wall structure having an internal spring wall with an anti-rotation protrusion, wherein the anti-rotation protrusion is configured to be positioned in an anti-rotation recess formed in the elastic member.

74. The electrical connector assembly of claim 73, wherein, The anti-rotation recess is formed between a pair of spring arms of the spring member.

75. The electrical connector assembly of claim 64, wherein, When the male terminal body is in the ready-to-receive position P R When the male terminal body is in the ready-to-use position P, the receiving portion of the male terminal body has a first front dimension. U At that time, the receiving part has a second front dimension, wherein the second front dimension is smaller than the first front dimension.

76. The electrical connector assembly of claim 75, wherein, The at least one spring arm of the spring member includes a pair of main spring arms, each main spring arm having a curved portion defining a spring arm vertex, wherein an external dimension of the main spring member is defined between the spring arm vertices, and wherein the external dimension of the main spring member is larger than the second front dimension of the receiving portion of the male terminal body.

77. The electrical connector assembly of claim 75, wherein, The at least one spring arm of the spring member further includes a pair of secondary spring arms, each secondary spring arm having a curved portion defining a spring arm vertex, wherein an external dimension of the secondary spring member is defined between the spring arm vertexes, and wherein the external dimension of the secondary spring member is larger than the second front dimension of the receiving portion of the male terminal body.

78. The electrical connector assembly of claim 75, wherein, The at least one spring arm of the spring member further includes a pair of secondary spring arms, each secondary spring arm having a curved portion defining a vertex of the spring arm, wherein an external dimension of the secondary spring member is defined between the vertices of the spring arms, and wherein the external dimension of the secondary spring member is substantially equal to the external dimension of the secondary spring member.

79. The electrical connector assembly of claim 64, wherein, The base portion of the male terminal body has an outer surface, and wherein the contact arm of the male terminal body includes a linear extension having an outer surface coplanar with the outer surface of the base portion.

80. The electrical connector assembly of claim 64, wherein, The male terminal body includes a support rib extending from the base portion, the length of which is less than the length of the contact arm of the male terminal body.

81. The electrical connector assembly of claim 64, wherein, The at least one spring arm includes a first spring arm having the sheath protrusion extension and a second spring arm having a front portion with an overcompression extension, wherein the first spring arm is located on the side of the second spring arm and has an upper edge positioned at a distance from the overcompression extension.

82. The electrical connector assembly according to claim 81, wherein, The overcompression extension includes opposing flanges extending outward from the free end of the second spring arm.

83. The electrical connector assembly according to claim 81, wherein, The sheath protrusion extension of the first spring arm is located in front of and beyond the overcompression extension of the second spring arm.

84. The electrical connector assembly of claim 64, wherein, The male terminal body includes multiple contact arms, and the spring member includes multiple spring arms, wherein the number of contact arms is equal to the number of spring arms, and wherein, in the fully assembled state S FA In the middle, a single spring arm is located below a single contact arm.

85. The electrical connector assembly of claim 64, further comprising a female connector assembly, the female connector assembly including a female housing assembly and a female terminal assembly.

86. The electrical connector assembly of claim 85, wherein, The male connector assembly and the female connector assembly are in connection state S C They are operatively connected together, wherein the front extension of each of the male terminal body, the spring member, and the sheath is received in the female terminal assembly.

87. The electrical connector assembly of claim 64, wherein, The at least one spring arm of the spring member includes (i) a first pair of spring arms having a front portion with a sheathed protrusion extension, wherein the first pair of spring arms are in a relative positional relationship; and (ii) a second pair of spring arms having a front portion with an overcompression extension, wherein the second pair of spring arms are in a relative positional relationship; and The first pair of spring arms and the second pair of spring arms are oriented at a 90-degree angle.

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