Connectors with a tongue connection for a power connector system

Abstract

Connector (104) comprising: a housing (130) with a plug end (132) and a cable end (134), wherein the plug end (132) is designed to be mated with a header connector (102) in a mating direction, and a tongue connector (116) which is held in the housing (130) at the plug end (132), wherein the tongue connector (116) has a front edge (212) which is designed to be mated with a header connector (114) of the header connector (102) when the connector (104) is mated with the header connector (102), wherein the front edge (212) is tapered inwards so that the tongue connector (116) is mated sequentially with the header connector (114) during mating.

Description

The present subject matter relates generally to connectors for power connector systems. Power terminals are used to establish a power connection between components in high power applications, such as in electric or hybrid vehicles, between the battery and other components, such as the electric motor, inverter, charger, and the like.EP 2 426 788 A1 discloses an electrically conductive contact arrangement having a fork-shaped spring contact unit and a blade contact unit which can be fixed in an electrically conductive manner in the spring contact unit, wherein the fork-shaped spring contact unit is constructed from a plurality of flat or plate-like spring fork contacts which are held connected to one another at least partially directly adjoining one another at a carrier. The carrier is in particular connected to a connection unit for at least one electrical conductor or a printed circuit board.However, due to the high power requirements, the electrical connectors typically include many contacts to increase the current carrying capacity of the circuits. Many contact points result in high connector mating forces. Moreover, the power terminals, especially in automotive applications, are subject to vibrations and wear over time. The spring arms that establish the electrical connection between the power terminals may deteriorate over time and reduce the stability of the system. The use of spring arms with higher normal force to compensate for such stability problems results in high connector mating forces. There remains a need for a power connector system with reduced connector mating forces without sacrificing the number of contact points or contact normal force.One solution to the problem is provided by a connector as disclosed herein having a housing with a mating end and a cable end. The mating end is designed to mate with a header connector (header or header connector) in a mating direction. A tongue terminal is held in the housing at the plug end. The tab terminal has a front edge configured to mate with a header terminal (header terminal) of the header connector when the connector is mated with the header connector. The front edge is formed to taper inwardly so that the tongue terminal is sequentially fitted to the header terminal during fitting.In another embodiment, a connector according to the invention comprises a housing having a mating end and a cable end, the mating end being configured to mate with a header connector in a mating direction, and a tab terminal retained in the housing at the mating end. The tab terminal has a front edge configured to mate with a header terminal of the header connector when the connector is mated with the header connector. The front edge is formed in a tapered manner, so that the tongue terminal is sequentially fitted to the header terminal during fitting. The tab terminal also has a rear edge opposite to the front edge, which has the same shape as the front edge.The invention also includes a power connector system comprising a header connector having a header terminal with contact surfaces; and a connector according to the invention wherein the leading edge of the tab terminal is angled relative to the contact surfaces of the header terminal.The invention will now be described by way of example with reference to the accompanying drawings. In which: FIG. 1 is a perspective view of a power connector system formed according to an exemplary embodiment and showing a connector and a header connector in an assembled and mated state. FIG. 2 is a perspective view of the power connector system showing the connector and the header connector in an unmated state. FIG. 3 is a bottom perspective view of the connector according to an exemplary embodiment. FIG. 4 is a top plan view of the header connector according to an exemplary embodiment. FIG. 5 is a perspective view of a portion of the power connector system showing tab terminals and header terminals. FIG. 6 is a side view of a portion of the power connector system showing the male terminal ready for mating with the header terminals. FIG. 7A shows the plug connection partially plugged together with the header connections. FIG. 7B is a close-up view of the contact surface between the male terminal and one of the header terminals along a first angled surface of the male terminal. FIG. 8 shows the plug connection which is completely plugged together with the header connections. FIG. 9 is a side view of the male terminal according to an exemplary embodiment. FIG. 10 is a side view of the male terminal according to an exemplary embodiment. FIG. 11 is a diagram illustrating the insertion forces between a plug connection and contact elements of a header connection with simultaneous contact attack. FIG. 12 is a diagram illustrating the insertion forces between a plug connection and contact elements of a header connection with offset contact engagement.FIG. 1 is a perspective view of a power connector system 100 formed according to an example embodiment in an assembled and plugged-together state. FIG. 2 is a perspective view of the power connector system 100 in an unmated state. The power connector system 100 includes a header connector 102 and a connector 104 configured to mate with the header connector 102. In an exemplary embodiment, power connector system 100 is a high power connector system used to transfer power between various components as part of a high power circuit. In one particular application, the power connector system 100 is a battery system, such as a battery system of a vehicle, such as an electric vehicle or a hybrid electric vehicle; however, the power connector system 100 is not intended to be limited to such battery systems.The connector 104 is configured to be electrically connected to a component 110, for example, via one or more power cables 106. For example, the connector 104 may be electrically connected to a battery, charging device, inverter, electric motor, or other type of component. The header connector 102 is configured to be electrically connected to a component 112, for example, via a power bus 108; however, the header connector 102 may also be electrically connected to the component 112 by another means, such as a terminal, a power wire, or another connector. For example, the header connector 102 may be electrically connected to a battery pack, such as via a battery distribution unit, a manually operable disconnect device, a charger, an inverter, an electric motor, or another type of component. The battery distribution unit may manage the power capacity and functionality of the power connector system 100, for example, by measuring the current and regulating the power distribution of the battery pack.The power connector system 100 is a right angle connector system in which the connectors 102, 104 are mated in a direction perpendicular to the power wires. Optionally, the connector 104 may be removably coupled to the header connector 102 for disconnecting the high power circuit of one or more of the components, such as the battery pack, the electric motor, the inverter, or other components of the vehicle, for example, for maintenance, repair, or other purposes. In the plugged-together state, one or more header terminals 114 (FIG. 2 ) of the header connector 102 are plugged together with the corresponding plug terminals 116 (shown in FIG. 3 ) of the plug connector 104, e.g., at their contact surfaces. A larger number of terminals 114 and / or 116 increase the current carrying capacity of the system 100. Optionally, each male terminal 116 may be connected to a corresponding power cable 106.In an exemplary embodiment, the header connector 102 and / or the connector 104 may include a high voltage interlock (HVIL) circuit to control the high voltage power circuit when opening and closing or mating and unmating the connectors 102, 104. For example, both connectors 102, 104 may include corresponding HVIL terminals. The HVIL circuit may be electrically connected to the component 112 and / or the component 110. In an exemplary embodiment, the connector 104 uses a lever 118 to mate or disengage the connectors 102, 104 that can open / close the high voltage circuit and the HVIL circuit upon disengagement from the mating / mating of the connectors 102, 104. The HVIL circuit may be opened during the disconnection from the connector to shut down the high voltage circuit before the terminals 116, 114 are opened or disconnected, which may reduce the likelihood of damage, such as from arcs. In an exemplary embodiment, the high voltage conductive surfaces of the connectors 102, 104 are finger resistant and touch resistant.The header connector 102 includes a header housing (header or header housing) 120 having a mating end 122. The header housing 120 holds one or more of the header terminals 114. Optionally, the header terminals 114 may be bifurcated terminals having socket members defined by spring arms on both sides of the socket members to mate with both sides of the plug terminal 116, as described in more detail below; however, other types of header terminals may also be used in alternative embodiments. The header terminals 114 may be sheathed to protect the header terminals 114. For example, the header terminals 114 may have covers or touch protection elements 124, such that the header terminals 114 are touch-proof. The header housing 120 includes a flange 126 for securing the header housing 120 to another component, such as a frame or other support structure. Optionally, the header housing 120 may be mounted horizontally, but other orientations are possible in alternative embodiments. In an exemplary embodiment, the header housing 120 includes guide members 128 for guiding mating of the electrical connector 104 with the header connector 102. The guide members 128 may be, for example, ribs, columns, slots, coding members, or other types of guide members.The connector 104 includes a connector housing 130 configured to be coupled to the header housing 120. The plug housing 130 includes a plug end 132 and a cable end 134. The power cables 106 extend from the cable end 134. The mating end 132 is connected to the mating end 122 of the header housing 120. In an exemplary embodiment, the housing 130 is a rectangular housing that holds the power cables 106 and the plug terminals 116 perpendicular to a plugging direction along a plugging axis 136. The power cables 106 are arranged at right angles with respect to the plug axis 136. Other orientations are possible in alternative embodiments.In an exemplary embodiment, the lever 118 is rotatably coupled to the housing 130. The lever 118 is configured to engage the header housing 120, such as corresponding guide members 128, to attach the connector 104 to the header connector 102. Optionally, the lever 118 may include a slot that receives corresponding guide members 128 for controlling mating and unmating of the connector 104 with the header connector 102. For example, when the lever 118 is rotated to the closed position, the housing 130 may be pulled down onto the header housing 120. Conversely, when the lever 118 is lifted, the housing 130 can be pushed away from the header housing 120 and can be released from the plug connection with the header housing 120. The high power circuit and the HVIL circuit of the power connector system 100 may be opened and closed when the connector 104 is disconnected from and plugged into the header connector 102.FIG. 3 is a bottom perspective view of the connector 104 according to an example embodiment. The plug housing 130 holds the plug terminals 116 in a plug chamber 138. The plug chamber 138 is open at a bottom 140 of the plug housing 130 to expose the plug terminals 116. Portions of the header connector 102 (shown in FIG. 2 ) may be received by the bottom surface 140 in the plug chamber 138. For example, the header terminals 114 (shown in FIG. 2 ) may be received in the plug chamber 138 for electrical connection to the plug terminals 116.In an exemplary embodiment, the connector 104 includes cover or touch protection elements 144 such that the male terminals 116 are touch-proof. The touch protection elements 144 can be, for example, bridges or beams that extend over the underside of the plug connections 116. The touch protection elements 144 are formed of a dielectric material, such as plastic. The touch protection elements 144 are positioned relative to portions of the connector housing 130 such that gaps or spaces are small enough to be touch-proof.In an exemplary embodiment, the connector 104 includes a shield 146 for electrically shielding the connector 104. Optionally, the shield 146 may be at least partially positioned within the plug chamber 138 such that the shield 146 surrounds the plug chamber 138 and / or the plug terminals 116. The shield 146 may be electrically connected to the electrical shield of the power cables 106. The shield 146 may be configured to be electrically connected to the header connector 102. Optionally, the connector 104 may include a seal 148 in or around the connector chamber 138. The seal 148 may engage the header connector 102 to provide an environmental seal between the connector 104 and the header connector 102.FIG. 4 is a top plan view of the header connector 102 according to an example embodiment. The header connector 102 is configured to be mounted to a frame 150 or other support structure. Optionally, the header connector 102 may be electrically connected to the frame 150 to ground. The header housing 120 defines a header chamber 152 configured to receive a portion of the connector 104 (shown in FIG. 3 ). For example, the header chamber 152 may be defined by shroud walls 154 of the header housing 120.The header terminals 114 are supported by the header case 120. The header ports 114 may be supported by port support walls 156. The terminal support walls 156 may define the touch protection elements 124 to form the header connector 102 in a touch-proof manner. The terminal support walls 156 may be provided, for example, along the sides and / or ends of the header terminals 114.In an exemplary embodiment, two header ports 114 are configured to mate with each plug port 116 (shown in FIG. 3 ). The header terminals 114 may define various circuits or may be part of common circuits. For example, the two header ports 114 plugged together with the same plug port 116 may be part of a common circuit, and the header ports 114 plugged together with different plug ports 116 may define different circuits. Optionally, the provision of multiple header terminals 114 increases the current capacity of the header connector 102. The header connector 102 includes four header ports 114 in the embodiment shown, but may include fewer or more header ports 114 in other embodiments.In an exemplary embodiment, the header connector 102 includes a shield 162 supported by the header housing 120. The shield 162 serves to electrically shield the header terminals 114. The shield 162 is provided in the header chamber 152 and may extend to the bottom of the header connector 102 to electrically connect to the frame 150. For example, the shield 162 may be grounded to the frame 150.FIG. 5 is a perspective view of a portion of the power connector system 100 having the header housing 120 and the plug housing 130 removed to illustrate the plug terminals 116 and the header terminals 114. The plug terminals 116 are connected to the power cables 106. The plug terminals 116 may be welded to the power cables 106, for example. The male terminal 116 may be connected to the power cable 106 by other means, such as crimping, in an alternative embodiment. In the embodiment shown, the male terminals 116 are tab terminals that include tab or blade portions. The male terminals 116 will be referred to as tab terminals 116 below. Each tongue terminal 116 is generally planar (at least along the tongue or knife portion) and extends between a mating end 200 and a cable end 202.The tab terminal 116 includes the first and second sides 204, 206 that extend along a longitudinal axis 208 between a tip 210 of the tab terminal 116 and the cable end 202. The tab terminal 116 includes a front edge 212 and a rear edge 214 on the lower and upper sides of the tab terminal 116, respectively. The leading edge 212 is the edge of the tab terminal 116 that is plugged into one or more of the header terminals 114.The header terminals 114 are configured to be electrically connected to the tab terminals 116. In an exemplary embodiment, the header terminals 114 are also electrically connected to the power buses 108 of the header connector 102 (shown in FIG. 2 ). However, in alternative embodiments, the header ports 114 may be integrally formed with the power buses 108. In the embodiment shown, the header ports 114 are dual-ended bifurcated ports and may be referred to as bifurcated ports 114 below.Each of the header terminals 114 includes a series of contact elements 160 stacked side by side. Each contact element 160 includes a main body 220 between a first mating end 222 and a second mating end 224. The contact elements 160 each include a pair of spring arms 226 defining a socket 228 at the first mating end 222 and a pair of spring arms 230 defining a socket 232 at the second mating end 224. When the contact elements 160 are stacked together to define the header terminal 114, the receptacle elements 228 of the contact elements 160 are aligned within the header terminal 114 to define a tongue receptacle 234 at the first mating end 222. The tab socket 234 at the first mating end 222 is configured to receive the leading edge 212 of the tab terminal 116. Similarly, the receptacle members 232 of the individual contact members 160 within the header terminal 114 are aligned to define a bus bar receptacle 236 at the second mating end 224 that is configured to receive a mating end 238 of the corresponding power bus 108. In the embodiment shown, the spring arms 226 of the contact elements 160 in each header terminal 114 define a cradle contact 223 at the first mating end 222 and the spring arms 230 of the contact elements 160 define a cradle contact 225 at the second mating end 224.The spring arms 226, 230 are deflectable to receive the tab terminal 116 and the power bus 108, respectively. In the plugged-together state, the spring arms 226, 230 are spring-biased against the tongue connection 116 or the power bus 108. The spring arms 226 are disposed on both sides of the socket 228 to engage the first and second sides 204, 206 of the tab terminal 116.In an exemplary embodiment, each spring arm 226 defines a contact surface 240 at or near a distal end of the spring arm 226. The contact surfaces 240 may be defined by bumps or protrusions at the distal ends of the spring arms 226. In an exemplary embodiment, each fork contact 223 defined by a plurality of spring arms 226 stacked together includes a plurality of contact points with the tab terminal 116. For example, each contact surface 240 on a spring arm 226 in the stack defines a different contact point with the tab terminal 116. The provision of multiple contact elements 160 in each header terminal 114 defines multiple contact points between the tab terminal 116 and the header terminal 102. Increasing the number of contact elements 160 in each header terminal 114 and / or increasing the number of header terminals 114 increases the current capacity of the header connector 102.The cradle contact 225 at the second mating end 224 (e.g., the power bus mating side) of each header port 114 may operate the same as or similar to the cradle contact 223. Thus, the fork contacts 223, 225 of a header terminal 114 can be identical, for example, wherein the tongue terminal 116 is designed for insertion into the tongue socket 234 and the power bus 108 is designed for insertion into the busbar socket 236. The header terminals 114 are easy to manufacture and assemble. For example, the contact elements 160 may be stamped and formed, and any number of contact elements 160 may be arranged in common within each of the header terminals 114.FIG. 6 is a side view of a portion of the power connector system 100 showing the tab terminal 116 ready for mating with two header terminals 114. The header housing 120 and the plug housing 130 are removed for clarity. In an exemplary embodiment, the tab terminal 116 is shaped to reduce the plugging forces with the header terminals 114 (and their contact elements 160). The front edge 212 is angled non-orthogonally, for example, in order to enable sequential mating with the contact elements 160 of the header connections 114. For example, in the embodiment shown, the leading edge 212 is tapered inwardly to create a concave shape that may resemble a loop. For example, the front edge 212 includes a first angled surface 250 and a second angled surface 252 at different angles. For example, the first angled surface 250 may have a positive slope, while the second angled surface 252 may have a negative slope. The front edge 212 may have other shapes in alternative embodiments. For example, the front edge 212 cannot taper towards the inside, but rather can be formed so as to taper towards the outside, wherein the angled surfaces are e.g. angular. In further various embodiments, the leading edge 212 may include more than two angled surfaces. Optionally, the rear edge 214 may have an identical shape to the front edge 212 such that each edge of the tab terminal 116 may be inserted into the tab terminal 234 during mating. Optionally, instead of arranging the front edge 212 along the side, the front edge (e.g., the portion of the tab terminal 116) inserted into the tab socket 234 may be arranged at the tip 210.In an exemplary embodiment, the leading edge 212 is angled relative to the longitudinal axis 208. For example, the leading edge 212 is non-parallel relative to the longitudinal axis 208. In the embodiment shown, the first angled surface 250 is angled relative to the longitudinal axis 208 and the second angled surface 252 is angled relative to the longitudinal axis 208. The front edge 212 is not at right angles relative to the plug-in direction along the plug-in axis 136.The contact elements 160 of the header connections 114 are designed such that they engage with the tongue connection 116 at different times during the mating process. Thus, in the embodiment shown, for example, two header connections 114 are shown. One of the header terminals 114 is aligned with the first angled surface 250 and engages the tab terminal 116 on the first angled surface 250, while the second header terminal 114 is aligned with and engages the second angled surface 252. The contact elements 160 of the header connections 114 generally initially engage with the tongue connection 116 at different times during the mating process. For example, since the first angled surface 250 is angled relative to the contact surfaces 240 of the contact elements, each contact element 160 in the first header terminal 114 will make plug-in contact with the tab terminal 116 at a different time when the tab terminal 116 is inserted into the tab terminal 234. Similarly, each contact element 160 in the second header terminal 114 engages the second angled surface 252 at a different time.Optionally, the contact elements 160 of the first header terminal 114 may engage the tab terminal 116 while at the same time the corresponding contact elements 160 of the second header terminal 114 engage the tab terminal 116. For example, the outermost contact elements 160 in each header terminal 114 may simultaneously engage the tab terminal 116 when the tab terminal 116 is mated with the header terminals 114, and the innermost contact elements 160 of each header terminal 114 may simultaneously and also engage therebetween. However, since the majority of the contact elements 160 initially engage with the tongue terminal 116 at another point in time, the plugging forces are reduced. For example, each contact element 160 may have a maximum mating force at a particular point during mating with the tab terminal 116. Because each of the contact elements 160 within a single header terminal 114 engages the tab terminal 116 at a different time, the maximum mating forces are offset over time, reducing the overall mating force between the tab terminal 116 and the header terminals 114. As used herein, the times at which the contact elements 160 within the header terminals 114 engage the tab terminal 116 during mating refer to the times at which each contact element 160 first contacts the tab terminal 116.In an exemplary embodiment, the leading edge 212 has the concave shape with two opposing angled surfaces 250, 252 to balance mating forces during mating. For example, when the tab terminal 116 is inserted into the header terminal 114, the first angled surface 250 may tend to urge the tab terminal 116 to the right, while the second angled surface 252 may tend to urge the tab terminal 116 to the left. The mating forces are generally the same and opposite so that the tab terminal 116 is neither moved left nor right during mating. FIG. 6 shows the tab terminal 116 immediately prior to inserting the tab terminal 116 into the header terminals 114. For example, the contact surfaces of the outermost contact elements 160 of the header terminals 114 are immediately below the leading edge 212.FIG. 7A shows the tab terminal 116 partially mated with the header terminals 114. FIG. 7B shows a close-up view of the contact surface between the tab terminal 116 and one of the header terminals 114 along the first angled surface 252 of the tab terminal 116. FIG. 8 shows the tab terminal 116 fully mated with the header terminals 114. For example, as shown in FIGS. 7A and 7B, only the contact surfaces 240 of some outer contact elements 160 of the header terminals 114 engage the leading edge 212. The contact surfaces 240 of some inner contact elements 160 of the header terminals 114 are located below the front edge 212 (and are not connected to the tab terminal 116, for example). In contrast, FIG. 8 shows the tab terminal 116 being sufficiently inserted into the tab socket 234 of each of the header terminals 114 such that the contact surface 240 of each of the contact elements 160 engages the tab terminal 116.The leading edge 212 of the tab terminal 116 defines a plurality of contact surfaces 260. Each contact pad 260 is disposed in alignment directly over a contact pad 240 of the corresponding contact element 160 of the header terminals 114. As the tab terminal 116 is pressed down into the tab socket 234, the contact surfaces 260, 240 are sequentially plugged together. Thus, for example, at the time when one of the contact surfaces 260 comes into contact with the corresponding contact surface 240, the directly adjacent contact surface 260 on one side has already been plugged together beforehand, while the contact surface 260 on the opposite side remains unmated. Thus, only one of the contact surfaces 260 (along the first angled surface 252) is plugged together at a time. For example, FIG. 7B shows the contact pads 240A, 240B, 240C of adjacent contact elements 160 of a header terminal 114 aligned with the corresponding contact pads 260A, 260B, 260C of the tab terminal 116. The second contact pads 240B, 260B are located at the center of the first and third contact pads 240A, 240C, 260A, 260C. FIG. 7B shows the second contact pads 240B, 260B at the initial mating. The first contact pads 240A, 260A have been previously plugged together such that the spring arms 226 of the contact element 160 comprising the first contact pad 240A advance a distance along the sides 204, 206 (shown in FIG. 5 ) of the tab terminal 116. The third contact surfaces 240C, 260C are not yet in contact, but are the next contact surfaces that come into contact when the tab terminal 116 is advanced downward. The third contact pad 240C is arranged a short distance below the third contact pad 260C, such that the contact element 160 comprising the third contact pad 240C is not directly electrically connected to the tab terminal 116.FIG. 9 is a side view of an alternative tab terminal 116A. FIG. 10 is a side view of another alternative tab terminal 116B. The tab terminals 116A, 116B have different shapes than the tab terminal 116 (shown in FIG. 6 ). For example, the front edges 212A, 212B may be shaped differently than the front edges 212 (shown in FIG. 6 ). The front edges 212A, 212B are angled non-parallel to the longitudinal axis. The front edges 212A, 212B are not angled at right angles to the plugging direction. The tab terminal 116A has a tapered taper, while the tab terminal 116B has a widening taper. For example, the width of tab terminal 116A at tip 210 is narrower than near cable end 202, while the width of tab terminal 116B at tip 210 is wider than near cable end 202. In alternative embodiments, differently shaped tab terminals may be provided.FIG. 11 is a diagram showing insertion forces between a tab terminal and six contact points of a header terminal as provided by six contact elements with simultaneous contact engagement (in which all contact surfaces simultaneously engage, for example, when a flat or parallel leading edge is provided). FIG. 12 is a diagram showing insertion forces between a tab terminal and six contact points with offset contact engagement (with the contact surfaces engaging at different times, such as tab terminal 116 with angled leading edge 212 as shown in FIG. 6 ).During the mating process, for each contact element in the header terminal, the contact engagement between the tab terminal and the contact element exhibits an initially increasing insertion force, since the leading edge is first introduced into the tab terminal of the header terminal. The insertion force is increased to a maximum insertion force, after which the insertion force decreases slightly and can level. The insertion forces are defined by frictional forces between the contact elements and the tab terminal. For example, when the spring arms of the contact elements slide or wipe along the tab terminal, the header terminal receives an insertion force. Such frictional forces are influenced by the spring forces or clamping forces of the spring arms on the tongue connection, which can change if the spring arms are deflected outwards as a result of the tongue connection being introduced into the tongue socket, which leads to the maximum insertion force curve.When a plurality of contact elements in a header terminal are fitted to the tab terminal, the insertion forces have a cumulative effect. When the contact members are simultaneously fitted to the tab terminal, the maximum insertion forces simultaneously occur at the insertion distance D 1, resulting in a high total insertion force Fmax, as shown in FIG. 11. However, if the mating between the contact members and the tab terminal is performed offset, the mating forces are also offset, resulting in a reduced overall insertion force. For example, as shown in Fig. 12, since each of the force peaks is offset and occurs at different insertion distances D'1, D'2, D'3, D'4, D'5, D'6, the total insertion force F'max is reduced. However, the insertion force increases over a larger insertion distance (e.g., F'max is at D'6 as opposed to Fmax is at D1).It is to be understood that the above description is illustrative and not restrictive. For example, the above-described embodiments (and / or aspects thereof) may be used in combination with each other. Moreover, many changes may be made to adapt a particular situation or material to the teachings of the invention without departing from the scope of the disclosure. Dimensions, types of materials, orientations of the various components, as well as the number and position of the various components described herein are intended to define parameters of particular embodiments, are by no means limiting, and are merely exemplary embodiments. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those skilled in the art upon review of the foregoing description. The scope of the disclosure of the invention should therefore be determined with reference to the appended claims.

Claims

A connector (104) comprising: a housing (130) having a mating end (132) and a cable end (134), the mating end (132) configured to be mated with a header connector (102) in a mating direction; and a tab terminal (116) held in the housing (130) at the mating end (132), the tab terminal (116) having a front edge (212) configured to be mated with a header terminal (114) of the header connector (102) when the connector (104) is mated with the header connector (102), the front edge (212) being formed to taper inwardly such that the tab terminal (116) is sequentially mated with the header terminal (114) during mating.The connector (104) of claim 1, wherein the tab terminal (116) has a rear edge (214) opposite the front edge (212), the rear edge (214) having the same shape as the front edge (212).A connector (104) comprising: a housing (130) having a mating end (132) and a cable end (134), the mating end (132) configured to mate with a header connector (102) in a mating direction; and a tab terminal (116) retained in the housing (130) at the mating end (132), the tab terminal (116) having a front edge (212) configured to mate with a header terminal (114) of the header connector (102) when the connector (104) is mated with the header connector (102), the front edge (212) being tapered such that the tab terminal (116) is sequentially mated with the header terminal (114) during mating, and wherein the tongue terminal (116) has a rear edge (214) opposite the front edge (212), wherein the rear edge (214) has the same shape as the front edge (212).The connector (104) of any preceding claim, wherein the leading edge (212) is non-orthogonally angled relative to the mating direction.The connector (104) of any preceding claim, wherein the tab terminal (116) extends along a longitudinal axis (208) to a tip (210), the leading edge (212) angled non-parallel to the longitudinal axis.The connector (104) of any preceding claim, wherein sequentially mating with the header terminal (114) reduces the force of engagement of the tab terminal (116) with the header terminal (114).The connector (104) of any preceding claim, wherein the tab terminal (116) has first and second sides (204, 206) both configured to engage the header terminals (114).The connector (104) of any preceding claim, wherein the leading edge (212) comprises a first angled portion (250) and a second angled portion (252) having different angles.A power connector system (100) comprising a header connector (102) having a header terminal (114) with contact surfaces (240); and a connector (104) according to any preceding claim, wherein the leading edge (212) of the tab terminal (116) is angled relative to the contact surfaces (240) of the header terminal (114).The power connector system (100) of claim 9, wherein the tab terminal (116) includes a plurality of contact pads (260) along the leading edge (212), wherein adjacent contact pads (260) of the tab terminal (116) contact corresponding contact pads (240) of the header terminal (114) at different times.The power connector system (100) of claim 9 or 10, wherein the header terminal (114) comprises a plurality of contact elements (160) arranged in a stacked arrangement, wherein the leading edge (212) of the tab terminal (116) sequentially engages various contact elements (160) of the header terminal (114) during mating.

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