Connector system for use in power distribution systems

Abstract

The present invention provides a connector system for use in electrical power distribution systems found in automotive vehicles, including features that enhance the safety, durability, and reliability of the connector system and electrical power distribution system. The connector system includes a female connector assembly having a female housing, a female terminal assembly that is inserted into the female housing using a first force, and a touchproof member that is inserted into the female terminal assembly using a second force directed opposite the first force. The touchproof member prevents insertion of foreign objects into the female terminal assembly. The connector system also includes a male connector assembly having a male terminal assembly, and a male housing assembly having a touchproof element opening that receives an extent of the touchproof member. The male terminal assembly includes a male terminal body having a contact arm, the contact arm having a neck portion having a neck width and a body portion having a body width greater than the neck width. The male terminal assembly also includes a spring member that resides within a receiving portion of the male terminal body, the spring arm of the spring member applying an outward biasing force to the contact arm during operation of the electrical power distribution system.

Description

[Technical field]

[0001] The present disclosure relates to a connector system for use in electrical power distribution systems found in automotive vehicles such as cars, buses, or trucks. In particular, the connector system includes features that improve the safety, durability, and reliability of the connector system while reducing the time required to install the connector system in the electrical power distribution system and automotive vehicle.

[0002] (CROSS REFERENCE TO RELATED APPLICATIONS) This application claims priority to U.S. Provisional Application No. 63 / 222,859, filed July 16, 2021, and International Application No. PCT / US2021 / 043686, filed July 29, 2021, which are incorporated by reference herein and make a part of this specification. [Background technology]

[0003] Over the past several decades, the number of electrical components used in automobiles and other on-road and off-road vehicles, such as pickup trucks, commercial vans and trucks, truck trailers, motorcycles, all-terrain vehicles, and sport utility vehicles (collectively, "automotive vehicles") has increased dramatically. Electrical components are used in automotive vehicles for a variety of reasons, including, but not limited to, monitoring, improving, and / or controlling vehicle performance, emissions, safety, and creating comfort for automotive vehicle occupants. Although significant time, resources, and energy have been expended to develop electrical distribution components that meet the various needs and complexities of the automotive market, traditional electrical distribution components suffer from various shortcomings.

[0004] Automotive vehicles are harsh electrical environments for both electrical components and connector assemblies due to several conditions including, but not limited to, space constraints that make initial installation difficult, harsh operating conditions, wide ambient temperature ranges, long term vibration, heat loads, and life spans, all of which can lead to component and / or connector failure. For example, incorrectly installed connectors, which typically occur in the assembly plant, and loose connectors, which typically occur in the field, are two significant failure modes for electrical components and automotive vehicles. Each of these failure modes leads to significant repair and warranty costs. For example, the combined annual warranty costs incurred by automotive manufacturers and all of their direct suppliers are estimated to be between $50 billion and $150 billion worldwide. Summary of the Invention

[0005] The present disclosure relates to a connector system that provides a sealed and grounded electrical connection for components of a power distribution system, such as a battery pack, that complies with industry standards and / or specifications set by regulatory bodies as required for automotive vehicles. The connector system is suitable for use with mechanically and electrically connecting components or devices in power distribution systems found in aircraft, automotive vehicles, military vehicles, buses, locomotives, tractors, marine applications, or telecommunications hardware. Thus, the connector system is well suited to electrically and mechanically connect components or devices installed in vehicles in these high stress applications to ensure reliable long term performance and operation of the components, devices, and vehicles.

[0006] The connector system includes a female connector assembly having a female housing, a female terminal assembly inserted into the female housing using a first force, and a touchproof member inserted into the female terminal assembly using a second force directed opposite the first force. The touchproof member prevents insertion of foreign objects into the female terminal assembly. In one version, the touchproof member has a base and a touchproof fixation assembly having an arrangement of deformable retention members that resiliently deform from an original state to a deformed state during insertion of the touchproof member into the female terminal assembly. The touchproof member also has a touchproof element having a first end wall, a second end wall, and a connecting wall extending between the first and second end walls. In another version, the touchproof member includes a resiliently deformable base having a first base portion and a second base portion separated by a recess, the first base portion including at least one retention member depending therefrom, and the second base portion including at least one retention member depending therefrom. The touchproof element has a first extent extending from the resiliently deformable base and having a slot aligned with the recess separating the first and second base portions. When the touchproof member is inserted into the female terminal assembly, a foreign body distance of 5 mm or less is defined between the touchproof element and the first wall of the female terminal assembly.

[0007] The connector system also includes a male connector assembly having a male terminal assembly and a male housing assembly having a touchproof element opening for receiving an area of ​​the touchproof member. The male terminal assembly includes a male terminal body having a contact arm, the contact arm having a neck portion having a neck width and a body portion having a body width greater than the neck width. The male terminal assembly also includes a spring member residing within the receiver of the male terminal body, the spring arm of the spring member applying an outward biasing force to the contact arm to retain the male terminal assembly within the female terminal assembly during operation of the power distribution system.

[0008] The spring member also includes an arrangement of spring arms, a first spring arm having a locating projection extending from a free end thereof and a second spring arm having no locating projection. In the seated state, the spring member resides within the spring receiver whereby the locating projection of the first spring arm overlaps or wraps around an inner corner region of the first contact arm. The spring member further includes a third spring arm having a locating projection extending from a free end thereof. In the seated state, the locating projection of the third spring arm overlaps or wraps around an inner corner region of the third contact arm of the male terminal body. In the seated state, the engagement of the first and third spring arms with the first and third contact beams holds the spring member within the male terminal body and centers the spring member within the contact arm by limiting the amount the spring member can rotate within the male terminal body during operation of the power distribution system.

[0009] Additional structural and functional aspects and advantages of the connector system are disclosed in the detailed description and drawings. [Brief description of the drawings]

[0010] The accompanying drawings or figures, which are included to provide a further understanding, 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, like reference numbers refer to the same or similar elements throughout. In these drawings, [Figure 1] FIG. 1 is a perspective view of a first embodiment of a connector system for use in an electrical power distribution system. [Diagram 2] FIG. 2 is an exploded view of the connector system of FIG. 1, the connector system including a male connector assembly and a female connector assembly. [Diagram 3]FIG. 3 is a perspective view of the male connector assembly of FIG. 2 in an exploded state, the male connector assembly including (i) a male housing assembly, (ii) male terminal assemblies each having a male terminal and a spring member, (iii) a male shield assembly, and (vi) a male interlock ("MIL"). [Figure 4] FIG. 4 is a bottom perspective view of one of the male terminals of FIG. 3. [Figure 5A] 5 is a first side view of the male terminal of FIG. 4. [Figure 5B] 5 is a second side view of the opposite side of the male terminal of FIG. 4. FIG. [Figure 6A] FIG. 5 is a bottom view of the male terminal of FIG. [Figure 6B] FIG. 5 is a top view of the male terminal of FIG. [Figure 7A] FIG. 5 is a front view of the male terminal of FIG. [Figure 7B] FIG. 5 is a rear view of the male terminal of FIG. [Figure 8] FIG. 4 is a perspective view of the spring member of FIG. [Figure 9A] FIG. 8 is a plan view of the spring member of FIG. [Figure 9B] FIG. 8 is a bottom view of the spring member of FIG. [Figure 10] FIG. 8 is a side view of the spring member of FIG. [Figure 11] FIG. 8 is an end view of the spring member of FIG. [Figure 12] FIG. 4 is a perspective view of the male terminal assembly of FIG. 3 in an unseated state. [Figure 13A] FIG. 4 is a bottom view of one of the male terminal assemblies of FIG. 3 in a seated position. [Figure 13B] FIG. 12 is an end view of the male terminal assembly of FIG. [Figure 14A] 4 is a perspective view of the male terminal assembly and male terminal holder of FIG. 3 in an uncoupled state. [Figure 14B] 14 is a side view of the male terminal assembly and male terminal holder of FIG. 13 in a coupled state. [Figure 15] 15 is a perspective cross-sectional view of the male terminal assembly and male terminal holder taken along line 15-15 of FIG. 14B. [Figure 16] FIG. 16 is a cross-sectional view of the male terminal assembly and male terminal holder taken along line 16-16 of FIG. 14B. [Figure 17] 4 is a perspective view of the male connector assembly of FIG. 3 in a first partially assembled state, separated from the male terminal assembly, male terminal holder, and conductor lead. [Figure 18] FIG. 2 is a perspective view of a male shield assembly that is not separated from and partially surrounds the male terminal assembly, the male terminal holder, and the conductor lead. [Figure 19] 13 is a side view of the male connector assembly in a second partially assembled state with the primary locking member partially coupled to the main housing member and the secondary locking member omitted. FIG. [Figure 20] 20 is a cross-sectional view of the male connector assembly taken along line 20-20 of FIG. 19. [Figure 21] FIG. 21 is an enlarged view of area A of the male connector assembly of FIG. 20 showing the accidental engagement assembly. [Figure 22] FIG. 4 is a bottom perspective view of the male connector assembly of FIG. 3 in a third partially assembled state, with the primary locking member coupled to the main housing and the secondary locking member in a non-receiving state. [Diagram 23] FIG. 4 is a bottom perspective view of the male connector assembly of FIG. 3 in an assembled state, with the primary locking member coupled to the main housing member and the secondary locking member in a receiving state. [Figure 24] FIG. 2 is a side view of the male connector assembly in a ready to engage / disengage state with the primary locking member in an unlocked state. [Diagram 25] 25 is a cross-sectional view of the male connector assembly taken along line 25-25 of FIG. 24. [Figure 26] FIG. 26 is an enlarged view of region B of the male connector assembly of FIG. 25 showing the accidental engagement assembly. [Figure 27] 1 is a bottom perspective view of the male connector assembly in a limited engagement state with the primary locking member in a locked state; FIG. [Figure 28]FIG. 3 is a perspective view of the female connector assembly of FIG. 2 in an exploded state, the female connector assembly including (i) a female housing assembly, (ii) a touch-proof member, (iii) a female terminal assembly, (iv) a female shield assembly, and (v) a female interlock ("FIL"). [Figure 29] FIG. 29 is an end view of the female connector assembly of FIG. 28 in a first partially assembled state, with the FIL in a non-receiving position and the touchproof assembly in a non-installed position. [Diagram 30] 30 is a cross-sectional view of the female connector assembly taken along line 30-30 of FIG. 29. [Diagram 31] FIG. 29 is a perspective view of the female connector assembly of FIG. 28 in a second partially assembled state, with the FIL in a receiving position and the touchproof assembly in a non-installed position. [Diagram 32] FIG. 29 is a perspective view of the touchproof assembly of FIG. 28. [Diagram 33] FIG. 33 is a side view of the touchproof assembly of FIG. 32. [Diagram 34] FIG. 33 is an end view of the touchproof assembly of FIG. 32. [Diagram 35] FIG. 33 is a top view of the touchproof assembly of FIG. 32. [Diagram 36] FIG. 33 is a bottom perspective view of the touchproof assembly of FIG. 32. [Figure 37] FIG. 33 is a bottom view of the touchproof assembly of FIG. 32. [Figure 38] A bottom view of the female connector assembly of Figure 28 in a second, partially assembled state. [Figure 39] A cross-sectional view of the female connector assembly taken along line 39-39 of Figure 38. [Diagram 40] A bottom view of the female connector assembly of Figure 28 in a second, partially assembled state. [Diagram 41] 41 is a cross-sectional view of the female connector assembly taken along line 41-41 of FIG. 40. [Diagram 42]2 is an end view of the female terminal assembly and touchproof assembly of FIG. 1, the touchproof assembly being in an uninstalled position; [Diagram 43] A cross-sectional view of the female terminal assembly and the touchproof assembly taken along line 43-43 in Figure 42. [Diagram 44] FIG. 29 is an end view of the female connector assembly of FIG. 28 in a third partially assembled state, with the touchproof assembly in a partially installed position. [Diagram 45] A cross-sectional view of the female connector assembly taken along line 45-45 of Figure 44. [Figure 46] 29 is a perspective view of the female connector assembly of FIG. 28 in an assembled state. [Figure 47] FIG. 47 is a top view of the female connector assembly of FIG. 46. [Figure 48] FIG. 47 is a bottom view of the female connector assembly of FIG. 46. [Figure 49] A cross-sectional view of the female connector assembly taken along line 49-49 of Figure 48. [Figure 50] FIG. 2 is a bottom perspective view of the female terminal assembly and the touchproof assembly in an installed position. [Figure 51] FIG. 51 is a side view of the female terminal assembly and touchproof assembly of FIG. 50. [Figure 52] A cross-sectional view of the female terminal assembly and the touchproof assembly taken along line 52-52 of Figure 51. [Figure 53] FIG. 51 is an end view of the female terminal assembly and touchproof assembly of FIG. 50. [Figure 54] A cross-sectional view of the female terminal assembly and the touchproof assembly taken along line 54-54 in Figure 53. [Figure 55A] FIG. 2 is a bottom perspective view of the male connector assembly of FIG. 1 in an unlocked state with the primary locking member in a ready to engage / disengage state. [Figure 55B] FIG. 29 is a top view of the female connector assembly of FIG. 28 in an assembled state. [Figure 56A]FIG. 2 is a side view of the connector system of FIG. 1 in a disconnected state, with the male connector assembly in a ready-to-engage state and the male connector assembly spaced apart from the female connector assembly; [Figure 56B] A cross-sectional view of the connector system taken along line 56B-56B of Figure 56A. [Figure 57] FIG. 2 is a side view of the connector system of FIG. 1 in a partially connected state, where the male connector assembly is in a ready-to-engage state and the male connector assembly is not fully seated within the female connector assembly. [Figure 58] FIG. 58 is a cross-sectional view of the connector system taken along line 58-58 of FIG. 57. [Figure 59] FIG. 59 is an enlarged view of region C of the connector system of FIG. 58 showing the contingency engagement assembly. [Figure 60] FIG. 2 is a side view of the connector system of FIG. 1 in a partially connected state. [Figure 61] FIG. 61 is a cross-sectional view of the connector system taken along line 61-61 of FIG. [Figure 62] FIG. 62 is an enlarged view of region D of the connector system of FIG. 61 showing the contingency engagement assembly. [Figure 63] FIG. 2 is a top view of the connector system of FIG. 1 in a partially connected state. [Figure 64] FIG. 64 is a cross-sectional view of the connector system taken along line 64-64 of FIG. [Figure 65] FIG. 65 is an enlarged view of region E of the connector system of FIG. 64 showing the accidental disengagement assembly. [Figure 66] FIG. 65 is an enlarged view of area F of the connector system of FIG. 64 showing the CPA assembly. [Figure 67] FIG. 2 is a side view of the connector system of FIG. 1 in a connected state, with the male connector assembly fully seated within the female connector assembly and the primary locking member in an unlocked state. [Figure 68] FIG. 68 is a cross-sectional view of the connector system taken along line 68-68 of FIG. [Figure 69]FIG. 70 is an enlarged view of area G of the connector system of FIG. 68 showing the contingency engagement assembly. [Figure 70] FIG. 2 is a side view of the connector system of FIG. 1 in a connected state. [Figure 71] FIG. 71 is a cross-sectional view of the connector system taken along line 71-71 of FIG. [Figure 72] FIG. 72 is an enlarged view of region H of the connector system of FIG. 71 showing the contingency engagement assembly. [Figure 73] FIG. 2 is a plan view of the connector system of FIG. 1 in a connected state. [Figure 74] 74 is a cross-sectional view of the connector system of FIG. 73 taken along line 74-74. [Figure 75] FIG. 65 is an enlarged view of region I of the connector system of FIG. 64 showing the bracing assembly. [Figure 76] FIG. 65 is an enlarged view of region J of the connector system of FIG. 64 showing the CPA assembly. [Figure 77] FIG. 2 is a side view of the connector system of FIG. 1 in a ready-to-use condition, with the male connector assembly fully seated within the female connector assembly and the primary locking member in a locked condition. [Figure 78] FIG. 78 is a cross-sectional view of the connector system taken along line 78-78 of FIG. 77. [Figure 79] FIG. 70 is an enlarged view of region K of the connector system of FIG. 68 showing the contingency engagement assembly. [Figure 80] FIG. 2 is a side view of the connector system of FIG. 1 in a ready-to-use state. [Figure 81] FIG. 81 is a cross-sectional view of the connector system taken along line 81-81 of FIG. [Figure 82] FIG. 82 is an enlarged view of region L of the connector system of FIG. 81 showing the contingency engagement assembly. [Figure 83] FIG. 2 is a top view of the connector system of FIG. 1 in a ready-to-use state. [Figure 84] FIG. 84 is a cross-sectional view of the connector system taken along line 84-84 of FIG. 83. [Figure 85]FIG. 85 is an enlarged view of region M of the connector system of FIG. 84 showing the accidental disengagement assembly. [Figure 86] FIG. 85 is an enlarged view of region N of the connector system of FIG. 84 showing the CPA assembly. [Figure 87] FIG. 85 is an enlarged view of area O of the connector system of FIG. 84 showing the bracing assembly. [Figure 88] FIG. 2 is a side view of the connector system of FIG. 1 in a ready-to-use state. [Figure 89] FIG. 89 is a cross-sectional view of the connector system taken along line 89-89 of FIG. [Figure 90] FIG. 2 is a side view of the connector system of FIG. 1 in a ready-to-use state. [Figure 91] FIG. 91 is a cross-sectional view of the connector system taken along line 91-91 of FIG. [Figure 92] FIG. 2 is a bottom perspective view of the connector system of FIG. 1 in a connected state with all components omitted except for the male terminal assembly, the female terminal assembly, and the touchproof assembly. [Figure 93] FIG. 93 is a side view of the male terminal assembly, the female terminal assembly, and the touchproof assembly of FIG. 92. [Figure 94] 94 is a cross-sectional view of the male terminal assembly, the female terminal assembly, and the touchproof assembly taken along line 94-94 of FIG. 93. [Figure 95] FIG. 93 is a side view of the male terminal assembly, the female terminal assembly, and the touchproof assembly of FIG. 92. [Figure 96] 96 is a cross-sectional view of the male terminal assembly, the female terminal assembly, and the touchproof assembly taken along line 96-96 of FIG. 95. [Figure 97] FIG. 2 is a side view of the connector system of FIG. 1 in a connected state with non-conductive components removed. [Figure 98] FIG. 98 is a cross-sectional view of the connector system taken along line 98-98 of FIG. 97. [Figure 99A] FIG. 2 is a top view of the connector system of FIG. 1 in a ready-to-use state. [Figure 99B] A cross-sectional view of the connector system taken along line 99B-99B of Figure 99A. [Figure 100] FIG. 1 is a perspective view of a first embodiment of a power distribution system including a battery pack having at least one connector system. [Figure 101] FIG. 101 is a perspective view of the battery pack of FIG. 100 installed within the skateboard mounting platform of a vehicle. [Figure 102] FIG. 102 is a perspective view of a vehicle including the skateboard mounting platform of FIG. 101. [Figure 103] FIG. 1 is a perspective view of a passenger bus including a power distribution system having at least one connector system. [Figure 104] FIG. 1 is a perspective view of a marine vessel including a power distribution system having at least one connector system. [Figure 105] FIG. 1 is a perspective view of a vessel including an electrical power distribution system having at least one connector system. [Fig. 106] FIG. 1 is a perspective view of a second embodiment of a connector system for use in an electrical power distribution system. [Figure 107] FIG. 107 is an exploded view of the connector system of FIG. 106, the connector system including (i) a male connector assembly having a male terminal assembly, and (ii) a female connector system. [Figure 108] FIG. 108 is a perspective view of the male terminal assembly of FIG. 107 in an unseated state. [Fig. 109] FIG. 108 is a perspective view of the female connector assembly of FIG. 107 in an exploded state. [Figure 110] FIG. 109 is a perspective view of the female connector assembly of FIG. 109 in a first partially assembled state, with the second embodiment of the touchproof assembly in an uninstalled position. [Figure 111] FIG. 111 is a top perspective view of the touchproof assembly of FIG. 110. [Figure 112] FIG. 112 is a bottom perspective view of the touchproof assembly of FIG. 111. [Figure 113] FIG. 112 is a perspective view of the touchproof assembly of FIG. [Fig. 114] FIG. 112 is an end view of the touchproof assembly of FIG. 111. [Figure 115] FIG. 112 is a bottom view of the touchproof assembly of FIG. 111. [Fig. 116] FIG. 112 is a top view of the touchproof assembly of FIG. 111. [Figure 117] FIG. 111 is an end view of the female terminal assembly and touchproof assembly of FIG. 110 in a disengaged position. [Fig. 118] A cross-sectional view of the female terminal assembly and the touchproof assembly taken along line 118-118 of Figure 117. [Figure 119] FIG. 109 is an end view of the female connector assembly of FIG. 109 in a second partially assembled state, with the touchproof assembly in a partially installed position. [Figure 120] 120 is a cross-sectional view of the female connector assembly taken along line 120-120 of FIG. 119. [Figure 121] FIG. 111 is a top view of the female connector assembly of FIG. 109 in an assembled state. [Figure 122] 122 is a cross-sectional view of the female connector assembly taken along line 122-122 of FIG. 121. [Figure 123] FIG. 122 is a perspective view of the female connector assembly of FIG. 121. [Figure 124] 124 is a cross-sectional view of the female connector assembly taken along line 124-124 of FIG. 123. [Fig. 125] FIG. 125 is an enlarged view of region P of the connector system of FIG. [Fig. 126] 1 is a perspective view of a female terminal assembly and a touchproof assembly, the touchproof assembly being in an engaged position; [Figure 127] FIG. 127 is a bottom perspective view of the female terminal assembly and touchproof assembly of FIG. 126. [Figure 128] FIG. 127 is an end view of the female terminal assembly and touchproof assembly of FIG. 126. [Figure 129] 129 is a cross-sectional view of the female terminal assembly and the touchproof assembly taken along line 129-129 of FIG. 128. [Fig. 130] FIG. 127 is a perspective view of the female terminal assembly and touchproof assembly of FIG. 126. [Fig. 131] 131 is a cross-sectional view of the female terminal assembly and the touchproof assembly taken along line 131-131 of FIG. 130. [Fig. 132] FIG. 107 is a top view of the connector system of FIG. 106 in a ready-to-use state. [Fig. 133] 133 is a cross-sectional view of the connector system taken along line 133-133 of FIG. 132. [Fig. 134] FIG. 107 is a side view of the connector system of FIG. 106 in a ready-to-use state with all components omitted except for the male and female terminal assemblies. [Fig. 135] 135 is a cross-sectional view of the male and female terminal assemblies taken along line 135-135 of FIG. 134. [Fig. 136] FIG. 13 is a top perspective view of a third embodiment of a touchproof assembly configured for use with the second embodiment of the connector system. [Fig. 137] FIG. 137 is a bottom perspective view of the touchproof assembly of FIG. 136; [Figure 138] FIG. 137 is an end view of the touchproof assembly of FIG. 136. [Figure 139] FIG. 137 is a bottom view of the touchproof assembly of FIG. 136. [Fig. 140] FIG. 137 is a top view of the touchproof assembly of FIG. 136. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] In the following detailed description, numerous specific details are set forth by way of example in order to provide a thorough understanding of the teachings involved. However, it will be apparent to those skilled in the art that the teachings may be practiced without such detailed descriptions. In other instances, well-known methods, procedures, components, and / or electronic circuits are described at a relatively general level and without detailed descriptions in order to avoid unnecessarily obscuring aspects of the teachings. In the drawings, like reference numerals refer to the same or similar elements throughout the drawings.

[0012] The figures show two embodiments of a connector system 10, 1010 including a harness connector assembly or male connector assembly 200, 1200 and a component / device connector assembly or female connector assembly 600, 1600. Both versions of the connector system 10, 1010 include features integrated into both the male connector assembly 200, 1200 and the female connector assembly 600, 1600. Specifically, the first embodiment of the connector system 10 generally includes the following features: (i) a retention assembly 20 having a connector position assurance ("CPA") assembly 80, (ii) an optional touchproof assembly 40, (iii) an optional shield assembly 60, and (iv) an optional interlock ("IL") assembly 100. These features structurally and functionally interact to enable the connector system 10 to meet various industry performance standards and regulations, including (a) certain aspects of USCAR (e.g., USCAR12, USCAR25, USCAR38), (b) certain aspects of ISO (e.g., ISO20076:2019 and ISO20653:2013), (c) certain aspects of IEC (e.g., IEC60529-2020), and (d) performance and installation requirements including T4 / V4 / S3 / D2 / M2 and Push-Click-Tug-Scan (PCTS).

[0013] The retention assembly 20 of the connector system 10 is formed from a plurality of recesses and protrusions that structurally and functionally interact to secure the system 10 and to a predetermined high force threshold (e.g., 500 Newtons of force), i.e., (a) the accidental engagement force F AE (b) moving the male connector assembly 200 from a “ready to engage” state to a “limitedly engaged” state via an accidental disengagement force F AD , moving the system 10 from a “ready to use” state to a “connected” state; and (c) when the system 10 is in the “ready to use” state, applying an accidental engagement force F DIS 4, requires a threshold force to remove male connector assembly 200 from female connector assembly 600. The primary components of retention assembly 20 are (i) male retention assembly 222, which includes male accidental engagement assembly 336, accidental disengagement assembly 347, male bracing assembly 351, and male CPA assembly 400, and (ii) female retention assembly 622, which includes female accidental engagement assembly 652, female bracing assembly 648, and female CPA assembly 700. While CPA assembly 20 is part of retention assembly 20, CPA assembly 80 also enables system 10 to be PCTS compliant, eliminates the need for an air-assisted tool (e.g., air gun) to connect male terminal assembly 430 to female terminal assembly 800, and enables the generation of records indicative of proper installation of system 10 for accounting and system management purposes. Overall, the retention assembly 20 is beneficial because it (i) reduces installation time by reducing the need for additional tooling and ensuring that the male connector assembly 200 is ready to be coupled to the female connector assembly 600, (ii) increases durability by reducing inadvertent disengagement of the system 10, and (iii) provides accurate record-keeping that indicates that proper connections were made, as well as when and where such connections were made in the assembly process.

[0014] The optional touchproof assembly 40 allows the connector system 10 to meet industry regulations (e.g., USCAR12, ISO20076:2019, and ISO20653:2013) to protect against inadvertent insertion of foreign objects having a diameter greater than a certain size (e.g., 6 mm) into the female terminal assembly 800. These foreign objects may cause damage to installers / operators and machinery involved in assembling the connector system 10 and / or the power distribution system 5. The optional touchproof assembly 40 includes a male touchproof element opening 242 and a female touchproof member 720. Unlike conventional connector systems that may have components that allow them to meet industry regulations, the touchproof assembly 40 allows an installer or operator to add the female touchproof member 720 after the female connector assembly 600 is installed in an environment, application, system, component, or device. The subsequent addition of the female touchproof member 720 enables the touchproof assembly 40 to provide significant advantages to the connector system 10 of the present invention over conventional connectors because (i) the female touchproof member 720 does not add weight to the system 10 if this component is not desired, (ii) the female touchproof member 720 can be removed and / or replaced without tools or without requiring the installer / operator to spend valuable time disassembling the entire system 10, (iii) the female touchproof member 720 reduces maintenance costs since the component can be easily removed and provides access to the female terminal body 800, (iv) components of the system 10 can be manufactured at different times, shipped at different times, and installed at different times, which may be beneficial if there are shortages or delays in the supply chain that manufactures the touchproof assembly 40 including the female touchproof member 720, and (v) provides other benefits that will be apparent to one of ordinary skill in the art based on the following disclosure and figures.

[0015] The optional shield assembly 60 allows the connector system 10 to reduce electromagnetic noise that may otherwise be introduced into the automotive vehicle and operating environment in which the system 10 is installed. The reduction in electromagnetic noise allows for additional mounting locations for the system 10 near or adjacent to other electronic devices or components that are sensitive to electromagnetic noise, such as under the hood of the automotive vehicle. Finally, the optional interlock ("IL") assembly 100 ensures that no electrical current is applied to the connector system 10 before the male connector assembly 200 is fully engaged with the female connector assembly 600. In addition, unlike conventional connector systems that may have configurations that provide an interlock assembly, the disclosed connector system 10 allows an installer / operator to optionally add or remove the IL assembly 10 from the system 10. This selective addition or removal of the IL assembly 100 is advantageous over other disclosed systems because: (i) it does not add weight to the system if this component is not desired; (ii) it reduces the number of parts / stock keeping units ("SKUs") that the manufacturer defines and maintains; and (iii) it has other advantages that will be apparent to one of ordinary skill in the art based on the following disclosure and figures.

[0016] The second embodiment of the connector system 1010 includes the following features: (i) a CPA assembly 80, and (ii) an optional touch-proof assembly 1040. These features structurally and functionally interact to enable the connector system 1010 to meet various industry performance standards and regulations, including (a) certain aspects of USCAR (e.g., USCAR12, USCAR25, USCAR38, ISO20653), (b) certain aspects of ISO (e.g., ISO20653), and (c) performance and installation requirements including T4 / V4 / S3 / D2 / M2 and push-click tag scanning (PCTS). For the sake of brevity, the features and functions of the second embodiment of the connector system 1010 are similar to the features and functions of the first embodiment of the connector system 10. It should be understood that these omissions should not limit the disclosure of this application, but instead refer the reader to disclosures of similar structures that may be discussed in other sections of this application or in other applications incorporated by reference herein.

[0017] Unlike conventional connector systems that rely on ultrasonic welding of portions of the female housing together to form an electrical connection between the female terminal assembly and the housing of the power distribution component having the capacitor assembly, the disclosed connector system 1010 provides a combination of protrusions, recesses, and openings that work together to mechanically join and seal portions of the female housing 620 together. This is beneficial because it substantially increases the durability, operational performance, and lifespan of the system 1010. Additionally, the CPA assembly 80 and optional touchproof assembly 1040 enable the connector system 1010 to provide the same advantages provided by and described above in connection with the first embodiment of the connector system 10.

[0018] As shown in the figures, the connector system 10, 1010 is designed to provide mechanical and electrical coupling of conductors, leads or bus bars to components included in the power distribution system 5. The connector system 10, 1010 and the power distribution system 5 may be installed in an application. As used herein, the term "application" refers to an airplane, an automotive vehicle (e.g., an automobile, a bus, a van, a truck, or a motorcycle), a military vehicle (e.g., a tank, a personnel carrier, a lorry, and a naval carrier), a locomotive, a tractor, a boat, a submarine, a battery pack, a computer server, a 24-48 volt system, or any application or product requiring high power, high current, or high voltage. It should be understood that multiple connector systems 10, 1010 may be used in a single installation environment, application, product, component, or device. For example, multiple connector systems 10, 1010 may be used with a single component of the power distribution system 5. As another example, multiple connector systems 10, 1010 may be used in a first component of a power distribution system 5 and multiple connector systems 10, 1010 may be used in a second component of the same power distribution system 5, which is installed in a single application, such as an automotive vehicle.

[0019] Although the present disclosure includes embodiments in many different forms, the drawings show specific embodiments, which are described in detail herein, with the understanding that the disclosed method and system are considered as illustrative of its principles and are not intended to limit the broad aspects of the disclosed overview to the illustrated embodiments. As realized, the disclosed method and system are capable of other different configurations, and some details can be changed without departing from the scope of the disclosed method and system. For example, one or more of the following embodiments can be combined in part or in whole consistently with the disclosed method and system. Thus, the drawings and detailed description should be regarded as illustrative in nature, rather than restrictive or limiting.

[0020] First embodiment 1-98, a first embodiment of a connector system 10 includes a male connector assembly 200 and a female connector assembly 600. The male and female connector assemblies 200, 600 include the following features integrated into the assemblies 200, 600: (i) a retention assembly 20 including a male retention assembly 222 and a female retention assembly 622, (ii) a connector position assurance ("CPA") assembly 80 including a male CPA assembly 400 and a female CPA assembly 700, (iii) a touchproof assembly 40 including a male touchproof receptacle 242 and a female touchproof member 720, (iv) a shield assembly 60 including a male shield assembly 530 and a female shield assembly 930, and (v) an interlock ("IL") assembly 100 including a male IL assembly 590 and a female IL assembly 980.

[0021] 1. Male Connector Assembly 1-27, 55, and 57-98, connector system 10 includes male connector assembly 200. Male connector assembly 200 includes (i) male housing assembly 220 having male retaining assembly 222 having male CPA assembly 400, (ii) male terminal assembly 430, (iii) male shield assembly 530, and (iv) male IL assembly 590. Male retaining assembly 222 includes (i) male accidental engagement assembly 336 formed of two accidental engagement portions 337a, 337b, (ii) accidental disengagement assembly 347, and (iii) male bracing assembly 351 and male CPA assembly 400. As described below, (i) the first portion 377a of the male contingent engagement assembly includes (a) the contingent engagement slots 294a, 294b, and (b) the contingent engagement recesses 300a, 300b; (ii) the second portion 377b of the male contingent engagement assembly includes (a) the contingent engagement recesses 331a, 331b, (b) the contingent engagement retainers 332a, 332b, and (c) the contingent engagement members 338a, 338b; (iii) the contingent disengagement assembly 347 includes a first disengagement projection 287 and a disengagement member 348 having a second disengagement projection 342; (iv) the male bracing assembly 351 has a bracing opening 354; and (v) the male CPA assembly 400 includes a deformable male CPA member 406.

[0022] A. Male Housing Assembly As best shown in Figures 3 and 13-17, male housing assembly 220 includes (i) male terminal holder 230, (ii) shield insulator 260, (iii) main housing 280, (iv) primary locking member 320, (v) secondary locking member 360, (vi) end cap 380, and (vii) seals 390, 392. With reference to Figures 13-15, male terminal holder 230 is configured to receive male terminal assembly 430, isolate male shield assembly 530 from male terminal assembly 430, facilitate positioning and retention of male terminal assembly 430 within male connector assembly 200, and facilitate other functions that will be apparent to one of ordinary skill in the art based on the following disclosure and drawings. Male terminal holder 230 is bowl-shaped and has an interior wall arrangement 232 configured to snugly receive male terminal assembly 430. Specifically, the inner wall arrangement 232 includes two side walls 234a, 234b, two end walls 236a, 236b, and a bottom wall 238. Contact arm openings 240a, 240b are formed in the middle portions of the two side walls to allow the male terminal assembly 430 to contact the female terminal assembly 800 when the connector system 10 is in a connected state. As best shown in FIG. 16, the distance D2 between the opposing outermost extents of the contact arms 494a-494h is greater than the distance D1 between the opposing outermost surfaces of the side walls 234a, 234b. This configuration allows the contact arms 494a-494h to contact the female terminal assembly 800 without being impeded by the side walls 234a, 234b. This configuration provides additional rigidity to the male terminal assembly 430 and limits the amount of exposure of the male terminal assembly 430. However, due in part to the contact arm openings 240a, 240b, the entire male terminal assembly 430 is not received by the male terminal holder 230.

[0023] It should be appreciated that the further the male terminal assembly 430 extends beyond the outer surface of the side walls 234a, 234b, the greater the likelihood that the male terminal assembly 430 will inadvertently contact a foreign object. Thus, the extent to which the male terminal assembly 430 extends beyond the outer surface of the side walls 234a, 234b must balance the ability to form a proper connection with the female terminal assembly 800. The design disclosed herein balances these factors, with the extent of the male terminal assembly 430 extending beyond the outer surface of the side walls 234a, 234b by less than 2 mm, and preferably less than 0.5 mm. Compared to the length of the contact arm openings 240a, 240b, the extent to which the male terminal assembly 430 extends beyond the outer surface of the side walls 234a, 234b is less than 5% of the length, and preferably less than 3% of the length. The bottom wall 238 of the inner wall arrangement 232 includes a touchproof element opening 242 designed to receive a range of female touchproof members 720 when the connector system 10 is in a connected state. Notably, the touchproof element opening 242 mirrors the shape of the touchproof element 720. Here, the touchproof element 720 has an "I-shape," and thus the touchproof element opening 242 also has an "I-shape." As described below, other shapes of the touchproof element 720 are contemplated by the present disclosure, and thus other shapes of the touchproof element opening 242 are also contemplated by the present disclosure.

[0024] The male terminal holder 230 also includes an outer wall arrangement 244 that (i) surrounds the side and end walls 234a, 234b, 236a, 236b, (ii) is spaced from the inner wall arrangement 232 by a receptacle distance D3, and (iii) separates the male shield assembly 530 from the male terminal assembly 430. Specifically, the receptacle distance D3 is designed to receive the extent of the female terminal assembly 800 when the connector is in a connected state. However, the receptacle distance D3 is configured not to be large enough to receive the insertion of an assembler's finger, a probe, or another foreign object. For example, the receptacle distance D3 may be less than 10 mm, preferably less than 6 mm, and most preferably less than 3.5 mm. Outer wall arrangement 244 includes (i) mating openings 246a, 246b designed to receive a portion of shield insulator 260, (ii) a plurality of protrusions 248 that secure a portion of male shield assembly 530 to male terminal holder 230, (iii) an arrangement of recesses 250a-d designed to receive a portion of secondary locking member 360, and (iv) a first portion of retaining lip 252a positioned adjacent a front edge of male terminal connection plate 474. Each of these features is described below in conjunction with other components of connector system 10.

[0025] The male terminal holder 230 is configured to be placed in contact with both the shield assembly 60 and the male terminal assembly 430. Therefore, it is desirable to form the male terminal holder 230 from a non-conductive material. It should be understood that the non-conductive material selected should be capable of sufficiently insulating the terminal assembly 430 even when a high current load is flowing through the terminal assembly 430. As described elsewhere in this application, the male terminal holder 230 may be formed using any suitable method, such as injection molding techniques, 3D printing, casting, thermoforming, or any other similar technique. In other embodiments, the configurations of the inner wall arrangement 232 and the outer wall arrangement 244 may have different configurations to accommodate male terminal assemblies 430 of different shapes. For example, the inner wall arrangement 232 may be modified to include openings formed in the end walls 236a, 236b to accommodate male terminal assemblies 430 including contact arms 494a-494h positioned on all sides of the assembly 430 to conform to 360°. Alternatively, the interior wall arrangement 232 may have a substantially circular, triangular, or hexagonal configuration.

[0026] 13-17, the shield insulator 260 includes a cap 262 and a shroud 270 that are designed to mechanically interact or engage with the male terminal holder 230. In particular, the cap 262 includes (i) a horizontal portion, (ii) two vertically deformable projections 264a, 264b extending downwardly from the horizontal portion, (iii) two fixing elements 266a, 266b extending from the vertically deformable projections 264a, 264b, (iv) a second extent of the retaining lip 252b, and (v) a fixing recess 268. When the cap 262 is secured to the male terminal holder 230, (i) the fixing elements 266a, 266b are positioned within the mating openings 246a, 246b, and (ii) the vertically deformable projections 264a, 264b are removably positioned between the male terminal assembly 430 and the outer wall arrangement 244. In this secured position, the male terminal assembly 430 is mechanically secured within the male terminal holder 230 and insulated from the shield assembly 60 .

[0027] The shroud 270 includes (i) a rectangular arrangement of walls 272 designed to surround the male terminal connection plate 474 and the area of ​​the conductors 598, and (ii) a mating feature 274 that secures the shroud 270 to the male terminal holder 230. Specifically, the mating feature 274 is designed to interact with the first and second areas of the retaining lips 252a, 252b to separate the shield assembly 60 from the male terminal connection plate 474 to ensure that the cap 262 is not accidentally dislodged from the male terminal holder 230. Similar to the male terminal holder 230, the shield insulator 260 is designed to be placed in contact with both the male terminal assembly 430 and the shield assembly 60. For this reason, the shield insulator 260, similar to the male terminal holder 230, is desirably formed of a non-conductive material. It should be understood that the non-conductive material selected should be able to sufficiently insulate the terminal assembly 430 even when a high current load is flowing through the terminal assembly 430. As described elsewhere in this application, the shield insulator 260 may be formed using any suitable method, such as injection molding techniques, 3D printing, casting, thermoforming, or any other similar technique.

[0028] Main or primary housing 280 is a complex structure that includes numerous projections, recesses and openings to facilitate functions associated with male connector assembly 200. Specifically, main housing 280 can be broken down into two major portions: (i) a first portion is head or engagement portion 282 configured to receive male terminal assembly 430 and a majority of male terminal holder 230, and (ii) a second portion is body or support portion 310 configured to receive male terminal assembly 430 and a minor portion of conductor 598. Engagement portion 282 includes (i) an upper portion of sidewall 284, (ii) top wall 286, (iii) a lower portion of sidewall 288 depending from the upper portion of sidewall 284, and (iv) male CPA assembly 400. As best shown in Figures 65 and 85, the top wall 286 of the engagement portion 282 extends between the upper portions of the side walls 284 and includes a first disengagement projection 287 extending upwardly from the outer surface of the top wall 286. The first disengagement projection 287 has a sloping or sloped curved surface 290a and a forward angled flat surface 290b that forms an acute angle with the outer surface of the top wall 286, which together function to help ensure that the primary locking member 320 is not accidentally unlocked. As best shown in Figure 99B, the engagement portion 282 also includes two deformable male coupling projections 292a, 292b that extend rearwardly from the front wall of the upper portion of the side walls 284. The deformable male coupling protrusions 292 a , 292 b interact with locking recesses 268 formed in the shield insulator 260 to secure the male terminal holder 230 , and thereby the male terminal assembly 430 within the main housing 280 .

[0029] The outer surface of the lower portion of the sidewall 288 is positioned outside or beyond the outer surface of the upper portion of the sidewall 284. In other words, the distance between the opposing outer surfaces of the lower portion of the sidewall 288 is greater than the distance between the opposing outer surfaces of the upper portion of the sidewall 284. This arrangement makes the cross-sectional area of ​​the lower portion of the sidewall 288 greater than the cross-sectional area of ​​the upper portion of the sidewall 284. Specifically, the cross-sectional area of ​​the lower portion of the sidewall 288 is at least 5% greater than the cross-sectional area of ​​the upper portion of the sidewall 284, preferably 15% greater, and most preferably 25% greater. This is beneficial because the upper portion of the sidewall 284 primarily receives only the male terminal assembly 430, the male terminal holder 230, and the shield insulator 260, while the lower portion of the sidewall 288 receives the sealing member 390 and the secondary locking member 360. It should be understood that other configurations are contemplated by this disclosure, including where a lower location of sidewall 288 is aligned with an upper location of sidewall 283 .

[0030] The lower portion of the sidewall 288 includes (i) two contingency engagement slots or engagement slots 294a, 294b that are part of the first portion 337a of the contingency engagement assembly 336, (ii) two locating slots 296a, 296b, (iii) two stabilizing slots 297a, 297b, (iv) a CPA slot 298, (v) contingency engagement recesses or engagement recesses 300a, 300b that are part of the first portion 337a of the contingency engagement assembly 336, and (iv) a rear lip 301. The contingency engagement slots 294a, 294b are formed in the sidewall of the lower portion of the sidewall 288 and extend along a majority of the height of the sidewall 288 and are positioned between the rear wall of the lower portion of the sidewall 288 and the contingency engagement recesses 300a, 300b. As described in more detail below, the accidental engagement slots 294a, 294b help secure the male connector assembly 200 to the female connector assembly 600, facilitate movement of the locking member 320 from an unlocked state to a locked state, and are configured to prevent accidental movement of the male connector assembly from a ready to engage / disengage state to a limitedly engaged state. The accidental engagement recesses 300a, 300b extend downwardly from an upper edge of the lower disposed side wall of the side wall 288 and do not pass completely through the lower disposed side wall of the side wall 288. In particular, the accidental engagement recesses 300a, 300b include two areas: (i) a first area is an angled wall 302a, 302b extending forward from a front edge of the accidental engagement recesses 300a, 300b, and (ii) a second area is a flat wall 303a, 303b offset or recessed from the lower disposed sidewall of the sidewall 288 by more than 0.1 mm, preferably more than 0.75 mm, and substantially parallel to the lower disposed sidewall of the sidewall 288. The accidental engagement recesses 300a, 300b are configured to receive the areas of the primary locking member 320 when the primary locking member 320 is in a locked state.

[0031] The positioning slots 296a, 296b and the stabilizing slots 297a, 297b are positioned between the accidental engagement recesses 300a, 300b and the CPA slot 298 and are designed to receive a substantial protrusion that helps stabilize the connection between the male connector assembly 200 and the female connector assembly 600. The CPA slot 298 included in the male CPA assembly 400 is formed in the front wall of the lower arrangement of the sidewalls 288 and is designed to receive the extent of the female CPA assembly 700 when the system 10 is in a ready-to-use state. Surrounding the CPA slot 298 is a CPA sidewall arrangement 402, which, together with the front walls of the lower arrangement of the sidewalls 288 and the upper arrangement of the sidewalls 284, form a CPA receiving portion 404. The CPA receiving portion 404 is designed to accommodate a deformable male CPA member 406. The male CPA member 406 includes (i) two lateral connecting members 408a, 408b, (ii) two vertical support members 410a, 410b coupled to the lateral connecting members 408a, 408b, (iii) a horizontal engagement member 412 extending between the two lateral connecting members 408a, 408b, and (iv) a head or upper user interaction structure 414. The lateral connecting members 408a, 408b extend away from the front wall of the lower arrangement of sidewalls 288 toward the forward-most point of the CPA sidewall arrangement 402. The lateral connecting members 408a, 408b thus enable the male CPA member 406 to be transformed from a first or original position to a second or transformed position when the systems 10 are coupled together.

[0032] As per International Application PCT / US2020 / 049870, which is incorporated herein by reference for all purposes, the head, top, or user interaction structure 414 is designed such that the primary locking member 320 can interact therewith to place the CPA assembly 80 in the locked position. In addition, the user interaction structure 414 is also designed to be accessible by an installer such that a force can be applied to the user interaction structure 414 to disengage the elastically deformable male CPA member 406 from the extent of the female CPA assembly 700. The horizontal engagement member 412 is designed to interact with the extent of the female CPA assembly 700. Specifically, when the CPA assembly is in the locked position, the horizontal engagement member 412 (i) prevents the male connector assembly 200 from being coupled with the female connector assembly 600, or (ii) prevents the male connector assembly 200 from being accidentally disconnected from the female connector assembly 600. Finally, the CPA sidewall arrangement 402 protects the deformable male CPA member 406 and prevents it from being accidentally damaged or disengaged from the female connector 600. It should also be understood that the configuration of the male CPA assembly 400, and therefore the CPA assembly 80, can include different arrangements, combinations, or numbers of components. For example, the CPA assembly 80 can use magnetic forces, spring forces, require a partial rotation, or require a full rotational force, or a combination of these forces, to place the CPA assembly 80 in a locked or unlocked position.

[0033] The rear lip 301 extends downwardly from the rearmost portion of the head or engagement portion 282. Thus, any structure positioned forward of the rear surface of the rear lip is received within the engagement portion 282 of the main housing 280, and anything positioned rearward of the rear surface of the rear lip is received within the support portion 310 of the main housing 280. The support portion 310 includes (i) a wall arrangement 311 forming a substantially rectangular body, (ii) a securing assembly 312 formed from a raised lip 313 and a plurality of locking projections 314a, 314b, and (iii) end cap mating projections 315a-d. The locking assembly 312 is designed to prevent the primary locking member 320 from sliding too far back or too far forward. Specifically, the raised lip 312 prevents the primary locking member 320 from sliding too far back and prevents the plurality of locking projections 314a, 314b from sliding too far forward. The support portion 310 of the main housing 280 includes readable indicia 316 positioned adjacent and forward of the raised lip 312. The indicia 316 is configured to be arranged in two different configurations depending on the configuration of the connector system 10 and the CPA assembly 80, in one configuration the indicia 316 is not readable by the recording system and in the other configuration the indicia 316 is readable by the recording system. The indicia 316 may include a serial number, a part number, application information (e.g., vehicle identification number), component information (e.g., power distribution system), or device information (e.g., alternator). The indicia 316 may be a barcode (e.g., a single or multi-dimensional barcode), a quick response (QR) code, SnapTag, Microsoft Tag, Blipper, MaciCode, Data Matrix, Bokode, Aztec Code, CueCat, PDF417, Semacode, ShotCode, Touchatag, SPARQCode, SQR code, RFID, NFC, Bluetooth, a collection of shapes that can be read by the recording system, a radio-based device that can be read by the recording system, a collection of protrusions that can be read by the recording system, a collection of different color shapes, or a combination of the above.In other words, the indicia 316 can be any pattern, any color, have any texture, and can have a two-dimensional or three-dimensional configuration.

[0034] The primary or first locking member or locking member 320 is positioned on the exterior of the main housing 280 and is configured to overlap (i) the entire engagement portion 282 and (ii) a portion of the support portion 310. The primary locking member 320 is designed to slidably engage with the main housing 280. This sliding engagement is designed to help prevent the connector system 10 from accidentally (a) moving the male connector assembly 200 from a “ready to engage state” to a “limited engagement state”, (b) moving the system 10 from a “ready to use state” to a “connected state”, and (c) removing the male connector assembly 200 from the female connector assembly 600 when the system 10 is in the “ready to use state”. Specifically, the primary locking member 320 is designed to slide back and forth in response to the application of a first force in a first plane, while the connector is designed to couple to the female connector assembly 600 in response to the application of a second force in a second plane that is substantially perpendicular to the first plane. In other words, the first and second forces are not parallel to each other, but instead are substantially perpendicular to each other. In other words, the first plane may be the XY plane, and the second plane may be the YZ plane that is substantially perpendicular to the XY plane.

[0035] The primary locking member 320 includes (i) a sidewall 322 arrangement including an upper wall arrangement 324 and a lower wall arrangement 330, (ii) a second portion 337b of the contingency engagement assembly 336, (iii) a top wall 346 integrally formed with the upper wall arrangement 324, (iv) a bottom rail 350, (v) a rear connector mating projection 352, and (vi) a locking CPA assembly 356. The upper wall arrangement 324 includes (i) two sidewalls 325a, 325b having locking openings 326, and (ii) a front wall 325c having a CPA opening 327 formed therethrough. The locking openings 326 interact with the locking projections 314a, 314b to ensure that the primary locking member 320 cannot be easily removed from the main housing 280. CPA opening 327 is included in locking CPA assembly 356 and provides access to male CPA member 406, and specifically user interaction structure 414 of male CPA assembly 400. As described below, CPA opening 327 provides access that allows a user to press user interaction structure 414 forward and downward to move horizontal engagement member 412 sufficiently forward out of range of female CPA assembly 700 to allow male CPA assembly 400 to disengage from female CPA assembly 700.

[0036] Similar to the main housing 280, the exterior surface of the lower wall arrangement 330 is positioned outside or beyond the exterior surface of the upper wall arrangement 324. In other words, the distance between the opposing exterior surfaces of the lower wall arrangement 330 is greater than the distance between the opposing exterior surfaces of the upper wall arrangement 324. This arrangement substantially matches the arrangement of the lower arrangement of the side wall 288 and the upper arrangement of the side wall 284. The lower wall arrangement 330 includes (i) accidental engagement recesses or engagement recesses 331a, 331b, (ii) accidental engagement retainers or engagement retainers 332a, 332b, (iii) a locking CPA wall arrangement 333, (iv) a stabilizing protrusion 334, and (v) a plurality of locking indentations 335 configured to align with the accidental engagement slots 294a, 294b, the positioning slots 296a, 296b, and the CPA slot 298. The locking CPA wall arrangement 333 is included in the locking CPA assembly 356 and extends forward from the front wall of the bottom wall arrangement 330 and is designed to interact with the CPA sidewall arrangement 402 to protect the male deformable male CPA member 406. The locking CPA wall arrangement 333 is thus configured to be positioned outboard of the CPA sidewall arrangement 402 in a particular operating position. The stabilizing projection 334 is designed to be received by the extent of the female connector assembly 600 and further strengthen the connection between the male connector assembly 200 and the female connector assembly 600 when the system 10 is in a ready-to-use state. Finally, the locking recess 335, like the accidental engagement slots 294a, 294b, the positioning slots 296a, 296b, and the CPA slot 298, is configured to help secure the male connector assembly 200 to the female connector assembly 600 and to facilitate movement of the primary locking member 320 from an unlocked state to a locked state.

[0037] The contingency engagement recesses 331a, 331b and the contingency engagement retainers 332a, 332b are part of the second portion 337b of the contingency engagement assembly 336 and are formed on the inner surface of the bottom wall arrangement 330. The contingency engagement recesses 331a, 331b allow one or more contingency engagement members 338a, 338b to (i) be positioned between the extents of the male and female housings 220, 620 and (ii) be elastically deformable under certain operating conditions (as will be described in more detail below). Meanwhile, the contingency engagement retainers 332a, 332b are positioned within the contingency engagement recesses 331a, 331b and retain the contingency engagement members 338a, 338b within the bottom wall arrangement 330. It should be understood that other configurations of the accidental engagement assembly 336 are contemplated by the present disclosure and that these structures serve to ensure that the primary locking member 320 is not accidentally engaged, locked, or moved forward prior to securely placing the male terminal assembly 430 within the female terminal assembly 800.

[0038] An upper wall 346 of the locking member 320 is integrally formed with and extends between the upper wall arrangements 324. The upper wall 346 includes an accidental disengagement member 348 that is part of an accidental disengagement assembly 347 and is configured to prevent the locking member 320 from being accidentally disengaged, unlocked, or moved rearwardly. Specifically, the disengagement member 348 is formed in the upper wall 336 by removing material from the upper wall 336 to form a pivot strip 339, a rear or locking cantilever segment 340b, and a front or unlocking cantilever segment 340a. A second disengagement projection 342 is formed on the inside of the rear or unlocking cantilever segment 340b and includes a sloped or angled curved surface 344a and a front angled flat surface 344b that forms an acute angle with the inside surface of the top wall 346, which work together to help ensure that the locking member 320 is not accidentally unlocked. As described in more detail below, the pivot strip 339 allows the unlocking cantilever segment 340a and the locking cantilever segment 340b to angularly shift inwardly or outwardly about a pivot point 346 formed on or near the pivot strip 339. It should be understood that other configurations of the accidental disengagement assembly 347 are contemplated by the present disclosure and that these structures help to ensure that the primary locking member 320 is not accidentally disengaged, unlocked, or moved backwards after the connector system 10 is in a ready-to-use state.

[0039] The bottom rail 350 of the locking member 320 extends downwardly from a lower surface of the bottom wall arrangement 330 and provides additional rigidity to the male connector assembly 200 and helps secure / stabilize the male connector assembly 200 when mated with the female connector assembly 600. The rear connector coupling projection 352 is positioned adjacent the bottom rail 350 and extends downwardly from the bottom wall arrangement 330 and includes a lower surface positioned below the bottom rail 350 and includes at least one, and preferably two, bracing openings 354a, 354b that are part of the male bracing assembly 351. The bracing openings 354a, 354b of the male bracing assembly 351 are configured to receive a range of the female connector assembly 600 when the connector system 10 is under a particular operating condition (e.g., a ready-for-use state).

[0040] 2-3, 17, and 22-23, the secondary locking member or terminal locking member 360 is designed to (i) secure the male terminal holder 230 within the primary housing 280 and (ii) prevent movement of the locking member 320 before the secondary locking member 360 is secured in the locked position. The secondary locking member 360 includes (i) an IL assembly opening 362, (ii) an arrangement of protrusions 364 designed to interact with an arrangement of recesses 250a-d of the male terminal holder 230, and (iii) at least one, and preferably three or more, deformable fastening members 368a-c configured to secure the secondary locking member 360 to the primary housing 230. The IL assembly opening 362 is an opening formed in the secondary locking member 360 that is designed to receive a range of female IL assemblies 980 when the connector system 10 is in a ready-to-use state. The arrangement of protrusions 364 includes at least one, and preferably four, protrusions 366a-366d, each protrusion substantially surrounding a corner of the male terminal holder 230. Finally, deformable locking members 368a-368c are positioned between the arrangement of protrusions 364 and designed to interact with protrusions formed on the primary housing 230 to secure the secondary locking member 360 to said housing 230. The fixation of the secondary locking member 360 to the housing 230 helps to support and secure the male terminal assembly 430 in the proper position to facilitate mating with the female terminal assembly 800 when the connector system 10 is in a connected or ready-to-use state.

[0041] B. Male Terminal Assembly 3-14A show a first embodiment of a male terminal assembly 430, and FIG. 107-108 show a second embodiment of the male terminal assembly. With particular reference to the first embodiment, the male terminal assembly 430 includes a spring member 440d and a male terminal 470. A first embodiment of the spring member 440d is shown in FIG. 8-11, and two other embodiments 440c are shown in FIG. 108. Further disclosure of these embodiments is included in International Application No. PCT / US2021 / 033446, International Application No. PCT / US2021 / 043686, and International Application No. PCT / US2021 / 057959, each of which is incorporated herein by reference. Returning to the first embodiment of the spring member 440d, the spring member 440d includes an arrangement of spring member side walls 442a-442b and a rear spring wall 444. The arrangement of spring member side walls 442a-442b includes (i) first or arched spring sections 448a-448h, and (ii) second spring sections or spring arms 452a-452h. The arched spring sections 448a-448h extend between the rear spring wall 444 and the spring arms 452a-452h and position the spring arms 452a-452h substantially perpendicular to the rear spring wall 444. In other words, the outer surfaces of the spring arms 452a-452h are substantially perpendicular to the outer surface of the rear spring wall 444.

[0042] The spring arms 452a-452h extend from the arched sections 448a-448h and terminate at free ends 446 away from the rear spring wall 444. The spring arms 452a-452h are not connected to one another and are therefore separated by spring arm gaps 455a-455f. The gaps 455a-455f aid in the omnidirectional expansion of the spring arms 452a-452h, which facilitates mechanical coupling between the male terminal 470 and the female terminal assembly 800. In other embodiments, the spring arms 452a-452h may be coupled to other structures to limit their omnidirectional expansion. The number and width of the individual spring arms 452a-452h and openings may vary. Additionally, the widths of the individual spring arms 452a-452h (excluding the positioning and retaining means 453) are typically equal to one another. However, in other embodiments, one of the spring arms 452a-452h may be wider than the other spring arms.

[0043] In contrast to the embodiments 440a, 440b shown in International Application PCT / US2019 / 036010 (herein incorporated by reference), the spring member 440d of the present invention includes at least one spring arm 452 including a positioning and retention means 453. The positioning and retention means 453 is shown as a "J-shaped" positioning projection 454a-454d extending laterally from an edge of the spring arm 452a, 452d, 452e, 452h. Preferably, the positioning projection 454a-454d extends from the free end 446 of the spring arm 452a, 452d, 452e, 452h, as opposed to the intermediate edge of the spring arm 452a, 452d, 452e, 452h. Specifically, positioning protrusions 454a-454d are configured to (i) retain spring member 440d within male terminal body 472 and (ii) center and, in some cases, eliminate measurable rotation of spring member 440d within contact arms 494a-494h by limiting the amount spring member 440d can rotate within body 472. In the version shown in Figures 8-16, spring member 440d includes (i) at least two regular planar spring arms 452b, 452c, 452f, 452g that do not have positioning protrusions 454a-454d, and (ii) at least two irregular non-planar spring arms 452a, 452d, 452e, 452h that include positioning protrusions 454a-454d. In the figure, regular planar spring arms 452b, 452c, 452f, 452g are positioned between irregular non-planar spring arms 452a, 452d, 452e, 452h, and therefore regular planar spring arms 452b, 452c, 452f, 452g can be considered intermediate spring arms and irregular non-planar spring arms 452a, 452d, 452e, 452h can be considered peripheral or outer spring arms.

[0044] Unlike the spring arms disclosed in Figures 4-8 of PCT / US2018 / 019787, the free ends 446 of the spring arms 452a, 452d, 452e, 452h do not have an inwardly curved component. Instead, the spring arms 452a, 452d, 452e, 452h have a substantially flat outer surface (except for the positioning and retaining means 453). This configuration is beneficial because it ensures that the outward force exerted by the spring member 440d of the present invention is applied substantially perpendicular to the free end 488 of the male terminal body 472. In contrast, the curved components of the spring arms disclosed in Figures 4-8 of PCT / US2018 / 019787 do not apply forces in this manner. When considering the positioning and retaining means 453, the outer four spring arms 452a, 452d, 452e, 452h are non-planar. Under this interpretation, spring member 440d includes (i) a curvilinear component that is not bent or angled inwardly toward the center of the connector, but instead is oriented away from the center of the connector, and (ii) a limited extent of spring member 440d is positioned outside of spring receiver 486. Additionally, a single spring arm 452a, 452d, 452e, 452h can be positioned between curvilinear components 448a-448h, 454a-454d that are positioned in two different planes.

[0045] In contrast to the spring member 440c disclosed in International Application PCT / US2021 / 033446 and other PCT applications incorporated herein, the spring member 440d does not include four side walls, but instead includes only two side walls 442a-442b. This is because the disclosed male connector assembly 430 does not include contact arms on all four sides and therefore does not conform to 360°. In addition, the spring member 440d does not include a base section that extends between the arched section and the spring arms. In other words, the spring arm section gaps 455a-455f extend all the way to the rear wall 444. Another difference between these spring members 440a-440d is that the side walls 442a-442b of the spring members are no longer planar due to the inclusion of curved positioning protrusions 454a-454d. Finally, due to the positioning and retention means 453, the spring 440d cannot be suitably used in conjunction with other male terminal bodies disclosed in other PCT applications (e.g., International Application No. PCT / US2019 / 036010 and International Application No. PCT / US2020 / 049870).

[0046] In other embodiments, the spring member 440d may include at least one spring arm 452b, 452c, 452f, 452g and only two spring arms 452a, 452d, 452e, 452h, with the locating protrusions 454 arranged in either an opposing or diagonal relationship on either side of the spring member 440d. This configuration may be beneficial because it limits the number of spring arms that need to be bent in the second direction. In other embodiments, the spring member 440d may include only a single irregular non-planar spring arm in conjunction with including the front or rear wall of the male terminal body 472. In this embodiment, the front or rear wall stops the spring member from sliding in that direction, while the single irregular non-planar spring arm prevents this embodiment of the spring member from sliding in a direction opposite the front or rear wall. In other embodiments, the positioning and retention means 453 may be (i) a protrusion or protrusions or tabs that extend from one or more of the free ends 446 of the spring arms 452a-452h and wrap around a substantial portion of the curved lower extent of the contact arms 494a-494h, i.e., that overlap or wrap around the interior corner regions 493a-493d of the outer contact arms 494a, 494d, 494e, 494h; or (ii) a protrusion or protrusions that do not extend from the spring arms 452a-452h, but instead extend from the rear spring wall 444 around the extent of the upper male terminal body wall 480. (iii) protrusion(s) that are not positioned near the free ends 446 of the spring arms 452a-452h, but instead are positioned near the upper extents of the spring arms 452a-452h and wrap around the neck portions 491a-491h of the contact arms 494a-494h; (iv) protrusion(s) extending from the rear spring wall 444 and configured to be positioned between the inner surface of the upper male terminal body wall 480 and the uppermost extent of the male terminal front wall 483; or (v) any combination of these protrusions or tabs having similar structural and functional attributes.

[0047] The spring member 440d is typically formed from a single piece of material (e.g., metal). Thus, the spring member 440d is either a one-piece spring member 440d or has integrally formed features. In particular, the following features are integrally formed: (i) rear spring wall 444, (ii) curved sections 448a-448h, (iii) spring arms 452a-452h, and (iii) positioning protrusions 454a-454d. To integrally form these features, the spring member 440d is typically formed using a die forming process. The die forming process mechanically shapes the spring member 440d. As described in more detail below and in International Application PCT / US2019 / 036010, when spring member 440d is formed from a flat sheet of metal, placed within male terminal body 472, connected to female terminal assembly 800, and exposed to high temperatures, spring member 440d exerts an outward spring thermal force S on contact arms 494a-494h due in part to the fact that spring member 440d attempts to return to a flat sheet. TF It should be understood, however, that other types of forming spring member 440d may be utilized, such as casting, or using an additive manufacturing process (e.g., 3D printing). In other embodiments, the features of spring member 440d may not be formed from a single piece or integrally formed, but instead may be formed from separate pieces that are welded together.

[0048] 4-7B, a first embodiment of a male terminal 470 includes (i) a male terminal body 472 and (ii) a male terminal connection plate 474. The male terminal connection plate 474 is configured to receive a range of conductors 598, a bus bar, or any other type of electrical connector. The conductors 598 are typically welded to the connection plate 474. However, other methods of connecting the conductors 598 to the connection plate 474 are contemplated by the present disclosure. Turning now to the male terminal body 472, the male terminal body 472 has (i) a top wall 480, (ii) a first side wall 482a, (iii) an opposing second side wall 482b, (iv) a front wall 483, and (v) a rear wall 484. The walls 480, 482a-482b, 483, and 484 in combination form a wall arrangement 479 that defines a spring receiving portion 486 having a right angle prism shape. The arrangement of the first and second side walls 482a-482b includes (i) contact arms 494a-494h, each contact arm 494a-494h having a first or neck portion 491a-491h and a second or body portion 492a-492h, (ii) base sections 490a-490b extending between the rear wall 484 and the contact arms 494a-494h, and (iii) a plurality of contact arm openings 496a-496h, each contact arm opening 496a-496h having a first extent or neck gap 498a-498h and a second extent or body gap 499a-499h. This configuration features: (i) the side edges of each contact arm 494a-494h have non-linear edges; (ii) the side edges of neck portions 491a-491h are parallel but not coplanar with the side edges of body portions 492a-492h; (iii) the elongated boundaries of contact arm openings 496a-496h are non-linear; (iv) contact arms 494a-494h have non-uniform widths; and (v) contact arm openings 496a-496h have non-uniform widths.

[0049] Contact arms 494a-494h (i) extend away from upper male terminal wall 480 and (ii) span contact arm openings 496a-496h. This configuration has advantages over the configuration of the terminal shown in Figures 9-15, 18, 21-31, 32, 41-42, 45-46, 48, and 50 of International Application PCT / US2018 / 019787 because (i) it can have a shorter overall length, which means less metal material is required to form and male terminal 470 can be placed in a tighter, more confined space, (ii) it has a higher current carrying capacity, (iii) it is easier to assemble, and (iv) it allows for other advantageous features disclosed herein or that may be inferred by one of ordinary skill in the art from this disclosure.

[0050] The contact arms 494a-494h extend away from the upper male terminal wall 480 at an outward angle. In particular, the outward angle may be between 0.1 degrees to 16 degrees, preferably 5 degrees to 12 degrees, and most preferably 7 degrees to 8 degrees, between the outer surface of the base sections 490a-490b and the outer surface of the contact arms 494a-494h. This configuration allows the contact arms 494a-494h to be biased or displaced inwardly and toward the center of the male terminal 470 by the female terminal assembly 800 when the male terminal assembly 430 is inserted into the female terminal assembly 800. This inward bias helps ensure that a proper mechanical and electrical connection is made by ensuring that the contact arms 494a-494h are placed in contact with the female terminal assembly 800.

[0051] The first or neck portions 491a-491h of the contact arms 494a-494h have a neck width W N and the second portions, i.e., body portions, 492a-492h of the contact arms 494a-494h have a body width W B In the embodiment of the male terminal body 472 shown in the figures, the neck width W N (For example, 1.9 mm) is the body width W B (e.g., 3.2 mm). Specifically, the neck width W N is the body width WB is preferably smaller than the neck width W N is the body width W B at least 10% smaller than the neck width W N is the body width W B at least 20% smaller than the neck width W N is the body width W B In other words, the neck width W N is the body width W B The body width W B Neck width W compared to N This reduction in reduces the force required to deflect or displace contact arms 494a-494h inward and toward the center of male terminal 470 when mating male terminal assembly 430 to female terminal assembly 800. This is beneficial because it reduces the insertion force associated with male terminal body 472, which is desirable to meet industry standards (e.g., USCAR), reducing installer fatigue, shortening installation time, and reducing installation errors.

[0052] The neck portions 491a-491h of the contact arms 494a-494h reduce the insertion force associated with the male terminal body 472, but also do not act as a current choke because the volume of the neck is greater than the volume of the contact arms 494a-494h that contact the female terminal assembly 800. This is important because the creation of a current choke by the neck portions 491a-491h makes this design less desirable than other designs that do not have neck portions that created a current choke. Specifically, the neck volume is approximately 4.5 mm 3 (For example, 3 mm in length × 1.9 mm in width × 0.8 mm in thickness) and the volume of the contact area is about 2 mm 3(e.g., 0.8 mm (length) x 3.2 mm (width) x 0.8 mm (thickness). In other words, the volume of the contact area is 44% of the volume of the neck. It is therefore possible to substantially reduce the volume of the neck before it forms a current choke. In other words, it is theoretically possible to reduce the width of the neck to 0.9 mm, keeping all other measurements the same, before the neck forms a theoretical current choke. It should be understood that in other embodiments, other measurements may be utilized and are non-limiting.

[0053] By reducing the insertion force associated with male terminal body 472 of male connector assembly 200, the designer can either (i) maintain this reduced insertion force by using the same spring member 440d, or (ii) maintain the same or similar insertion force as male connector assembly 200 utilizing a male terminal body that does not include contact arms with reduced width neck portions, i.e., a male terminal body similar to that disclosed in International Application PCT / US2020 / 049870, by using a spring member having a first biasing force greater than a second biasing force associated with spring member 440d. If the second option is selected when the designer desires to build a connector system 10 that has the same insertion force requirements as those associated with a similar connector system that includes contact arms with straight edges, the designer reallocates the forces associated with the components that contribute to the insertion force such that more reliability is provided for spring member 440d and less reliability is provided for male terminal body 472. This heavy reliance on internal spring members can be beneficial because designers can easily change the characteristics of connector system 10 without requiring changes to terminal body 472. For example, a designer can insert a stiffer spring member within spring receiver 486 to increase the current capability of system 10. Alternatively, if there are specific customer requirements that dictate a target insertion force, the designer can simply select a spring member that meets those requirements without having to redesign male terminal body 472. This modularity and flexibility of connector system 10 is a substantial improvement over the prior art, reducing the number of product SKUs, increasing the ability to meet customer demands without redesigning or redesigning connectors, and / or limiting testing and other steps required to utilize new / different connectors.

[0054] The first or neck portions 491a to 491h of the contact arms 494a to 494h have a neck length L N and the second portions, i.e., body portions, 492a-492h of the contact arms 494a-494h have a body length L BIn the embodiment of the male terminal body 472 shown in the figures, the neck length L N (e.g. 3mm) is the body length L B (e.g., 9.7 mm). Specifically, the neck length L N is the body length L B Preferably, the neck length is shorter than the neck length L N is the body length L B and more preferably at least 10% shorter than the neck length L N is the body length L B and most preferably at least 40% shorter than the neck length L N is the body length L B The neck gaps 498a-498h of the contact arm openings 496a-496h are at least 65% shorter than the neck gap width W NG The contact arm openings 496a to 496h have body gaps 499a to 499h with a body gap width W BG In the embodiment of the male terminal body 472 shown in the figures, the neck gap width W NG (For example, 1.9 mm) is the body gap width W BG (e.g., 0.6 mm). Specifically, the neck gap width W NG is the body gap width W B and preferably, the neck gap width W NG is the body gap width W BG More preferably, the neck gap width W NG is the body gap width W BG At least 40% greater than the neck gap width W NG is the body gap width W BG is at least 65% greater than

[0055] The neck gaps 498a to 498h of the contact arm openings 496a to 496h are each a neck gap length L NG The contact arm openings 496a to 496h have body gaps 499a to 499h each having a body gap length L BG In the embodiment of the male terminal body 472 shown in the figures, the neck gap length L NG (For example, 3 mm) is the body gap length L BG(e.g., 9.7 mm). Specifically, the neck gap length L NG is the body gap length L BG and preferably, the neck gap length L NG is the body gap length L BG At least 10% smaller than the neck gap length L NG is the body gap length L BG and most preferably at least 40% smaller than the neck gap length L NG is the body gap length L BG The front wall 483 of the male terminal body 472 has a front wall length L FW (e.g., 4.5 mm), which has (i) a body length L B Or the body gap length L BG (ii) the neck width W N or neck gap width W NG In fact, the length of the front wall L FW is (i) about 35% of the length of the contact arms 494a to 494h, and (ii) the length L of the contact arm body. B and (iii) the length of the contact arm neck L N The length of front wall 483 is approximately 1.5 times that of male terminal assembly 430. Reducing the length of front wall 483 is beneficial because it reduces the weight, manufacturing expense, and cost of materials utilized in male terminal assembly 430. These advantages are substantial improvements over the male terminal assemblies disclosed in International Application No. PCT / US2019 / 036010 and International Application No. PCT / US2020 / 049870.

[0056] Unlike the male terminal bodies disclosed in International Application No. PCT / US2019 / 036010 and International Application No. PCT / US2020 / 049870, the male terminal body 472 disclosed herein does not have a U-shaped sidewall portion surrounding the contact arms 494a-494h. This configuration reduces weight, manufacturing costs, and material costs. However, this reduces the durability of the male terminal assembly 430. This reduced durability is not a drawback of the disclosed system 10 due to the substantial male terminal holder 230 and other non-conductive members of the connector system 10. Although the male terminal body 472 disclosed herein does not have the U-shaped sidewall portion of PCT / US2019 / 036010, the male terminal body 472 includes terminal ends 488a-488h that are (i) positioned within the spring receiving portion 486, (ii) have inner surfaces that are flush with the inner surfaces of the base sections 490a-490b of the contact arms 494a-494h, and (iii) are configured to be placed in contact with the flat outer surfaces of the spring arms 452a-452d when the spring member 440d is inserted into the spring receiving portion 486. This configuration is advantageous over the configuration shown in Figures 3-8 of PCT / US2018 / 019787 because an assembler of the male terminal assembly 430 does not need to apply significant force to outwardly deform the majority of the contact arms 494a-494h to accommodate the spring member 440d. This required deformation can be best shown in FIG. 6 of PCT / US2018 / 019787 due to the inclination of the contact arms and the fact that the outer surface of the spring arm and the inner surface of the contact arm are adjacent to each other without forming a gap between them. In contrast to FIGS. 3-8 of PCT / US2018 / 019787, the present application shows a gap formed between the outer surface of the spring member 440d and the inner surface of the contact arms 494a-494h. Thus, the force required to insert the spring member 440d into the spring receiver 486 is very small due to the fact that the assembler does not need to apply force to significantly deform the contact arms 494a-494h during insertion of the spring 440d.

[0057] The male terminal 470 is typically formed from a single piece of material (e.g., metal). Thus, the male terminal 470 is a one-piece male terminal 470 and has integrally formed features. To integrally form these features, the male terminal 470 is typically formed using a die-cut process. However, it should be understood that other types of forming the male terminal 470 may be utilized, such as, for example, casting or using an additive manufacturing process (e.g., 3D printing). In other embodiments, the features of the male terminal 470 may not be formed from a single piece or integrally formed, but may instead be formed from separate pieces that are welded together. It should be understood that in forming the male terminal 470, any number of contact arms 494a-494h (e.g., 1-100) may be formed within the male terminal 470.

[0058] The male terminal assembly 430 is assembled by moving the spring member 440d from an unseated state to a seated state. In particular, FIG. 10 shows the spring member 440d in an unseated state and spaced from the male terminal body 472. The installer then applies an insertion force to the spring member 440d to place the spring member 440d within the spring receiver 486. The insertion force is applied to the spring member 440d until the rear spring wall 444 is positioned adjacent the inner surface of the upper male terminal wall 480, the free end 446 of the spring member 440d is substantially aligned with the free end 488 of the male terminal body 472, and portions of the side walls 442a-442b of the spring member 440d are positioned adjacent the male terminal side walls 482a-482b. In this position, the spring member 440d has moved from an unseated state to a seated state.

[0059] In a seated state, best shown in Figures 11-16, the spring member 440d contacts three separate surfaces of the male terminal body 472, including (i) contact between the outer surface of the spring member 440d and the inner surface of the male terminal body 472, (ii) contact between the inner surfaces of the "J-shaped" positioning projections 454a and 454d of the spring member 440d and the first end surfaces of the contact arms 494a-494h of the male terminal body 472 (which are the outer surfaces of the contact arms 494a and 494h), and (iii) contact between the inner surfaces of the "J-shaped" positioning projections 454b and 454c of the spring member 440d and the second end surfaces of the contact arms 494a-494h of the male terminal body 472 (which are the outer surfaces of the contact arms 494d and 494e). In this manner, each of the positioning projections 454a, 454b, 454c, 454c engages with and wraps around the inner corner regions 493a-493d (see Figures 12 and 13) of the outer contact arms 494a, 494d, 494e, 494h of the male terminal body 472, but does not wrap around the inner contact arms 494b, 494c, 494f, 494g. The overlapping or wrapping engagement of internal corner regions 493a-493d by positioning protrusions 454a, 454b, 454c, 454c ensures proper centering and retention of spring member 440d within spring receiving portion 486 of male terminal body 472 and is structurally and functionally different from the spring arm and male terminal assemblies disclosed in other PCT applications incorporated by reference herein (e.g., International Application No. PCT / US2019 / 036010 and International Application No. PCT / US2020 / 049870).

[0060] As best shown in FIG. 11, the circumferences of the inner lower edges of all spring arms 452a-452h are not equal, and none of the circumferences of the inner lower edges of all spring arms 452a-452h are equal to the circumferences of the inner lower edges of contact arms 494a-494h. Specifically, the circumferences of middle spring arms 452b-452c and 452f-452g are equal to a first length (e.g., 2 mm), the circumferences of outer spring arms 452a, 452d, 452e, 452h are equal to a second length (e.g., 4.1 mm), and the circumferences of contact arms 494a-494h are equal to a third length (e.g., 5.3 mm), where the first length is shorter than the second length, and the second length is shorter than the third length. Unlike other male terminal assemblies, the first length (e.g., 2 mm) of the intermediate spring arms 452b-452c and 452f-452g is not equal to the third length (e.g., 5.3 mm) around the perimeter of the contact arms 494a-494h. Also, the spring arm width W of the intermediate spring arms 452b-452c and 452f-452g is not equal to the third length (e.g., 5.3 mm) around the perimeter of the contact arms 494a-494h. S (For example, 2 mm) is the body width W of the contact arms 494a to 494h. B (e.g. 3.2mm) or neck width W N (e.g., 1.9 mm). As shown here, the spring arm width W S is the contact arm body width W B On the other hand, the spring arm width W S is the contact arm neck width W N Other widths and other width ratios are contemplated by this disclosure, however, changes in these width / width ratios will likely affect the insertion forces of connector system 10 and therefore should be carefully considered when making any modifications to connector system 10.

[0061] The first embodiment of the male terminal assembly 430 illustrates a male terminal 470 that is not 360° compliant because the outer surfaces of the contact arms 494a-494h are designed to contact only two opposing side walls of the female terminal receiving portion 814, rather than all four side walls of the female terminal receiving portion 814. Thus, the spring biasing force S BFis applied in only two directions, and not all four directions. It should be understood that because the outer surfaces of contact arms 494a-494h are designed to contact all four side walls of female terminal receiving portion 814, some embodiments of male terminal assembly 430 may not conform to 360°.

[0062] The male terminal 470, including the contact arms 494a-494h, may 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 Annealed Copper Standard, i.e., an empirically derived standard value for the conductivity of commercially available copper). For example, C151 has a conductivity of 95% of the standard for pure copper, which typically conforms to the IACS. Similarly, C110 has a conductivity of 101% of the IACS. In certain operating environments or technical applications, it may be preferable to select C151, as it has desirable corrosion resistance properties for high stress and / or harsh weather applications. The first material of the male terminal 470 is C151, which is reported to have a modulus of elasticity (Young's modulus) of approximately 115-125 gigapascals (GPa) at room temperature and a terminal coefficient of expansion (CTE) of 17.6 ppm / °C (20-300°C) and 17.0 ppm / °C (20-200°C) in accordance with the ASTM B747 standard.

[0063] The spring members 440a, 440b, 440d may be formed from 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., as measured by Young's modulus) and greater resilience than the first material of the male terminal 470. The second material preferably has a lower electrical conductivity than that of the first material. The second material also has a Young's modulus at room temperature, which may be about 193 GPa, and a coefficient of terminal expansion (CTE) of about 17.8 ppm / °C (0-315°C) and 16.9 ppm / °C (0-100°C).

[0064] Based on the above-described exemplary embodiment, the Young's modulus and CTE of the spring member 440d are greater than those of the male terminal 470. Thus, when the male terminal 470 is used in a high power application that subjects the system 10 to repeated thermal cycling at high temperatures (e.g., about 150° C.), (i) the male terminal 470 becomes malleable and loses some mechanical resilience, i.e., the copper material in the male terminal 470 softens, and (ii) the spring member 440d does not become malleable or loses significant mechanical stiffness compared to the male terminal 470. Thus, when utilizing a mechanically cold shaped spring member 440d (e.g., using a die forming process), the spring member 440d is exposed to high temperatures that cause the spring member 440d to return to at least its uncompressed state, which occurs prior to inserting the male terminal assembly 430 into the female terminal assembly 800, and preferably to return to its original flat state, which occurs prior to forming the spring member 440d. By doing so, the spring member 440d applies a thermal spring force S substantially in the outward direction to the free end 488 of the male terminal 470. TF This thermal spring force S TF is dependent on the local temperature conditions, including hot and / or cold, in the environment in which the system 10 is installed. Thus, the spring biasing force S BF and thermal spring force S TF The combination of these results in a biasing force S RBF which ensures that when male terminal 470 is inserted into female terminal assembly 800 and during operation of system 10, the outer surfaces of contact arms 494a-494h are forced into contact with the inner surfaces of female terminal assembly 800, ensuring electrical and mechanical connection. Furthermore, even during repeated thermal cycling events, male terminal assembly 430 withstands the resultant outward spring force S applied to female terminal assembly 800 during repeated operation of system 10. RBFIt should be understood that further details regarding male terminal 470 and spring 440d are discussed in International Application No. PCT / US2019 / 036010, International Application No. PCT / US2019 / 036070, International Application No. PCT / US2019 / 036127, International Application No. PCT / US2021 / 043686, International Application No. PCT / US2021 / 043788, and International Application No. PCT / US2021 / 057959, each of which is incorporated herein by reference.

[0065] C. Male Shield Assembly As best shown in FIGS. 17-18 and 97-99B, the shield assembly 60 includes a male shield assembly 530 present within the male housing assembly 220 and designed to interact with the female shield assembly 930 to reduce electromagnetic interference ("EMI") noise emitted by the male connector assembly 200. The male shield assembly 530 includes (i) a male terminal body shield 532, (ii) a male connecting plate shield 538, (iii) a bottom shield 542, (vi) a shield cap 546, and (v) a shield connector 556. Each of these components is connected to a cable shield and is coupled to one another to form an electrical path that partially surrounds the male terminal assembly 430. The male terminal body shield 532 is positioned adjacent the outer wall arrangement 244 of the male terminal holder 230 and the cap 262 of the shield insulator 260, and is configured to interact with the male connecting plate shield 538 and the bottom shield 542. The male terminal body shield 532 has (i) two opposing side walls 534a, 534b with three deformable coupling members 536a-536c formed on one side wall 534a and three deformable coupling members 536d-536f formed on the opposing side wall 534b, (ii) a front wall 5346 with two deformable coupling members 536g-534h formed on the front wall 534c, and (iii) a top wall 534d having a divot that matches a locking recess 268 formed in the cap 262. The bottom shield 542 has an arrangement of walls 544 that form a bowl-shaped receiver that partially surrounds the male connector plate 474 and is positioned adjacent the extent of the male terminal holder 230 and is configured to interact with the male terminal body shield 532 and the male connection plate shield 538. Bottom shield 542 includes one deformable coupling member 536i extending from the bottom wall of arrangement of walls 544. The combination of male terminal body shield 532 and bottom shield 542 provides nine deformable coupling members 536d-536i (e.g., six on the sides of terminal assembly 430, two on the front of terminal assembly 430, and one on the rear of terminal assembly 430).It should be understood that other numbers of shield coupling members 536a-536i forming the shield coupling assembly 535 are contemplated by the present disclosure, including between one shield coupling member and fifty shield coupling members.

[0066] Male connection plate shield 538 includes an arrangement of walls 540 that surround male connection plate 474 and form a rectangular receptacle designed to interact with bottom shield 542, male terminal body shield 532, and shield cap 546. To facilitate these interactions, male connection plate shield 538 includes front connection element 542a and rear connection element 542b. Shield cap 546 also includes an arrangement of walls 548 that form a rectangular receptacle designed to surround male connection plate 474 and an area of ​​conductor 598. Further, shield cap 546 is designed to interact with male connection plate shield 538 and shield connector 556. Finally, shield connector 556 is designed to surround an area of ​​conductor 598 and interact with shielding integrated into shield cap 546 and conductor 598. It should be understood that other configurations, elements, and components that function together to connect an integrated conductor shield to a structure that surrounds most of male terminal assembly 430 are contemplated by this disclosure. Further, it should be understood that the inclusion of the male shield assembly 530 is optional and can be omitted if desired. The male shield assembly 530 is formed from a conductive material, such as a metal. Other conductive materials (e.g., conductive plastics) that can be utilized are disclosed in International Application PCT / US2020 / 013757, which is incorporated herein by reference.

[0067] 14A and 14B, to move the combination of components from an uncoupled state to a coupled state, a force is applied to the male terminal assembly 430 to position the male terminal assembly 430 within the male terminal holder 230. Once the male terminal assembly 430 is positioned within the male terminal holder 230, a force can be applied to the cap 262 of the shield insulator 260 to couple the cap 262 to the male terminal holder 230 and secure the male terminal assembly 430. An upward force is then applied to the bottom shield 542 to position the bottom shield 542 around a lower area of ​​the male terminal holder 230. After the bottom shield 542 is in place, a downward force is applied to the male terminal body shield 532 to position the male terminal body shield 532 into contact with (i) the area of ​​the male terminal holder 230, (ii) the area of ​​the cap 262, and (iii) the area of ​​the bottom shield 542. In this configuration, shield coupling members 536a-536i form nine contact points (e.g., six on the sides of terminal assembly 430, two in front of terminal assembly 430, and one at the rear of terminal assembly 430) designed to contact female shield assembly 930 when system 10 is in a ready-to-use state.

[0068] Once the bottom shield 542 and male terminal body shield 532 are properly positioned about the male terminal assembly 430, a force is applied to the male connection plate shield 538 to bring the front and rear connection elements 542a, 542b into contact with the bottom shield 542 and male terminal body shield 532. Next, the conductor 598 is welded to the male connection plate 474, after which the shield cap 546 is bonded to the bottom shield 542 and male terminal body shield 532. Finally, the shield cap 546 is connected to a shield connector 556 that is crimped to the shield of the conductor.

[0069] D. Male Interlock Assembly As shown and described in more detail in International Application PCT / US2021 / 043686, the male interlock or MIL 590, which is part of the IL assembly 100, is a design that helps prevent arcing from occurring during mating of the connector assemblies 200, 600. To accomplish this, the IL assembly 100 prevents current from being applied to a portion of the connector system 10, namely the female connector assembly 600, before the connector system is placed in a connected state. This function is accomplished using an interlock circuit, which may include (i) components of the battery distribution system, including a sensing module and a disconnect controller, and (ii) a disconnect switch. The sensing module is coupled to the FIL receptacle 982 and detects when a circuit is closed by insertion of the MIL jumper 592. When the circuit is closed, the sensing module sends a signal to the disconnect controller to close the disconnect switch. When the disconnect switch is closed, current can flow from the power source through the switch to the connector system 10. Alternatively, if the MIL jumper 592 is not inserted into the FIL receptacle 982, the sensing module sends a signal to the disconnect controller to open the disconnect switch. When the disconnect switch is open, no current can flow from the power source through the switch to the connector system 10. For clarity, a chart illustrating the operation of these components is shown in FIG. 74B of International Application PCT / US2021 / 043686, and other examples of interlock circuits are disclosed in U.S. Patent Nos. 7,084,361, 7,508,097, 7,586,722, 8,466,586, 9,327,601, 9,533,639, or 9,851,387, each of which is incorporated by reference in its entirety.

[0070] As shown, the MIL 590 includes a jumper 592 having two connection elements 594a, 594b connected to each other. The jumper is positioned between the male terminal assemblies 430. These connection elements 594a, 594b are designed to short and connect wires included in the IL circuit and connected to the FIL receiver 982 when the connection elements 594a, 594b are received by the FIL receiver 982. It should be understood that the MIL 590 can be molded into the male housing assembly 220 or can be added after the connector assembly 200 is fully assembled. It should also be understood that other structures designed to short wires included in the FIL 980 are contemplated by the present disclosure.

[0071] E. Assembling the Male Connector Assembly As shown in FIG. 3, the male connector assembly 200 is in a disassembled state. As described above and shown in FIGS. 12-13B, the first step in assembling the male connector assembly 200 is to move the male terminal assembly 430 from an unseated state to a seated state by positioning the spring member 440d in the spring receiving portion 486 of the male terminal body 472. As shown in FIG. 14A, the second step in assembling the male connector assembly 200 is to move the male terminal assembly 430 from an unmated state to a mated state by positioning the male terminal assembly 430 in the male terminal holder 230. As shown in FIGS. 14B-17, the next step in assembling the male connector assembly 200 is to finish assembling the non-conductive elements surrounding the male terminal assembly 430. In particular, this step includes coupling the shield insulator 260 to the male terminal holder 230. Upon completion of this step, the male connector assembly 200 is in a first partially assembled state.

[0072] To move male connector assembly 200 from the first partially assembled state to the second partially assembled state, (i) male shield assembly 530 is placed about the non-conductive elements of male terminal assembly 430 in the manner described above, (ii) the combination of male terminal assembly 430, housing members 230, 260, and shield assembly 530 is inserted into main housing 280, and (iii) primary locking member 320 is partially coupled to main housing 280 by applying a rearwardly directed force to primary locking member 320, as shown in Figures 19-21.

[0073] Application of a rearwardly directed force to the primary locking member 320 causes the primary locking member 320 to default to the locked or forward state. To move the primary locking member 320 from this locked state, the installer applies a downward pivot force F to pivot the rear or locking cantilever segment 340a about the pivot strip 339 to move the lowermost extent of the second disengaging protrusion 342 above the uppermost extent of the first disengaging protrusion 287. P While applying a downward force to the forward or unlocking cantilever segment 340a, the installer also applies a rearward unlocking force F to the primary locking member 320 to move the second disengaging protrusion 342 behind the first disengaging protrusion 287. UL In this state, the locking member 320 is in the rearward or unlocked state. The required downward pivot force F P is a force less than 25 Newtons, while the required unlocking force F UL is a force less than 25 Newtons. To move male connector assembly 200 from the second sub-assembled state to the third sub-assembled state, secondary locking member 360 is positioned within main housing 280 but is not coupled thereto (i.e., secondary locking member 360 is in a non-receiving state). To move male connector assembly 200 from the third sub-assembled state to the assembled state, an upward force is applied to secondary locking member 360 to move it from the non-receiving state to the receiving state (see Figures 22-23).

[0074] 2. Female Connector Assembly 28-31 and 38-99B provide various views of female connector assembly 600. Female connector assembly 600 includes (i) a female housing 620 having a female CPA assembly 700, (ii) a female touchproof member 720, (iii) a female terminal assembly 800, (iv) a female shield assembly 930, and (v) a female IL assembly 980.

[0075] A. Female Housing Assembly As best shown in FIG. 28, the female housing assembly 620 includes (i) a female terminal holder 630, (ii) a main housing 640, and (vii) a seal 998. The female terminal holder 630 is configured to receive the terminal assembly 800, isolate the female shield assembly 930 from the female terminal assembly 800, facilitate positioning and retention of the female terminal assembly 800 within the female connector assembly 600, and facilitate other functions that will be apparent to those skilled in the art based on the following disclosure and figures. The female terminal holder 630 has an arrangement of walls 632 having terminal retaining projections 634 and terminal retaining recesses 636, the outer surfaces of the projections substantially conforming to the outer surfaces of the end walls of the female terminal assembly 800, and the terminal retaining recesses 636 receiving the extent of the side walls of the female terminal assembly 800. The female terminal holder 630 is configured to be placed in contact with both the shield assembly 60 and the female terminal assembly 800. It is therefore desirable to form the female terminal holder 630 from a non-conductive material. It should be appreciated that the non-conductive material selected should be able to sufficiently insulate the female terminal assembly 800 even when high current loads are flowing through the terminal assembly 800. As described elsewhere in this application, the female terminal holder 630 may be formed using any suitable method, such as injection molding techniques, 3D printing, casting, thermoforming, or any other similar technique.

[0076] The female primary housing 640 includes (i) a base wall 642, (ii) an arrangement of inner walls 644, (iii) an arrangement of outer walls 646, (iv) a female bracing assembly 648, (v) an arrangement of terminal securing projections 670, (vi) an FIL retainer 674, and (vii) a female CPA assembly 700. As shown in FIGS. 28-31, the base wall 642 is designed to be positioned adjacent a range of components 8 included in a power distribution system to facilitate coupling of the female terminal assembly 800 to the components. Accordingly, the base wall 642 has a substantial thickness to help ensure proper mounting, and has four connector openings 654a-d formed therethrough. The connector openings 654a-d are designed to receive a range of elongated couplers configured to secure the female connector assembly 200 to the components.

[0077] The arrangement of interior walls 644 extends upwardly from base wall 642 and includes first and second arrangements of housing receiving walls 658a, 658b. Each of the arrangements of housing receiving walls 658a, 658b includes (i) two side walls 660a, 660b and (ii) two end walls 660c, 660d. The combination of side walls 660a, 660b and end walls 660c, 660d forms a rectangular receiving portion 662 designed to receive a range of female terminal assemblies 800. In particular, side walls 660a, 660b have an upper portion that (i) extends above female terminal assembly 800 and (ii) includes contact arm displacement means 663 for displacing contact arms 494a-494h during insertion of male terminal assembly 430. Here, the contact arm displacement means 663 is an inner segment 664 at the top of the side walls 660a, 660b, which has an inclined surface designed to slidingly engage with a range of contact arms 494a-494h of the male terminal assembly 430 during insertion of the male terminal assembly 430 into the receptacle 653 of the female housing 620. The inner segment 664 is angled or inclined at an interior angle relative to the exterior surface of the side walls 660a, 660b. In this exemplary embodiment, the interior angle α is between 0.01 degrees and 15 degrees, preferably between 1 degree and 7 degrees, and most preferably 5 degrees. Also, the interior angle α is substantially constant. This inclined inner segment 664 is designed to gently compress the contact arms 494a-494h inward as these two components slide into engagement while an operator (e.g., a worker or a robot) inserts the male connector assembly 200 into the receptacle of the female connector assembly 600.

[0078] It should be understood that in other embodiments, the slope or angled configuration of the interior segments 664 may not be constant, the dimensions may vary, and the interior segments 664 may be continuous within the housing 620. It should also be understood that the interior segments 664 are typically formed from the same material, such as a polymer (e.g., nylon or plastic), from which the remainder of the female housing 640 is formed. Utilizing a polymeric material is beneficial because there is less friction between the metal contact arms 494a-494h and the polymeric material of the interior segments 664 compared to either (i) the friction between the metal contact arms 494a-494h and an alternative interior segment 664 made from metal, or (ii) the friction between the metal contact arms 494a-494h and the metal female terminal assembly 800. In alternative embodiments, the interior segments 664 may be lined or coated using a coating, lining, or other material to reduce friction with the contact arms 494a-494h.

[0079] The outer wall arrangement 646 also extends upwardly from the base wall 642 and surrounds the inner wall arrangement 644. The outer wall arrangement 646 includes two side walls 650a, 650b including (i) a female contingency engagement assembly 652 having contingency engagement projections 654a, 654b, (ii) positioning structures 656a, 656b, and (iii) stabilizing projections 658a, 658b. As described in more detail below, when the male connector assembly 800 is connected to the female connector assembly 600, the contingency engagement projections 654a, 654b are configured to be received by the contingency engagement slots 294a, 294b, the positioning structures 656a, 656b are configured to be received by the positioning slots 296a, 296b, and (iii) the stabilizing projections 658a, 658b are configured to be received by the stabilizing slots 297a, 297b. The female bracing assembly 648 extends rearwardly from the base wall 642 and includes two bracing projections 649a, 649b that are configured to fit within the two bracing openings 354 when the primary locking member 320 is in the locked state.

[0080] The arrangement of terminal securing projections 670 includes a plurality of terminal securing projections 672a-672c that are configured to be positioned below the extent of the female terminal assembly 800 to secure the female terminal assembly 800 within the female main housing 640. Also formed in the bottom extent of the base wall 642 is a FIL retention portion 674. The FIL retention portion 674 is a deformable FIL projection 676 that allows an FIL to be optionally added to the system 10. This is advantageous over other disclosed systems because (i) it does not add weight to the system if this component is not desired, (ii) it reduces the number of parts / SKUs that manufacturing maintains, and (iii) other advantages that will be apparent to one of ordinary skill in the art based on the following disclosure and figures. The female CPA assembly 700 includes a female coupling member 702 coupled to the outer wall 646 of the main housing 640, and includes a CPA body 704 and a CPA retention member 706 extending from the CPA body 704. CPA body 704 and CPA retention member 706 are configured to be positioned within CPA slot 298 formed in male connector assembly 200 when male connector assembly 800 is connected to female connector assembly 600 .

[0081] As mentioned above, the optional touchproof assembly 40 includes the male touchproof element opening 242 and the female touchproof member 720. The touchproof assembly 40 is designed to (i) help ensure that foreign objects cannot contact the female terminal assembly 800 when the female connection assembly 600 is not coupled to the male connector assembly 200, and (ii) stabilize the connection between the male terminal assembly 430 and the female terminal assembly 800. To accomplish both of these tasks, the female touchproof member 720 includes (i) a touchproof fastening assembly 762 and (ii) a touchproof element 780. The touchproof fastening assembly 762 is best shown in FIGS. 28-45 and includes (i) an arrangement of deformable retaining members 764 having first and second end deformable retaining members 768a and 768b, respectively, and (ii) a base portion 776. The first and second end deformable retention members 768a, 768b extend downwardly from a base portion 776 and include bodies 770a, 770b, protrusions 772a, 772b, and angled rear walls 774a, 774b. It should be appreciated that each of these structures aids in enabling the female touchproof member 720 to be installed after the female connector system 600 is coupled to a component.

[0082] As described in more detail below, the configuration of the deformable retaining member 764 has (i) an original or undeformed state when the touchproof member 720 is in a non-installed or installed state, and (ii) a non-original or deformed state when the touchproof member 720 is in a partially installed state. Because the configuration of the deformable retaining member 764 is part of the touchproof fastening assembly 762, which is part of the touchproof member 720, the state from the configuration of the deformable retaining member 764 applies to the touchproof fastening assembly 762 and the touchproof member 720. In other words, when the configuration of the deformable retaining member 764 is (i) in the original state, the touchproof fastening assembly 762 and the touchproof member 720 are also in the original state, and (ii) when in the deformed state, the touchproof fastening assembly 762 and the touchproof member 720 are also in the deformed state. Base portion 776 has a substantially rectangular shape that substantially matches the shape of the female terminal receiving portion and includes (i) an opening formed therethrough to permit coupling of member 720 and reduce weight, and (ii) a downwardly depending protrusion designed to support base portion 776 and ensure that base portion 776 is offset from the lowermost extent of the receiving portion.

[0083] The touchproof element 780 includes three integrally formed walls 782 extending upwardly from the base portion 776, including (i) a first end wall 784a, (ii) a second end wall 784b, and (iii) a connecting or paddle wall 786 positioned between the end walls 748a, 748b. The combination of the end walls 748a, 748b and the connecting wall 786 forms an "I-shaped" projection. In other words, the touchproof element 780 has an I-shaped cross-sectional configuration. The "I-shaped" projection provides a substantial advantage over previous versions of the touchproof post disclosed in the incorporated PCT application because the end walls 748a, 748b provide additional rigidity to the connecting or paddle wall 786. Without this additional stiffness, foreign objects may displace the connecting wall or paddle wall 786, and therefore the touchproof post may not provide the desired functionality, resulting in the connector system not meeting various industry regulations. Alternative methods of adding additional stiffness to the connecting wall or paddle 786 are contemplated, but each alternative has issues that make it less desirable to utilize. For example, one method of providing additional stiffness is to increase the thickness of the connecting wall or paddle wall 786. However, increasing the thickness of the connecting wall or paddle wall 786 is undesirable as it may interfere with the compression of the spring member 440d when the connector system 10 is in a connected or ready-to-use state. Another method of providing additional stiffness is to use a different material that has a higher stiffness. However, this is undesirable as it increases the cost of the touchproof post and the complexity associated with manufacturing the touchproof post. Another method of providing additional stiffness is to use a support wall that helps to couple the connecting wall or paddle wall 786 to the base portion 776. However, this is undesirable as the additional support wall may interfere with the connection of the male connector assembly 200 and the female connector assembly 600. In addition to the above examples, it should be understood that the "I-shaped" design of the touchproof element 780 may be replaced with other shapes, such as a triangular prism, a pentagonal prism, a hexagonal prism, an octagonal prism, a sphere, a cone, a tetrahedron, a rectangular prism, a dodecahedron, an icosahedron, an octahedron, or an ellipsoid.

[0084] B. Female terminal assembly 28, 41-45, 49-53, 55B, 56B, 58, 61, 68, 71, 78, 81, 91-99B show various views of female terminal assembly 800. Female terminal assembly 800 includes (i) female terminal body 810 and (ii) female terminal connecting plate 816. Connecting plate 816 is directly connected to female terminal body 810 and is configured to be coupled to a structure (e.g., a radiator fan) outside of connector system 10. Female terminal body 810 is comprised of (i) an arrangement of female terminal walls 812a-812d coupled together to form a substantially rectangular shape, and (ii) a rear wall 813 positioned substantially perpendicular to walls 812a-812d. Specifically, one female terminal side wall 812a of the arrangement of female terminal walls 812a-812d is (i) substantially parallel to another female terminal side wall 812c of the arrangement of female terminal walls 812a-812d, and (ii) substantially perpendicular to the two female terminal end walls 812b, 812d of the arrangement of female terminal walls 812a-812d. The female terminal body 810 defines a female terminal receiving portion 814. The female terminal receiving portion 814 is designed and configured to be both electrically and mechanically coupled to an extent of the male terminal 470 when the male terminal 470 is inserted into the female terminal receiving portion 814.

[0085] The female terminal assembly 800 is typically formed in a single piece of material (e.g., metal). Thus, the female terminal assembly 800 is a one-piece female terminal assembly 800 and has integrally formed features. In particular, the connection plate 816 is integrally formed with the female terminal body 810, and specifically, is integrally formed with one female terminal side wall 812c. To integrally form these features, the female terminal assembly 800 is typically formed using a die-cut process. However, it should be understood that other types of forming the female terminal assembly 800, such as casting or additive manufacturing processes (e.g., 3D printing), may be utilized. In other embodiments, the features of the female terminal assembly 800 may not be formed in a single piece or may not be integrally formed, but may instead be formed from separate pieces that are welded together.

[0086] C. Female Shield Assembly The shield assembly 60 also includes a female shield assembly 930 present within the female housing assembly 620 and designed to interact with the male shield assembly 530 to reduce electromagnetic interference ("EMI") noise emitted by the male connector assembly 200. The female shield assembly 930 is comprised of a female terminal body shield 932 having a component coupling element 940 designed to interact with a range of components 8 included in the power distribution system. The female terminal body shield 932 is formed from an arrangement of side walls 934 forming a substantially rectangular tubular component. The component coupling element 940 extends downwardly from a lower edge of the arrangement of side walls 934 and is deformable so that it can deform inwardly to adequately contact a range of components 8 when the female connector assembly 600 is coupled to the component. It should be understood that other configurations, elements, and components that function together to connect the integrated conductor shield to a structure that largely surrounds the female terminal assembly 800 are contemplated by the present disclosure. It should further be understood that the inclusion of the female shield assembly 930 is optional and can be omitted if desired. The female shield assembly 930 is formed from a conductive material, such as a metal. Other conductive materials that may be utilized (e.g., conductive plastics) are disclosed in International Application PCT / US2020 / 013757, which is incorporated herein by reference.

[0087] D. Female Interlock Assembly As mentioned above and disclosed in International Application PCT / US2021 / 043686, the female interlock or FIL 980 that is part of the IL assembly 100 is designed to help prevent arcing during mating of the connector assemblies 200, 600. As shown, the FIL 980 is a receiving structure 982 formed in a non-conductive housing 984. Specifically, the receiving structure 982 includes two receiving portions 986a, 986b. The housing 984 can be optionally added to the system 10 by fastening it to the housing assembly 620 via the deformable FIL protrusions 676. The receiving portions 986a, 986b include conductive elements 988a, 988b that are coupled to the IL circuitry described above. The conductive elements 988a, 988b are designed to receive the connecting elements 594a, 594b of the MIL 590 during certain operating conditions, thereby shorting and connecting the wires connecting to the FIL 980, closing the circuit and allowing electrical current to flow between the male terminal assembly 430 and the female terminal assembly 800.

[0088] E. Assembling the Female Connector Assembly As shown in Figure 28, the female connector assembly 600 is in a disassembled state. As shown in Figure 30, the first step in assembling the female connector assembly 600 is (i) assembling the female terminal assembly 800 with the female terminal holder 630, and (ii) securing the assembly ( すなわち, 630, 800) to the female housing assembly 620, applying a female terminal coupling force FFTC in the first direction or upward direction to the combination of the female terminal holder 630 and the female terminal assembly 800 in the first direction, and (iii) coupling the female shield door assembly 930 to the female housing assembly 620. When the above steps are completed, the connector assembly 600 is in a first partially assembled state. In this first partially assembled state, all the main components of the connector assembly 600 are installed except for the FIL 980 and the female touch-proof member 720. (i) The FIL 980 is partially separated from the housing 620 and is in a non-receiving position. (ii) The female touch-proof member 720 is partially separated from the housing 620 and is in a non-installed position. At this point, the installer can determine whether they include the FIL 980 or omit it from the system 10. If the installer can determine to omit the FIL 980, the connector assembly 600 skips the second partially assembled state and moves directly to the third partially assembled state.

[0089] If the installer determines to include the FIL 980, insert the FIL 980 into the FIL opening in the main body 640 and use the FIL holding portion 674 to fix the FIL 980 in the opening, applying a FIL force F in the first direction or upward direction FIL to the FIL 980. When the FIL 980 is coupled to the main body 640, the connector assembly 600 is moving from the first partially assembled state to the second partially assembled state. In this state, the FIL 980 is coupled to the main body 640 via the FIL holding portion 674, and thus the FIL 980 is in the receiving position. To move the connector assembly 600 to the third partially assembled state, a TPM force F in the second or downward direction TPMA downward force is applied to the female touchproof member 720 to move it from a separated, unseated state to a partially seated position in which the angled rear walls 774a, 774b of the first and second end deformable retaining members 768a, 768b engage the rear wall 813 of the terminal assembly 800. Continued application of a downward force to the female touchproof member 720 causes the first and second end deformable retaining members 768a, 768b to continue to elastically deform outward or away from the center of the female touchproof member 720.

[0090] When the first and second end deformable retention members 768a, 768b are sufficiently elastically deformed (e.g., each member deforms beyond a predetermined amount -0.7 mm) to allow the projections 772a, 772b to pass through the rear wall 813 of the terminal assembly 800, the first and second end deformable retention members 768a, 768b can return to their undeformed or original state, thereby coupling the touchproof member 720 within the female terminal assembly 800. In other words, the touchproof member 720 is coupled to the female terminal assembly 800 when the first and second end deformable retention members 768a, 768b are in their undeformed or original state and the projections 772a, 772b are positioned below the rear wall of the terminal assembly 800. When the components are in this positional relationship, the female connector assembly 600 is in an assembled state. As discussed above, the female terminal coupling force F FTC and FIL force F FIL is in the first direction and the TPM force F TPM7 is in a second, opposite direction. In other words, the female terminal assembly 800 is configured to be inserted into the female housing 620 using a force (e.g., a female terminal mating force) directed in a first direction (e.g., upward) and the touchproof member 720 is configured to be inserted into the female housing 620 using a force (e.g., a TPM force) directed in a second direction (e.g., downward), the first direction (e.g., upward) being opposite the second direction (e.g., downward). The above method is beneficial because it can be added to the system 10 after the system 10 is in use. The directional insertion of the touchproof member 720 disclosed herein provides substantial advantages over previous designs of elements that (i) are designed to limit the insertion of foreign objects into the female terminal assembly 800 and (ii) are inserted into the housing assembly 220 in the same direction as the female terminal assembly 800. In particular, the disclosed directional insertion of the touchproof member 720 allows this component to be an optional component that can be added after the component-side connector assembly 600 has been installed on a component or part (i.e., post-installation). In contrast, the FIL 980 is an optional component that can only be added with pre-installation of the component-side connector assembly 600. Other structures that allow for post-installation of the touchproof member 720 are contemplated by the present disclosure.

[0091] As discussed above, the rear wall 813 of the female terminal assembly 800 defines (i) an inner terminal length L spanning the inner distance between the opposing end walls 812b, 812d. IT (e.g., 25 mm), (ii) a rear wall length L spanning the distance between the outermost edges of the rear wall 813 RW (e.g., 17.5 mm), (iii) an original protrusion length L extending between the first and second protrusions 772a, 772b of the arrangement of the deformable retaining members 764 when the female touchproof member 720 is in an original state. OP (e.g., 16.5 mm), and (iv) a deformed protrusion length L extending between the first and second protrusions 772a, 772b of the arrangement of deformable retaining members 764 when the female touchproof member 720 is in a deformed state. DP(e.g., 17.6 mm). It should be understood that (i) the original protrusion length is shorter than the deformed protrusion length, (ii) the deformed protrusion length is longer than the length of the rear wall, and (iii) the deformed protrusion length is shorter than the length of the inner terminal. Specifically, the deformed protrusion length is (i) about 0.5% longer than the original protrusion length, (ii) about the same as or slightly longer than the length of the rear wall, and (iii) about 30% shorter than the length of the inner terminal.

[0092] Thus, a fixed gap 820 is formed between the outer edge of the rear wall 813 and the inner surface of the end walls 812b, 812d. When the touch-proof member 720 is inserted into the female terminal receiving portion 814, the original protrusion length of the first and second protrusions 772a, 772b expands to a deformed protrusion length to allow the first and second protrusions 772a, 772b to clear the rear wall length. When the first and second protrusions 772a, 772b exceed the length of the rear wall and are inserted into the fixed gap 820 of the female terminal assembly 800, the deformed protrusion length of the first and second protrusions 772a, 772b is reduced to the original protrusion length, thereby positioning the extent of the first and second protrusions 772a, 772b below the rear wall 813 of the female terminal assembly 800.

[0093] When the female touchproof member 720 is in the installed state, the distance between the inner surface of the female terminal assembly 800 and the outer surface of the female touchproof member 720 varies due to the configuration of the female touchproof member 720. For example, the distance between the end faces of end walls 748a, 748b of the touchproof element 780 and the inner surfaces of end walls 812b, 812d is approximately D TPE end distance (e.g., 2.5 mm in FIG. 54), and the distance between the outer surface of the connecting wall 786 of the touchproof element 780 and the inner surfaces of the side walls 812a, 812b is approximately D TPS 52), and the distance between the sides of the end walls 748a, 748b of the touchproof element 780 and the inner surfaces of the side walls 812a, 812b is approximately D TPS52. Although these distances vary, each of the above distances is less than the distances specified in various industry regulations (e.g., ISO 20076:2019, ISO 20653:2013, USCAR12, Revision 5, and IEC 60529-2020). Thus, by including touchproof member 720, female connector assembly 600 can pass or comply with each of these standards (e.g., ISO 20076:2019, ISO 20653:2013, USCAR12, Revision 5, and IEC 60529-2020).

[0094] 3. Assembling the Connector System Once the male connector assembly 200 and the female connector assembly 600 are in an assembled state (as shown in FIGS. 55A and 55B), the system 10 can be transitioned from a disassembled state (FIGS. 56A-56B), to a partially connected state (FIGS. 57-64), to a connected state (FIGS. 67-74), to a ready-to-use state (FIGS. 77-84, 88-91). In the disconnected state, the male connector assembly 200 is spaced apart from a portion of the female connector assembly 600. In this disconnected state, the male connector assembly 200 is assembled and can be in either (i) a ready-to-engage state or (ii) a limitedly engaged state.

[0095] In the ready-to-engage state, primary locking member 320 is moved rearward until (i) accidental engagement members 338a, 338b are positioned within accidental engagement slots 294a, 294b, as shown in Figures 24-26, and (ii) second disengagement projection 342 is positioned rearward of first disengagement projection 287. When male connector assembly 200 is disposed in the ready-to-engage state, a predetermined amount of accidental engagement ( 例えば In order to prevent this, it is necessary to apply an accidental engagement force FAE of more than 500 Newtons of force to the primary locking member 320. AEmust be large enough to bias the contingency engagement members 338a, 338b from their positions within the contingency engagement slots 294a, 294b. L (explained below) is the accidental engagement force F AE The preferred locking force F L is the accidental engagement force F AE The most preferred fastening force F is at least 10 times smaller than L is the accidental engagement force F AE The predetermined amount of accidental engagement is 20 times smaller than the amount of accidental engagement. The large predetermined amount of accidental engagement helps ensure that the primary locking member 320 is not accidentally engaged prior to installation. This helps reduce installation time, but the installer does not have to troubleshoot why a connector may not be able to mate due to the positioning of the primary locking member 320.

[0096] Accidental engagement force F AE When a force greater than a predetermined contingency engagement amount is applied to the primary locking member 320, the contingency engagement members 338a, 338b are forced from their positions within the contingency engagement slots 294a, 294b and the male connector assembly 200 is moved from the ready to engage / disengage state to the limiting engagement state (i.e., the primary locking member 320 is in a locked state). In this limiting engagement state, the contingency engagement members 338a, 338b are positioned forward of the edges of the contingency engagement slots 294a, 294b and the second disengagement projection 342 is positioned forward of the first disengagement projection 287. The male connector assembly 200 shown in FIG. 14 is in this limiting engagement state and is unable to mate with the female connector assembly 600 due to the positional relationship of the primary locking member 320. For example, the male bracing assembly 351 and the female bracing assembly 648, which together form the bracing assembly 349, prevent the connector assemblies 200, 600 from mating with each other.

[0097] When the male connector assembly 200 is moved from the ready-to-engage state to the limited engagement state, a downwardly directed pivot force F is applied to pivot the rear or locking cantilever segment 340a about the pivot strip 339 to move the lowermost extent of the second disengagement projection 342 above the uppermost extent of the first disengagement projection 287. P The connector can be returned to the ready-to-engage state by applying a downward force to the forward or unlocking cantilever segment 340a. While applying a downward force to the forward or unlocking cantilever segment 340a, the installer also applies a rearward unlocking force F to the primary locking member 320 to move the second disengaging protrusion 342 rearward of the first disengaging protrusion 287. UL As mentioned above, the required downward pivot force F P is a force less than 25 Newtons, the required unlocking force F UL is less than 25 Newtons of force. However, due to the accidental engagement of the primary locking member 320, the connector assembly 200 should be inspected prior to its use.

[0098] A. Partially connected state Assuming that the male connector assembly 200 is in a ready-to-engage / disengage state, the installer applies a downward connection force F to transition the system 10 from a disconnected state to a partially connected state. Cmay begin to be added to male connector assembly 200. In this partially connected state, the structures are in the following positions: (i) accidental engagement protrusions 654a, 654b are aligned with and partially received by accidental engagement slots 294a, 294b, (ii) stabilizing protrusions 658a, 658b are aligned with and partially received by stabilizing slots 297a, 297b, (iii) touchproof element 780 is aligned with and partially received by touchproof element opening 242, and (iv) CPA body 704 is aligned with CPA slot 298 and partially received thereby. (v) the MIL 590 is not electrically connected to the FIL 980, or in other words, the male IL jumper 592 is not received by the female IL receiving portion 982, thereby preventing current from flowing between the male terminal assembly 200 and the female terminal assembly 600; and (vi) the contact arms 494a-494h begin to engage with the contact arm displacement means 663 (i.e., the inner segments 664 at the tops of the side walls 660a, 660b).

[0099] To move the system 10 from the partially connected state toward the connected state, the installer applies a downward connection force F C This downward connection force F C(i) the contingency engagement projections 654a, 654b are substantially received by the contingency engagement slots 294a, 294b, thereby displacing the contingency engagement members 338a, 338b from the contingency engagement slots 294a, 294b and into the contingency engagement recesses 331a, 331b formed in the lower wall arrangement 330 of the primary locking member 320; (ii) the stabilizing projections 658a, 658b are substantially received by the stabilizing slots 297a, 297b; (iii) the positioning structures 656a, 656b are substantially received by the positioning slots 296a, 296b; and (iv) the CPA body 704 is substantially received by the CPA slot 298, and the CPA retention member 706 resiliently displaces the male deformable male CPA member 406 to the deformed position, wherein: a) the horizontal engagement member 412 of the male deformable male CPA member 406 is displaced toward the front of the system 10, (b) the user interaction structure 414 of the male deformable male CPA member 406 is displaced toward the rear of the system 10, (v) the touchproof element 780 is received by the touchproof element opening 242, (vi) the MIL 590 is not electrically connected to the FIL 980, or in other words, the male IL jumper 592 is not received by the female IL receiving portion 982, thereby preventing current from flowing between the male terminal assembly 200 and the female terminal assembly 600, and (vii) the contact arms 494a-494h are displaced toward the center of each terminal assembly 430 by the contact arm displacement means 662 (i.e., the inner segments 664 at the tops of the side walls 660a, 660b).

[0100] B. Connection Status The system 10 is in a connected state when the male terminal assembly 430 is received in the female terminal receiving portion 814, and therefore the installer must apply a downward connection force F CIn the connected state, (i) the contingency engagement protrusions 654a, 654b are received by the contingency engagement slots 294a, 294b, which displace the contingency engagement members 338a, 338b out of the contingency engagement slots 294a, 294b and into the contingency engagement recesses 331a, 331b formed in the bottom wall arrangement 330 of the primary locking member 320, (ii) the stabilizing protrusions 658a, 658b are received by the stabilizing slots 297a, 297b, (iii) the positioning structures 656a, 656b are received by the positioning slots 296a, 296b, and (iv) the CPA body 704 is received by the CPA slot 298 and the male deformable male The CPA member 406 returns to its original position, the horizontal engagement member 412 of the male deformable male CPA member 406 is positioned under the CPA retaining member 706, (v) the touchproof element 780 is received by the touchproof element opening 242, (vi) the MIL 590 is electrically connected to the FIL 980, or in other words, the male IL jumper 592 is received by the female IL receiving portion 982, thereby allowing current to flow between the male terminal assembly 200 and the female terminal assembly 600, and (vii) the contact arms 494a-494h are displaced toward the center of each terminal assembly 430 and contact the inner surfaces of the side walls 812a, 812c of the female terminal assembly 800.

[0101] With particular reference to male terminal assembly 430 and female terminal assembly 800, the combination of the outer surfaces of contact arms 494a-494h form a rectangle having a width that is slightly larger (e.g., 0.1%-15%) than the width of the rectangle associated with female terminal assembly 800. When the slightly larger male terminal assembly 430 is inserted into the slightly smaller female terminal receiving portion 814, the outer surfaces of contact arms 494a-494h are forced toward the center of male terminal assembly 430. As the outer surfaces of contact arms 494a-494h are forced toward the center of male terminal assembly 430, free end 446 of spring member 440d is also forced toward the center of male terminal assembly 430. Spring 440d exerts a spring biasing force S BF This inward displacement is resisted by providing a spring biasing force SBF is directed generally outwardly relative to the free end 488 of the male terminal 470. In other words, this spring biasing force S BF provides an outwardly directed biasing force, wedging function, or simmering effect on the contact arms 494a-494h, thereby holding the outer surfaces of the contact arms 494a-494h in engagement with the female terminal assembly 800.

[0102] In this connected state, the primary locking member 230 remains in the unlocked position, whereby the second unlocking projection 342 is positioned behind the first unlocking projection 287, and the bracing projections 649a, 649b are not positioned within the bracing openings 354. C It should be noted that the connector 10 requires less than 100 Newtons of force, preferably less than 76 Newtons of force to meet USCAR 25 Class 3, and more preferably less than 46 Newtons of force to meet USCAR 25 Class 2. It should also be noted that the system 10 provides substantial advantages over conventional connector systems because it has high current carrying capabilities without the need for lever assist to aid in mating the male and female connector assemblies 200, 600.

[0103] To move the system 10 from the connected state toward the ready-to-use state, the installer applies a forwardly directed locking force F L This forward-directed locking force F L (This is due to the downward-directed bonding force F C ) moves the primary locking member 320 forward, such that (i) the contingency engagement members 338a, 338b are substantially displaced into the contingency engagement recesses 300a, 300b, (ii) the bracing projections 649a, 649b are substantially positioned within the bracing openings 354, and (iii) the sloped or beveled curved surface 344a of the second disengaging projection 342 interacts with the sloped or beveled curved surface 290a of the first disengaging projection 287 to generate (a) an engagement force F Evia, (a) the rear or unlocking cantilever segment 340a is displaced upwardly about the pivot strip 339 to position the lowermost extent of the second disengaging projection 342 above the uppermost extent of the first disengaging projection 287, and (b) the front or unlocking cantilever segment 340a is displaced downwardly about the pivot strip 339.

[0104] C. Ready for use state When the primary locking member 320 is in the locked state, the system 10 is ready for use, and therefore the installer applies a forwardly directed locking force F L In the ready-to-use state, (i) the accidental engagement members 338a, 338b are displaced from the accidental engagement recesses 331a, 331b and positioned within the accidental engagement indentations 300a, 300b, (ii) the bracing projections 649a, 649b are positioned within the bracing openings 354, and (iii) the extent of the primary locking member 320 is extended beyond the male deformable male CPA member 406 to prevent the male deformable male CPA member 406 from elastically deforming. (iv) the second disengaging projection 342 is positioned forward of the first disengaging projection 287 such that the forward inclined flat surface 344b of the second disengaging projection 342 is positioned forward of the forward inclined flat surface 290b of the first disengaging projection 287; and (v) the indicia 316 disposed on the main housing 280 is visible / readable by an installer and / or machine.

[0105] To read the indicia 316, the installer positions the indicia reading device above the connector system 10 and orients the indicia reading device 4 downward so that it scans the top of the connector system 10. This downward scanning direction corresponds to (i) the magnitude of the connecting force F applied to the male connector assembly 200 to connect the male connector assembly 200 to the female connector assembly 600. C and / or (ii) the spring biasing force F applied by the spring member 440d to the contact arms 494a-494h of the male terminal body 472. SB3. Information obtained from the indicia (i.e., QR code) 316 includes (i) the connector type, (ii) the materials contained within the connector, (iii) the company that manufactured the connector, (iv) when the connector was manufactured, and (v) where the connector was manufactured. Once the indicia 316 is read, the indicia reading device informs the installer that the connector system 10 is ready for use and thus the primary locking member 320 is in the locked position.

[0106] When the system 10 is placed in a ready-to-use state, a predefined accidental disengagement force FAD must be applied to the primary locking member 320 in order to move the primary locking member 320 from the locked or forward state to the unlocked or rearward state. In particular, this accidental disengagement force F AD must be large enough to urge the second disengaging projection 342 rearwardly of the first disengaging projection 287, which is prevented by the interaction between the forwardly inclined flat surface 344b of the second disengaging projection 342 and the forwardly inclined flat surface 290b of the first disengaging projection 287. The predetermined amount of accidental disengagement is large enough to help ensure that the primary locking member 320 is not accidentally disengaged after installation, which helps reduce possible connection failures. The accidental disengagement force F AD is applied to the primary locking member 320 in an amount that exceeds the predetermined accidental disengagement amount, the connector system 10 is moved from a ready-to-use state to a connected state and the male connector assembly 200 is moved to a ready-to-disengage state (i.e., the primary locking member 320 is in an unlocked state).

[0107] D. Connection Status Once the system 10 is placed in the ready-to-use condition, the system 10 applies a downwardly directed pivot force F to pivot the rear or locking cantilever segment 340a about the pivot strip 339 to move the lowermost extent of the second disengagement protrusion 342 above the uppermost extent of the first disengagement protrusion 287. PTo move the second disengaging protrusion 342 behind the first disengaging protrusion 287, a downward pivoting force F P While applying a forward or unlocking force F to the cantilever segment 340a, the installer also applies a rearward unlocking force F UL is applied to the primary locking member 320. The rearwardly directed unlocking force F UL (i) displaces the contingent engagement members 338a, 338b from the contingent engagement recesses 300a, 300b due to (a) interaction between the contingent engagement members 338a, 338b and the angled walls 302a, 302b, (b) positioning within the contingent engagement recesses 331a, 331b, (ii) removes the bracing projections 649a, 649b from the bracing openings 354, and (iii) reduces the extent of the primary locking member 320 from being positioned adjacent the user interaction structure 414 of the male deformable male CPA member 406. As discussed above, the required downward pivot force F P is a force less than 25 Newtons, the required unlocking force F UL is a force less than 25 Newtons. P Note that if not properly applied, the second disengagement protrusion 342 will interact with the first disengagement protrusion 287. This can prevent the installer from accidentally applying a disengagement force F AD The primary locking member 320 is prevented from unlocking unless the unlocking force F is applied in an amount greater than 500 Newtons. UL is the accidental disengagement force F AD Smaller and more favorable unlocking force F UL is the accidental disengagement force F AD and the most preferred unlocking force F UL is the accidental disengagement force F AD 20 times smaller than

[0108] E. Disconnected state When the system 10 is placed in the connected state, the system 10 (i) applies a rear CPA force FCPA is displaced toward the rear of the system 10, thereby displacing the horizontal engagement member 412 of the male deformable male CPA member 406 toward the front of the system 10; and (ii) an upward separation force F DIS It can be transitioned to the disconnected state by adding

[0109] Second embodiment As shown in Figs. 106-135, the second embodiment of the connector system 1010 includes multiple components designed to electrically and mechanically connect one device or component to another device or component within the power distribution system 5. For the sake of brevity, the above disclosure related to the connector assembly 10 will not be repeated below. However, it should be understood that the disclosure related to the male terminal assembly 430 and the female terminal assembly 800 applies with equal force to the male terminal assembly 1430 and the female terminal assembly 1800. In addition, all other structures not disclosed in this application (e.g., bus bar 1700 and capacitor assembly 1750) are fully disclosed in International Application PCT / US2021 / 033446 and are incorporated herein by reference. It should be understood that like numbers represent like structures. For example, the disclosure of International Application PCT / US2021 / 033446 regarding the bus bar 700 applies equally to the bus bar 1700 disclosed herein. Further, it should be understood that any one or more features of connector assembly 10 can be used in conjunction with those disclosed with respect to connector assembly 1010, and any one or more features of connector assembly 1010 can be used in conjunction with those disclosed with respect to connector assembly 10. For example, any feature of touchproof member 720 or touchproof member 2942 can be used in conjunction with those disclosed with respect to touchproof member 1942, and any feature of touchproof member 1942 can be used in conjunction with those disclosed with respect to touchproof member 720 or touchproof member 2942.

[0110] A second embodiment of the connector system 1010 includes (i) a male connector assembly 1200 and a female connector assembly 1600. The male connector assembly 1200 includes (i) a male housing assembly 1220 and (ii) a male terminal assembly 1430 having a male terminal 1470 and a spring member 1440c. The male housing assembly 1220 includes (i) an outer housing 1222 and (ii) a terminal holder 1246 that removably couples the male terminal assembly 1430 within the outer housing 1222. The female connector assembly 1600 includes (i) a female housing 1610, (ii) a bus bar 1700, (iii) a capacitor assembly 1750, and (iv) a female terminal assembly 1800. The female housing 1610 is designed to at least (i) protect the female terminal assembly 1800 from external objects by enclosing a majority of the female terminal assembly 1800, (ii) facilitate the coupling of the male terminal assembly 1430 to the female terminal assembly 1800, (iii) provide a sealed environment to house the capacitor assembly 1750, (iv) support the coupling of the capacitor assembly 1750 to the female terminal assembly 1800, and (v) provide a seal between the male connector assembly 1200 and the component 8 of the power distribution system 5 via a pair of capacitors 1754, 1758. To achieve these design objectives, the female housing 1610 is comprised of a lower female housing 1612 and an upper female housing 1650.

[0111] The primary differences between the connector system disclosed in International Application PCT / US2021 / 033446 and the connector system 1010 disclosed herein are (i) the female housing 1610 (e.g., lower female housing 1612 and upper female housing 1650), and (ii) the modification of the second embodiment of the touchproof member 1942. Specifically, the lower housing member is modified (i) to fit within the upper female housing 1650, (ii) to include an arrangement of coupling projections 1634 extending from an outer surface of the lower arrangement of the sidewall 1626, and (iii) to omit the two attachment regions 1646a, 1646b and the openings 1647a, 1647b formed therethrough. The arrangement of coupling projections 1634 includes a plurality of pyramidal shaped structures 1636a-1636f. The pyramidal structures 1636a-f are configured to be received by an arrangement of apertures 1680 formed in the top wall 1678 of the upper adapter housing 1650. In particular, the arrangement of apertures 1680 includes a plurality of elliptical openings 1682a-f configured to receive the pyramidal structures 1636a-f when the lower female housing 1612 is coupled to the upper female housing 1650. In addition to the arrangement of apertures 1680, the upper female housing 1650 is modified to include attachment regions 1684a, 1684b. The attachment regions 1684a, 1684b include openings 1686a, 1686b formed therethrough designed to receive elongated fasteners that secure the housing 1610 (and the female connector assembly 600) to the component 8.

[0112] The modifications to the housing 610 shown and described above provide improvements over the housing 1610 disclosed in International Application PCT / US2021 / 033446 because the housing 1610 disclosed herein (i) does not rely solely on ultrasonic welding of the lower female housing 1612 and the upper female housing 1650 to maintain a sealed connector 600. Instead, the disclosed housing 1610 (a) utilizes a mechanical method of fastening the upper female housing 1650 to the lower female housing 1612 (i.e., the arrangement of the coupling projections 1634 and the arrangement of the openings 1680), (b) utilizes a mechanical method of fastening the upper female housing 1650 directly to the component 8 (i.e., elongated fasteners passing through the attachment areas 1684a, 1684b of the upper female housing 1612) to seal the lower female housing 1650 within the upper female housing 1650, and (ii) increases the thickness of the bottom wall to prevent bending or separation from the component 8. Other variations between these housing designs may be apparent to those of ordinary skill in the art, and such variations may provide additional advantages that may also be apparent to those of ordinary skill in the art.

[0113] The touchproof member 1942 shown in Figures 106-135 offers substantial improvements over the third embodiment of the touchproof member 2942 disclosed in Figures 136-140. In particular, these improvements include better fixation of the member 1942 within the female terminal assembly 1800 and less force required to insert the touchproof member 1942 into the female terminal assembly 1800. The optional touchproof assembly 1040 includes a male touchproof element opening 1242 and a female touchproof member 1942. The touchproof assembly 1040 is designed to (i) help ensure that foreign objects cannot contact the female terminal assembly 1800 when the female connection assembly 1600 is not coupled to the male connector assembly 1200, and (ii) stabilize the connection between the male terminal assembly 1430 and the female terminal assembly 1800. To accomplish both of these tasks, the female touchproof member 1942 includes (i) a touchproof fastening assembly 1944 and (ii) a touchproof element 1960. The touchproof fastening assembly 1944 includes an arrangement of deformable retaining members 1946 having (i) a first base portion 1948a having a first retaining member 1950a and a second retaining member 1950b, (ii) a second base portion 1948b having a third retaining member 1950c and a fourth retaining member 1950d, and (iii) a touchproof recess 1951 extending between the first base portion 1948a and the second base portion 1948b. Retention members 1950a-d depend or extend downwardly from their base portions 1948a, 1948b and include bodies 1952a-d, projections 1954a-d, and angled rear walls 1956a-d. It should be appreciated that each of these structures aids in allowing the female touch proof member 1942 to be installed after the female connector system 600 is coupled to a component.

[0114] The configuration of the deformable retaining member 1946 has (i) an original or undeformed state when the touchproof member 1942 is in a non-installed or installed state, and (ii) an original or deformed state when the touchproof member 1942 is in a partially installed state. In the original or undeformed state, the touchproof recess 1951 has a first original width, and in the original or deformed state, the touchproof recess 1951 has a second compressed width, the first original width being greater than the second compressed width. The configuration of the deformable retaining member 1946 is part of the touchproof fastening assembly 1944, which is part of the touchproof member 1942, so the states from the configuration of the deformable retaining member 1946 apply to the touchproof fastening assembly 1944 and the touchproof member 1942. In other words, when the arrangement of the deformable retaining member 1946 is (i) in its original state, the touchproof fixing assembly 1944 and the touchproof member 1942 are also in their original state, and (ii) when it is in its deformed state, the touchproof fixing assembly 1944 and the touchproof member 1942 are also in their deformed state.

[0115] The first and second base portions 1948a, 1948b have a substantially rectangular shape, with the combined periphery of the base portions 1948a, 1948b and the touchproof recess 1951 substantially conforming to the shape of the female terminal receiving portion 1814. In addition to the arrangement of the deformable retention members 1946 depending downwardly from the base portions 1948a, 1948b, the touchproof member 1942 also includes downwardly depending support protrusions 1958a, 1958b designed to support the base portions 1948a, 1948b and ensure that the base portions 1948a, 1948b are offset from the lowermost extent of the female terminal receiving portion 1814. A touch proof element 1960 including a first region 1961a and a second region 1962b extends upwardly from the base portions 1948a, 1948b (i.e. opposite the arrangement of the deformable retention member 1946 and the support protrusions 1958a, 1958b). The first region 1961a extends from both of the base portions 1948a, 1948b and has a substantially solid periphery except for a slot 1953 formed through the first region 1961a. The slot 1953 reduces the stiffness of the first region 1961a and is positioned or aligned in cooperation with the recess 1951. The slot 1953 and the recess 1951 enable the first area 1961a to act as a living hinge to facilitate elastic deformation of the first and second base portions 1948a, 1948b during insertion of the touch proof member 1942 into the female terminal assembly 1800.

[0116] The second extent 1961b extends from the first extent 1961a and includes three integrally formed walls 1962 including (i) a first end wall 1964a, (ii) a second end wall 1964b, and (iii) a connecting wall 1966 positioned between the end walls 1964a, 1964b and defining a groove between the end walls 1964a, 1964b and aligned with the recess 1951 and the slot 1953. The combination of the end walls 1964a, 1964b and the connecting wall 1966 provides the second extent 1961b with an "I-shaped" cross-sectional configuration. In this configuration, the slot 1953 does not extend into the second extent 1961b of the element 1960 formed from the walls 1962, helping to ensure that the touchproof element 1960 is sufficiently rigid to meet required industry standards. It should be understood that in other embodiments, the touchproof member 1942 can have the recess 1951 and slot 1953 formed as (i) two recesses perpendicular to one another, thereby forming the base portion in a quarter; (ii) two slots perpendicular to one another, thereby forming the touchproof element in a quarter; (iii) a combination of the above, where both the base portion and the touchproof element are formed in a quarter; or (iv) the base portion and / or the touchproof element can be formed into any number (e.g., 1-10) of distinct segments or portions to (i) increase or decrease the force required to insert the touchproof member 1942 into the female terminal receiving portion 1814 and (ii) increase or decrease the force required to displace the touchproof element 1960 using a foreign object.

[0117] The female terminal assembly 1800 and touchproof member 1942 have (i) an inner terminal length L spanning the inner distance between the opposing end walls 1812b, 1812d. IT (e.g., 20 mm), (ii) an original overhang length L extending between the first retaining member 1950a and the third retaining member 1950c of the arrangement of deformable retaining members 1946 when the female touchproof member 1942 is in an original state OP(e.g., 22 mm), and (iv) a deformation protrusion length L extending between the first retaining member 1950a and the third retaining member 1950c of the arrangement of deformable retaining members 764 when the female touchproof member 1942 is in a deformed state. DP (e.g., less than 20 mm). It should be understood that (i) the original protrusion length is greater than the deformed protrusion length, and (ii) the deformed protrusion length is greater than the length of the inner terminal. The first and second deformable retaining members 768a of the first embodiment of the female touchproof member 720 are extended away from each other in their deformed state, while the first and third retaining members 1950a, 1950c are compressed toward each other in their deformed state. When the female touchproof member 1942 is inserted into the female terminal receiving portion 1814, the original protrusion lengths of the first and third retaining members 1950a, 1950c are compressed to the deformed protrusion length to allow the first and third retaining members 1950a, 1950c to be inserted into the female terminal receiving portion 1814. When the first and third retaining members 1950a, 1950c pass through the length of the side walls 1812a-1812d and are inserted into the fixed opening 1970 of the female terminal assembly 1800, the deformed protrusion lengths of the first and third retaining members 1950a, 1950c are expanded to their original protrusion lengths, thereby positioning the range of the protrusions 1954a-1954d below the side walls 1812a-1812d of the female terminal assembly 1800.

[0118] When the female touchproof member 1942 is in the installed state, the distance between the inner surface of the female terminal assembly 1800 and the outer surface of the female touchproof member 1942 varies due to the configuration of the female touchproof member 1942. For example, the distance between the end faces of end walls 1964a, 1964b of the touchproof element 1942 and the inner surfaces of end walls 1812b, 1812d is approximately D TPE end distance (e.g., 4.85 mm), and the distance between the outer surface of the connecting wall 1966 of the touchproof element 1942 and the inner surfaces of the side walls 1812a, 1812b is approximately D TPSA side distance (e.g., 6.85 mm) between the female connector assembly 1600 and the touchproof member 1942 is 1.0 mm. Although these distances vary, each of the above distances is less than the distances specified in various industry regulations (e.g., ISO 20076:2019, ISO 20653:2013, USCAR12, Revision 5, and IEC 60529-2020). Thus, by including the touchproof member 1942, the female connector assembly 1600 can pass or comply with each of these standards (e.g., ISO 20076:2019, ISO 20653:2013, USCAR12, Revision 5, and IEC 60529-2020).

[0119] Third embodiment 136-140 show a third embodiment of the touchproof member 2942. It should be understood that this third embodiment of the touchproof member 2942 is configured to be utilized with the second embodiment of the connector system 1010. Thus, the figures and related disclosures relating to the second embodiment 1010 are not repeated for this third embodiment of the touchproof member 2942. The omission of these figures and related disclosures is in no way limiting for this third embodiment, and instead, the reader should refer back to the figures and disclosures discussed above in connection with the second embodiment of the connector system 1010. In addition, it should also be understood that certain disclosures related to the second embodiment of the touchproof member 1942 are not repeated here for the third embodiment of the touchproof member 2942. Instead, it should be understood that like numbers represent like structures. For example, the disclosures from the retaining member 1950a are applied with equal force to the retaining member 2950a. Further, it should be understood that any one or more features of the touchproof member 720 or the touchproof member 1942 can be used with those disclosed with respect to the touchproof member 2942, and any one or more features of the touchproof member 2942 can be used with those disclosed with respect to the touchproof member 720 or the touchproof member 1942. The main differences between the second embodiment of the touchproof member 1942 and the third embodiment of the touchproof member 2942 are that (i) the touchproof recess is omitted, and (ii) the first extent of the touchproof element 2960 is also omitted. Thus, the wall 2962 extends in a directional manner from the base portion 2948. Because this embodiment cannot rely on folding the touchproof recess 1951 to allow the touchproof member 2942 to move from an original or undeformed state to an unoriginal or deformed state, this functionality is provided by the retaining members 2950a-2950d. Nonetheless, this third embodiment of the touchproof member 2942 provides the same overall functionality as described above for the second embodiment of the touchproof member 1942.

[0120] The system 10, 1010 is T4 / V4 / S3 / D2 / M2, where the system 10, 1010 meets and exceeds (i) T4 is exposure of the system 100 to 150°C, (ii) V4 is severe vibration, (iii) S1 is high pressure spray sealed, (iv) D2 is 200 km durability, and (v) M2 is less than 45 Newtons of force required to connect the male terminal assembly 430, 1430 to the female terminal assembly 800, 1800. The terminal assembly 430, 1430 shown in the following figures is rated to operate with a rise over ambient (RoA) of 55°C or 80°C with 80% derating, and Figures 1-99B show the 100mm 2 The conductor can carry 365 amperes, and Figures 106 to 135 show the 50 mm 2 245 amps on conductor, 75mm 2 280 amps on conductor, 100mm 2 The conductors are capable of carrying 330 amps. Additionally, other performance specifications of the system 10 disclosed herein will be apparent to those skilled in the art.

[0121] While the figures and disclosure contained herein illustrate two different embodiments of the connector system 10, 1010, it should be understood that these are merely exemplary embodiments and that other embodiments are possible. For example, any number of male terminal assemblies 430, 1430 may be positioned within a single male housing assembly 220, 1220. Specifically, the male housing assembly 220, 1220 may be configured to accommodate a plurality (e.g., 3-30, preferably 3-8, most preferably 3-4) of male terminal assemblies 430, 1430. The female terminal assembly 800, 1800 may be reconfigured to receive these multiple male terminal assemblies into a single female terminal assembly 800, 1800. Alternatively, the female terminal assembly 800, 1800 may be reconfigured to include multiple female terminal assemblies 800, 1800, with each female terminal assembly 800, 1800 receiving a single male terminal assembly 430, 1430. In other words, the systems disclosed herein may include (i) any number of male terminal assemblies 430, 1430, and (ii) a number of female terminal assemblies 800, 1800 that is equal to or less than the number of male terminal assemblies 430, 1430. It should also be understood that when multiple male terminal assemblies 430, 1430 are utilized, the male terminal assemblies 430, 1430 may have the same shape, similar shapes, or different shapes.

[0122] It should further be understood that the male terminal assembly 430, 1430 may have any number of contact arms 494, 1494 (e.g., 2-100, preferably 2-50, and most preferably 2-8) and any number of spring arms 452, 1452 (e.g., 2-100, preferably 2-50, and most preferably 2-8). As discussed above, the number of contact arms 494, 1494 may not be equal to the number of spring arms 452, 1452, the width of the spring arms 452, 1452 may be greater than or equal to the width of the contact arms 494, 1494, or the width of each spring arm 452, 1452 or each contact arm 494, 1494 may differ from the width of the other spring arms 452, 1452 or contact arms 494, 1494 included in the same terminal assembly 430, 1430. For example, there may be more contact arms 494, 1494 than spring arms 452, 1452. Alternatively, there may be fewer contact arms 494, 1494 than spring arms 452, 1452.

[0123] Materials and Disclosures Incorporated by Reference PCT Application Number, International Application No. PCT / US2021 / 057959, International Application No. PCT / US2021 / 047180, International Application No. PCT / US2021 / 043788, International Application No. PCT / US2021 / 043686, International Application No. PCT / US2021 / 033446, International Application No. PCT / US2020 / 049870, International Application No. PCT / US2020 / 050018, International Application No. PCT / US2020 / 014484, International No. PCT / US2020 / 013757, International Application No. PCT / US2019 / 036127, International Application No. PCT / US2019 / 036070, International Application No. PCT / US2019 / 036010, and International Application No. PCT / US2018 / 019787, U.S. Patent Application No. 16 / 194,891, and U.S. Provisional Patent Application No. 63 / 222,859, each of which is incorporated by reference in its entirety and made a part of this specification.

[0124] USCAR standards: (i) SAE / USCAR-2, Revision 6, February 2013 ISBN: 978-0-7680-7998-2; (ii) SAE / USCAR-12, Revision 5, August 2017 ISBN: 978-0-7680-8446-7; (iii) SAE / USCAR-21, Revision 3, December 2014; (iv) SAE / USCAR-25, Revision 3, March 2016 ISBN: 978-0-7680-8319-4; (v) SAE / USCAR-37, Revision 3, August 2008 ISBN: 978-0-7680-2098-4; (vi) SAE / USCAR-38, Revision 1, May 2016 ISBN:978-0-7680-8350-7, each of which is incorporated by reference in its entirety and made a part of this specification.

[0125] ISO specifications including Road vehicles - Test methods and performance requirements for voltage class B connectors (ISO20076:2019) and Road vehicles - Degrees of protection (IP code) - Protection of electrical equipment against foreign objects, water and access (ISO20653:2013).

[0126] Each of the IEC specifications, including the degree of protection provided by an enclosure (IP Code) (IEC 60529-2020), is hereby incorporated by reference in its entirety and made a part of this specification.

[0127] The SAE Standard, J1742_201003, entitled "Connections for High Voltage On-Board Vehicle Electrical Wiring Harnesses-Test Methods and General Performance Requirements," last revised March 2010, is hereby incorporated by reference in its entirety and made a part hereof.

[0128] The following ASTM standards are hereby incorporated by reference in their entirety: (i) D4935-18, entitled "Standard Test Method for Measuring the Electromagnetic Shielding Effectiveness of Planar Materials," and (ii) ASTM D257, entitled "Standard Test Methods for DC Resistance or Conductance of Insulating Materials."

[0129] The DIN standard, Connectors for electronic equipment-Tests and measurements-Part 5-2: Current-carrying capacity tests; Test 5b: Current-temperature de-rating (IEC60512-5-2:2002), is incorporated by reference in its entirety and forms a part of this specification.

[0130] ESD Specifications, including Surface Resistance Measurements of Static Dissipative Planar Materials (ANSI / ESD STM11.11), each of which is fully incorporated by reference and made a part hereof.

[0131] Other standards include American National Standards Institute standards that correspond or have counterparts to the standards listed above, as well as Federal Test Standards 101C and 4046, each of which is fully incorporated by reference and made a part of this specification.

[0132] Although several implementations have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the present disclosure. The scope of protection is limited only by the scope of the accompanying claims. For example, the overall shape of the above-mentioned components may be modified to a triangular prism, a pentagonal prism, a hexagonal prism, an octagonal prism, a sphere, a cone, a tetrahedron, a cube, a dodecahedron, an icosahedron, an octahedron, an ellipsoid, or other similar shapes.

[0133] It should be understood that the following terms as used herein shall generally mean the following: "High power" shall mean (i) a voltage between 20 volts and 600 volts, regardless of the current, or (ii) any current of 80 amps or greater, regardless of the voltage. "High current" shall mean a current of 80 amps or greater, regardless of the voltage. "High voltage" shall mean a voltage between 20 volts and 600 volts, regardless of the current.

[0134] Headings and subheadings, if any, are used for convenience only and are not limiting. The word exemplary is used to mean serving as an example or illustration. Where terms include, use, and the like are used, such terms are intended to be included in the same manner as the term "comprise" would be interpreted when used as a transitional word in the claims. Relative terms such as first and second may be used to distinguish one entity or action from another without necessarily requiring or suggesting any actual such relationship or order between the entities or actions.

[0135] The phrases "one aspect," "that aspect," "another aspect," "some aspects," "one or more aspects," "one implementation," "that implementation," "another implementation," "some implementation," "one or more implementations," "one embodiment," "that embodiment," "another embodiment," "some embodiments," "one or more embodiments," "one configuration," "that configuration," "another configuration," "some configuration," "one or more configurations," the subject technology, the disclosure, the present disclosure, other variations thereof, and similar phrases are used for convenience and do not imply that the disclosure associated with such phrases is essential to the subject technology or that such disclosure applies to all configurations of the subject technology. The disclosure associated with such phrases may apply to all configurations, or to one or more configurations. The disclosure associated with such phrases may provide one or more examples. Phrases such as "aspect" or "some aspects" may refer to one or more aspects, and vice versa, as with the other aforementioned phrases.

[0136] Numerous modifications to the present disclosure will be apparent to those skilled in the art in light of the foregoing description. Preferred embodiments of the present disclosure are described herein, including the best mode known to the inventors for carrying out the disclosure. Of course, it is to be understood that the illustrated embodiments are illustrative only and should not be construed as limiting the scope of the present disclosure.

Claims

1. A connector system for use in a power distribution system, the connector system comprising a male terminal assembly, the male terminal assembly comprising a male terminal body including a first contact arm, a second contact arm, and a spring receiving portion, a spring member including (i) a first spring arm having a positioning protrusion extending from a free end of the first spring arm, and (ii) a second spring arm, the spring member being present within the spring receiving portion so as to define a seated state, whereby the positioning protrusion encompasses a perimeter of an inner corner region of the first contact arm, a connector system.

2. The connector system according to claim 1, wherein the second spring arm has a planar configuration and no positioning protrusion.

3. The spring member further includes a third spring arm, the third spring arm having a positioning protrusion extending from a free end of the third spring arm, in the seated state, the positioning protrusion of the third spring arm encompassing a perimeter of an inner corner region of a third contact arm of the male terminal body, the connector system according to claim 2.

4. The connector system according to claim 3, wherein the first and third spring arms extend from both sides of a rear wall of the spring member.

5. a female housing formed of a non-conductive material, a female terminal assembly formed of a conductive material, the female terminal assembly being configured to be inserted into the female housing using a first force directed in a first direction, a touch-proof member formed of a non-conductive material, the touch-proof member being configured to be inserted into the female terminal assembly using a second force directed in a second direction opposite to the first direction, when the touch-proof member is inserted into the female terminal assembly, the touch-proof member preventing insertion of foreign objects into the female terminal assembly, the connector system according to claim 1.

6. The connector system according to claim 5, wherein the touch-proof member has a base and a touch-proof fixing assembly having an arrangement of deformable retaining members that elastically deform during insertion of the touch-proof member into the female terminal assembly.

7. the deformable holding member elastically deforms from its original state to a deformed state during insertion of the touch-proof member into the female terminal assembly, the deformable holding member elastically deforms from the deformed state back to the original state after the touch-proof member is fully inserted into the female terminal assembly and reaches the installed state, the connector system according to claim 6.

8. the touch-proof member has a touch-proof element having a first end wall, a second end wall, and a connecting wall extending between the first end wall and the second end wall, the connector system according to claim 5.

9. when the touch-proof member is inserted into the female terminal assembly, a foreign object distance of 5 mm or less is defined between the touch-proof element and a first wall of the female terminal assembly, the connector system according to claim 8.

10. the touch-proof member includes an elastically deformable base having a first base portion and a second base portion separated by a recess, the first base portion includes at least one holding member hanging down from the first base portion, and the second base portion includes at least one holding member hanging down from the second base portion, the connector system according to claim 5.

11. the touch-proof member further includes a touch-proof element extending from the elastically deformable base, and the touch-proof element has a first range having a slot aligned with the recess separating the first and second base portions, the connector system according to claim 10.

12. the slot and the recess are combined to facilitate the first and second base portions to function as a living hinge during insertion of the touch-proof member into the female terminal assembly, the connector system according to claim 11.

13. the touch-proof element has a second range adjacent to the first range, and the second range has a pair of end walls and a connecting wall providing an I-shaped cross-sectional configuration in the second range, the connector system according to claim 12.

14. A connector system for use in a power distribution system, the connector system comprising a male terminal assembly, the male terminal assembly being, A male terminal body including a first contact arm, a second contact arm, and a spring receiving portion, A spring member including a first spring arm and a second spring arm having positioning and holding means, The spring member is present in the spring receiving portion so as to define a seated state, whereby the positioning and holding means of the first spring arm wraps around a part of the first contact arm and is present adjacent to at least an end face of the first contact arm, a connector system.

15. The second spring arm includes positioning and holding means, In the seated state, the positioning and holding means of the second spring arm wraps around a part of the second contact arm of the male terminal body and is present adjacent to at least an end face of the second contact arm, the connector system according to claim 14.

16. In the seated state, the positioning and holding means of the second spring arm wraps around the peripheral of the inner corner region of the second contact arm, the connector system according to claim 15.

17. The first and second spring arms extend from both sides of the rear wall of the spring member, and the first and second spring arms are in an oblique positional relationship, the connector system according to claim 15.

18. The first and second spring arms extend from both sides of the rear wall of the spring member, and the first and second spring arms are in an opposing positional relationship, the connector system according to claim 15.

19. The spring receiving portion is formed by the wall arrangement of the male terminal body, and at least one of the first and second contact arms has (i) a neck portion having a neck width and (ii) a body portion having a body width larger than the neck width, the connector system according to claim 14.

20. The male terminal assembly includes an upper wall, and at least one of the first and second contact arms extends at an outward angle of 5 to 12 degrees from the upper wall, the connector system according to claim 19.

21. During the operation of the power distribution system, the first and second spring arms apply an outward biasing force to the first and second contact arms, the connector system according to claim 19.

22. The connector system according to claim 19, wherein the neck width is at least 10% smaller than the body width, and this reduction in the neck width compared to the body width reduces the force required to deflect or displace at least one of the first and second contact arms inwardly and towards the center of the male terminal when coupling the male terminal assembly to the female terminal assembly.

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