Electrical connector system with high ampacity

Abstract

To provide a connector system including a male terminal assembly and female terminal assembly having high ampacity performance in a variety of installations and applications.SOLUTION: A connector system 100 for use in a power distribution system includes a male terminal assembly, a female terminal assembly 2430, and an internal spring 1440a. The male terminal assembly includes a male terminal body 1472 formed with a spring receiver, a base wall 1478a to 1478b, and a plurality of contact arms extending forward from the base wall and arranged along a curvilinear contact arm path. The contact arms are spatially arranged such that a contact arm opening resides between a pair of contact arms in the plurality of contact arms and no intervening structure of the male terminal body resides between a pair of contact arms in the plurality of contact arms. The internal spring is dimensioned to reside within the spring receiver and includes a plurality of spring arms arranged along a curvilinear spring arm path.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] (Related Applications) This application claims the benefit of U.S. Provisional Patent Application No. 63 / 068,622, filed August 21, 2020, the disclosure of which is incorporated herein by reference.

[0002] FIELD OF THE INVENTION The present disclosure relates to electrical connectors, and more particularly to a connector system including a male terminal assembly with an internal spring member. The male terminal assembly has a shape that includes a range of curves and meets stringent industry performance standards and production requirements. The connector system also includes a female terminal assembly with a receptacle configured to receive the range of male terminal assemblies. These male and female terminal assemblies provide a connector system with high current carrying capacity in a variety of equipment and applications. [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 trucks, truck trailers, motorcycles, all-terrain vehicles, and sport utility vehicles (collectively, "motor vehicles"), has increased dramatically. Electrical components are used in motor vehicles for a variety of reasons, including, but not limited to, monitoring, improving, and / or controlling vehicle performance, emissions, safety, and the physical comfort of motor vehicle occupants. These electrical components are mechanically and electrically connected within the motor vehicle by conventional connector assemblies consisting of eyelets and threaded fasteners. Although considerable time, resources, and energy have been expended to develop connector assemblies that meet the various needs and complexities of the motor vehicle market, conventional connector assemblies suffer from various drawbacks.

[0004] Automotive vehicles are challenging 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 weather conditions, vibration, thermal loads, and longevity. All of these conditions 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 total annual warranty costs incurred by automotive manufacturers and all of their direct suppliers is estimated to be between $50 billion and $150 billion worldwide.

[0005] A more suitable and robust connector system must be resistant to harsh operating conditions, prolonged vibration, and excessive heat loads, especially those that build up "under the hood" of a vehicle. To create a robust solution, many companies have designed various spring-activated connectors with features that hold the connector in place. Such spring-activated connectors typically have some kind of indication that they are fully inserted. Sometimes, the spring-activated features of the connector are made from plastic. In other cases, the spring-activated features of the connector are manufactured from spring steel. While more recent connectors are an improvement over older connectors that used eyelets and threaded connectors, unfortunately, there are still many failures.

[0006] Part of the reason conventional spring-actuated connector assemblies are prone to failure in automotive applications is due to the assembly design, i.e., the location of spring elements, such as tabs, on the periphery of the connector. By placing the spring tabs on the exterior of the connector, manufacturers attempt to make the engagement of the assembly components readily apparent to workers assembling the parts in the factory. Unfortunately, for both plastic and metal, the elevated temperatures of the automotive environment make peripheral springs susceptible to premature failure. It is not uncommon for automotive engine compartments to reach or exceed 100°C, and for individual components of automotive engines to reach or exceed 180°C. At 100°C, most plastics begin to plasticize, reducing the retention force of peripheral spring-actuated elements. At 100°C, thermal expansion of spring steel reduces the retention force of peripheral spring-actuated connectors. Additionally, for spring-actuated features formed from spring steel, the inherent residual material memory effect of spring steel as it is repeatedly thermally cycled between high and low temperatures is a contributing factor. After many temperature cycles, the spring steel begins to return to its original preformed shape, reducing the retention of the spring-actuated element with other components of the connector system. This behavior makes conventional connector systems susceptible to vibration and failure, each of which significantly reduces the performance and reliability of conventional connectors. For these and many other reasons, the automotive industry needs more reliable connector systems that are low-cost, vibration-resistant, heat-resistant, and have better overall electrical and mechanical performance.

[0007] There is clearly a market need for a mechanically simple, lightweight, inexpensive, vibration-resistant, and heat-resistant robust electrical connector system with high current capacity for use in power distribution systems such as those found in motor vehicles. Statements provided in the Background section should not be assumed to be prior art merely because they are mentioned in or related to the Background section. The Background section may include information that describes one or more aspects of the subject technology. Summary of the Invention [Problem to be solved by the invention]

[0008] According to one aspect of the present disclosure, a connector system is characterized by high current carrying capabilities and includes a male connector assembly and a female connector assembly. Both the male connector assembly and the female connector assembly have a housing and terminals. The male terminal assembly is designed and configured to mate within the female terminal, forming both a mechanical and electrical connection therebetween. In particular, the male terminal assembly includes an internal spring member designed to interact with a region of the male terminal to ensure a proper connection between the male and female terminals. The female terminal assembly includes a receptacle configured to receive the region of the male terminal assembly.

[0009] The male terminal assembly includes a rearmost male terminal body including a plurality of contact arms. A spring member is nested within the male terminal body. The spring member resists inward deflection and applies an outward force to the contact arms, thereby creating a secure connection and retention force of the male terminal relative to the female terminal within the female terminal. Unlike other prior art connection systems, the connection between the male and female terminals becomes stronger when the connector system is subjected to high temperatures, thermal cycling, and the application of power, especially high current loads.

[0010] Other aspects and advantages of the present disclosure will become apparent upon consideration of the following detailed description and the accompanying drawings, in which like numbers refer to like structure throughout. [Brief explanation of the drawings]

[0011] The accompanying drawings, which are included to provide a further understanding and are incorporated in and constitute a part of this specification, illustrate the disclosed embodiments and, together with the description, serve to explain the principles of the disclosed embodiments. [Figure 1] FIG. 1 is a perspective view of a first embodiment of a connector system featuring high current carrying capabilities and having a male connector assembly and a female connector assembly in a disconnected state (SDCON). [Figure 2] FIG. 2 is an exploded view of the connector system of FIG. [Figure 3]FIG. 3 is an exploded view of the male connector assembly of FIG. 1 in a disengaged state (SDC), the male connector assembly having a housing and a male terminal assembly including a male terminal body and a spring member. [Figure 4] 4 is a perspective view of the male terminal body of FIG. 3 in a released joint state (SDJ). [Figure 5] 5 is a side view of the inner portion of the male terminal body of FIG. 4. FIG. [Figure 6] 6 is a perspective view of the inner portion of the male terminal body of FIG. 5. FIG. [Figure 7] 7 is a perspective view of the male terminal body shown in FIG. 3 in a joined state (SJ). [Figure 8] 8 is a side view of the male terminal body of FIG. 7. FIG. [Figure 9] 9 is a front view of the male terminal body of FIG. [Figure 10] 10 is a top view of the male terminal body of FIG. 7. FIG. [Figure 11] 11 is a front perspective view of a spring member of the male connector assembly of FIG. 3; FIG. [Figure 12] FIG. 12 is a front view of the spring member of FIG. [Figure 13] FIG. 13 is a top view of the spring member of FIG. [Figure 14] 14 is a rear perspective view of the spring member of FIG. 11. FIG. [Figure 15] FIG. 15 is an exploded view of the male terminal assembly of FIG. 3 in a uncoupled condition (SDC). [Figure 16] 16 is a perspective view of the male terminal assembly of FIG. 3 in a coupled state (SC). [Figure 17] 17 is a top view of the male terminal assembly of FIG. 16. FIG. [Figure 18] 18 is a front view of the male terminal assembly of FIG. 16. FIG. [Figure 19] 19 is a side view of the male terminal assembly of FIG. 16. FIG. [Figure 20] 20 is a cross-sectional view of the male terminal assembly of FIG. 19 taken along line 20-20. [Figure 21]21 is a front view of the housing area of the male connector assembly of FIG. 3. FIG. [Figure 22] 22 is a cross-sectional view of the housing of FIG. 21 taken along line 22-22. [Figure 23] 23 is a rear perspective view of the housing area of the male connector assembly of FIG. 21; [Figure 24] FIG. 24 is a perspective view of the male connector assembly of FIG. 3 in a disassembled state (SDA), with the rear extent of the housing omitted. [Figure 25] 25 is a perspective view of the male connector assembly of FIG. 42 in a partially assembled state (SPA). [Figure 26] 26 is a side view of the male connector assembly of FIG. 25. FIG. [Figure 27] 27 is a top view of the male connector assembly of FIG. 25. FIG. [Figure 28] 28 is a cross-sectional view of the male connector assembly of FIG. 27 taken along line 28-28. [Figure 29] 29 is a cross-sectional view of the male connector assembly of FIG. 27 taken along line 29-29. [Figure 30] 30 is a perspective view of the male connector assembly of FIG. 3 in a partially assembled state (SPA). [Figure 31] 31 is a perspective view of the male connector assembly of FIG. 3 in a fully assembled state (SFA). [Figure 32] 32 is a side view of the male connector assembly of FIG. 31. FIG. [Figure 33] 33 is a cross-sectional view of the male connector assembly of FIG. 32 taken along line 33-33. [Figure 34] 34 is a front view of the male connector assembly of FIG. 31. FIG. [Figure 35] 35 is a cross-sectional view of the male connector assembly of FIG. 34 taken along line 35-35. [Figure 36] 36 is a top view of the male connector assembly of FIG. 31. FIG. [Figure 37] 37 is a perspective view of the female terminal assembly of FIG. 3. FIG. [Figure 38]38 is a front view of the female terminal assembly of FIG. 37. FIG. [Figure 39] 39 is a cross-sectional view of the female terminal assembly of FIG. 38 taken along line 39-39. [Figure 40] FIG. 40 is a side view of the connector system of FIG. 1 in a disconnected state (SDCON). [Figure 41] 41 is a cross-sectional view of the high current capacity connector system of FIG. 40 taken along line 41-41. [Figure 42] 42 is a side view of the connector system of FIG. 1 in a partially connected state (SPCON). [Figure 43] 43 is a cross-sectional view of the connector system of FIG. 42 taken along line 43-43. [Figure 44] FIG. 44 is a side view of the connector system of FIG. 1 in a fully connected state (SFCON). [Figure 45] 45 is a cross-sectional view of the connector system of FIG. 44 taken along line 45-45. [Figure 46] FIG. 46 is a side view of the connector system of FIG. 1 in a fully connected state (SFCON). [Figure 47] 47 is a cross-sectional view of the connector system of FIG. 46 taken along line 47-47. [Figure 48] FIG. 48 is a perspective view of a second embodiment of a connector system featuring high current carrying capabilities and having a male connector assembly and a female connector assembly in a disconnected state (SDCON). [Figure 49] FIG. 49 is an exploded view of the connector system of FIG. [Figure 50] FIG. 50 is an exploded view of the connector system of FIG. 48 in a disassembled state (SDA), in which the male connector assembly has a housing and a male terminal assembly including a male terminal body and a spring member. [Figure 51] 51 is a perspective view of a male terminal body of the male terminal assembly of FIG. 50. FIG. [Figure 52] 52 is a top view of the male terminal body of FIG. 51. FIG. [Figure 53] 53 is a front view of the male terminal body of FIG. 51. FIG. [Figure 54] 54 is a side view of the male terminal body of FIG. 51. FIG. [Figure 55] FIG. 55 is a perspective view of the male terminal assembly of FIG. 50 with the male terminal body and spring member in the uncoupled condition (SDC). [Figure 56] FIG. 56 is a perspective view of the male terminal assembly of FIG. 50 in a coupled condition (SC) with the spring member residing within the male terminal body. [Figure 57] 57 is a front view of the male terminal assembly of FIG. [Figure 58] 58 is a top view of the male terminal assembly of FIG. [Figure 59] 59 is a side view of the male terminal assembly of FIG. [Figure 60] 60 is a cross-sectional view of the male terminal assembly of FIG. 59 taken along line 60-60. [Figure 61] 61 is a rear perspective view of the housing area of the male connector assembly of FIG. 50; FIG. [Figure 62] 62 is a perspective view of the male connector assembly of FIG. 50 in a disassembled state (SDA). [Figure 63] 63 is a perspective view of the male connector assembly of FIG. 50 in a fully assembled state (SFA). [Figure 64] 64 is a front view of the male connector assembly of FIG. 63. FIG. [Figure 65] 65 is a side view of the male connector assembly of FIG. 63. FIG. [Figure 66] 66 is a cross-sectional view of the male connector assembly of FIG. 65 taken along line 66-66. [Figure 67] 67 is a side view of the male connector assembly of FIG. 63. FIG. [Figure 68] 68 is a cross-sectional view of the male connector assembly of FIG. 67 taken along line 68-68. [Figure 69] 69 is a side view of the male connector assembly of FIG. 63. FIG. [Figure 70] 70 is a cross-sectional view of the male connector assembly of FIG. 69 taken along line 70-70. [Figure 71]FIG. 71 is a side view of the connector system of FIG. 48 in a disconnected state (SDCON). [Figure 72] 72 is a cross-sectional view of the connector system of FIG. 71 taken along line 72-72. [Figure 73] 73 is a side view of the connector system of FIG. 48 in a partially connected state (SPCON). [Figure 74] 74 is a cross-sectional view of the connector system of FIG. 73 taken along line 74-74. [Figure 75] FIG. 75 is a side view of the connector system of FIG. 48 in a fully connected state (SFCON). [Figure 76] 76 is a cross-sectional view of the high current capacity connector system of FIG. 75 taken along line 76-76. [Figure 77] FIG. 77 is a perspective view of a vehicle skateboard having a battery pack, the vehicle skateboard including a connector system. [Figure 78] FIG. 78 is a perspective view of a vehicle having a battery pack, the vehicle including a connector system. [Figure 79] FIG. 79 is a block diagram illustrating the components of the connector system 100 of the present invention, including a male connector assembly 1000 and a female connector assembly 2000. [Figure 80] FIG. 80 is a block diagram illustrating the components of the male housing assembly 1100 of the connector system 100. [Figure 81A] FIG. 81A is a block diagram illustrating the components of the inner male housing portion 1104 of the male housing assembly 1100 of the connector system 100. [Figure 81B] FIG. 81B is a block diagram illustrating the components of the outer male housing portion 1150 of the male housing assembly 1100 of the connector system 100. [Figure 82] FIG. 82 is a block diagram illustrating the components of a male terminal 1470 of the connector system 100. [Figure 83] FIG. 83 is a block diagram illustrating the components of the spring member 1440a of the connector system 100. [Figure 84]FIG. 84 is a flow chart showing the assembly of the connector system 100. DETAILED DESCRIPTION OF THE INVENTION

[0012] In the following detailed description, numerous specific details are set forth by way of example to provide a thorough understanding of the relevant teachings. However, it will be apparent to those skilled in the art that the present teachings may be practiced without such detailed descriptions. In other instances, well-known methods, procedures, components, and / or electronic circuits have been described at a relatively general level, without going into detail, to avoid unnecessarily obscuring aspects of the present teachings.

[0013] The figure shows a high-current-carrying connector system 100 designed to mechanically and electrically couple a power source (e.g., an alternator or battery) to a device (e.g., a radiator fan, a heated seat, a power distribution component, or another current-drawing component). The high-current-carrying connector system 100 may be used in power distribution systems 10 installed in a variety of applications, including airplanes, motor vehicles, military vehicles (e.g., tanks, personnel carriers, large trucks, and troop carriers), buses, locomotives, bulldozers, excavators, watercraft (e.g., yachts, pleasure boats, cargo carriers, naval warships), submarines, mining equipment, forestry equipment, agricultural equipment (e.g., tractors, cutters, planters, combines, threshing equipment, harvesters), battery packs, or 24-48 volt systems. Stable and reliable operation of power distribution components is essential to meet industry standards, manufacturing requirements, and performance requirements for power distribution systems and these applications. It should be understood that multiple high current capacity connector systems 100 may be used in a single power distribution system 10 in a single application.

[0014] As used herein, the following terms should generally be understood to mean the following: a. "High power" shall mean (i) any voltage between 20 and 1,000 volts regardless of current, or (ii) any current above 80 amperes regardless of voltage. b. "High current" shall mean a current of 80 amps or more, regardless of voltage, that will not cause damage to the connector. c. "Current carrying capacity" shall mean the maximum current a connector can carry continuously under operating conditions without exceeding its temperature rating. d. "High current capacity" shall mean the ability of a connector to carry at least 500 amperes during operation without damage to or degradation of the connector. e. "High voltage" shall mean a voltage between 20 and 1,000 volts, regardless of current.

[0015] Generally, the high-current-carrying connector system 100 includes a male connector assembly 1000 and a female connector assembly 2000. The male assembly includes a male terminal body 1472 and a spring member 1440. The male terminal body 1472 includes a plurality of contact arms 1494 having free ends arranged along a curved, or circumferential, path. Similarly, the spring member includes a plurality of spring arms 1452 having free ends arranged along a curved, or circumferential, path. The curved paths provided by the free ends are dimensioned to cooperate such that axial alignment of the spring member 1440 and the male terminal body 1472 results in mechanical interaction between the plurality of contact arms 1494 and the plurality of spring arms 1452 when the connector system 100 is in a particular state or is subjected to particular operating conditions associated with the power distribution system 10. The cooperative configuration and positioning of the spring arm 1452 and the contact arm 1494 results in a 360-degree compatible connector system 100 that meets and / or exceeds various standards (e.g., USCAR-2, USCAR-12, USCAR-21, USCAR-25, USCAR-37, and / or USCAR-38).

[0016] The high-current-capacity connector system 100 can include at least the following structural features or performance attributes: (i) a male housing assembly 1100 configured to ensure proper alignment between the terminal body 1472 and the spring member 1440, (ii) an approximately 1:1 ratio between the contact arm opening width and the contact arm width, as described in more detail below, (iii) no current choke points between the male terminal body and the connection plate, (iii) a base wall length that is at least 90% of the contact arm length, (iv) no male terminal body extension that surrounds the contact arm, (v) capable of meeting the less than 45 Newton insertion force requirement of a non-lever-assisted USCAR Class 2 connector, (vi) a current rating of at least 500 amps for a 120 mm2 wire size at 55°C rise over ambient (RoA) or at 80°C with an 80% current derating for each male terminal assembly 1430 included in the system, and (vii) a male terminal body that is fabricated from multiple separate and distinct pieces joined together.

[0017] While the present disclosure includes several embodiments of the high-current-carrying connector 100 in many different forms, these are shown in the drawings and specific embodiments are described in detail herein, with the understanding that the disclosure should be considered as an illustration of the principles of the disclosed method and system and is not intended to limit the broad aspects of the disclosed concepts to the illustrated embodiments. As will be understood, the disclosed method and system are capable of other different configurations and certain details may be modified without departing from the scope of the disclosed method and system. For example, one or more of the following embodiments may be consistently combined, in part or in whole, with the disclosed method and system. Accordingly, the drawings and detailed description should be considered exemplary in nature, and not restrictive or limiting.

[0018] 1) Male connector assembly Male connector assembly 1000 is primarily comprised of (i) a male housing assembly 1100, and (ii) a male terminal assembly 1430. Male connector assembly 1000 may have additional features not shown in the figures. However, such additional features are contemplated by this disclosure. For example, male connector assembly 1000 may include (i) a connector position assurance (CPA) assembly that meets USCAR standards (e.g., as described in International Application No. US2020 / 49870), (ii) an interlock (IL) or high voltage interlock (HVI) assembly, and (iii) a connector position assurance (CPA) assembly that meets USCAR standards (e.g., as described in International Application No. US2020 / 49870). The high current capacity connector system 100 may include an interlock (IL) or high voltage interlock (HVIL) (e.g., as described in International Application No. US2020 / 143686), where the interlock may be positioned on the outside of the terminal 1430, 2430 or may be positioned within the spring member 1440a; (iii) a shielding assembly that surrounds the confines of the terminal assembly 1430 and is formed from metal, conductive plastic (e.g., as described in International Application No. US2020 / 13757), or other material that may be used to minimize EMI noise; (iv) water-resistant sealing features (e.g., seals, connector coatings, etc.); (v) a locking handle, lever, or structure that aids in connecting the male connector assembly 1000 to the female connector assembly 2000 and / or helps ensure that the high current capacity connector system 100 remains fully connected; and / or (vi) any combination of these structures. Additionally, other structures disclosed in any of the applications incorporated herein may be used in connection with male connector assembly 1000.

[0019] 21-24, the male housing assembly 1100 is designed to (i) protect and isolate the male terminal assembly 1430 from foreign objects, (ii) add structural rigidity to the terminal assembly 1430, (iii) aid in coupling the male terminal assembly 1430 to the female terminal assembly 2430, and (iv) align the spring member 1440a within the male terminal body 1472. The male housing assembly 1100 generally includes an inner male housing portion 1104 and an outer male housing portion 1150. The inner male housing portion 1104 includes (i) an outer rear wall or mating ring 1106, (ii) outer side walls or contact arm walls 1110, (iii) a front wall 1114, (iv) an inner side wall 1116, (v) an inner rear wall 1120, and (vi) separator walls 1122a-p.

[0020] As shown in Figures 21-23, 26, 33, and 35, outer rear wall 1106 (i) has outer surface 1106a and inner surface 1106b, each of which has a curved configuration and is positioned to form a hollow cylinder or cylindrical shell shape having an outer diameter of 30 mm to 32 mm, preferably 31 mm, and an inner diameter of 20 mm to 22 mm, preferably 21 mm; (ii) is positioned rearward of outer sidewall or contact arm wall 1110 and has a height that positions the outer surface of 1106a radially outward from outer sidewall 1110; (iii) is positioned rearward of contact arms 1494a-1494p and spring arms 1452a-1452p; and (iv) surrounds rear wall assemblies 1478a-1478b of male terminal body 1472. 33, the majority of the outer rear wall 1106 is positioned rearward of the spring 1440a and the male terminal body 1472. Furthermore, the outer rear wall 1106 is positioned rearward of the male connector assembly 1000 when (i) the male connector assembly 1000 is in the fully assembled state S FA29 and 33, the male terminal body 1472 and, primarily, the contact arms 1494a-1494p are configured to insert into the male terminal body 1472 without compressing the male terminal body 1472 or the arms 1494a-1494p.

[0021] To secure the inner male housing portion 1104 to the outer male housing portion 1150, the housing assembly 1100 includes a housing coupling means 1140. The housing coupling means 1140 includes an inner housing coupling member 1142 and an outer housing coupling member 1146. In a first embodiment, the inner housing coupling member 1142 is formed in the outer rear wall 1106 and is comprised of a plurality of recessed angled protrusions 1143 and coupling apertures 1144. The coupling apertures 1144 are formed below the angled protrusions 1143, between the inner surface 1106b and the outer surface 1106a of the outer rear wall 1106. These coupling apertures 1144 allow the angled protrusions 1143 to be temporarily deformed toward the inside or center of the connector 1000 when the inner male housing portion 1104 is in the process of being coupled to the outer male housing portion 1150. As shown in the first embodiment, the inner housing coupling member 1142 includes four angled protrusions 1143 positioned 90 degrees from each other. It should be understood that the inner housing coupling member 1142 can (i) include additional structures (e.g., 5-30), (ii) include fewer structures (e.g., 1-3), and (iii) utilize other structures, such as openings, apertures, recesses, or different types of protrusions, cooperatively sized and designed to interact with the outer housing coupling member 1146.

[0022] 23, 30, and 34, the outer rear wall 1106 includes several recess keys or alignment recesses 1108. These recess keys 1108 are used to position the male connector assembly 1000 in the fully assembled state S FA When recess keys 1108 are recessed, they are cooperatively sized to receive protruding keys or alignment protrusions 1156 formed in outer male housing portion 1150 of male housing assembly 1100. The combination of recess keys 1108 and protruding keys 1156 is configured to assist in properly aligning male terminal assemblies 1430 within outer male housing portion 1150. In other embodiments, recess keys 1108 and protruding keys 1156 (i) may be replaced with additional (e.g., 5-30) similar structures, (ii) fewer (e.g., 1-3) similar structures, (iii) may utilize other structures such as openings, apertures, recesses, or different types of protrusions cooperatively sized and designed to properly align male terminal assemblies 1430 within outer male housing portion 1150, (iv) may be designed to interact with a range of female connector assemblies 2000, and / or (v) may assist in combining with or replacing housing coupling means 1140.

[0023] 21-24, 26, and 28, the outer sidewall or outer lateral wall 1110 extends laterally forward from the forward-most extent of the outer aft wall 1106 and has an outer surface 1110a positioned radially inward from the outer surface 1106a of the outer aft wall 1106 and an inner surface 1110b substantially aligned with the inner surface 1106b of the outer aft wall 1106. Based on this configuration, the outer surface 1110a and the inner surface 1110b have a curvilinear configuration and are positioned to form a hollow cylindrical or cylindrical shell shape having an outer diameter of 22 mm to 24 mm, preferably 22.8 mm, and an inner diameter of 20 mm to 22 mm, preferably 21 mm. Additionally, the outer sidewall 1110 includes an array of contact arm apertures 1111 formed therein and extending along the length of the outer sidewall 1110. The arrangement of contact arm apertures 1111 allows the male housing assembly 1100 to accommodate or enclose the majority of the male terminal assembly 1430 while still allowing the contact arms 1494a-1494p to contact the female terminal assembly 2430. The arrangement of contact arm apertures 1111 includes a plurality of contact arm apertures 1112a-1112p, each of which is designed to align with one of the contact arm recesses 1107a-1107p and receive a range of contact arms 1494a-1494p of the male terminal body 1472. It should be understood that because multiple contact arms 1494a-1494p can be positioned within a single aperture 1112a-1112p, fewer contact arm apertures 1112a-1112p may be used. For example, two contact arms 1494a-1494p may be located within a single aperture 1112a-1112p, or a single aperture may include all contact arms 1494a-1494p.

[0024] As best shown in FIGS. 22 and 33 , the forward wall 1114 extends from the outer sidewall 1110 and is positioned substantially perpendicular to the extent of the outer sidewall 1110. The forward wall 1114 includes an outer edge 1114a and an inner edge 1114b, each of which has a curved configuration and is positioned to form a hollow cylinder or cylindrical shell shape. The outer edge 1114a is substantially aligned with the outer surface 1110a of the outer sidewall 1110, and the inner edge 1114b is positioned radially inward from the inner surface 1110b of the outer sidewall 1110. Thus, the outer edge 1114a has a diameter of 22.8 mm and the inner edge 1114b has a diameter of 12.8 mm. The configuration of the outer sidewall 1110 is such that the male connector assembly 1000 is in a fully assembled state S FA 1494a-1494p and spring arms 1452a-1452p when the high current carrying capacity connector system 100 is in the fully connected state S. In fact, the inner surface 1114c of the front wall 1114 is disposed adjacent to and substantially abuts the free end 1446 of the spring member 1440a. The front wall 1114 is positioned such that the high current carrying capacity connector system 100 is in the fully connected state S. FCON 10. The connector 2000 is designed to contact a range of female connector assembly 2000 when in position (described in more detail below).

[0025] 22, 23, 29, and 33, the inner sidewall or inner lateral wall 1116 extends rearward from the forward wall 1114 and has a shape complementary to the outer sidewall 1110. In other words, the inner sidewall 1116 is substantially parallel to the outer sidewall 1110 and has a shorter length than the outer sidewall 1110. The inner sidewall 1116 has (i) an outer surface 1116a positioned radially inward from (a) the inner surface 1106b of the outer rear wall 1106 and (b) the outer edge 1114a of the forward wall 1114, and (ii) an inner surface 1116b substantially aligned with the inner edge 1114b of the forward wall 1114. Based on this configuration, the outer surface 1116a and the inner surface 1116b have a curved configuration and are positioned to form a hollow cylinder or cylindrical shell shape having an outer diameter of 12 mm to 15 mm, preferably 13.8 mm, and an inner diameter of 11 mm to 14 mm, preferably 12.8 mm. As best shown in FIGS. 29 and 47, the outer surface 1116a is configured to avoid contact with the internal spring member 1440a. In particular, the outer surface 1116a is configured to avoid contact with the internal spring member 1440a when the spring member 1440a is in an uncompressed state (i.e., when the male terminal body 1472 is not positioned within the female terminal body 2434) and the housing gap distance D HG In this uncompressed state, the housing gap distance D HG The housing gap distance D is 0.5 mm to 3 mm, preferably 1 mm (see FIG. 29). HG is in a compressed state when the spring member 1440a is in a compressed state (i.e., when the male terminal body 1472 is positioned within the female terminal body 2434, or when the connector 100 is in a fully connected state S FCON Specifically, the housing gap distance D HG This reduction is between 0.1 mm and 1 mm, preferably 0.4 mm (see FIG. 47). The inward positioning of the inner side wall 1116 ensures that this wall 1116 does not interfere with the operation of the male terminal assembly 1430.

[0026] 22, 23, 28, 29, and 47, the inner male housing portion 1104 includes separation walls 1122a-1122p configured to separate the contact arms 1494a-1494p and the spring arms 1452a-1452p from one another. In other words, the outer sidewall 1110, the front wall 1114, and the inner sidewall 1116 combine to form a male terminal body receiving portion 1124 that receives a range of male terminal bodies 1472. The separation walls 1122a-1122p are disposed within the male terminal body receiving portion 1124 and, specifically, extend between the outer surface 1116a of the inner sidewall 1116 and the inner surface 1110b of the outer sidewall 1110. Due to the configuration of the sidewalls 1110, 1116, the separation walls 1122a-1122p have a triangular shape, and therefore, the lateral surfaces are not parallel to one another. This triangular shape allows the lateral surfaces 1123 of the separation walls 1122a-1122p to be positioned adjacent to the lateral surfaces 1493 of the contact arms 1494a-1494p and the side surfaces 1451 of the spring arms 1452a-1452p. This positional relationship of the side surfaces 1123, 1493, 1451 helps to center the spring arms 1452a-1452p below the contact arms 1494a-1494p. In other words, this aligns the spring member 1440a with the spring receptacle 1486 of the male terminal body 1472. It should be understood that the lateral surfaces 1123 of the separation walls 1122a-1122p are configured not to contact the contact arms 1494a-1494p or the spring arms 1452a-1452p. However, due to manufacturing tolerances and installation procedures, some contact between these structures may occur. Nevertheless, separation walls 1122a-p provide additional rigidity to male connector assembly 1000, aid in the alignment of the components of male connector assembly 1000, and help ensure proper spacing between contact arms 1494a-p and spring arms 1452a-p to provide a 360-degree compatible connector assembly 1000.

[0027] The male connector assembly 1000 disclosed herein relies on the housing assembly 1100 to help position the spring member 1440a within the male terminal body 1472. This reliance on the housing 1100 contrasts with the terminal structure (e.g., lateral protrusions 1454a-1454d of the spring member 1440c and the inner surface of the male terminal body 1472) used to align the contact arms 1494a-1494p and spring arms 1452a-1452p of the connector system disclosed in International Application No. US2020 / 143686. In other words, the housing assembly 1100 disclosed in International Application No. US2020 / 143686 is not configured to center the spring member 1440c within the male terminal body 1472. Instead, male terminal assembly 1430 has been modified to help ensure that spring member 1440c is properly positioned within male terminal body 1472. Unlike housing assembly 1100 disclosed in International Application No. US2020 / 143686, housing assembly 1100 disclosed herein is more substantial, having a greater amount of material, which helps ensure that housing assembly 1100 is not deformed by terminal assembly 1430. It should be understood that in alternative embodiments, the mass of housing assembly 1100 disclosed herein may be reduced and / or structure disclosed in International Application No. US2020 / 143686 may be added to spring member 1440a to facilitate proper positioning of spring member 1440a within male terminal body 1472.

[0028] 22 and 23 , the interior rear wall 1120 extends from the interior sidewall 1116 and is positioned (i) substantially perpendicular to the extent of the interior sidewall 1116 and (ii) substantially parallel to the front wall 1114. The interior rear wall 1120 includes an outer edge 1120a that has a curved configuration and is substantially aligned with the outer surface 1116a of the interior sidewall 1116. As such, the outer edge 1120a has a diameter of 13.8 mm and is disk-like in shape. The interior rear wall 1120 also (i) extends from the interior sidewall 1116 when the connector system 100 is in the fully connected state S FCON, and (ii) a front surface 1120c configured to be positioned adjacent a portion of the female connector assembly 2000 when the male terminal assembly 1000 is in the fully assembled state S FA , and a rear surface 1120d configured to be positioned adjacent spring member 1440a when high current capacity connector system 100 is in the fully connected state S . Additionally, the combination of inner side wall 1116 and inner rear wall 1120 form a connector receptacle 1126. As discussed in more detail below, connector receptacle 1126 is configured to be positioned adjacent spring member 1440a when high current capacity connector system 100 is in the fully connected state S . FCON , is designed to accept a range of female connector assemblies 2000.

[0029] As best shown in FIGS. 22, 23, and 33, a centering protrusion 1130 extends from the rear surface 1120d of the interior rear wall 1120. The centering protrusion 1130 is designed to fit within an opening 1445 in the spring member 1440a. In certain embodiments, the centering protrusion 1130 may include a rib designed to be received by a recess formed in the spring member 1440a to help ensure that the spring member 1440a does not rotate during installation or use. Additionally, the combination of the rear wall 1120, the inner sidewall 1116, and the front wall 1114 protects the male terminal assembly 1430 from several factors, including accidental discharge due to the insertion of a foreign object. It should be understood that the outer rear wall 1106, the outer sidewall 1110, the front wall 1114, the inner sidewall 1116, and the interior rear wall 1120 may be integrally formed or may be formed from separate pieces. For example, these structures 1106, 1110, 1114, 1116, 1120 may be integrally formed using an injection molding process or a 3D printing process. Alternatively, each or a combination of these structures may be formed and then bonded to one another after formation. Bonding of these structures may include deformable or other mechanical bonding means.

[0030] The outer male housing portion 1150 of the male housing assembly 1100 is designed to enclose a substantial portion of the male terminal body 1472. The outer male housing portion 1150 is primarily comprised of a front area 1154 and a rear area 1170. The front area 1154 encloses the contact arms 1494a-1494p and protects them from multiple factors, including accidental contact with foreign objects. Due to the height of the outer rear wall 1106, the inner surface 1154a of the front area 1154 is at a receiving height H from the outer surface 1116a of the inner side wall 1116. R (for example, 3 mm to 5 mm, preferably 4.3 mm) apart. R is designed to allow the female terminal assembly 2430 to contact the male terminal assembly 1430 and is determined by the designer by balancing protection of the contact arms 1494a-1494p, the thickness of the female connector assembly 2000 that will mate within this space, and manufacturing / installation tolerances. Balancing these factors should be done to optimize protection of the contact arms 1494a-1494p while ensuring that the high current capacity connector system 100 can function properly.

[0031] As discussed above and best shown in FIG. 33 , the forward extent 1154 includes the outer mating housing member 1146 of the housing coupling means 1140. The outer housing coupling member 1146 has protrusions 1147 cooperatively sized to mate with the protrusions 1143 of the inner housing coupling member 1142. Mating of the outer housing coupling member 1146 with the inner housing coupling member 1142 couples the outer male housing portion 1150 to the inner male housing portion 1104. As discussed above, it should be understood that the outer housing coupling member 1146 can (i) include additional structures (e.g., 5-30), (ii) include fewer structures (e.g., 1-3), and (iii) utilize other structures, such as openings, apertures, recesses, or different types of protrusions cooperatively sized and designed to interact with the outer housing coupling member 1146.

[0032] As best shown in Figures 30, 31, 33, and 35, rearward extent 1170 is integrally formed with forward extent 1154 and is configured to substantially receive the rearward extent of male terminal body 1472. Thus, rearward extent 1170 includes an arrangement of sidewalls 1172 positioned adjacent to the sidewalls of terminal body 1472. Housing assembly 1100, specifically inner male housing portion 1104 and rearward extent 1170 of outer male housing portion 1150, are fabricated from a non-conductive material using any known technique (e.g., injection molding techniques, 3D printing, casting, thermoforming, etc.). Specifically, non-conductive materials are discussed in International Application No. US2019 / 36127, which is incorporated herein by reference.

[0033] 1-36 and 40-47 provide various views of a male terminal assembly 1430 of this first embodiment of connector system 100. Male terminal assembly 1430 includes a spring member 1440a and a male terminal 1470. Male terminal 1470 includes a male terminal body 1472 and a male terminal connecting member or plate 1474. Male terminal body 1472 includes (i) a plurality of contact arms 1494a-p, (ii) base walls or bands 1478a-b, and (iii) rear male terminal wall assemblies 1480a-b. The combination of contact arms 1494a-p, base walls 1478a-b, and rear male terminal wall assemblies 1480a-b form a spring seat 1486 designed to receive spring member 1440a.

[0034] 11-20, spring member 1440a includes spring member sidewall 1442 and rear spring wall 1444. Spring member sidewall 1442 includes (i) a plurality of first sections or curvilinear spring sections 1448a-1448p and (ii) a plurality of second sections or spring arms 1452a-1452p. Curvilinear spring sections 1448a-1448p extend between rear spring wall 1444 and spring arms 1452a-1452p and position spring arms 1452a-1452p substantially perpendicular to rear spring wall 1444.

[0035] The spring arms 1452a-p extend from the curved spring sections 1448a-p and terminate at a free end 1446 away from the rear spring wall 1444. The spring arms 1452a-p are arranged along a curved spring arm path. In the illustrated embodiment, this curved spring arm path is in the form of a circle. It should be understood that in other embodiments, the curved spring arm path may not be circular, but instead may be oval, oval, elliptical, crescent, curved triangular, quatrefoil, teardrop, or any other shape having a curved path. In yet another embodiment, the path followed by the spring arms 1452a-p may not be completely curved, but instead may have only one curved aspect and other aspects that are substantially linear. For example, in this alternative embodiment, the spring arms may be arranged in a modified square in which the upper linear portion of the square is removed and replaced with a curved portion. It is to be understood that other similar combinations are contemplated by this disclosure.

[0036] Spring arms 1452a-1452p have a substantially linear outer surface 1453 and a width of 1 mm to 3 mm, preferably 2 mm. As discussed in more detail below, the width of each spring arm 1452a-1452p is slightly greater than the width of its associated contact arm 1494a-1494p. This slight increase in width helps ensure that spring member 1440a can properly and uniformly apply a biasing force to contact arms 1494a-1494p when connector system 100 is in various states or subjected to certain operating conditions. Also, as shown in the figure, spring member 1440a, i.e., spring arms 1452a-1452p, lack structure (e.g., lateral protrusions 1454a-1454d of spring member 1440c) used to align spring arms 1452a-1452p with contact arms 1491a-1494p, as disclosed in connection with the connector system discussed in International Application No. US2020 / 143686.

[0037] As shown, the spring arms 1452a-p are not directly connected to one another. In other words, there are spring arm gaps 1450a-p that extend (i) between the spring arms 1452a-p, (ii) between the curved spring sections 1448a-p, and (iii) within the rear wall 1444. This configuration allows for omnidirectional movement of the spring arms 1452a-p, which facilitates mechanical coupling between the male terminal 1470 and the female terminal assembly 2430. It should be further understood that the spring arms 1452a-p are not surrounded or partially surrounded by sidewall structure. Instead, the spring arms 1452a-p alternate with the spring arm gaps 1450a-p along a curved spring arm path. In other embodiments, the spring arms 1452a-1452p may be coupled to other structures to limit their omnidirectional expansion. The number and width of the individual spring arms 1452a-1452p and openings may vary. Furthermore, the widths of the individual spring arms 1452a-1452p are typically equal to one another. However, in other embodiments, one or more of the spring arms 1452a-1452p may be wider than the other spring arms.

[0038] The spring member 1440a is typically formed from a single piece of material (e.g., metal). Thus, the spring member 1440a may be a one-piece spring member 1440a or may have integrally formed features. In particular, the curved spring sections 1448a-p and the spring arms 1452a-p are integrally formed with one another. To integrally form these features, the spring member 1440a is typically formed using a die-forming process, which mechanically presses the spring member 1440a into the appropriate shape. As discussed in more detail in International Application Nos. US2018 / 19787 and US2019 / 36010, when spring member 1440a is formed from a flat metal plate and placed within male terminal 1472, inserted into female receptacle 2472, and exposed to high temperatures, spring member 1440a exerts an outward spring thermal force S on contact arms 1494a-1494p, in part due to spring member 1440a attempting to return to its flat plate state. TF However, it should be understood that other methods of forming spring member 1440a may be utilized, such as stamping, pressing, drawing, casting, printing, or similar manufacturing methods. In other embodiments, the features of spring member 1440a may not be formed from one piece or may be integrally formed, but may instead be formed from separate pieces that are welded together.

[0039] Unlike the spring arms 31 disclosed in Figures 4-8 of International Application No. US 2018 / 19787, the free ends 1446 of the spring arms 1452a-1452p do not have a curved component extending along the length of the spring arms 1452a-1452p. Instead, the spring arms 1452a-1452p have a substantially flat outer surface. This configuration is beneficial because it ensures that the force associated with the spring 1440a is applied substantially perpendicular to the free end 1488 of the male terminal body 1472. In contrast, the curved components of the spring arms 31 disclosed in Figures 4-8 of International Application No. US 2018 / 19787 do not apply force in this manner. Additionally, unlike the spring 1440c disclosed in International Application No. US2020 / 143686, the spring 1440a disclosed herein does not include lateral protrusions 1454a-1454d used to properly position the spring member 1440c within the male terminal body 1472.

[0040] In an alternative embodiment not shown, each spring arm 1452a-p may not have a substantially linear configuration, but instead may have a curved configuration along the width of the spring arm 1452a-p. In another embodiment, the width of each spring arm 1452a-p may be increased (thus reducing the number of spring arms 1452a-p), and each spring arm 1452a-p may have a curved configuration. In this embodiment, the spring member may have three spring arms, where each spring arm extends around a range of a circle (e.g., 110 degrees). In further embodiments, each spring arm 1452a-p may have a curved configuration that is not based on a circle, but instead is based on an oval, elliptical, crescent, curved triangle, four-lobe, teardrop, or any other shape having a curved range.

[0041] In further alternative embodiments, spring member 1440a may include (i) centering means (e.g., spring member 1440c disclosed in International Application No. US2020 / 143686), and / or (ii) recesses and associated reinforcing ribs (e.g., spring member 1440b disclosed in International Application No. US2019 / 36010). Centering means may be (i) formed as part of interior rear wall 1120, (ii) formed by a protrusion extending inward from an inner wall of male housing assembly 1100 (e.g., a protrusion that fits between a pair of contact arms 1494a-1494p), (iii) a protrusion extending outward from spring member 1440a and fitting into a recess formed in male housing assembly 1100, or (iv) a combination of these structures.

[0042] The above modifications to the configuration of the spring member 1440a, or other modifications to the spring member 1440a (e.g., thickness), can change the force associated with the spring 1440a. Changing the force associated with the spring 1440a changes the force associated with coupling / uncoupling the male connector assembly 1000 and the female connector assembly 2000. In particular, the spring bias force S BF is the amount of force applied by the spring member 1440a to resist inward deflection of the free end 1446 of the spring member 1440a when the male terminal assembly 1430 is inserted into the female terminal assembly 2430. Specifically, as best shown in FIGS. 20 and 47, the inner spring member 1440a has an outer spring diameter D OS In this uncompressed state, the spring outer diameter D OS The spring outer diameter D is 16 mm to 22 mm, preferably 18 to 20 mm, and most preferably 18.8 mm (see FIG. 20). OS is in a compressed state when the spring member 1440a is in a compressed state (i.e., when the male terminal assembly 1430 is positioned within the female terminal body 2434 or when the connector 100 is in a fully connected state S FCON) is reduced because the outer surface area of the male terminal body 1472 is slightly larger (1% to 20% larger) than the inside of the female receptacle 2472. In this compressed state, the spring outer diameter D OS is 14 mm to 20 mm, preferably 18 mm (see FIG. 47).

[0043] In other words, when the male terminal assembly 1430 is inserted into the female terminal assembly 2430, the area of the outer surface is forced radially inward toward the center 1490 of the male terminal 1470. This inward force against the outer surface displaces the free end 1446 of the spring member 1440a inward (i.e., toward the center 1490). The spring member 1440a exerts a spring biasing force S BF This inward displacement is resisted by providing a spring biasing force S BF is associated with the inward deflection that occurs during insertion of the male terminal assembly 1430 into the female terminal assembly 2430, and therefore the spring biasing force S BF takes into account the insertion force associated with mating male connector assembly 1000 with female connector assembly 2000. This insertion force for this connector 100 is targeted to be no greater than 45 Newtons, the maximum allowed by a connector to meet USCAR 25 Class 2, and is less than 75 Newtons, the maximum allowed by a connector to meet USCAR 25 Class 3. Thus, the disclosed connector 100 (i) can meet the insertion force requirements of both USCAR Class 2 and 3, (ii) does not require lever assistance, and (iii) provides a high current capacity rated to transmit or carry at least 500 amps of current over time without the connector 100 experiencing performance degradation and / or failure.

[0044] 1-36 and 40-47, male terminal connecting plate 1474 is coupled to male terminal body 1472 and configured to receive a range of structures (e.g., leads or wires) that connect male terminal assembly 1430 to a device (e.g., an alternator) or component of an electrical distribution system external to high current capacity connector system 100. Male terminal connecting plate 1474 has (i) a height H between 18 mm and 29 mm, preferably 23.6 mm; CP (ii) a length L of 18 mm to 29 mm, preferably 23 mm CP and (iii) a thickness T of 1 mm to 3 mm, preferably 1.65 mm. CP To ensure that connector 100 does not contain current choke points, the cross-sectional area of male terminal connecting plate 1474 at body connection location BCL (i.e., where male terminal connecting plate 1474 is coupled to male terminal body 1472) should be equal to or greater than the cross-sectional area of contact arms 1494a-1494p at terminal connection location TCL (i.e., where arms 1494a-1494p contact the inner surface of female receptacle 2472). In other words, the height H of male terminal connecting plate 1474 CP (e.g., 23.6 mm) * Thickness T of male terminal connection plate 1474 CP (e.g., 1.65 mm) is the thickness T of the contact arms 1494a to 1494p. CA (e.g., 0.8 mm) * number of contact arms (e.g., 16) * contact width W of contact arms 1494a to 1494p CA (e.g., 1.9 mm) or more. Therefore, the cross-sectional area of the male terminal connecting plate 1474 at the body connecting location (i.e., 38.94 mm) is larger than the cross-sectional area of the contact arms 1494a-1494p at the terminal connecting location (i.e., 24.32 mm). Therefore, no current choke point is formed between the male terminal connecting plate 1474 and the male terminal body 1472.

[0045] It should be understood that the height or thickness of the male terminal connecting plate 1474 may be reduced so long as the cross-sectional area of the male terminal connecting plate 1474 is equal to or greater than the cross-sectional area of the contact arms 1494a-1494p. However, reducing the height or length of the male terminal connecting plate 1474 should be considered in light of the fact that the male connector assembly 1000 is currently designed to accept a 120 mm2 wire 1495 to enable the connector assembly 100 to carry over 500 amps. In other words, reducing the size of the male terminal connecting plate 1474 to a size that precludes the connector 100's ability to accept a 120 mm2 wire 1495 may have a greater effect on reducing the current carrying capacity of the connector 100 than on creating small current choke points that may form between the male terminal connecting plate 1474 and the male terminal body 1472. In light of the above discussion, designers of similar connector systems must consider multiple factors (e.g., cross-sectional area of male terminal mating plate 1474, cross-sectional area of contact arms 1494a-1494p, terminal material properties, wire size, etc.) when designing a connector system intended to meet USCAR standards, current-carrying capacity, and other requirements. Thus, theoretical designs that attempt to modify conventional connectors or combine a range of conventional designs are insufficient, technically unsound, and flawed because they are merely design exercises unconstrained by the complex realities of designing, testing, manufacturing, and certifying actual connectors such as connector system 100.

[0046] As shown in FIGS. 4-10, male terminal body 1472 is formed as two separate and distinct portions: first or right portion 1473a, and second or left portion 1473b. In the embodiment shown, both first and second portions 1473a-1473b are identical, thereby reducing manufacturing costs, assembly time, and potential parts shortages. These identical portions 1473a-1473b are then joined together using joining means 1475. In this embodiment, joining means 1475 are tabs 1476a-1476b that allow portions 1473a-1473b to be joined together in a joined state (S J ), (i) extends outward from the outer edge of portions 1473a-1473b, and (ii) is configured to be positioned below the area of abutment portions 1473a-1473b. Forming male terminal body 1472 from two separate and distinct portions 1473a-1473b simplifies manufacturing and helps ensure that terminal body 1472 has a curved configuration that is in the shape of a circle. In other embodiments, joining means 1475 may be other mechanical joining structures (e.g., recesses, openings, protrusions, etc.) or chemical joining structures (e.g., welding, brazing, etc.).

[0047] It should also be understood that the male terminal 1470 can be formed from a single metal sheet or from more (e.g., four) sections. Additionally, it should be understood that each piece of the male terminal 1470 includes several integrally formed structures (e.g., contact arm 1494, bases 1478a-1478b, and rear male terminal wall assemblies 1480a-1480b). However, in other embodiments, these structures may not be integrally formed, or other manufacturing methods may be utilized. For example, stamping, pressing, drawing, casting, printing, or similar manufacturing methods may be utilized. Additionally, the integrally formed structures may be formed separately and welded together.

[0048] As shown in Figures 4-10, rear male terminal wall assemblies 1480a-1480b are coupled between the male terminal connecting plate 1474 and the base walls 1478a-1478b. Each rear wall assembly 1480a-1480b is formed of two sections: a first or forward transition section 1482a-1482b and a second or rear transition section 1484a-1484b. The second transition section or rear transition section 1484a-1484b (i) is coupled between the first or forward transition section 1482a-1482b and the male terminal connecting plate 1474, and (ii) begins the angular transition from the linear connecting plate 1474 to the base walls 1478a-1478b. In particular, the angle alpha α extending between the outer surface of the connecting plate 1474 and the outer surface of the rear transition areas 1484a-1484b is between 120 degrees and 170 degrees, preferably 155 degrees, and the angle beta β extending between the outer upper surface of the connecting plate 1474 and the outer surface of the rear transition areas 1484a-1484b is between 150 degrees and 210 degrees, preferably 185 degrees. The angular transition can also be seen by the increase in thickness of the terminal body 1472 as it extends from about 1.65 mm to about 12 mm at its widest point. Overall, this transition section has a length L which is about 11 mm. R and an internal width W extending from the centerline to its most forward extent of approximately 5.22 mm. IR and a height that is reduced from 23.6 mm to 22 mm.

[0049] The first or front transition ranges 1482a-1482b (i) are coupled between the base walls 1478a-1478b and the second or rear transition ranges 1484a-1484b and (ii) complete the angular transition from the linear connecting plate 1474 to the base walls 1478a-1478b. In particular, the angle gamma γ extending between the outer surface of the rear transition ranges 1484a-1484b and the outer surface of the front transition ranges 1482a-1482b is between 170 degrees and 190 degrees, preferably 180 degrees, and the angle delta δ extending between the outer surface of the rear transition ranges 1484a-1484b and the outer surface of the front transition ranges 1482a-1482b is between 160 degrees and 190 degrees, preferably 177.5 degrees. Additionally, the angle epsilon ε extending between the outer surface of the forward transition ranges 1482a-b and the base walls 1478a-b is between 180 degrees and 225 degrees, preferably 205 degrees, and the angle zeta ζ extending between the outer surface of the forward transition ranges 1482a-b and the base walls 1478a-b is between 160 degrees and 200 degrees, preferably 176 degrees. The angular transition can also be seen by the increase in thickness of the terminal body 1472 as it extends from about 12 mm to about 21 mm at its widest point. Overall, this transition portion has a length L that is about 10 mm. F and an inner width W of approximately 4.16 mm extending from the forward-most extent of the rear transition ranges 1484a-1484b to the forward-most extent of the forward transition ranges 1482a-1482b. IF and a height that reduces from 22 mm to 21 mm. It should be appreciated that in alternative embodiments, rear male terminal wall assemblies 1480a-b may be formed from a single area extending between the plate and base walls 1478a-b.

[0050] Base walls or bands 1478a-1478b extend forward from first or forward transition areas 1482a-1482b. Base walls 1478a-1478b have outer surfaces 1479a with a curved configuration and inner surfaces 1479b with a similarly curved configuration. The curved configurations of inner and outer surfaces 1479a-1479b form a hollow cylinder or cylindrical shell shape with (i) a curved, specifically cylindrical, leading edge 1477 and (ii) an outer diameter D of 20 mm-22 mm, preferably 21 mm. CA (iii) an inner diameter (e.g., a radius of 9.7 mm) that is between 18 mm and 20 mm, preferably 19.4 mm. Referring to FIG. 8, base walls 1478a-1478b have a length L of between 8 mm and 12 mm, preferably 9 mm. B The contact arms 1494a to 1494p have a length L of 8 mm to 12 mm, preferably 9.5 mm. CA Therefore, the base wall length L B and contact arm length L CA There is a ratio of approximately 1:1 between the base wall length L B is the contact arm length L CA The base wall length L B The contact arm length L CA A reduction of the base wall length L below 90% of the base wall length L of the connector system 100 disclosed herein can make it difficult to manufacture male terminal bodies 1472 having diameters greater than a predetermined value (e.g., 12 mm). Among other manufacturing difficulties, these difficulties may include the inability to properly form circular connectors that meet quality control requirements, USCAR specifications, predetermined manufacturing tolerances, or other similar requirements using conventional mass-produced connector tooling. B and contact arm length L CAThis approximately 1:1 ratio between sidewall length and contact arm length is significantly different and beneficial from the 1.5:1 ratio between sidewall length and contact arm length (i.e., the sidewall length is approximately 67% of the contact arm length) disclosed in the connector shown in International Application No. US2020 / 143788. In other words, if the connector shown in International Application No. US2020 / 143788 is scaled up so that its diameter exceeds a certain value (e.g., 12 mm), the 1.5:1 ratio between sidewall length and contact arm length of this connector will lead to manufacturing difficulties.

[0051] 4-10, the contact arms 1494a-1494p (i) extend forwardly from the leading edge 1477 of the base walls 1478a-1478b, (ii) extend away from (a) the base walls 1478a-1478b, (b) the rear male terminal wall assemblies 1480a-1480b, and (c) the male terminal connection plate 1474, and (iii) have outer surfaces 1495a-1494p that extend radially from the outer surface 1479a of the base walls 1478a-1478b. In particular, the angle eta η extending between the outer surfaces 1495a-1494p of the contact arms 1494a-1494p and the outer surface 1479a of the base walls 1478a-1478b is between 150 degrees and 179.9 degrees, preferably 168 degrees. In other words, the contact arms 1494a-1494p extend upwardly from parallel to the outer surfaces 1479a of the base walls 1478a-1478b at an angle, perhaps between 0.1 degrees and 20 degrees, preferably between 8 degrees and 16 degrees, and most preferably 12 degrees. This angled outer surfaces 1495a-1494p of the contact arms 1494a-1494p relative to the outer surfaces 1479a of the base walls 1478a-1478b causes the outermost extent of the contact arms 1494a-1494p to be 3 mm larger than the outermost extent of the base walls 1478a-1478b. In other words, the maximum outer diameter D CA is 24 mm (i.e., the maximum outer diameter R CA The outer diameter D of the base walls 1478a to 1478b is 12 mm. OBOr 21 mm thick. This increase in the outer diameter of the contact arms 1494a-1494p allows the contact arms 1494a-1494p to compress, deflect, or displace inward toward the center 1490 of the male terminal 1470 when the male terminal assembly 1430 is inserted into the female terminal assembly 2430 without causing the base walls 1478a-1478b to inappropriately contact the female terminal assembly 2430.

[0052] As shown, the contact arms 1494a-1494p are not directly connected to one another. In other words, there are contact arm openings 1496a-1496p positioned between and extending along the lateral lengths of the contact arms 1494a-1494p. This configuration allows for omnidirectional movement of the contact arms 1494a-1494p, which facilitates mechanical coupling between the male terminal 1470 and the female terminal assembly 2430. When the male terminal assembly 1430 is in the fully coupled state S FC , the contact arm openings 1496a-1496p are aligned with the spring arm gaps 1450a-1450p. This configuration of the gaps 1450a-1450p creates the same number of spring arms 1452a-1452p as the number of contact arms 1494a-1494h. In other words, this embodiment includes 16 spring arms 1452a-1452p and 16 contact arms 1494a-1494p. It should be understood that in other embodiments, the number of spring arms 1452a-1452p may not match the number of contact arms 1494a-1494p. For example, there may be fewer spring arms 1452a-1452p than contact arms 1494a-1494p.

[0053] To help ensure that the connector system 100 is 360 degree compatible and does not have disconnection related issues, the contact arm openings W CO is the contact arm width W C In other words, when the outer diameter of the connector exceeds a predetermined value (for example, 12 mm) and the contact arm width W CContact arm opening W CO If the ratio is greater than 1:1, the connector system 100 may not be able to meet the 360 degree compatibility requirement. CO and contact arm width W C is between 1.5 mm and 2.5 mm, preferably 1.9 mm. It should be understood that other measurements are contemplated by this disclosure, so long as the outer diameter of the connector exceeds a predetermined value (e.g., 12 mm) and an approximately 1:1 width ratio applies to these alternative embodiments. However, it should be understood that this 1:1 width ratio is an approximation, and that the ratio may deviate by up to 20% without causing 360-degree compatibility issues that lead to disconnection problems.

[0054] Contact arm width W C Contact arm opening width W CO This one-to-one ratio is also shown in the figures disclosed in International Application No. US2020 / 143788. Specifically, these figures show connector systems with contact arm opening widths and contact arm widths ranging from 2.5 mm to 3.5 mm, preferably 2.9 mm. While both connector system 100 disclosed herein and the connector system disclosed in International Application No. US2020 / 143788 have substantially similar mechanical width ratios, contact arms 1494a-1494p disclosed herein do not have the current choke points formed within the contact arms of the connector disclosed in International Application No. US2020 / 143788. Thus, the effective electrical width of the contact arms of the connector disclosed in International Application No. US2020 / 143788 is approximately 1.9 mm, which is not an effective width equivalent to the mechanical width of 2.9 mm. Thus, the connector disclosed in International Application No. US2020 / 143788 has a mechanical ratio of 1 to 1 and an electrical ratio of 2 to 1. In contrast, connector system 100 disclosed herein does not have a similar current choke point in contact arms 1494a-1494p, and as a result, connector system 100 has a 1 to 1 mechanical and electrical ratio.

[0055] Additionally, Figures 87-96 of International Application No. US2020 / 143788 disclose a connector system with a contact arm opening width of 2-2.8 mm and a contact arm width of 1-1.4 mm. Therefore, the connector system disclosed in Figures 87-96 of International Application No. US2019 / 36010 has a substantially different 2:1 ratio than connector system 100 disclosed herein. In other words, if a modified male terminal were created by increasing the outer diameter of the male terminal disclosed in Figures 87-96 of International Application No. US2019 / 36010 from approximately 6.5 mm to 24 mm, the modified male terminal would fail certain 360-degree fit test requirements. In fact, even connectors with a 1.45:1 ratio failed certain 360-degree fit test requirements. In summary, the approximately 1:1 ratio provided by the disclosed connector system 100 ensures that the connector system 100 meets 360-degree fit testing requirements, providing a substantial advantage over connectors that are unable to meet these fit testing requirements.

[0056] As shown in FIG. 7, the free ends 1488 of the terminals or contact arms 1494a-1494p are (i) oriented inwardly of the inner surfaces 1479b of the base walls 1478a-1478b (i.e., approximately 0.25 mm from the free ends W FE(ii) positioned substantially parallel to the extent of base walls 1478a-1478b, and (iii) positioned in contact with the flat outer surfaces of spring arms 1452a-1452p when spring member 1440a is inserted into spring receptacle 1486. A configuration in which terminal or free end 1488 is positioned within inner surface 1479b of base walls 1478a-1478b and in contact with the flat outer surfaces of spring arms 1452a-1452p is advantageous over the terminal or free end design associated with the contact arms disclosed in Figures 87-96 of International Application No. US 2019 / 36010 for several reasons, including manufacturing challenges, current choke points, and mating issues. Additionally, the configuration of male terminal assembly 1430 disclosed herein is advantageous over the configuration shown in Figures 3-8 of International Application No. US 2018 / 19787. This is because an assembler of the male terminal assembly 1430 does not have to apply a large amount of force to deform most of the contact arms 1494a-1494p outward to accommodate the spring member 1440a. This necessary deformation is best shown in FIG. 6 of International Application No. US2018 / 19787 and is due to the tilt of the contact arms 11 and the fact that the outer surface of the spring arm 31 and the inner surface of the contact arm 11 are adjacent to each other without any gaps between them. In contrast to FIGS. 3-8 of International Application No. US2018 / 19787, FIG. 30 of the present application shows a very small gap formed between the outer surface of the spring member 1440a and the inner surfaces of the contact arms 1494a-1494h. Thus, little, if any, force is required to insert spring member 1440a into spring receiver 1486 because the assembler does not need to significantly deform contact arms 1494a-1494h during insertion of spring 1440a.

[0057] As disclosed above, the contact arms 1494a-p extend forward from the curved leading edges 1477 of the base walls 1478a-b, and thus the contact arms 1494a-p and their associated free ends 1488 are disposed along a curved contact arm path, which in the illustrated embodiment is in the form of a circle. It should also be understood that the shape of the contact arm path substantially corresponds to the shape of the spring arm paths. Indeed, these paths are cooperatively sized and positioned to allow mechanical interaction to occur between the plurality of contact arms 1494a-p and the plurality of spring arms 1452a-p when the connector system is in a particular state (e.g., fully assembled) or when exposed to certain operating conditions (e.g., when exposed to a high thermal environment). It should be understood that in other embodiments, the curved contact arm path may not be circular, but instead may be oval, oval, elliptical, crescent, curved triangular, quatrefoil, teardrop, or any other shape having a curved path. In yet another embodiment, the path followed by the contact arms 1494a-1494p may not be completely curved, but instead may have only one curved aspect and other aspects that are substantially linear. For example, in this alternative embodiment, the contact arms 1494a-1494p may be arranged in a modified square, where the upper linear area of the square is removed and replaced with a curved area. It should be understood that other similar combinations are contemplated by this disclosure.

[0058] Unlike the sidewall portions disclosed in connection with International Application Nos. US2020 / 143788, US2020 / 143686, US2020 / 133446, US2020 / 50018, US2020 / 49870, US2020 / 14484, US2020 / 13757, US2019 / 36127, US2019 / 36070, and US2019 / 36010, the extent of male terminal body 1472 does not surround or flank the extent of contact arms 1494a-1494p. In other words, the contact arms 1494a-1494p are spatially arranged to define a gap therebetween and be separated by the contact arm opening 1450, but such that no intervening structure of the male terminal body 1472 (e.g., a sidewall portion between two contact arms 1494) is adjacent to or between the contact arms 1494a-1494p. Furthermore, no structure of the male terminal body 1472 surrounds or flanks the spring arms 1494a-1494p. Additionally, the configurations of the contact arms 1494a-1494p disclosed herein are advantageous over the terminal configurations shown in Figures 9-15, 18, 21-31, 32, 41-42, 45-46, 48, and 50 of International Application No. US 2018 / 19787. This is because (i) contact arms 1494a-1494p can have a shorter overall length, which requires less metal material to form and means male terminal 1470 can be placed in a tighter, more restricted space; (ii) connector 100 has a higher current capacity; (iii) male terminal 1470 is easier to assemble; and (iv) other beneficial features disclosed herein or that can be determined by one skilled in the art from a study of this disclosure.

[0059] In further alternative embodiments not shown, each contact arm 1494a-1494p may not have a curved configuration (as shown) but may instead have a substantially linear configuration along its width. Additionally, the width of contact arms 1494a-1494p may be increased so that fewer contact arms (e.g., from fourteen to three) are required to form a male terminal body 1472 that is 360-degree compatible. Furthermore, the curved configuration of the width of each contact arm may not be based on a circle, but instead may be based on an oval, elliptical, oval, crescent, curved triangle, four-lobe, teardrop, or any other shape having a curved extent.

[0060] Figure 15 shows the uncoupled state S DC 16 provides a first embodiment of a male terminal assembly 1430 in a fully coupled state S FC 15 provides a first embodiment of a male terminal assembly 1430 in a decoupled state S. The first stage of assembling the male terminal assembly 1430 is shown in FIG. 15, where the spring member 1440a is separated from the male terminal 1470. This configuration of the male terminal 1470 exposes the spring seat 1486 and places the male terminal 1470 in a state ready to receive the spring member 1440a. The male terminal assembly 1430 is then placed in a decoupled state S. DC to the fully connected state S FC In order to move the spring member 1440a to the I is applied to insert the spring member 1440a into the spring receiver 1486. I is applied to the spring member 1440a until the second or rear male terminal wall 1484 is positioned adjacent to the rear spring wall 1444 and the free end 1488 of the male terminal 1470 is positioned inside the free end 1446 of the spring member 1440a.

[0061] Assembling the outer connector assembly 1000 is accomplished in multiple steps or stages. The first step in assembling the outer connector assembly 1000 is assembling the male terminal assembly 1430, which is shown in Figures 15-16 and described above. When the male terminal assembly 1430 is in the fully mated state S FCAfter this, the male terminal assembly 1000 is put into the disassembled state S DA (Figure 24) Partial assembly state S PA 25-30, the inner male housing portion 1104 is engaged with a first engagement force F C1 Finally, the male terminal assembly 1430 can be connected to a wire 1495, returning the male terminal assembly 1000 to the partially assembled state S PA (Figure 30) Fully assembled state S FA (FIGS. 31 to 36) C2 can be used to couple the outer male housing portion 1150 to the inner male housing portion 1104.

[0062] 2) Female connector assembly 40-45, female connector assembly 2000 is primarily comprised of (i) female housing assembly 2100, and (ii) female terminal assembly 2430. Female connector assembly 2000 may have additional features not shown in the figures, however, these features are contemplated by the present disclosure. For example, the female connector assembly 2000 may include: (i) a connector position assurance (CPA) assembly that meets USCAR standards (e.g., as described in International Application No. US2020 / 49870); (ii) an interlock (IL) or high voltage interlock (HVIL), where the interlock may be positioned on the exterior of the housing 2100 or may be positioned within the spring member 1440a (e.g., as described in International Application No. US2020 / 143686); (iii) a shield assembly where the female housing assembly 2100 is formed from metal, conductive plastic (e.g., as described in International Application No. US2020 / 133686); 757), or other materials that may be used to minimize EMI noise, (iv) water-resistant sealing features (e.g., seals, coatings for the connectors, etc.), (v) locking handles or structures that aid in connecting the male connector assembly 1000 to the female connector assembly 2000 and / or help ensure that the high-current capacity connector system 100 remains fully connected, (v) locking handles or structures that aid in connecting the male connector assembly 1000 to the female connector assembly 2000 and / or help ensure that the high-current capacity connector system 100 remains fully connected, and / or (vi) any combination of these structures. Additionally, other structures disclosed in any of the applications incorporated herein may be used in connection with the female connector assembly 2000.

[0063] The female housing assembly 2100 is designed to (i) protect and isolate the female terminal assembly 2430 from foreign objects, and (ii) aid in the coupling of the male terminal assembly 1430 to the female terminal assembly 2430. To accomplish this, the female housing assembly 2100 generally includes an inner female housing portion 2104 and an outer female housing portion 2150. The inner female housing portion 2104 includes a wall configuration that (i) is cooperatively sized to fit within the connector receptacle 1126, (ii) has retention protrusions that help retain the inner female housing portion within the female terminal assembly 2430, and (iii) has structure that helps align the female connector assembly 2000 with the male connector assembly 1000.

[0064] As shown in FIGS. 1 and 40-47, the outer female housing portion 2150 includes a sidewall 2152 that substantially surrounds the female terminal assembly 2430. The sidewall 2152 has a ramped or sloped wall 2170 that extends inward from a front edge of the sidewall 2152 and assists in compressing the contact arms 1494a-1494p of the terminal assembly 1430. The configuration and design of the ramped or sloped wall 2170 are described in detail in International Application No. US 2019 / 36070, which is incorporated herein. The ramped or sloped wall 2170 has a rear edge that abuts the edge of the female terminal assembly 2430. Thus, the female terminal assembly 2430 is held in contact with the ramped or sloped wall 2170. It is to be understood that other configurations for retaining the female terminal assembly 2430 within the female housing assembly 2100 may be used and are contemplated by the present disclosure.

[0065] The female terminal assembly 2430 includes a connection plate 2474 and a side wall 2434 that forms a female receptacle 2472. The connection plate 2474 may be configured as a bus bar lug, a threaded pin, a tubular lug, or any other type of connection. The female receptacle 2472 is designed to receive a range of the male terminal assembly 1430, primarily contact arms 1494a-1494p. Referring to Figures 38, 41, 43, and 45, the cross-sectional shape of the female receptacle 2472 is substantially circular, and the female terminal diameter DFT is between 21 mm and 25 mm, preferably 23.2 mm. However, it should be understood that the cross-sectional shape of the female receptacle 2472 may be varied to substantially match the outer shape of the terminal assembly with which it mates (e.g., oval, elliptical, crescent, curved triangular, four-lobe, teardrop, etc.). This further means that the inner terminal assembly 3430 may have a different configuration than the outer terminal assembly 1430, and therefore the cross-sectional shape of the female receptacle 2472 may vary over the length of the female terminal assembly 2430.

[0066] Further details regarding the female terminal assembly 2430 are outlined in International Application Nos. US2020 / 13757, US2019 / 36127, US2019 / 36070, and US2019 / 36010, which are incorporated herein, and therefore these details will not be repeated here. For example, these PCT applications disclose that the inner dimensions of the female terminal assembly 2430 are smaller than the outer dimensional range of the male terminal assembly 1430. This dimensional relationship ensures that the terminal assemblies 1430, 2430 are in proper electrical and mechanical connection with each other.

[0067] 3) Connect the connector system 40 to 47 show the high current capacity connector system 100 in the disconnected state S of FIGS. 40 to 41. DCON From the complete connection state S in Figures 44 to 47 FCON The disconnected state S DCON 40-41. The high current capacity connector system 100 then transitions to this disconnected state S DCON From the partial connection state S shown in Figs. PCONAs shown in these figures, contact arms 1494a-1494p of male connector assembly 1000 are about to make contact with angled or ramped surface 2170 of female connector assembly 2000. This ramped or ramped surface 2170 gently and smoothly compresses contact arms 1494a-1494p until they can easily slide into contact with the inner surface of female receptacle 2472. This process is described in more detail in International Application No. US2019 / 36070. Once male connector assembly 1000 is fully connected to intermediate connector assembly 2000, high-current-carrying connector system 100 is in a partially connected state S2 shown in FIGS. 44-47. PCON to fully connected state S FCON This fully connected state S FCON In this state, the range of contact arms 1494a-1494p and the range of spring arms 1452a-1452p are positioned within female receptacle 2472 of female terminal assembly 2430. Additionally, as discussed elsewhere in this application, system 100 may be in this fully connected state S FCON When in this position, the spring arms 1452a-1452p are in mechanical interaction with the contact arms 1494a-1494p to bias the contact arms 1494a-1494p outwardly into engagement with the inner surface of the female receptacle 2472.

[0068] 4) Terminal characteristics and functions As best shown in Figures 29, 45, and 47, the outer surface of one or more of the spring arms 1452a-1452p contacts the free end 1488 of a respective contact arm 1494a-1494p. As noted above, the outermost extents (i.e., O D ) is the inner range of the female terminal body 2434 (i.e., D FT ) is slightly larger than the center of the spring member 1440a. Therefore, when these components are mated together, the spring member 1440a is compressed. This compression of the spring member 1440a exerts an outward biasing force S on the contact arms 1494a-1494p, away from the center of the spring member 1440a. BFGenerate.

[0069] The male terminal body 1472, including the contact arms 1494a-1494p, 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 International Annealed Copper Standard (IACS), i.e., an empirically derived standard value for the conductivity of commercially available copper. For example, C151 typically has a conductivity of 95% of the standard IACS-compliant pure copper. Similarly, C110 has a conductivity of 101% of the IACS. In certain operating environments or technical applications, C151 may be the preferred choice due to its corrosion-resistant properties, which are desirable for high-stress and / or harsh weather applications. The first material of the male terminal body 1472 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 coefficient of terminal expansion (CTE) of 17.6 ppm / degrees Celsius (20-300 degrees Celsius) and 17.0 ppm / degrees Celsius (20-200 degrees Celsius), in accordance with ASTM B747 standards.

[0070] The spring member 1440a may be formed from a second material, such as spring steel, stainless steel (e.g., 301SS, 1 / 4 hardness), an iron-containing alloy, and / or another suitable material having greater stiffness (e.g., as measured by Young's modulus) and resilience than the first material of the male terminal body 1472. The second material preferably has a lower electrical conductivity than the first material. The second material also has a Young's modulus that may be approximately 193 GPa at room temperature and a terminal coefficient of expansion (CTE) of 17.8 ppm / °C (0-315°C) and 16.9 ppm / °C (0-100°C). For contemplated high-voltage applications, the cross-sectional area of the copper alloy forming the male terminal body is balanced with the electrical conductivity of the selected copper alloy. For example, if a copper alloy with a lower electrical conductivity is selected, the contact arms 1494a-1494p formed therefrom will have a larger cross-sectional area to adequately conduct electricity. Similarly, selecting a first material with a higher electrical conductivity may allow for contact arms 1494a-1494p to have a relatively smaller cross-sectional area while still meeting electrical conductivity specifications.

[0071] In an exemplary embodiment, the CTE of the second material may be greater than the CTE of the first material, i.e., the CTE of spring member 1440a is greater than the CTE of male terminal body 1472. Thus, when the assembly of male terminal body 1472 and spring member 1440a is subjected to a high voltage and temperature environment typical of use in the electrical connectors described in this disclosure, spring member 1440a will expand relatively more than male terminal body 1472. Thus, the outward force S created by spring member 1440a on contact arms 1494a-1494p of male terminal body 1472 BF increases with increasing temperature, which is the thermal spring force S TF It is called.

[0072] An exemplary application of the present disclosure, such as in a vehicle alternator, is suitable for deployment in Class 5 automotive environments such as those found in passenger cars and commercial vehicles. Class 5 environments are often found under the hood of a vehicle, e.g., at an alternator, where ambient temperatures currently are 150°C and routinely reach 200°C. When copper and / or highly conductive copper alloys are exposed to temperatures above approximately 150°C, the alloys become malleable and lose mechanical resilience, i.e., the copper material softens. However, the steel forming the spring member 1440a retains its hardness and mechanical properties when exposed to similar conditions. Thus, when both the male terminal body 1472 and the spring member 1440a are exposed to high temperatures, the first material of the male terminal body 1472 softens, maintaining the structural integrity of the spring member 1440a formed from the second material, thereby reducing the force applied by the spring member 1440a to the softened contact arms 1494a-1494p to the fully engaged position S. FC , the softened contact arms 1494a to 1494p are more effectively displaced outward relative to the inside of the male terminal body 1472.

[0073] The male terminal body 1472, spring member 1440a, and female terminal body 2434 are configured to maintain electrical conductivity and mechanical engagement while withstanding the high temperatures and thermal cycling resulting from high-power, high-voltage applications to which the connector assembly is subjected. Additionally, the male terminal body 1472 and the female terminal body 2434 may undergo thermal expansion as a result of the high temperatures and thermal cycling resulting from high-voltage, high-temperature applications, which increases the outward force applied by the male terminal body 1472 to the female terminal body 2434. The configuration of the male terminal body 1472, spring member 1440a, and female terminal body 2434 increases the outward connection force therebetween while allowing the connector system 100 to withstand thermal expansion resulting from thermal cycling at the connection location PC.

[0074] Based on the above exemplary embodiment, the Young's modulus and CTE of the spring member 1440a are greater than the Young's modulus and CTE of the male terminal body 1472. Thus, when the male terminal body 1472 is used in a high-power application that subjects the connector system 3100 to repeated thermal cycling at high temperatures (e.g., about 150 degrees Celsius), (i) the male terminal body 1472 becomes malleable and loses some mechanical resiliency, i.e., the copper material within the male terminal body 1472 softens, and (ii) the spring member 1440a does not become malleable or loses significant mechanical stiffness compared to the male terminal body 1472.

[0075] Thus, when utilizing spring member 1440a that has been mechanically formed by a cold forced process (e.g., utilizing a die forming process), and when spring member 1440a is then exposed to high temperatures, spring member 1440a will at least attempt to return to its uncompressed state, which occurs prior to insertion of male terminal assembly 1430 into female terminal assembly 1430, and preferably before returning to its original flat state, which occurs prior to formation of spring member 1440a. In doing so, spring member 1440a exerts a generally outward thermal spring force S on free ends 1488 of contact arms 1494a-1494p. TF (See "S" in Figure 47. TF This thermal spring force S TF is dependent on the local temperature conditions, including hot and / or cold temperatures, in the environment in which the system 100 is installed. BF and thermal spring force S TF The combination of these results in a biasing force S RBF , which ensures that the outer surfaces of the contact arms 1494a-1494p are forced into contact with the inner surface of the female terminal body 2434, ensuring electrical and mechanical connection when the male terminal assembly 2430 is inserted into the female terminal 6430 and during operation of the system 100. Additionally, in the event of repeated thermal cycling, the male terminal assembly 1430 will be forced to release the resulting outwardly oriented spring force S RBF, which is applied to the female terminal assembly 2430 during repeated operation of the system 100.

[0076] As further shown in FIG. 47, the fully connected state S FC In the system 100, the male terminal assembly 1430 provides 360° compatibility with the female terminal assembly 6430, and a sufficient amount of outward force F is applied by the male terminal assembly 1430 to the female terminal assembly 2430 to ensure electrical and mechanical connection in all four cardinal directions. This attribute allows for the elimination of keying and / or other features designed to ensure the desired orientation of the components during connection. The 360° compatibility attribute of the system 100 also helps maintain mechanical and electrical connections under severe mechanical conditions, such as vibration. In conventional blade- or fork-shaped connectors with 180° compatibility, i.e., connections made only on two opposing sides, vibration can generate harmonic resonances that cause the 180°-compatible connector to vibrate with greater amplitude at certain frequencies. For example, harmonic resonances in the fork-shaped connector can cause the fork-shaped connector to open. Opening a fork-shaped connector during electrical conduction is undesirable because momentary mechanical separation of the fork-shaped connector from its associated terminal can result in electrical arcing. Arcing can have significant adverse effects on the 180° compatible terminal and the entire electrical system it is a component of. However, the 360° compatibility feature of the present disclosure can prevent catastrophic failure that can be caused by strong vibrations and electrical arcing.

[0077] 5) Second embodiment of the connector system 48-76 disclose an alternative configuration of the high-current-carrying connector system 100. It should be understood that this second embodiment of the connector system 3100 includes similar structures, features, and / or functions as those disclosed in connection with the first embodiment of the connector system 100. Accordingly, reference numerals separated by 3000 are used in connection with this second embodiment to indicate structures and / or features similar to those disclosed in the first embodiment. For example, the contact arms of the first embodiment are labeled 1494a-1494p, and the contact arms of the second embodiment are labeled 4494a-4494p. Therefore, one skilled in the art should assume that the contact arms 1494a-1494p of the first embodiment have similar structures, features, and / or functions compared to the contact arms 4494a-4494p of the second embodiment. Additionally, one skilled in the art should understand that similar structures, features, and / or functions do not necessarily mean that the structures, features, and / or functions are identical.

[0078] The primary difference between the first and second embodiments of connector systems 100, 3100 disclosed herein is the fact that the plates 1474, 2474 of the first embodiment 100 are substantially parallel to the terminal bodies 1472, 2472, while the plates 4474, 5474 of the second embodiment 3100 are substantially perpendicular to the terminal bodies 4472, 5472. The change in orientation from the 180-degree connector shown in the first embodiment 100 to the 90-degree connector shown in the second embodiment 3100 results in other minor changes to the male housing 4100 and terminal assembly 4430. For example, the second connector embodiment 3100 does not include a rear male terminal wall assembly and is not formed from two separate and distinct pieces.

[0079] As discussed above in connection with the first embodiment 100 of the connector, the second embodiment 3100 of the connector includes at least the following: (i) a male housing assembly 4100 including separation walls 4122a-p to eliminate the need to modify the spring member 4440a to ensure proper alignment within the spring receptacle 4486, (ii) free ends 4446 of the spring arms 4452a-p and free ends 4488 of the contact arms 4494a-p arranged along a curved path (i.e., a circular path), (iii) the spring arms 4452a-p and contact arms 4494a-p are cooperatively sized and positioned to allow mechanical interaction between the multiple contact arms and the multiple spring arms when placed in a particular state or subjected to certain operating conditions, and (iv) a contact arm opening width W CO and contact arm width W C (iv) no current choke points are included between the male terminal body 4472 and the plate 4474; (v) a contact arm length L CA The base wall length L is 90% to 110% of B (vi) does not include the extent of male terminal body 1472 surrounding the extent of contact arms 1494a-1494p; (vii) has a high current capacity rated to carry at least 500 amps at RoA 55°C or at 80°C with a wire size of 120 mm2 and an 80% current derating; (viii) is T4 / V4 / S3 / D2 / M2 compliant; (ix) is 360 degree compatible; (x) is capable of meeting the insertion force requirement of less than 45 Newtons for USCAR Class 2 connectors without lever assistance; (xi) includes the terminal features and functions discussed above in connection with the first embodiment; and (xii) other features or functions that will be apparent to one of ordinary skill in the art based on a review of this specification and its figures.

[0080] As discussed above in connection with the current choke point between male terminal body 4472 and plate 4474, the cross-sectional area of male terminal connecting plate 4474 at the point where male terminal connecting plate 4474 is coupled to male terminal body 4472 is greater than the cross-sectional area of contact arms 1494a-1494p at the point where contact arms 1494a-1494p contact the inner surface of female receptacle 5472. In other words, the height H of male terminal connecting plate 4474 is CP (12.4mm)*Thickness T of male terminal connection plate 4474 CP (2.5mm) is the thickness T of contact arms 4494a~4494p CA (0.8mm) * Number of contact arms (16) * Contact width W of contact arms 4494a~4494p CA (1.9 mm) or more. Therefore, in this embodiment, the cross-sectional area of the male terminal connecting plate 4474 at the body connecting location BCL is 31 mm2, which is larger than the cross-sectional area of the contact arms 4494a-4494p at the terminal connecting location TCL, which is 24.32 mm2. Therefore, no current choke point is formed between the male terminal connecting plate 4474 and the male terminal body 4472. In this embodiment, the thickness T CP It should be noted that the height H of the 12.4 mm CP If a thickness of 1.65 mm is used, a choke point would be created because the cross-sectional area of the male terminal connection plate 4474 (i.e., 20.46 mm2) would be smaller than the cross-sectional area of the contact arms 4494a-4494p (i.e., 24.32 mm2).

[0081] To ensure that no current choke points are created, the height H of the male terminal connection plate 4474 CP is the thickness T of the male terminal connection plate 4474 CP However, it should be understood that the height H of the male terminal connection plate 4474 can be increased while decreasing. CP The reduction in the base wall length L B is the contact arm length LCA Reducing the length of the base walls 4478a-4478b to a point where the base wall length L is less than 90% of the base wall length L may lead to significant manufacturing difficulties for male terminal bodies 1472 having diameters greater than 12 mm. B is the contact arm length L CA In other words, the base wall length L B is 11 mm to 13 mm, preferably 12.4 mm, and the contact arm length L CA is 9 mm to 10 mm, preferably 9.5 mm. Therefore, the base wall length L B is the contact arm length L CA Other dimensions of the male terminal body 4472 are shown in relation to FIG. 54, where the base wall diameter O B is 19 mm to 23 mm, preferably 20.5 mm, and the total length L is 22 mm to 44 mm. CP As shown in FIG. 54, the connection plate 4474 has three distinct rectangular sections, where the first section (designed to be coupled to the wire 4495) has a height H of 24.4 mm. CP1 and length L of 20.8 mm CP1 and the second section has a height H of 19.4 mm. CP2 and length L of 6.2 mm CP2 and the third section has a height H of 12.4 mm. CP3 and length L of 6.85 mm CP3 It has.

[0082] 6) Related information for System 100 and 3100 The system 100, 3100 is T4 / V4 / S3 / D2 / M2, where the system 100, 3100 meets and exceeds the following: (i) T4 is exposure of the system 100 to 150°C, (ii) V4 is severe vibration, (iii) S1 is high pressure spray, (iv) D2 is a 200k mile durability, and (v) M2 is a force of less than 45 Newtons required to connect the male terminal assembly 1430, 4430 to the female terminal assembly 2430, 5430. In addition to being T4 / V4 / S3 / D2 / M2 compliant, the system 100, 3100 is push, click, tug, scan (PCTS) compliant, additional information about this standard is disclosed in International Application No. US2020 / 49870.

[0083] It should be understood that the male terminal assemblies 1430, 4430 and female terminal assemblies 2430, 5430 disclosed herein are rated to carry at least 500 amps on a 120 mm wire size at an R of 55°C or 80°C with an 80% current derating. In comparison, the connectors disclosed herein, a conventional 14 mm circular connector sold by Amphenol under the name PowerLok, (i) have similar current carrying capabilities, (ii) are approximately 25% lighter, (iii) are approximately 50% less expensive to manufacture, and (iv) are more robust, as they are capable of meeting USCAR 2 T4 / V4 ratings. These mechanical and electrical advantages over conventional connectors provide significant advantages over these conventional connectors while meeting industry regulations and requirements. It should therefore be understood that theoretical designs that attempt to modify connectors or combine a range of conventional designs are insufficient (and in some cases entirely insufficient) as they represent mere design exercises unbound by the complex realities of designing, testing, manufacturing, and certifying connector system 100 to obtain these mechanical and electrical advantages over conventional connectors.

[0084] The spring members 1440a, 4440a disclosed herein may be substituted for the spring members shown in International Application No. US2019 / 36010 or U.S. Provisional Patent Application No. 63 / 058,061. Furthermore, it should be understood that alternative configurations of the connector assemblies 1000, 2000, 4000, 5000 are possible. For example, any number of male terminal assemblies 1430, 4430 (e.g., 2-30, preferably 2-8, and most preferably 2-4) can be positioned within the housing 1100, 4100. In addition, alternative configurations of the connector system 100, 3100 are possible. For example, the female connector assembly 2000, 5000 may be reconfigured to accept multiple male terminal assemblies 1430, 4430 into a single female terminal assembly 2430, 5430. It should also be understood that the male terminal assembly can have any number of contact arms 1494, 5494 (e.g., 2 to 100, preferably 2 to 50, and most preferably 2 to 8) and any number of spring arms 1452, 5452 (e.g., 2 to 100, preferably 2 to 50, and most preferably 2 to 8). As discussed above, the number of contact arms 1494, 5494 does not have to equal the number of spring arms. For example, there can be more contact arms 1494, 5494 than spring arms 1452, 5452. Alternatively, there can be fewer contact arms 1494, 5494 than spring arms 1452, 5452.

[0085] Materials and Disclosures Incorporated by Reference International Application Nos. US2020 / 143788, US2020 / 143686, US2020 / 133446, US2020 / 50018, US2020 / 49870, US2020 / 14484, US2020 / 13757, US2019 / 36127, US2019 / 36070, US2019 / 36010, and US2018 / 19787; No. 16 / 194,891 and U.S. Provisional Patent Applications Nos. 62 / 897,658, 62 / 897,962, 62 / 988,972, 63 / 051,639, 63 / 058,061, 63 / 068,622, 63 / 109,135, 63 / 159,689, 63 / 222,859, and 63 / 234,320, each of which is incorporated by reference in its entirety and made a part of this specification.

[0086] 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, each of which is incorporated by reference in its entirety and made a part hereof.

[0087] The ASTM standards, (i) D4935-18, entitled "Standard Test Method for Measuring the Electromagnetic Shielding Effectiveness of Planar Materials," and (ii) ASTM D257, entitled "Standard Test Methods for DC Resistance or Conductance of Insulating Materials," are each incorporated by reference in their entirety and made a part of this specification.

[0088] The American National Standards Institute and / or EOS / ESD Association, Inc. standard ANSI / ESD STM11.11 Surface Resistance Measurements of Static Dissipative Planar Materials, each of which is incorporated by reference in its entirety and made a part hereof.

[0089] The DIN standard, Connectors for electronic equipment - Tests and measurements - Part 5-2: Current-carrying capacity tests; Test 5b: Current-temperature derating (IEC60512-5-2:2002), is incorporated by reference in its entirety and made a part of this specification.

[0090] USCAR standards include: (i) SAE / USCAR-2, 6th Edition, February 2013, ISBN: 978-0-7680-7998-2; (ii) SAE / USCAR-12, 5th Edition, August 2017, ISBN: 978-0-7680-8446-7; (iii) SAE / USCAR-21, 3rd Edition, December 2014; (iv) SAE / USCAR-25, 3rd Edition, March 2016, ISBN: 978-0-7680-8319-4; (v) SAE / USCAR-37, 3rd Edition, August 2008, ISBN: 978-0-7680-2098-4; and (vi) SAE / USCAR-38, 1st Edition, 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.

[0091] Other standards, including Federal Test Method Standards 101C and 4046, are each incorporated by reference in their entirety and made a part of this specification.

[0092] Industrial Applicability While several implementations have been illustrated and described, numerous modifications are envisioned without significantly departing from the spirit of this disclosure. The scope of protection is limited only by the scope of the appended claims. For example, the overall shape of the components described above may be modified to a triangular prism, pentagonal prism, hexagonal prism, octagonal prism, sphere, cone, tetrahedron, cube, dodecahedron, icosahedron, octahedron, ellipsoid, or other similar shape.

[0093] 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 the terms include, use, and the like are used, such terms are intended to be inclusive in the same manner as the term "comprises" 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.

[0094] The use of phrases such as "one aspect," "that aspect," "another aspect," "some aspects," "one or more aspects," "one implementation," "that implementation," "another implementation," "some implementations," "one or more implementations," "one embodiment," "that embodiment," "another embodiment," "some embodiments," "one or more embodiments," "one configuration," "that configuration," "another configuration," "some configurations," "one or more configurations," the subject technology, the disclosure, the present disclosure, other variations thereof, and similar phrases is for convenience and does not imply that the disclosure associated with such phrases is essential to the subject technology or that the 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.

[0095] 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 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. 1. A connector system for use in an electrical power distribution system, said connector system comprising: a male terminal assembly; a male terminal housing that surrounds at least a portion of the male terminal assembly; Equipped with The male terminal assembly is a male terminal body formed from a first material, the male terminal body having (i) a spring seat, (ii) a base wall having a forwardmost extent, and (iii) a plurality of contact arms extending forwardly from the forwardmost extent of the base wall, the plurality of contact arms being arranged along a contact arm curved path, the contact arms being spatially arranged such that a contact arm opening is between a pair of contact arms of the plurality of contact arms and such that no intervening structure of the male terminal body is between the pair of contact arms of the plurality of contact arms; a spring member formed from a second material, the spring member being sized to reside within the spring receptacle of the male terminal body and having a plurality of spring arms arranged along a curved spring arm path; the curved path of the contact arm and the curved path of the spring arm are sized and positioned to allow mechanical interaction between the plurality of contact arms and the plurality of spring arms; A connector system, wherein the male terminal housing includes a plurality of separation walls positioned between each of the contact arms within the plurality of contact arms and between each of the spring arms within the plurality of spring arms.

2. the base wall has a rearward-most extent and a forward-most extent, a base wall length extending between the rearward-most extent and the forward-most extent, and each contact arm of the plurality of contact arms has a contact arm length extending between the forward-most extent of the base wall and the forward-most extent of the contact arm; 2. The connector system of claim 1, wherein the base wall length is at least 90% of the contact arm length.

3. each contact arm of the plurality of contact arms has a width defining a contact arm width, and each contact arm opening has a width defining a contact arm opening width; 2. The connector system of claim 1, wherein the contact arm width is at least 80% of the contact arm opening width to ensure that the male terminal assembly provides 360 degree compatibility with the connector system.

4. each contact arm of the plurality of contact arms has a width defining a contact arm width, and a contact arm opening extending between the contact arms has a contact arm opening width; 2. The connector system of claim 1, wherein the contact arm opening width is no more than 20% greater than the contact arm width to ensure that the male terminal assembly provides 360-degree compatibility with the connector system.

5. The connector system of claim 1 , wherein the spring member is devoid of structure configured to align the plurality of spring arms within the plurality of contact arms.

6. 2. The connector system of claim 1, wherein a contact arm in the plurality of contact arms includes a free end that resides in contact with an outer surface of a spring arm in the plurality of spring arms when the spring member is positioned in the spring receiver.

7. 2. The connector system of claim 1, wherein the first material of the male terminal body comprises copper and the second material of the spring member comprises iron.

8. The connector system of claim 1 , wherein the male terminal housing encloses a majority of the male terminal assembly.

9. 9. The connector system of claim 8, wherein the male terminal housing includes a plurality of contact arm openings, each contact arm aperture configured to receive only a single contact arm contact of the plurality of contact arms.

10. 9. The connector system of claim 8, wherein the male terminal housing includes an outer housing portion surrounding the contact arms and positioned outwardly of the contact arms.

11. 11. The connector system of claim 10, wherein the outer housing portion is positioned a distance from the contact arm to form a gap between the contact arm and the outer housing portion of the male terminal housing.

12. 1. A connector system for use in an electrical power distribution system, said connector system comprising: a male terminal assembly; a male terminal housing that surrounds at least a portion of the male terminal assembly; Equipped with The male terminal assembly is a male terminal body formed from a first material, (i) a spring bearing; (ii) a base wall having a rearward-most extent and a forward-most extent, a base wall length extending between the rearward-most extent and the forward-most extent; (iii) a male terminal body having a plurality of contact arms extending forwardly from the forwardmost extent of the base wall and arranged along a curvilinear contact arm path, each contact arm of the plurality of contact arms having a contact arm length extending between the forwardmost extent of the base wall and the forwardmost extent of the contact arm, and the base wall length being at least 90% of the contact arm length; a spring member sized to reside within the spring receptacle and having a plurality of spring arms; A connector system, wherein the male terminal housing includes a plurality of separation walls positioned between each of the contact arms within the plurality of contact arms and between each of the spring arms within the plurality of spring arms.

13. The connector system of claim 12 , wherein the spring member is formed from a second material.

14. The connector system of claim 13 , wherein the spring member is devoid of structure configured to align the plurality of spring arms within the plurality of contact arms.

15. The connector system of claim 13 , wherein the plurality of spring arms are arranged along a curved spring arm path.

16. 16. The connector system of claim 15, wherein the curved path of the contact arm and the curved path of the spring arm are dimensioned and positioned to allow mechanical interaction between the plurality of contact arms and the plurality of spring arms.

17. The connector system of claim 12 , wherein the male terminal body lacks an area surrounding any one of the contact arms included in the plurality of contact arms.

18. each contact arm of the plurality of contact arms has a width defining a contact arm width, and a contact arm opening extending between the contact arms has a contact arm opening width; 13. The connector system of claim 12, wherein the contact arm width is at least 80% of the contact arm opening width to ensure that the male terminal body provides 360 degree compatibility with the connector system.

19. each contact arm of the plurality of contact arms has a width defining a contact arm width, and a contact arm opening extending between the contact arms has a contact arm opening width; 13. The connector system of claim 12, wherein the contact arm opening width is no more than 20% greater than the contact arm width to ensure that the male terminal body provides 360 degree compatibility with the connector system.

20. 1. A connector system for use in an electrical power distribution system, said connector system comprising: a male terminal assembly; a male terminal housing that surrounds at least a portion of the male terminal assembly; Equipped with The male terminal assembly is a male terminal body formed from a first material, (i) a plurality of contact arms arranged along a curved contact arm path and defining a spring seat, each contact arm of the plurality of contact arms having a width defining a contact arm width; (ii) a plurality of contact arm openings, each contact arm opening of the plurality of contact arm openings extending between a pair of adjacent contact arms such that each contact arm opening defines a contact arm opening width; a male terminal body, the contact arm width being at least 80% of the contact arm opening width to ensure that the male terminal body provides 360 degree compatibility with the connector system; a spring member sized to reside within the spring receptacle and having a plurality of spring arms; A connector system, wherein the male terminal housing includes a plurality of separation walls positioned between each of the contact arms within the plurality of contact arms and between each of the spring arms within the plurality of spring arms.

21. The connector system of claim 20 , wherein the spring member is formed from a second material.

22. 22. The connector system of claim 21, wherein the spring member is devoid of structure configured to align the plurality of spring arms within the plurality of contact arms.

23. 22. The connector system of claim 21, wherein the plurality of spring arms are arranged along a curved spring arm path.

24. 24. The connector system of claim 23, wherein the curved path of the contact arm and the curved path of the spring arm are sized and positioned to allow mechanical interaction between the plurality of contact arms and the plurality of spring arms.

25. 21. The connector system of claim 20, wherein the male terminal body lacks an area surrounding any one of the contact arms included in the plurality of contact arms.

26. the male terminal body includes a base wall having a rearward-most extent and a forward-most extent, a base wall length extending between the rearward-most extent and the forward-most extent, and each contact arm of the plurality of contact arms has a contact arm length extending between the forward-most extent of the base wall and the forward-most extent of the contact arm; 21. The connector system of claim 20, wherein the base wall length is at least 90% of the contact arm length.

27. The connector system of claim 20, wherein the male terminal housing surrounds a majority of the male terminal body.

28. 28. The connector system of claim 27, wherein the male terminal housing includes a plurality of contact arm apertures, each contact arm aperture configured to receive only a single contact arm contact within the plurality of contact arms.

29. 28. The connector system of claim 27, wherein the male terminal housing includes an outer housing portion surrounding the contact arms and positioned outwardly of the contact arms.

30. 30. The connector system of claim 29, wherein the outer housing portion is positioned a distance from the contact arm to form a gap between the contact arm and the outer housing portion of the male terminal housing.

31. 1. A connector system for use in an electrical power distribution system, said connector system comprising: a male terminal assembly; a male terminal housing that surrounds at least a portion of the male terminal assembly; Equipped with The male terminal assembly is a male terminal body formed from a first material, (i) a circumferential base wall; (ii) a plurality of contact arms extending from the base wall to define a spring seat, each contact arm of the plurality of contact arms having a width defining a contact arm width; (iii) a male terminal body having a plurality of contact arm openings, each contact arm opening of the plurality of contact arm openings being between a pair of adjacent contact arms such that each contact arm opening of the plurality of contact arm openings defines a contact arm opening width; a spring member sized to reside within the spring receptacle and having a plurality of spring arms; the contact arm opening width is no more than 20% greater than the contact arm width to ensure that the male terminal body provides 360 degree compatibility with the connector system; A connector system, wherein the male terminal housing includes a plurality of separation walls positioned between each of the contact arms within the plurality of contact arms and between each of the spring arms within the plurality of spring arms.

32. The connector system of claim 31 , wherein the spring member is formed from a second material.

33. 33. The connector system of claim 32, wherein the spring member is devoid of structure configured to align the plurality of spring arms within the plurality of contact arms.

34. 33. The connector system of claim 32, wherein the plurality of contact arms are arranged along a curved path of the contact arms and the plurality of spring portion arms are arranged along a curved path of the spring arms.

35. 35. The connector system of claim 34, wherein the curved path of the contact arm and the curved path of the spring arm are sized and positioned to allow mechanical interaction between the plurality of contact arms and the plurality of spring arms.

36. the male terminal body includes a base wall having a rearward-most extent and a forward-most extent, a base wall length extending between the rearward-most extent and the forward-most extent, and each contact arm of the plurality of contact arms has a contact arm length extending between the forward-most extent of the base wall and the forward-most extent of the contact arm; 32. The connector system of claim 31, wherein the base wall length is at least 90% of the contact arm length.

37. A connector system according to any preceding claim, further comprising a female connector assembly having female terminals with female receptacles.

38. 38. The connector system of claim 37, wherein the connector system (i) is configured to transfer more than 500 amps between the male terminal body and the female terminal at less than a 55°C rise above the ambient temperature at which the connector system is operating, and (ii) lacks a lever to assist in positioning the extent of the male terminal body within the female receptacle.

39. The connector system is in a fully connected state S ＦＣ 38. The connector system of claim 37, wherein an insertion force of less than 45 Newtons is required to position the area of the male terminal body within the female receptacle.

40. When the connector is in the fully connected state S ＦＣ 40. The connector system of claim 39, wherein the connector system is configured to transfer more than 500 amps between the male terminal body and the female terminal at an elevation of less than 55°C above the ambient temperature at which the connector system is operating.

41. The connector system is in a fully connected state S ＦＣ 38. The connector system of claim 37, wherein an insertion force less than the insertion force limit provided in the USCAR Class 2 standard is required to position the range of the male terminal body within the female receptacle to place it in place.

42. The fully connected state S ＦＣ 42. The connector system of claim 41, wherein the connector system is configured to transmit greater than 500 amps between the male terminal body and the female terminal with an 80% current derating at an 80°C rise above the ambient temperature at which the connector system is operating.

43. a connecting member coupled to a rearward extent of the male terminal body at a body connection location, the connecting member having a cross-sectional area defined at the body connection location; Fully connected state S ＦＣ the plurality of contact arms engage the areas of the female terminal at terminal connection locations when the areas of the male terminal body are positioned within the female receptacle to provide 38. The connector system of claim 37, wherein each contact arm of the plurality of contact arms has a cross-sectional area defined at the terminal connection location, the sum of the cross-sectional areas of the plurality of contact arms being less than the cross-sectional area of the connection member at the body connection location.

44. a female connector assembly having female terminals with female receptacles; The connector system of any one of claims 1 to 11, 16, 24, or 35, wherein mechanical interaction occurs when the male terminal body region is positioned within the female receptacle.

45. a female connector assembly having female terminals with female receptacles; 36. The connector system of any one of claims 1-11, 16, 24, or 35, wherein the mechanical interaction occurs when the area of the male terminal body is positioned within the female receptacle and exposed to an ambient temperature greater than 100 degrees Celsius.

46. 36. A connector system as described in any one of claims 1 to 11, 16, 24, or 35, wherein the mechanical interaction between the plurality of contact arms and the plurality of spring arms includes an outward biasing force applied to the plurality of contact arms by the plurality of spring arms.

47. 1. A connector system for use in an electrical power distribution system, said connector system comprising: a female connector assembly having female terminals with female receptacles; a male connector assembly; The male connector assembly a male terminal assembly; a male terminal housing that surrounds at least a portion of the male terminal assembly; Equipped with The male terminal assembly is a plurality of contact arms defining a spring seat; a spring member sized to reside within the spring receptacle and having a plurality of spring arms; The female connector assembly and the male connector assembly are (i) configured to transmit greater than 500 amperes between the male terminal assembly and the female terminal at less than a 55° C. rise above the ambient temperature at which the connector system is operating; and (ii) lacking a lever to assist in positioning the male connector assembly within the female receptacle; A connector system, wherein the male terminal housing includes a plurality of separation walls positioned between each of the contact arms within the plurality of contact arms and between each of the spring arms within the plurality of spring arms.

48. 1. A connector system for use in an electrical power distribution system, said connector system comprising: a female connector assembly having female terminals with female receptacles; a male connector assembly; The male connector assembly a male terminal assembly; a male terminal housing that surrounds at least a portion of the male terminal assembly; Equipped with The male terminal assembly is a plurality of contact arms defining a spring seat; a spring member sized to reside within the spring receptacle and having a plurality of spring arms; The connector system is in a fully connected state S ＦＣ an insertion force of less than 45 Newtons is applied to the male connector assembly to position the male connector assembly within the female receptacle; and The fully connected state S ＦＣ wherein the connector system is configured to transmit greater than 500 amperes between the male terminal assembly and the female terminal at less than a 55° C. rise above the ambient temperature at which the connector system is operating; A connector system, wherein the male terminal housing includes a plurality of separation walls positioned between each of the contact arms within the plurality of contact arms and between each of the spring arms within the plurality of spring arms.

49. 1. A connector system for use in an electrical power distribution system, said connector system comprising: a female connector assembly having female terminals with female receptacles; a male connector assembly; The male connector assembly a male terminal assembly; a male terminal housing that surrounds at least a portion of the male terminal assembly; Equipped with The male terminal assembly is a plurality of contact arms defining a spring seat; a spring member sized to reside within the spring receptacle and having a plurality of spring arms; The connector system is in a fully connected state S ＦＣ an insertion force less than the insertion force limit provided in the USCAR Class 2 standard is applied to the male connector assembly to position the male connector assembly within the female receptacle to place it in The fully connected state S ＦＣ wherein the connector system is configured to transmit greater than 500 amperes between the male terminal assembly and the female terminal at an 80% current derating at an 80° C. rise above the ambient temperature at which the connector system is operating; A connector system, wherein the male terminal housing includes a plurality of separation walls positioned between each of the contact arms within the plurality of contact arms and between each of the spring arms within the plurality of spring arms.

50. 1. A connector system for use in an electrical power distribution system, said connector system comprising: a female connector assembly having female terminals with female receptacles; a male connector assembly; The male connector assembly a male terminal assembly; a male terminal housing that surrounds at least a portion of the male terminal assembly; Equipped with The male terminal assembly is (i) a male terminal body having a circumferential base wall and a plurality of contact arms extending forwardly from said base wall; (ii) a connecting member coupled to a rearward extent of the male terminal body at a body connection location, the connecting member having a defined cross-sectional area at the body connection location; (iii) a spring member sized to reside within the spring receptacle, the spring member having a plurality of spring arms; Fully connected state S ＦＣ the plurality of contact arms engage the range of female terminals at terminal connection locations when the range of male connector assembly is positioned within the female receptacle to provide each contact arm of the plurality of contact arms has a cross-sectional area defined at the terminal connection location, the sum of the cross-sectional areas of the plurality of contact arms being less than the cross-sectional area of the connection member at the body connection location; A connector system, wherein the male terminal housing includes a plurality of separation walls positioned between each of the contact arms within the plurality of contact arms and between each of the spring arms within the plurality of spring arms.

51. A connector system according to any one of claims 47 to 49, wherein the male terminal housing surrounds most of the male terminal assembly.

52. 52. The connector system of claim 51, wherein the male terminal housing includes a plurality of contact arm openings, each contact arm aperture configured to receive only a single contact arm contact of the plurality of contact arms.

53. 52. The connector system of claim 51, wherein the male terminal housing includes an outer housing portion surrounding and positioned outwardly of the contact arms.

54. 54. The connector system of claim 53, wherein the outer housing portion is positioned a distance away from the contact arm to form a gap between the contact arm and the outer housing portion of the male terminal housing.

55. 50. A connector system according to any one of claims 47 to 49, wherein the male terminal assembly includes a male terminal body having a plurality of contact arms arranged along a curvilinear contact arm path.

56. 56. The connector system of claim 55, wherein the male terminal assembly is devoid of an area of the male terminal body surrounding any one of the contact arms included in the plurality of contact arms.

57. the male terminal body further includes a base wall having a forward-most extent; 56. The connector system of claim 55, wherein the plurality of contact arms extend forwardly from the forwardmost extent of the base wall.

58. the base wall has a rearward-most extent and a forward-most extent, a base wall length extending between the rearward-most extent and the forward-most extent, and each contact arm of the plurality of contact arms has a contact arm length extending between the forward-most extent of the base wall and the forward-most extent of the contact arm; 58. The connector system of claim 57, wherein the base wall length is at least 90% of the contact arm length.

59. each contact arm of the plurality of contact arms has a width defining a contact arm width, and a contact arm opening extending between the contact arms has a contact arm opening width; 56. The connector system of claim 55, wherein the contact arm width is at least 80% of the contact arm opening width to ensure that the male terminal body provides 360 degree compatibility with the connector system.

60. each contact arm of the plurality of contact arms has a width defining a contact arm width, and a contact arm opening extending between the contact arms has a contact arm opening width; 56. The connector system of claim 55, wherein the contact arm opening width is no more than 20% greater than the contact arm width to ensure that the male terminal body provides 360 degree compatibility with the connector system.

61. 56. The connector system of claim 55, wherein the spring member is devoid of structure configured to align the plurality of spring arms within the plurality of contact arms.

62. 56. The connector system of claim 55, wherein the plurality of spring arms are arranged along a curved spring arm path.

63. 63. The connector system of claim 62, wherein the curved path of the contact arm and the curved path of the spring arm are dimensioned and positioned such that mechanical interaction can occur between the plurality of contact arms and the plurality of spring arms.

64. the male terminal body is formed as two separate parts; A connector system according to any one of claims 1 to 36 or 50, wherein the two separate portions include a first portion and a second portion identical to the first portion.

65. 65. The connector system of claim 64, wherein the first portion and the second portion are joined using joining means configured to extend outward from outer edges of each of the first portion and the second portion.

66. the male terminal assembly includes a male terminal body including the plurality of contact arms; the male terminal body is formed as two separate parts; A connector system according to any one of claims 47 to 49, wherein the two separate portions include a first portion and a second portion identical to the first portion.

67. 65. The connector system of claim 64, wherein the first portion and the second portion are joined using joining means configured to extend outward from outer edges of each of the first portion and the second portion.

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