A splice block system that connects multiple components in an electrical distribution system

Abstract

The splice block system is configured to connect a plurality of components in an electrical power distribution system. The splice block includes: (i) an outer housing having a removable cover; (ii) a mating assembly coupled to the removable cover and including a first female terminal assembly, a second female terminal assembly, and a third female terminal assembly; (iii) a first male connector assembly having a first male terminal assembly; (iv) a second male connector assembly having a second male terminal assembly; and (v) a third male connector assembly having a third male terminal assembly. The positioning force F P is applied to each of the first, second and third male terminal assemblies to position the first, second and third male terminal assemblies within their respective first, second and third female terminal assemblies, applying a positioning force F P A bonding force Fc oriented substantially perpendicular to the removable cover is applied to the removable cover.

Description

[Technical field]

[0001] The present disclosure relates to a splice block system for use in electrically connecting multiple components in an electrical distribution system, such as found in an automobile. More specifically, the splice block system includes multiple electrical connector assemblies for electrically coupling one device or component to at least two other devices or components in the electrical distribution system or environment.

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 308,488, which is incorporated herein by reference in its entirety for all purposes. [Background technology]

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

[0004] Automobiles are challenging electrical environments for both electrical components and connector assemblies due to many conditions, including, but not limited to, space constraints that make initial installation difficult, harsh operating conditions, large ambient temperature ranges, extended vibration, thermal loading, and long life spans, all of which can lead to component and / or connector failure. For example, incorrect installation of connectors, which typically occurs in the assembly plant, and connector dislodgment, which typically occurs in the field, are two significant failure modes for electrical components and automobiles. Each of these failure modes results in significant repair and warranty costs. For example, the combined annual warranty costs of all automobile manufacturers and their direct distributors are estimated to be between $50 billion and $150 billion worldwide. Given this harsh electrical environment, a great deal of time, money, and energy has been expended to find power distribution components that meet the needs of the market. The present disclosure addresses the shortcomings of conventional power distribution components. A complete description of the features and advantages of the present disclosure is deferred to the following detailed description, which proceeds with reference to the accompanying drawings. Summary of the Invention

[0005] The present disclosure relates to an electrical connector system having an outer housing with a removable cover, wherein a first male connector assembly, a second male connector assembly, and a third male connector assembly are coupled to each other with a positioning force F. P The first, second and third male connector assemblies are positioned within the outer housing using a mating force Fc. The first, second and third male connector assemblies have first, second and third male terminal assemblies, respectively. The first, second and third male terminal assemblies include (i) a male terminal body having a front wall and a spring receiver, and (ii) an internal spring member. Also, a mating assembly is positioned within the outer housing and coupled to the removable cover, and includes (i) a first female terminal assembly, (ii) a second female terminal assembly, and (iii) a third female terminal assembly. A mating force Fc is applied to the cover, which positions the extent of the first, second and third male terminal assemblies within the first, second and third female terminal assemblies of the mating assembly, and a positioning force Fc is applied to the mating assembly. Pis oriented substantially perpendicular to the binding force Fc.

[0006] The electrical connector system further comprises an outer housing having (i) a sidewall structure and (ii) a bottom wall coupled to the sidewall structure; a first male connector assembly having a first male terminal assembly with a front wall; and a second male connector assembly having a second male terminal assembly with a front wall, the electrical connector system being configured to be in a fully assembled state S. FA The first male terminal assembly and the second male terminal assembly are positioned within the outer housing, and the front walls of the first male terminal assembly and the second male terminal assembly (i) may be substantially coplanar and (ii) may be positioned substantially parallel to the extent of the bottom wall.

[0007] Furthermore, the electrical connector system may include an outer housing having a conductive cover; and a mating assembly coupled to the cover, the mating assembly including: (i) a first female terminal assembly; (ii) a second female terminal assembly; (iii) a third female terminal assembly; (iv) a bridge coupled to the first, second, and third female terminal assemblies and configured to electrically couple the first, second, and third female terminal assemblies to one another; and (v) a non-conductive bridge housing positioned between the bridge and the cover and configured to substantially electrically isolate the bridge from the cover.

[0008] Other aspects and advantages of the present disclosure will become apparent from consideration of the following detailed description and the accompanying drawings, in which like numerals refer to like structure throughout. [Brief description of the drawings]

[0009] The accompanying drawings are included to provide a further understanding, and are incorporated in and constitute a part of this specification. The accompanying drawings illustrate disclosed embodiments and, together with the description, serve to explain the principles of the disclosed embodiments. The drawings are as follows:

[0010] [Figure 1]FIG. 1 is a perspective view of a splice block system with a plurality of electrical connector assemblies, the splice block system being shown in a connected state SCON. [Diagram 2] FIG. 2 is a perspective view of the splice block system of FIG. 1 in a disconnected state SDCON, in which an upper area of ​​the outer housing is disconnected from the outer housing to expose the mating assembly and the multiple male connector assemblies. [Diagram 3] FIG. 2 is a perspective view of one male connector assembly having a male terminal assembly and a strain relief assembly. [Figure 4] FIG. 4 is a perspective view of the male terminal assembly of FIG. 3 in an uncoupled state SDC. [Diagram 5] FIG. 4 is a perspective view of the male terminal assembly of FIG. 3 in a partially coupled state SPC. [Figure 6] FIG. 4 is a left side view of the male terminal assembly of FIG. 3 in a fully mated state SFC. [Figure 7] 7 is a cross-sectional view of the male terminal assembly taken along line 7-7 of FIG. 6. [Figure 8] FIG. 13 is a bottom perspective view of the upper extent of the outer housing and mating assembly. [Figure 9] 1 is a front view of a mating assembly having an inner female housing assembly, a plurality of female terminal assemblies, and a bridge. [Figure 10] FIG. 10 is a perspective view of the mating assembly of FIG. 9. [Figure 11] FIG. 13 is a front view of a plurality of female terminal assemblies connected to a bridge. [Figure 12] FIG. 13 is a perspective view of a female terminal assembly connected to a bridge. [Figure 13] FIG. 13 is a side view of a female terminal assembly connected to a bridge. [Figure 14] FIG. 2 is a perspective view of the splice block system in a disassembled state SDA. [Figure 15] FIG. 2 is a perspective view of the splice block system in a partially assembled state SPA. [Figure 16]FIG. 1 is a top view of the splice block system in a fully assembled state SFA. [Figure 17] FIG. 17 is a perspective view of the splice block system of FIG. [Figure 18] FIG. 1 is a perspective view of the splice block system in a disconnected state SDCON. [Figure 19] FIG. 1 is a side view of the splice block system in a connected state SCON. [Figure 20] FIG. 20 is a cross-sectional view of the splice block system taken along line 20-20 of FIG. 19. [Figure 21] FIG. 1 is a side view of the splice block system in a connected state SCON. [Figure 22] FIG. 22 is a cross-sectional view of the splice block system taken along line 22-22 of FIG. 21. [Figure 23] FIG. 1 is a side view of the splice block system in a connected state SCON. [Figure 24] FIG. 24 is a cross-sectional view of the splice block system taken along line 24-24 of FIG. 23. [Diagram 25] FIG. 1 is a side view of the splice block system in a connected state SCON. [Figure 26] FIG. 26 is a cross-sectional view of the splice block system taken along line 26-26 of FIG. 25. [Figure 27] FIG. 1 is a side view of the splice block system in a connected state SCON. [Figure 28] FIG. 28 is a cross-sectional view of the splice block system taken along line 28-28 of FIG. 27. [Figure 29] FIG. 1 is a partial cross-sectional view of the splice block system in a connected state SCON. [Diagram 30] FIG. 2 is a side view of the male terminal assembly and the mating assembly in the connected state SCON. [Diagram 31] 31 is a cross-sectional view of the male and female terminal assemblies taken along line 31-31 of FIG. 30. [Diagram 32]FIG. 1 is a perspective view of a vehicle skateboard (skateboard chassis) S attached to an automobile V including a splice block system. [Diagram 33] FIG. 1 is a perspective view of an automobile V including a splice block system. [Diagram 34] FIG. 1 is a perspective view of a bus including a splice block system. [Diagram 35] FIG. 1 is a perspective view of a vessel including a splice block system. [Diagram 36] FIG. 1 is a perspective view of a boat including a splice block system. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] In the following detailed description, numerous specific details are set forth by way of example in order to provide a thorough understanding of the relevant teachings. However, it will be apparent to those skilled in the art that the present teachings may be practiced without such details. In other instances, well-known methods, procedures, components, and / or circuits are described at a relatively high level, without detailed description, in order to avoid unnecessarily obscuring aspects of the present teachings.

[0012] The present disclosure includes embodiments in many different forms. However, certain embodiments are shown in the drawings and described in detail herein, with the understanding that the present 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 concept to the illustrated embodiments. As will be understood, the disclosed method and system are capable of other different configurations, and some details can be modified without departing from the scope of the disclosed method and system. For example, part or all of one or more of the following embodiments may be consistently combined with the disclosed method and system. Thus, the drawings and detailed description are to be considered as illustrative in nature, and not restrictive or limiting.

[0013] [I. Introduction] The figures show a splice block system 10 that is designed to mechanically and electrically couple one device or component to at least two other devices or components in an electrical power distribution system or environment. For example, the first device or component may be a current supplying component (e.g., a power source such as an alternator or battery) and the second and third devices or components may be two current drawing components (e.g., a radiator fan, a heated seat, a power distribution component, or another current drawing component). The above-mentioned electrical power distribution systems or environments including the splice block system 10 may be installed in aircraft, automobiles (see FIGS. 32 and 33), military vehicles (e.g., tanks, personnel carriers, lorries, troop carriers), buses (see FIG. 34), locomotives, tractors, boats (see FIG. 36), ships (see FIG. 35), submarines, battery packs, 24-48 volt systems, high power applications, high current applications, and high voltage applications. Power distribution components are necessary to meet industry standards, production specifications, and performance requirements of power distribution systems and automobiles. It is understood that multiple splice block systems 10 may be used in a single application, such as multiple splice block systems 10 in an automobile power distribution system.

[0014] Various aspects of the splice block system 10 are disclosed herein and illustrated in the drawings. Specifically, the splice block system 10 comprises (i) an outer housing 100, (ii) a plurality of male connector assemblies 1000, 2000, 3000, and (iii) a mating assembly 4000. As described below, the male connector assemblies 1000, 2000, 3000 are primarily comprised of (i) a male terminal assembly 1430, and (ii) a strain relief assembly 1800, 2800, 3800. The mating assembly 4000 is primarily comprised of (i) an internal female housing assembly 4010, (ii) a plurality of female terminal assemblies 4430, 4530, 4630, and (iii) an internal current distribution component such as a bridge or bus 4800. Although the drawings show three male connector assemblies 1000, 2000, 3000 connected via a mating assembly 4000, it is understood that fewer (i.e., two) male connector assemblies 1000, 2000, 3000 may be included in the splice block system 10, or additional (e.g., twenty) male connector assemblies 1000, 2000, 3000 may be included in the splice block system 10.

[0015] It is to be understood that (i) a first portion of the plurality of male connector assemblies 1000, 2000, 3000 is configured as a "supply" male connector assembly 1000 that supplies electrical current from an external device to the system 10, and (ii) a second portion of the plurality of male connector assemblies 1000, 2000, 3000 is configured as a "receiving" male connector assembly 2000, 3000 that receives electrical current from the system 10 and supplies it to the external device. Accordingly, various configurations of the supply and receiving male connector assemblies 1000, 2000, 3000 and the mating assembly 4000 are contemplated by the present application. For example, the system 10 may include one supply male connector assembly and three receiving male connector assemblies. In another example, the system 10 may include four supply male connector assemblies and one receiving male connector assembly. In a further example, the system 10 may include two supply male connector assemblies and five receiving male connector assemblies. In a final example, the system 10 may include six supply male connector assemblies and two receiving male connector assemblies. It is further understood that if the system 10 includes more supply male connector assemblies than receiving male connector assemblies, or if it utilizes supply male connector assemblies carrying higher currents and receiving male connector assemblies carrying lower currents, the power distribution system must be configured to ensure that the supply male connector assemblies do not over-power the receiving male connector assemblies. In the above example, the supply and receiving male connector assemblies may be electrically connected using multiple (e.g., 1 to 20) mating assemblies. Thus, the above disclosure is not intended to limit the combinations of supply male connector assemblies, receiving male connector assemblies, and mating assemblies.

[0016] [II. External housing] The outer housing 100 is primarily comprised of (i) an upper area 105, such as a cover or lid 105a, (ii) a lower area 110, such as a bottom, and (iii) a sidewall structure 115. The outer housing 100 protects and isolates the connector assemblies 1000, 2000, 3000 and the mating assembly 4000 from external forces and elements. To provide this protection and isolation, the housing 100 is formed from both conductive and non-conductive materials. The sidewall structure 115 is integrally formed with the lower area or bottom 110 and includes a number of openings 122, 124, 126 designed to receive the male connector assemblies 1000, 2000, 3000. Each of the openings 122, 124, 126 is sealed by the male connector assemblies 1000, 2000, 3000 when the male connector assemblies 1000, 2000, 3000 are installed in the system 10. In this manner, the system 10 is in a fully assembled state S FA (see FIGS. 16 and 17 ), the system 10 meets the IP67 standard, which means that the system 10 (i) can be temporarily immersed in liquid to a depth of 15 cm to 1 m for up to 30 minutes, and (ii) will not allow contact dust to enter the outer housing 100 during an 8-hour airflow-based airflow test.

[0017] The outer housing 100 also includes a lower insulator member, such as a plate 150, disposed between an area of ​​the bottom wall 110 and a rear wall of the male terminal body 1472, 2472, 3472. The lower insulator plate 150 is made from a non-conductive material and is configured to electrically isolate the male terminal assemblies 1430, 2430, 3430 from the bottom wall 110 and the lower area of ​​the housing 100. In addition to isolating the terminal assemblies 1430, 2430, 3430, the lower insulator plate 150 provides a locator function that tells the installer / operator / assembler exactly where to place the male terminal assemblies 1430, 2430, 3430 within the housing 100 and on the bottom wall 110. The locator function of the lower insulating plate 150 is provided by utilizing the following: (i) a recess, channel or cavity formed in the plate 150; (ii) an index on the plate 150; or (iii) an edge of the plate 150.

[0018] As best shown in Figures 16, 28 and 29, the outer housing 100 further includes a plurality of internal support walls 180a-180e that are positioned adjacent to and designed to engage a region of the mating assembly 4000. The positional relationship between the outer surface of the mating assembly 4000 and the internal support walls 180a-180e helps reduce failure modes of the system 10, improves the lifespan of the system 10, and helps ensure that the male connector assemblies 1000, 2000, 3000 do not move inadvertently within the housing 100. Referring to Figure 16, the lower insulating plate 150 includes at least one recess or gap that receives a lower region of the internal support walls 180a-180e such that these two components structurally interact. In Figure 16 and in the various cross-sectional views, the internal support walls 180a-180e have a substantial height as measured from the bottom housing wall 110. Preferably, the height of the interior support walls 180 a - 180 e is less than the height of the side walls 115 of the housing 100 .

[0019] 2, 8 and 18, the cover 105a is removably coupled to the sidewall structure 115 via: (i) a substantially vertical (e.g., downward or upward) coupling force Fc (see FIG. 18), (ii) inserting mechanical fasteners 120 into openings formed in the cover 105a and the sidewall structure 115, and (iii) tightening the mechanical fasteners 120 to secure / remove said cover 105a from the sidewall structure 115. The ability to secure / remove the cover 105a relative to the outer housing 100 is beneficial as it allows an installer to mechanically secure (e.g., using ferrule compression clips 130, 131, 132) the male connector assemblies 1000, 2000, 3000 within the outer housing 100 over a large area. In particular, the wires 1495, 2495, 3495 are secured directly to the bottom wall 110 of the outer housing 100, while the male connector assemblies 1000, 2000, 3000 are indirectly secured within the outer housing 100 via the direct securing of the wires 1495, 2495, 3495. This arrangement allows the male connector assemblies 1000, 2000, 3000 to be secured to the outer housing 100 without relying solely on the strain relief assemblies 1800, 2800, 3800 or additional structure disposed on the exterior of the side wall 115.

[0020] The configuration of the outer housing 100 allows the male terminal assemblies 1430, 2430, 3430 to withstand a substantially lateral or substantially horizontal positioning force F P The positioning force F P is oriented parallel to the horizontal support surface on which the housing 100 rests. P The first or supply male terminal assembly 1430 is oriented parallel to the plane in which the cover 105a lies and the plane in which the bottom housing wall 110 lies. Specifically, the first or supply male terminal assembly 1430 is subjected to a first substantially lateral positioning force F P1 The second or first receiving male terminal assembly 2430 is inserted using a second substantially lateral positioning force F P2The third or second receiving male terminal assembly 3430 is inserted using a third substantially lateral positioning force F P3 The first substantially lateral positioning force F P1 are second and third substantially lateral positioning forces F P2 and F P3 However, the first, second and third substantially lateral positioning forces F P1 Or F P3 are flush with each other. The essentially lateral positioning force F P1 Or F P3 is oriented in a direction substantially perpendicular to the substantially perpendicular bonding force Fc. This perpendicular arrangement results in a positioning force F P1 Or F P3 The positioning force F and the coupling force Fc are not aligned, collinear, coplanar, or parallel. P1 Or F P3 The arrangement of F and Fc results in an extremely high "pull-out force" F PO In this regard, low pull-out force is a potential failure mode of the system 10. Specifically, a pull-out force F PO is the positioning force F P1 Or F P3The force applied to the wire 1495, 2495, 3495 in a direction opposite to that of the male connector assembly 1000, 2000, 3000. The pull-out force failure mode is effectively eliminated because the pull-out force must be large enough to overcome both (i) the mechanical fixation of the male connector assembly 1000, 2000, 3000 (e.g., ferrule compression clips 130, 131, 132) and (ii) the connection between the wire 1495, 2495, 3495 and the male connector assembly 1000, 2000, 3000. In contrast, a smaller pull-out force can cause failure in conventional splice block devices where the positioning and mating forces are aligned or substantially collinear. Here, the male terminal assembly disengages from the female terminal assembly without the wire being disconnected from the male terminal assembly. In the present system 10, when the male connector assemblies 1000, 2000, 3000 are inserted and secured within the outer housing 100, the system 10 is in a partially assembled state S. PA (shown in Figure 15) to the fully assembled state S FA (shown in Figures 16 and 17).

[0021] Based on the above disclosure, it should be understood that the mating force Fc is directed substantially parallel to: (a) the vertical extent of the sidewall structure 115; and / or (b) the sidewall portions 1492b, 1492d. Also, the mating force Fc is directed substantially perpendicular to: (a) the horizontal extent or surface 105b of the cover 105a; (b) the horizontal extent of the bottom wall 110; and / or (c) the outer surface of the front male terminal wall 1480, 2480, 3480. P1 Or F P3 is relative to: (a) the vertical extent of the sidewall structure 115; and (b) the resulting spring bias force S F It is to be understood that the positioning force F is oriented substantially perpendicular to the first region of the sidewall 1492b, 1492d and / or (c) the first region of the sidewall 1492b, 1492d. P1 Or F P3is relative to: (a) the horizontal extent or surface 105b of the cover 105a; (b) the horizontal extent or surface 110a of the bottom wall 110; and (c) the resulting spring bias force S F and / or (d) a second area of ​​the outer surface of the front male terminal wall 1480, 2480, 3480. It is understood that in other embodiments, the outer housing 100 may be omitted, may have a different shape, and the cover 105a may include a portion or area of ​​the sidewall structure 115. Additionally, the outer housing 100 may not meet IP67 standards and may provide little, if any, electromagnetic interference shielding. Additionally, the outer housing 100 may be made of a conductive plastic and may be formed from any similar material by press molding, injection molding, 3D printing, or any similar method.

[0022] [III. Supply Male Connector Assembly] The first or supply male connector assembly 1000 , which supplies electrical current to the system 10 , is primarily comprised of: (i) a supply male terminal assembly 1430 ; (ii) a wire 1495 ; and (iii) a strain relief assembly 1800 .

[0023] [A. Supply male terminal assembly] 2-7, 14-18, 20, 22, and 28-31 show various views of the supply male terminal assembly 1430. The male terminal assembly 1430 includes a spring member 1440c and a male terminal 1470. The male terminal 1470 includes a male terminal body 1472 and a male terminal connecting member or plate 1474. The male terminal body 1472 described above includes (i) a first or front male terminal wall 1480, (ii) a configuration of male terminal side walls 1482a-d, and (iii) a second or rear male terminal wall 1484. The combination of these walls 1480 and 1482a-d form a spring receiver 1486 designed to receive an internal spring member, male spring member, or second spring member 1440c.

[0024] [1. Internal spring parts] 4, the interior spring member 1440c includes an arrangement of spring member side walls 1442a-d and a rear spring wall 1444. Each of the spring member side walls 1442a-d is comprised of (i) a first spring section or arched spring section 1448a-d, (ii) a second spring section, base spring section or mid spring section 1450a-d, (iii) a third spring section or spring arms 1452a-h, and (iv) a fourth spring section or centering means 1453. The arched spring sections 1448a-1448d extend between the rear spring wall 1444 and the base spring sections 1450a-1450d and dispose the base spring sections 1450a-1450d substantially perpendicular to the rear spring wall 1444. In other words, the outer surfaces of the base spring sections 1450a-1450d are substantially perpendicular to the outer surface of the rear spring wall 1444.

[0025] The base spring sections 1450a-1450d are disposed between the arcuate sections 1448a-1448d and the spring arms 1452a-1452h. As shown in FIG. 4, the base spring sections 1450a-1450d are not connected, and thus a gap is formed between the base spring sections 1450a-1450d of the spring member 1440c. This gap helps the spring arms 1452a-1452h to expand in all directions, facilitating mechanical coupling between the male terminal 1470 and the female terminal assembly 4430. The spring arms 1452a-1452h extend from the base spring sections 1450a-1450d of the spring member 1440c, extend away from the rear spring wall 1444, and terminate at a free end 1446. The spring arms 1452a-h are generally planar and are arranged such that the outer surfaces of the spring arms 1452a-h are flush with the outer surfaces of the base spring sections 1450a-d. Unlike the spring arms 31 disclosed in Figures 4-8 of PCT / US2018 / 019787, the free ends 1446 of the spring arms 1452a-h do not have a curvilinear component. Instead, the spring arms 1452a-h have a substantially planar outer surface. This configuration is beneficial because it ensures that the force associated with the spring 1440c is applied substantially perpendicular to the free end 1488 of the male terminal body 1472. In contrast, the curvilinear components of the spring arms 31 disclosed in Figures 4-8 of PCT / US2018 / 019787 do not apply force in this manner.

[0026] Similar to the base spring sections 1450a-1450d, the spring arms 1452a-1452h are not connected to one another. In other words, there are spring arm openings extending between the spring arms 1452a-1452h. This configuration allows the spring arms 1452a-1452h to move in all directions and facilitates mechanical coupling between the male terminal 1470 and the female terminal assembly 4430. In other embodiments, the spring arms 1452a-1452h may be coupled to other structures to limit their expansion in all directions. The number and width of the individual spring arms 1452a-1452h and openings may vary. Additionally, while the width of the individual spring arms 1452a-1452h is typically equal, in other embodiments, one of the spring arms 1452a-1452h may be wider than the other spring arms.

[0027] 5 and 6 of PCT / US2019 / 36127, previous designs of spring member 1440pd may not be perfectly aligned within male terminal body 1472pd of male terminal assembly 1430pd due to manufacturing tolerances and imperfect assembly methods. As such, spring member 1440pd may shift or tilt within male terminal body 1472pd during assembly of male terminal assembly 1430pd. To help avoid this shifting, spring member 1440c disclosed herein includes centering means 1453, shown as anti-rotation protrusions 1454a-d. Due to interaction between the outer surfaces of the protrusions 1454a through 1454d and the inner surfaces of the sidewall portions 1492a through 1492d of the male terminal body 1472, the anti-rotation protrusions 1454a through 1454d assist in centering the spring member 1440c by limiting the amount that the spring member 1440c can rotate within the male terminal body 1472.

[0028] Proper centering of the spring member 1440c within the male terminal body 1472 provides many advantages over terminals that are not properly centered or aligned within the male terminal assembly 1430. These advantages include: (i) ensuring that the spring member 1440c applies an adequate force to the male terminal body 1472 to provide a proper connection between the male terminal assembly 1430 and the female terminal assembly 4430; (ii) helps improve the durability and usable life of the terminal assemblies 1430, 4430. (iii) There are other beneficial features that are disclosed herein or that can be used by one of ordinary skill in the art from this disclosure.

[0029] It is to be understood that in other embodiments, the centering or aligning means 1453 may take other forms, for example: (i) protrusions extending outwardly from first and second spring arms 1452a, 1452b positioned within a single side wall; (ii) protrusions extending outwardly from the first and fifth spring arms 1452a, 1452e, the protrusions being diagonally opposite one another; (iii) protrusions extending outwardly from all of spring arms 1452a through 1452h, where the protrusions associated with (arms) 1452c, 1452d, 1452g, and 1452h are offset relative to the protrusions associated with (arms) 1452a, 1452b, 1452e, and 1452f; (iv) a protrusion extending inwardly from an inner wall of the male terminal body 1472; (v) protrusions extending inwardly from contact arms 1494a through 1494h toward the center of the connector; (vi) a cooperatingly dimensioned spring retainer; (vii) A protrusion, tab, groove, recess or extension of other structure designed to help ensure that the spring member 1440c is centered within the male terminal body 1472 and cannot rotate within the spring receiver 1486. For example, protrusions may extend from the front or rear wall of the male terminal body 1472 and they may be received by apertures formed in the spring member 1440c.

[0030] Further, it is to be understood that instead of utilizing mechanical centering or alignment means 1453, centering means 1453 may be force-based. Such available forces may be magnetic or chemical. In this example, the rear wall of spring member 1440c may be welded to the rear wall of male terminal body 1472. In contrast to mechanical or force-based centering means 1453, centering means 1453 may be a method or process of forming male terminal assembly 1430. For example, centering means 1453 may not be a structure, but instead may be a co-printing of spring member 1440c into male terminal body 1472 in a manner that does not require assembly. In other words, centering means 1453 may take many forms (e.g., mechanical, force, or process-based) to achieve the goal of centering spring member 1440c within male terminal body 1472.

[0031] The inner spring member 1440c is typically formed from one piece of material (e.g., metal), and thus the spring member 1440c is either an integral spring member 1440c or has several integrally formed features. In particular, the following features are integrally formed: (i) the arched spring sections 1448a-1448d, (ii) the base spring sections 1450a-1450d, (iii) the spring arms 1452a-1452h, and (iv) the centering means 1453. To integrally form these features, the spring member 1440c is typically formed using a die forming process, which applies forces to mechanically shape the spring member 1440c. As described below and in further detail in PCT / US2019 / 036010, when spring member 1440c is formed from a flat metal sheet, mounted within male terminal 1472, and connected to female receptacle 4472, and exposed to high temperatures, spring member 1440c exerts an outward thermal spring force S on contact arms 1494a through 1494h due in part to the spring member attempting to return to a flat sheet. TFIt is to be understood, however, that other types of forming the spring member 1440c may be utilized, such as, for example, casting, or using an additive manufacturing process (e.g., 3D printing). In other embodiments, features of the spring member 1440c may not be formed from one piece, or may not be integrally formed, but instead may be formed from separate pieces that are welded together.

[0032] In alternative embodiments not shown, the spring member 1440c may include recesses and associated reinforcing ribs. As described in PCT / US2019 / 036010, these changes in the configuration of the spring member 1440c change the force associated with the spring 1440c. In particular, the spring bias force S BF is the magnitude of force exerted by the spring member 1440c to resist inward deflection of the free end 1446 of the spring member 1440c when the male terminal assembly 1430 is inserted into the female terminal assembly 4430. Specifically, this inward deflection occurs because the extent of the exterior surface of the male terminal body 1472 is slightly larger than the interior of the female receptacle 4472 during insertion of the male terminal assembly 1430. Thus, when the male terminal assembly 1430 is inserted into the female terminal assembly 4430, the extent of the exterior surface is forced toward the center 1490 of the male terminal 1470. This inward force against the exterior surface displaces the free end 1446 of the spring member 1440c inward (i.e., toward the center 1490). The spring member 1440c exerts a spring biasing force S BF This inward displacement is resisted by providing

[0033] [2.Male terminal] 2-7, 14-18, 20, 22, and 28-31 show a supply male terminal 1470 including a male terminal body 1472 and a male terminal connecting plate 1474. Specifically, the male terminal connecting plate 1474 is coupled to the male terminal body 1472 and configured to receive a range of structures (e.g., leads or wires) that connect the male terminal assembly 1430 to a device (e.g., an alternator) external to the connector system 100 (splice block system 10). The wires 1495 are typically welded to the connecting plate 1474, although other methods of connecting the wires 1495 to the connecting plate 1474 (e.g., forming the wires 1495 as part of the connecting plate 1474) are contemplated by the present disclosure.

[0034] As shown in Figures 2-7, 14-18, 20, 22, and 28-31, the male terminal sidewalls 1482a-1482d are joined together to form a generally rectangular prism. The male terminal sidewalls 1482a-1482d include (i) sidewall portions 1492a-1492d having a generally "U-shaped" configuration, (ii) contact arms 1494a-1494h, and (iii) a plurality of contact arm openings 1496a-1496l (1496c). As best shown in Figures 4-7, the sidewall portions 1492a-1492d are substantially planar and have a U-shaped configuration. The U-shaped configuration is formed from three substantially straight segments, a second or intermediate segment 1500a-1500d coupled at one end to a first or end segment 1498a-1498d and at the other end to a third or opposite end segment 1502a-1502d. The contact arms 1494a-1494h (i) extend from the intermediate segments 1500a-1500d of the side wall portions 1492a-1492d, (ii) extend away from the rear male terminal wall 1484, (iii) traverse the contact arm openings 1496a-1496l, and (iv) terminate just short of the front male terminal wall 1480. This configuration has advantages over the terminal configurations shown in Figures 9-15, 18, 21-31, 32, 41, 42, 45, 46, 48, and 50 in PCT / US2018 / 019787 because it allows: (i) The overall length can be shortened, i.e., less metal material is required to form the male terminal 1470, allowing it to be placed in tight, confined spaces. (ii) It has a large current carrying capacity. (iii) It is easy to assemble. (iv) Since the contact arms 1494a through 1494h are disposed inside the first male terminal sidewall portions 1492a through 1492d, structural rigidity is improved. (iv) has benefit of the disclosures in connection with PCT / US2019 / 036010. (v) have other beneficial features disclosed herein or that can be inferred by one skilled in the art from this disclosure.

[0035] As shown in Figures 16 and 28, the outer surfaces of the side wall portions 1492a-1492d, 2492a-2492d, 3492a-3492d are (i) substantially parallel to the inner surface of the side wall structure 115, and (ii) substantially perpendicular to the inner surface 110b of the bottom wall 110 and the inner cover surface 105c. Furthermore, the outer surfaces of the side wall portions 2492a, 3492a and the outer surfaces of the side wall portions 2492c, 3492c are substantially coplanar. Furthermore, the outer surfaces of the front male terminal walls 1480, 2480, 3480 are (i) substantially perpendicular to the inner surface of the side wall structure 115, and (ii) substantially parallel to the inner surface of the bottom wall 110 and the inner surface 105c of the cover 105a. It is further understood that the exterior surfaces of the front male terminal walls 1480, 2480, 3480 are substantially coplanar.

[0036] The contact arm openings 1496a-1496l are integrally formed in the intermediate portions 1500a-1500d of the male terminal side walls 1482a-1482d. The contact arm openings 1496a-1496l extend along the lateral length of the contact arms 1494a-1494h to form a configuration that allows the contact arms 1494a-1494h not to be laterally connected to (i) another contact arm 1494a-1494h, or (ii) structure outside the extent of the male terminal side wall portions 1492a-1492d to which the contact arms 1494a-1494h are mated. Additionally, the contact arm openings 1496a-1496l are aligned with the spring arm openings. This configuration of apertures creates the same number of spring arms 1452a through 1452h as the number of contact arms 1494a through 1494h. In other words, Figures 4 through 7 show eight spring arms 1452a through 1452h and eight contact arms 1494a through 1494h. It is understood that in other embodiments, the number of spring arms 1452a through 1452h may not match the number of contact arms 1494a through 1494h. For example, the number of spring arms 1452a through 1452h may be fewer.

[0037] The contact arms 1494a-1494h extend away from the rear male terminal wall 1484 at an outward angle. In particular, the outward angle may be between 0.1° and 16°, preferably between 5° and 12°, and most preferably between 7° and 8°, between the outer surface of the area of ​​the male terminal side walls 1492a-1492d and the outer surface of the first area of ​​the contact arms 1494a-1494h. This outward angle is shown in multiple figures, but can be best visualized in conjunction with Figures 7 and 10. This configuration allows the contact arms 1494a-1494h to be deflected or displaced inwardly by the female receptacle 4472 toward the center 1490 of the male terminal 1470 when the male terminal assembly 1430 is inserted into the female terminal assembly 4430. This inward deflection is best seen in Figure 31 and is made evident by the gap 1550. This inward deflection helps ensure that contact arms 1494a through 1494h are placed in contact with female receptacle 4472, thereby ensuring that a proper mechanical and electrical connection is made.

[0038] As shown in Figures 4-7, when the spring member 1440c is inserted into the spring receiver 1486, the terminal ends of the contact arms 1494a-1494h are (i) disposed within the openings formed by the U-shaped sidewall portions 1492a-1492d, (ii) disposed substantially parallel to the male terminal sidewall portions 1492a-1492d, and (iii) disposed in contact with / adjacent to the planar outer surfaces of the spring arms 1452a-1452h. This configuration is more beneficial than the configuration shown in Figures 3-8 of PCT / US2018 / 019787 because the assembler of the male terminal assembly 1430 does not need to apply as much force to deform the majority of the contact arms 1494a-1494h outward to accommodate the spring member 1440c. This necessary deformation can be best shown in FIG. 6 of PCT / US2018 / 019787 due to the inclination of the contact arm 11 and the outer surface of the spring arm 31 and the inner surface of the contact arm 11 being adjacent to each other without a gap formed therebetween. In contrast to FIGS. 3-8 of PCT / US2018 / 019787, FIG. 7 of the present application shows a small gap formed between the outer surface of the spring member 1440c and the inner surfaces of the contact arms 1494a-1494h. Thus, the force required to insert the spring member 1440c into the spring receiver 1486 is very small due to the fact that the assembler does not need to apply force to the contact arms 1494a-1494h to cause significant deformation during insertion of the spring 1440c.

[0039] The male terminal 1470 is typically formed from one piece of material (e.g., metal), and thus the male terminal 1470 is a unitary male terminal 1470 and has several features integrally formed therein. To integrally form these features, the male terminal 1470 is typically formed using a stamping process. However, it is understood that other types of forming the male terminal 1470 may be utilized, such as, for example, casting, or using an additive manufacturing process (e.g., 3D printing). In other embodiments, the features of the male terminal 1470 may not be formed from one piece or integrally formed, but may instead be formed from separate pieces that are welded together. It is understood that any number of contact arms 1494a-1494h (e.g., 1-100) may be formed in the male terminal 1470 when forming the male terminal 1470.

[0040] [3. Positioning of the spring member inside the male terminal body] The positioning of the internal spring member 1440c in the male terminal assembly 1430 is performed in multiple steps or stages. DC 5 shows a first embodiment of a male terminal assembly 1430 in a partially coupled state S PC 6 shows a first embodiment of a male terminal assembly 1430 in a fully mated state S FC4 shows a first embodiment of the male terminal assembly 1430. The first stage of assembling the male terminal assembly 1430 is shown in FIG. 4, where the front male terminal wall 1480 is in an open or flat position Po and the spring member 1440c is separated from the male terminal 1470. In this open position Po, the front male terminal wall 1480 is substantially flush with the male terminal side wall 1482c. This configuration of the male terminal 1470 exposes the spring receiver 1486 and prepares the male terminal 1470 to receive the spring member 1440c. The second stage of assembling the male terminal assembly 1430 is shown in FIG. 5, where the front male terminal wall 1480 remains in the open or flat position Po and the spring member 1440c is positioned or inserted into the spring receiver 1486. ​​To reach the inserted state, an insertion force F is applied to insert the spring member 1440c into the spring receiver 1486. I is applied to the spring member 1440c. An insertion force F is applied until the second or rear male terminal wall 1484 is disposed adjacent the rear spring wall 1444. I is applied to spring member 1440c. Free end 1488 of male terminal 1470 is substantially aligned with free end 1446 of spring member 1440c and portions of male terminal sidewalls 1482a-d are disposed adjacent portions of spring member sidewalls 1442a-d.

[0041] The third stage of assembling the male terminal assembly 1430 is shown in Figure 6. (i) The front male terminal wall 1480 is closed or aligned vertically. CL and (ii) spring member 1440c is disposed within spring receiver 1486. ​​To close front male terminal wall 1480, an upward force Fu is applied to male terminal wall 1480, bending it at its seam and disposing it adjacent side walls 1482a-d. After front male terminal wall 1480 is in position, the upper edge is bonded (e.g., welded) to side walls 1480 of male terminal body 1472. Front male terminal wall 1480 is now closed or aligned vertically P CLThe presence of the spring member 1440c ensures that the spring member 1440c is retained within the male terminal 1470. It is to be understood that in other embodiments, the front male terminal wall 1480 may be omitted, may not have a touchproof post opening therethrough, may not extend entirely from the side walls 1482a-d (e.g., may extend partially from any of the side walls 1482a-d), or may be a separate piece coupled to both side walls 1482a-d.

[0042] [4. Strain relief assembly] The strain relief assembly 1800 includes several components, such as a strain relief cap 1810, that are designed to relieve strain resulting from the connection between the male terminal assembly 1430 and the wire 1495. Additional details regarding this strain relief assembly are disclosed in PCT / US2019 / 36070, which is incorporated herein by reference in its entirety.

[0043] [IV. Receiving Male Connector Assembly] The second or receiving male connector assembly 2000 and the third or receiving male connector assembly 3000 receive electrical current and mainly include (i) receiving male terminal assemblies 2430, 3430 and (ii) strain relief assemblies 2800, 3800. As shown in Figs. 2, 14 to 18, 22, 28 and 29, the receiving male terminal assemblies 2430, 3430 have the same configuration as the supplying male terminal assembly 1430. As such, it is understood that since similar structures have similar numbers, the reference numbers shown in the drawings may be omitted from the specification for simplicity. For example, the disclosure regarding the spring member 1440c is not repeated here, but applies to the spring members 2440c, 3440c as if repeated here. In other words, the omission of a reference number from the specification or the omission of a specific disclosure of the functionality of the structure shall not limit the disclosure of the present application. Instead, reference is made to disclosures of similar structures that may be described in other sections of this application or in other applications incorporated herein by reference.

[0044] While the male terminal assemblies 1430, 2430, 3430 are shown to have the same configuration, it is understood that in other embodiments, the male terminal assemblies 1430, 2430, 3430 may have different configurations. The male terminal assemblies may be any of the terminal assemblies disclosed in, for example, PCT applications PCT / US18 / 019787, PCT / US19 / 036010, PCT / US21 / 43788, PCT / US21 / 47180, PCT / US21 / 43686, PCT / US22 / 37508, PCT / US20 / 49870, PCT / IB22 / 61786, PCT / EP22 / 25551. As discussed above and shown herein, there may be multiple receiving male terminal assemblies 2430, 3430 coupled to a single supplying male terminal assembly 1430. Alternatively, a single receiving male terminal assembly may be coupled to multiple supplying male terminal assemblies 1430. The receiving male terminal assemblies 2430, 3430 may be coupled to a bus bar or any other type of electrical transmission member.

[0045] [V. Counterpart Assembly] The mating assembly 4000 of the system 10 is designed to electrically couple the male connector assemblies 1000, 2000, 3000 in a connected state Sc. Generally referring to Figs. 8 to 13, the mating assembly 4000 mainly includes (i) an internal female housing assembly 4010, (ii) a plurality of female terminal assemblies 4430, 4530, 4630, and (iii) an internal current distribution component, such as a bridge 4800, configured to electrically couple the female terminal assemblies 4430, 4530, 4630 to each other. To facilitate the electrical coupling of the male connector assemblies 1000, 2000, 3000, the mating assembly 4000, i.e., the internal female housing assembly 4010, is directly coupled to the upper region 105, i.e., the lid 105a, of the external housing 100. The above-mentioned mating assembly 4000 is designed to be placed in the external housing 100 in a connected state Sc. It is to be understood that in other embodiments, the mating assembly 4000 may not be affixed to the upper area 105 or lid 105a of the outer housing 100 (i.e., is a separate piece).

[0046] The internal female housing assembly 4010 includes a bridge housing 4116 and is designed to (i) receive and secure the female terminal assemblies 4430, 4530, 4630, (ii) facilitate mating of the male terminal assembly 1430 with the female terminal assemblies 4430, 4530, 4630, (iii) minimize the opportunity for foreign objects to inadvertently contact the female terminal assemblies 4430, 4530, 4630, and (iv) meet industry standards such as USCAR specifications. In the drawings, the internal female housing assembly 4010 includes a three-part wall structure 2110 (i.e., receivers 4121, 4122, 4123) having twelve integrally formed side walls 4112a-4112l. The side walls 4112a-4112l extend upwardly from the top surface 4116a of the bridge housing 4116 to form receivers having a configuration that substantially matches the configuration of each of the female terminal assemblies 4430, 4530, 4630. In the embodiment shown in the drawings, the female terminal assemblies 4430, 4530, 4630 have a cubical configuration and therefore the side walls 4112a-4112l have a linear configuration to form cubical receivers 4121, 4122, 4123. However, it is understood that a change in the shape of the female terminal assemblies 4430, 4530, 4630 (e.g., the use of cylindrical terminals) may require the shape and configuration of the side walls 4112a-4112l to more closely mirror the shape of the terminals (e.g., hollow cylinders).

[0047] As shown at least in Figures 8-20, the side walls 4112a-4112l have a height greater than the height of the female terminal assemblies 4430, 4530, 4630. The delta between these heights allows the side walls 4112a-4112l to include at least one male compression means 4140. With reference to Figures 9 and 10, the male compression means 4140 is a sloped or inclined compression surface 4144 that extends from the outermost edges 4120a-4120l of the side walls 4112a-4112l to the top edges 4437a-4437d, 4438a-4438d, 4439a-4439d of the female terminal assemblies 4430, 4530, 4630. In the disclosed embodiment, the sloped or inclined surface 4144 extends from each of the outermost edges 4120a-4120l and has a substantially linear configuration. However, it is to be understood that the slope or inclined surface 4144 may simply extend from one or two of the outermost edges 4120a-4120l. DCONThe male compression means 4140 and slope or inclined surface 4144 shown in the drawings are designed to compress the contact arms 1494a-1494h, 2494a-2494h, 3494a-3494h when moving from a disconnected state from the female terminal assembly 4430, 4530, 4630 at Sc to a connected state Sc within the range of the female terminal assembly 4430, 4530, 4630 by application of sufficient coupling force Fc (see Figs. 1 and 19-31). Thus, the distance between the opposing outermost edges 4120a-4120l is equal to a sidewall distance that is greater than the rearmost edge distance extending between the opposing rearmost edges 4124a-4124l of the slope or inclined surface 4144. The rearmost edge distance is equal to or greater than the receiver distance extending between the opposing inner surfaces of the receptacles 4472, 4473, 4474 of the female terminal assemblies 4430, 4530, 4630. In particular, the sidewall distance is 0.1% to 15% greater than the receiver distance, and the receiver distance is equal to the rearmost edge distance or 0.1% to 3% greater than the rearmost edge distance. In other words, the slope or inclined surface 4144 is angled with respect to the outer surfaces of the sidewalls 4112a to 4112l and / or the inner surfaces of the receptacles 4472, 4473, 4474 of the female terminal assemblies 4430, 4530, 4630. In particular, the interior angle extending between the inner surface of the slope or inclined surface 4144 and the outer surface of the sidewalls 4112a to 4112l is between 0.1° and 10°.

[0048] The slope or inclined surface 4144 is made from a polymer or plastic material and therefore has a lower coefficient of friction than that associated with a metal surface. In other words, a first friction value is created when a range of the male terminal assembly 1430, 2430, 3430 (e.g., contact arms 1494a-1494h, 2494a-2494h, 3494a-3494h) engages with a male terminal compression means 4140 formed from a non-metallic material (e.g., plastic). In an alternative embodiment, a second friction value is created when a range of the male terminal assembly 1430, 2430, 3430 (e.g., contact arms 1494a-1494h, 2494a-2494h, 3494a-3494h) attempts to engage with a male terminal compression means formed from a metallic material (e.g., copper). It is to be understood that by comparing the friction values, the first friction value is less than the second friction value.

[0049] The lower coefficient of friction reduces the force required to insert the male terminal assembly 1430, 2430, 3430 into the female terminal assembly 4430, 4530, 4630. This is beneficial to the performance of the system 10 because (i) industry specifications, including USCAR25, require that the insertion force cannot be greater than 45 Newtons for Class 2 connectors and 75 Newtons for Class 3 connectors, and (ii) it is desirable to use a higher spring bias force to increase the insertion force to help ensure that the contact arms of the male terminal assembly remain in contact with the inner surface of the receptacle 4472, 4473, 4474 of the female terminal assembly 4430, 4530, 4630. Additionally, this lower coefficient of friction allows the system 10 to be in the disconnected state S while meeting USCAR Class 2 / Class 3 specifications without the need for a handle or lever assist. DCONAdvantageously, the system 10 can be moved from engaged state Sc to engaged state Sc by removing the handle or lever assist. The elimination of the handle or lever assist reduces the size, weight, and manufacturing costs of the system 10. It is to be understood that to further reduce the coefficient of friction, the slope or inclined surface 4144 may be coated with a substance that further reduces the coefficient of friction, or the slope or inclined surface 4144 may be made from a material that has an even lower coefficient of friction.

[0050] The configuration of the male connector assemblies 1000, 2000, 3000 and the mating assembly 4000 places the system 10 in a disconnected state S DCONWhen moving from the connected state Sc to the connected state Sc, the coupling force Fc includes multiple components that are primarily due to the different sliding engagements. For example, a first force component of the coupling force Fc is required to move the male terminal assembly 1430, 2430, 3430 when the range of the male terminal assembly 1430, 2430, 3430, i.e., the contact arms 1494a-1494h, 2494a-2494h, 3494a-3494h, are in sliding engagement with the male terminal compression means 4140. When the range of the male terminal assemblies 1430, 2430, 3430, i.e., the contact arms 1494a-1494h, 2494a-2494h, 3494a-3494h, are positioned in the female terminal receptacles 4472, 4473, 4474, a second force component of the mating force Fc is required to move the male terminal assemblies 1430, 2430, 3430. Due to the structural and positional configuration of the system 10, the magnitude of the second force component of the mating force Fc is less than the magnitude of the first force component of the mating force Fc. The difference in magnitude between the first and second force components of the mating force Fc is beneficial because it provides tactile feedback to the user / operator / installer that notifies the user / operator / installer that each of the male terminal assemblies 1430, 2430, 3430 is properly seated within the respective female terminal assemblies 4430, 4530, 4630. In effect, this tactile feedback gives the user / operator / installer the impression that the male terminal assembly 1430, 2430, 3430 is being pulled further into the housing 110 or toward the female terminal assembly 4430, 4530, 4630. This facilitates proper connection. Additional information regarding the components of the coupling force Fc is disclosed in PCT / US19 / 036010, which is also incorporated herein by reference in its entirety.

[0051] The female terminal assemblies 4430, 4530, 4630 of the mating assembly 4000 include a female terminal body including a plurality of side walls 4431a through 4431d, 4432a through 4432d, 4433a through 4433d integrally formed with rear walls 4434, 4435, 4436. Each of the side walls 4431a through 4431d, 4432a through 4432d, 4433a through 4433d and the rear walls 4434, 4435, 4436 has an inner surface, and in combination they form cubical terminal receptacles 4472, 4473, 4474. These cubic terminal receptacles 4472, 4473, 4474 have a receiver distance extending between the inner surfaces of the opposing side walls 4431a-4431d, 4432a-4432d, 4433a-4433d. As discussed above, the receiver distance is (i) less than the side wall distance and (ii) equal to or greater than the rearmost edge distance. Additionally, the receiver distance is 0.1% to 15% less than the male terminal assembly distance extending between the outermost extents of the opposing contact arms 1494a-1494h, 2494a-2494h, 3494a-3494h. Forming the terminal receptacles 4472, 4473, 4474 with a receiver distance less than the male terminal assembly distance ensures that the contact arms 1494a through 1494h, 2494a through 2494h, 3494a through 3494h are compressed when the male terminal assembly 1430, 2430, 3430 is inserted into the female terminal assembly 4430, 4530, 4630. This compression of the male terminal assembly 1430, 2430, 3430 further leads to compression of the internal spring members 1440c, 2440c, 3440c. Thus, to facilitate electrical and mechanical coupling between the male terminal assemblies 1430, 2430, 3430 and the female terminal assemblies 4430, 4530, 4630, the spring members 1440c, 2440c, 3440c exert an outward biasing force on the contact arms 1494a through 1494h to help ensure that the contact arms 1494a through 1494h remain in reliable contact with the inner surfaces of the terminal receptacles 4472, 4473, 4474.

[0052] As shown in Figures 16 and 28, the outer surfaces of the side walls 4431a-4431d, 4432a-4432d, 4433a-4433d are (i) substantially parallel to the inner surface of the side wall structure 115, and (ii) substantially perpendicular to the inner surface 110b of the bottom wall 110 and the cover 105a. Furthermore, the outer surfaces of the side walls 4432a, 4433a and the outer surfaces of the side walls 4432c, 4433c are substantially coplanar. Furthermore, the outer surfaces of the rear walls 4434, 4435, 4436 are (i) substantially perpendicular to the inner surface of the side wall structure 115, and (ii) substantially parallel to the inner surface 110b of the bottom wall 110 and the inner surface 105c of the cover 105a. Furthermore, it is to be understood that the outer surfaces of the rear walls 4434, 4435, 4436 are substantially coplanar.

[0053] The female terminal assemblies 4430, 4530, 4630 are typically formed from a metal, preferably a highly conductive metal such as copper. The female terminal assemblies 4430, 4530, 4630 may be plated or clad with Ni-Ag. As shown in the drawings, the side walls 4431a-4431d, 4432a-4432d, 4433a-4433d are not integrally formed with each other, but instead are only integrally formed with the rear walls 4434, 4435, 4436. In other embodiments, the female terminal assemblies 4430, 4530, 4630 may have integrally formed side walls 4431a through 4431d, 4432a through 4432d, 4433a through 4433d, the side walls 4431a through 4431d, 4432a through 4432d, 4433a through 4433d may be formed from different materials, and / or the female terminal assemblies 4430, 4530, 4630 may not be plated or clad with Ni-Ag.

[0054] The bridge or bus 4800 has a substantially coplanar configuration and is designed to electrically interconnect the female terminal assemblies 4430, 4530, 4630 with one another. The bridge 4800 is coupled to the rear walls 4434, 4435, 4436 of the female terminal assemblies 4430, 4530, 4630 and indirectly attached to the inner surface 105c of the cover 105a. The bridge 4800 is made of a conductive material (e.g., copper). The bridge 4800 is disposed within a bridge housing 4116, which is configured to separate the bridge 4800 from the outer housing 100.

[0055] [VI. Terminal Characteristics and Functions] FIG. 31 shows a cross section of the male connector assembly 1000 coupled to a mating assembly 4000 in a connected state Sc. The male terminal body 1472 including the contact arms 1494a-1494d may be formed from a first material, such as copper, a high conductivity copper alloy (e.g., C151 or C110), aluminum and / or other suitable conductive material. The first material preferably has an electrical conductivity of 80% or more of the IACS (International Annealed Copper Standard, i.e., an empirically derived standard value for the electrical conductivity of commercially available copper). For example, C151 typically has a conductivity of 95% of standard pure copper according to the IACS. Similarly, the conductivity of C110 is 101% of the IACS. In certain operating environments or technical applications, it may be preferable to select C151 because it has corrosion resistance properties that are desirable for the high stress and / or harsh weather applications in which the system 10 is installed and used. The first material for the male terminal body 1472 is C151, which is reported according to ASTM B747 standard to have a modulus of elasticity (Young's modulus) of approximately 115 to 125 GPa (gigapascals) at room temperature and a coefficient of terminal expansion (CTE) of 17.6 ppm / °C (from 20 to 300°C) and 17.0 ppm / °C (from 20 to 200°C).

[0056] The spring member 1440c may be formed from a second material, such as spring steel, stainless steel (e.g., 301SS, 1 / 4 hard), and / or other suitable material having a 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 that of the first material. Furthermore, the second material has a Young's modulus that may be about 193 GPa at room temperature and a terminal coefficient of expansion (CTE) of 17.8 ppm / °C (from 0 to 315°C) and 16.9 ppm / °C (from 0 to 100°C). In the envisioned high voltage application, the cross-sectional area of ​​the copper alloy forming the first connector 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-1494d formed therefrom have a larger cross-sectional area to adequately conduct electricity. Similarly, selecting a first material having a higher electrical conductivity may allow the contact arms 1494a-1494d to have a relatively small cross-sectional area while still meeting the electrical conductivity specification.

[0057] 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 the spring member 1440c is greater than the CTE of the male terminal body 1472. Thus, when the assembly of the male terminal body 1472 and the spring member 1440c is exposed to a high voltage and high temperature environment typical of the use of the electrical connectors described in the present disclosure, the spring member 1440c will expand (expand) relatively more than the male terminal body 1472. Thus, the outward biasing force S generated by the spring member 1440c against the contact arms 1494a-1494d of the male terminal body 1472 will be BF increases with increasing temperature, and is referred to as the thermal spring force S TF It is called.

[0058] An exemplary installation of the system 10 is as a vehicle alternator in a Class 5 automotive environment such as found in passenger cars and commercial vehicles. Class 5 environments are often found under the hood of a car and can experience ambient temperatures of 150°C and routinely reach 200°C. When copper and / or highly conductive copper alloys are exposed to temperatures above 150°C, they become malleable and lose mechanical resilience. That is, the copper material softens. However, the steel from which the spring member 1440c is formed retains its hardness and mechanical properties when exposed to similar conditions. Thus, when both the male terminal body 1472 and the spring member 1440c are exposed to high temperatures, the first material of the male terminal body 1472 softens and the structural integrity of the spring member 1440c formed from the second material is maintained. As a result, the force applied to the softened contact arms 1494a through 1494d by the spring member 1440c more effectively displaces the softened contact arms 1494a through 1494d outwardly relative to the interior of the male terminal body 1472 in the connected state Sc.

[0059] In the connected state Sc, one or more of the exterior surfaces of the spring arms 1452a-1452d contact the free ends 1488 of the respective contact arms 1494a-1494d. As noted above, the outermost extents of the contact arms 1494a-1494d are slightly larger than the inner extent of the female terminal body. As a result, the spring member 1440c is compressed when these components are mated together. This compression of the spring member 1440c creates an outward biasing force S against the contact arms 1494a-1494d, away from the interior of the spring member 1440c. BF This configuration is designed to maintain conductive 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 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 exerted by the male terminal body 1472 on the female terminal body. The configuration of the male terminal body 1472, spring member 1440c, and the female terminal body increases the outward connection force therebetween.

[0060] Based on the above exemplary embodiment, the Young's modulus and CTE of the spring member 1440c are both greater than the Young's modulus and CTE of the male terminal body 1472. Thus, if the male terminal body 1472 is used in a high power application that subjects the system 10 to repeated thermal cycles at high temperatures (e.g., about 150° C.), (i) The male terminal body 1472 becomes malleable and loses some mechanical resilience, ie, the copper material in the male terminal body 1472 softens. (ii) the spring member 1440c is less malleable and loses less mechanical stiffness than the male terminal body 1472;

[0061] Thus, when a mechanically cold formed (e.g., using a die forming process) spring member 1440c is utilized, and the spring member 1440c is exposed to high temperatures, the spring member 1440c will attempt to return to at least its uncompressed state that occurs prior to the insertion of the male terminal assembly 1430, 2430, 3430 into the female terminal assembly 4430, and preferably to its original flat state that occurs prior to the formation of the spring member 1440c. In doing so, the spring member 1440c exerts a generally outward thermal spring force S on the free ends 1488 of the contact arms 1494a-1494d. TF (See Figure 31 for "S TF This thermal spring force S TF is dependent on the local temperature conditions, including hot and / or cold, in the environment in which the system 10 is installed. Thus, the spring bias force S BF and thermal spring force S TF The combination of these results in a force S F When the male terminal assembly 1430, 2430, 3430 is inserted into the female terminal 4430, and during operation of the system 10, the outer surfaces of the contact arms 1494a-1494d are driven or forced into contact with the inner surface of the female terminal body 2434 by a resultant biasing force S. FFurther, in the event of repeated thermal cycling events, the male terminal assemblies 1430, 2430, 3430 will withstand the outward spring bias S applied to the female terminal assemblies 4430, 4530, 4630 during repeated operation of the system 10. F Increase the

[0062] As further shown in FIG. 31, in the connected state Sc, the male terminal assembly 1430, 2430, 3430 provides 360° compliance to the female terminal assembly 4430, ensuring that a sufficient amount of outward force F is applied by the male terminal assembly 1430, 2430, 3430 to the female terminal assembly 4430 for electrical and mechanical connection in all four primary directions. This attribute allows the elimination of keying features and / or other structural features designed to ensure a desired orientation of the components during connection. Furthermore, the 360° compliance attribute of the system 10 helps maintain mechanical and electrical connection under severe mechanical conditions such as vibration. In conventional blade or fork connectors having a 180° compliance configuration, i.e., connectors that connect only on two opposing sides, vibration can cause harmonic resonances that cause the 180° compliant connector to oscillate at a certain frequency with a larger amplitude. For example, applying harmonic resonances to a fork connector can cause the fork connector to open. The opening of a forked connector during electrical conduction is undesirable because momentary mechanical separation of the forked connector from its associated terminal can result in electrical arcing. Arcing can have serious detrimental effects on not only the 180° oriented terminals, but also the entire electrical system of which the 180° oriented terminals are components. However, the 360° oriented feature of the present disclosure prevents problematic failure of the system 10 caused by strong vibrations and electrical arcing.

[0063] [VII. Other Related Information] System 10 is T4 / V4 / S3 / D2 / M2 compliant, where system 10 meets and exceeds the following conditions: (i) T4 is exposing system 10 to 150°C, (ii) V4 is severe vibration, (iii) S3 is high pressure spray sealed, (iv) D2 is a durability of 200,000 miles, and (v) M2 is requiring less than 45 Newtons of force to connect male terminal assembly 1430, 2430, 3430 to female terminal assembly 4430, 4530, 4630. In addition to being T4 / V4 / S3 / D2 / M2 compliant, system 10 is Push, Click, Tag (PCT) compliant, with additional information regarding this standard being disclosed in PCT / US2020 / 049870.

[0064] It is to be understood that the male terminal assemblies 1430, 2430, 3430 and female terminal assemblies 4430, 4530, 4630 disclosed herein may be replaced with the male and female terminal assemblies disclosed in PCT / US18 / 019787, PCT / US19 / 036010, PCT / US21 / 43788, PCT / US21 / 47180, PCT / US21 / 43686, PCT / US22 / 37508, PCT / US20 / 49870, PCT / IB22 / 61786, PCT / EP22 / 25551, or any other terminals known in the art (e.g., RADSOK, blade, etc.). Additionally, other performance specifications for the system 10 disclosed herein will be apparent to those skilled in the art.

[0065] It is further understood that the male terminal assembly may have any number of contact arms 1494, 2494, 3494 (e.g., between 2 and 100, preferably between 2 and 50, and most preferably between 2 and 8) and any number of spring arms 1452, 2452, 3452 (e.g., between 2 and 100, preferably between 2 and 50, and most preferably between 2 and 8). As noted above, the number of contact arms 1494, 2494, 3494 does not have to be equal to the number of spring arms. For example, the number of contact arms 1494, 2494, 3494 may be greater than the number of spring arms 1452, 2452, 3452. Or, the number of contact arms 1494, 2494, 3494 may be less than the number of spring arms 1452, 2452, 3452.

[0066] [Materials and disclosures incorporated by reference] PCT application PCT / EP2022 / 025574, PCT / IB2022 / 061786, PCT / EP2022 / 025551, PCT / US2022 / 037508, PCT / IB2022 / 0577 72,PCT / US2021 / 057959,PCT / US2021 / 047180,PCT / US2021 / 043788,PCT / US2021 / 043686,PCT / US2021 / 033446, Nos. PCT / US2020 / 050018, PCT / US2020 / 049870, PCT / US2020 / 014484, PCT / US2020 / 013757, PCT / US2019 / 036127, PCT / US2019 / 036070, PCT / US2019 / 036010, and PCT / US2018 / 019787, U.S. Patent Application No. 16 / 194,891, and U.S. Provisional Application No. 63 / 308,488, each of which is fully incorporated by reference herein and made a part hereof.

[0067] SAE Specification: J1742 201003, entitled "Connections - Test Methods and General Performance Requirements for High Voltage Automotive Electrical Harnesses" (last revised March 2010), which is hereby incorporated by reference in its entirety and made a part hereof.

[0068] ASTM specifications, i.e. (i) D4935-18, entitled "Standard Test Method for Measuring the Electromagnetic Shielding Effectiveness of Planar Materials"; and (ii) ASTM D257, entitled "Standard Test Method for DC Resistance or Conductance of Insulating Materials" and each of which is fully incorporated by reference herein and made a part hereof.

[0069] The specifications of the American National Standards Institute and / or the EOS / ESD Association, Inc., including ANSI / ESD STM11.11, Measurement of Surface Resistance of Static Dissipative Planar Materials, are each fully incorporated herein by reference and made a part hereof.

[0070] DIN Specification (Connectors for Electronic Equipment - Tests and Measurements - Part 5-2: Current-Carrying Capacity Tests; Test 5b: Current-Temperature Derating (IEC 60512-5-2:2002), which is fully incorporated herein by reference and made a part hereof.

[0071] USCAR specifications, i.e. (i) SAE / USCAR-2, Revision 6, last revised February 2013, ISBN: 978-0-7680-7998-2, (ii) SAE / USCAR-12, Revision 5, last revised August 2017, ISBN: 978-0-7680-8446-7, (iii) SAE / USCAR-21, Revision 3, last revised in December 2014; (iv) SAE / USCAR-25, Revision 3, Revised March 2016, ISBN: 978-0-7680-8319-4, (v) SAE / USCAR-37, revised in August 2008, ISBN: 978-0-7680-2098-4, (vi) SAE / USCAR-38, Revision 1, Revised in May 2016, ISBN: 978-0-7680-8350-7, each of which is fully incorporated by reference herein and made a part hereof.

[0072] IEC 60529:1989+A1:1999+A2:2013, applicable to the classification of the degree of protection provided by enclosures for electrical equipment having a rated voltage not exceeding 72,5 kV, revised January 2019, which is incorporated herein by reference in its entirety and made a part hereof.

[0073] Other standards, including Federal Test Standards 101C and 4046, are each fully incorporated by reference herein and made a part hereof.

[0074] [Industrial applicability] Although several implementations have been illustrated and described, numerous modifications are envisioned without significantly departing from the spirit of the present 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, a pentagonal prism, a hexagonal prism, an octagonal prism, a sphere, a cone, a tetrahedron, a cube, a dodecahedron, an icosahedron, an octahedron, an ellipsoid, or any other similar shape.

[0075] As used herein, the following terms shall be understood to mean broadly the following: a. "High power" shall mean (i) a voltage between 20 volts and 600 volts, regardless of current, or (ii) a current of 80 amperes or more, regardless of voltage. b. "High current" means currents of 80 amps or more, regardless of voltage. c. "High voltage" means a voltage between 20 volts and 600 volts, regardless of current.

[0076] Headings and subheadings, if any, are used merely for convenience and are not limiting. The word exemplary is used to mean serving as an example or illustration. To the extent that terms such as including, having, and the like are used, such terms are intended to be inclusive in a similar manner to the term "comprising," as "comprising" 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 act from another, but do not necessarily require or imply any actual relationship or order between such entities or acts.

[0077] Phrases such as aspect, relevant aspect, another aspect, some aspects, one or more aspects, implementation, relevant implementation, another implementation, some implementation, one or more implementations, embodiment, relevant embodiment, another embodiment, some embodiments, one or more embodiments, configuration, relevant configuration, another configuration, some configuration, one or more configurations, subject technology, disclosure, the present disclosure, other variations thereof, and similar expressions are for convenience and do not imply that the disclosure associated with such phrase(s) is essential to the subject technology or that such disclosure applies to all configurations of the subject technology. The disclosure associated with such phrase(s) may apply to all configurations or to one or more configurations. The disclosure associated with such phrase(s) may provide one or more examples. Phrases such as aspect and some aspects may refer to one or more aspects and vice versa. This applies to the other phrases mentioned above as well.

[0078] Numerous variations to the present disclosure will become apparent to those skilled in the art in light of the foregoing description. Preferred embodiments of the present disclosure are described herein, including the best mode known to the inventors for carrying out the disclosure. It is to be understood that the illustrated embodiments are illustrative only and are not intended to limit the scope of the present disclosure.

Claims

1. 1. A splice block system for use in an electrical distribution system, comprising: an outer housing having a removable cover; a mating assembly coupled to the removable cover, the mating assembly including a first female terminal assembly, a second female terminal assembly, and a third female terminal assembly; a first male connector assembly having a first male terminal assembly; a second male connector assembly having a second male terminal assembly; a third male connector assembly having a third male terminal assembly; Splice block system in disassembled state S ＤＡ From the fully assembled state S ＦＡ To move to the Ｐ is applied to each of the first male terminal assembly, the second male terminal assembly, and the third male terminal assembly, The splice block system is in the disconnected state S ＤＣＯＮ to connection status S ＣＯＮ In order to move the positioning force F Ｐ a bonding force Fc directed substantially perpendicular to said removable cover is applied to said removable cover, The connection state S ＣＯＮ (i) a range of the first male terminal assembly is positioned within the first female terminal assembly, (ii) a range of the second male terminal assembly is positioned within the second female terminal assembly, and (iii) a range of the third male terminal assembly is positioned within the third female terminal assembly. Splice block system.

2. The splice block system of claim 1 , wherein the first female terminal assembly includes a sidewall disposed substantially perpendicular to the removable cover.

3. The first male terminal assembly is in the connected state S ＣＯＮ The splice block system of claim 1 , further comprising a front wall disposed substantially parallel to said removable cover at said first and second ends.

4. The first male terminal assembly is in the connected state S ＣＯＮ The splice block system of claim 1 , further comprising a side wall disposed substantially perpendicular to said removable cover at said first end.

5. The connection state S ＣＯＮ the first female terminal assembly includes a sidewall disposed substantially parallel to a sidewall of the first male terminal assembly; The splice block system of claim 1 , wherein said side walls of said first female terminal assembly and said first male terminal assembly are disposed perpendicular to said removable cover.

6. The splice block system of claim 1 , wherein the mating assembly includes an inner female housing assembly coupled to the removable cover.

7. The inner female housing assembly comprises: (i) a first receiver having a cubical configuration and configured to receive the first female terminal assembly; (ii) a second receiver having a cubical configuration and configured to receive the second female terminal assembly; and 7. The splice block system of claim 6, further comprising: (iii) a third receiver having a cubical configuration and configured to receive the third female terminal assembly.

8. The splice block system of claim 6 , wherein said internal female housing assembly includes a male compression means.

9. When the splice block system is in the disconnected state S ＤＣＯＮ to the connection state S ＣＯＮ 9. The splice block system of claim 8, wherein said male compression means compresses an area of ​​said first male terminal assembly, said second male terminal assembly, and said third male terminal assembly when moved to said male compression means.

10. The splice block system of claim 8 , wherein said male compression means includes a compression surface, and an angle is formed between said compression surface and an exterior surface of said inner female housing assembly.

11. The splice block system of claim 10, wherein the angle is between 1° and 10°.

12. 2. The splice block system of claim 1, wherein the mating assembly includes a bridge, the bridge having a substantially planar configuration and configured to electrically interconnect the first, second and third terminal assemblies with one another.

13. The splice block system of claim 12 , wherein the mating assembly further comprises a bridge housing positioned between the bridge and the removable cover.

14. The disconnected state S ＤＣＯＮ to the connection state S ＣＯＮ 14. The splice block system of claim 1, wherein the coupling force Fc required to move to is less than 45 Newtons.

15. 14. The splice block system of claim 1, wherein the coupling force Fc meets USCAR Class 2 connector specifications.

16. The disconnected state S ＤＣＯＮ to the connection state S ＣＯＮ 14. The splice block system of claim 1, wherein the coupling force Fc required to move to is less than 75 Newtons.

17. 14. The splice block system of claim 1, wherein the coupling force Fc meets USCAR Class 3 connector specifications.

18. 14. The splice block system of claim 1, wherein the coupling force Fc has (i) a first force component and (ii) a second force component different from the first force component.

19. The splice block system of claim 18 , wherein a force associated with the first force component of the coupling force Fc is greater than a force associated with the second force component of the coupling force Fc.

20. 20. The splice block system of claim 18, wherein a difference between the first force component and the second force component provides tactile feedback to a user, the tactile feedback informing the user that each of the first, second and third male terminal assemblies is disposed within a respective one of the first, second and third female terminal assemblies.

21. The splice block system of claim 1 , wherein the first male terminal assembly includes a male terminal body having a receiver configured to receive a spring member.

22. 22. The splice block system of claim 21, wherein the first male terminal assembly includes a front wall, the front wall being movable from (i) an open position configured to receive the spring member within the receiver, to (ii) a closed position configured to secure the spring member within the receiver.

23. The first male terminal assembly includes: (i) a male terminal body having a rear wall; and (ii) a spring member having a rear wall; The first male terminal assembly is in a completely connected state S ＦＣ 14. The splice block system of claim 1, wherein the rear wall of the spring member is disposed adjacent the rear wall of the male terminal body when in the position indicated by arrows 14.

24. The first male terminal assembly includes: (i) a male terminal body having a contact arm with a free end; and (ii) a spring member having a spring arm; The first male terminal assembly is in a completely connected state S ＦＣ 14. The splice block system of claim 1, wherein the free ends of the contact arms abut against a planar surface of the spring arm when the contact arm is in a position such that the free ends abut against a planar surface of the spring arm.

25. the first male terminal assembly includes: (i) a male terminal body having a contact arm with an inner surface; and (ii) a spring member having a spring arm with an outer surface; The first male terminal assembly is in a completely connected state S ＦＣ 14. The splice block system of claim 1, wherein a gap is formed between an area of ​​the outer surface of the spring arm and the inner surface of the contact arm when the area of ​​the outer surface of the spring arm is at .

26. The first male terminal assembly includes: (i) a male terminal body having a contact arm; and (ii) a spring member having a spring arm; The connection state S ＣＯＮ 14. The splice block system of claim 1, wherein the spring arms of the spring member are configured to exert an outward spring biasing force on the contact arms of the first male terminal body.

27. The spring biasing force is the positioning force F Ｐ 27. The splice block system of claim 26, wherein the splice block is oriented substantially parallel to the

28. The spring biasing force is the positioning force F Ｐ 27. The splice block system of claim 26, wherein the splice block is oriented substantially perpendicular to the

29. 27. The splice block system of claim 26, wherein the spring bias force is oriented substantially perpendicular to the coupling force Fc.

30. The splice block system of claim 26 , wherein the spring bias force is oriented substantially parallel to the removable cover.

31. The first male terminal assembly includes: (i) a male terminal body having a contact arm; and (ii) a spring member having a spring arm with an anti-rotation protrusion; The connection state S ＣＯＮ 14. The splice block system of claim 1, wherein the anti-rotation projection of the spring arm is disposed adjacent an area of ​​a first of the male terminal bodies.

32. The first male terminal assembly includes: (i) a male terminal body having a contact arm formed on a side wall; and (ii) a spring member having a spring arm; 14. The splice block system of claim 1, wherein electrical current does not have to flow through the side walls to reach the contact arms.

33. The first male terminal assembly includes: (i) a male terminal body having a contact arm; and (ii) a spring member having a spring arm; The connection state S ＣＯＮ 14. The splice block system of claim 1, wherein the contact arm of the first male terminal assembly is sandwiched between the spring arm of the spring member and an inner surface of the first female terminal assembly.

34. 1. A splice block system for use in an electrical distribution system, comprising: an outer housing having (i) a sidewall structure and (ii) a bottom wall coupled to the sidewall structure; a first male connector assembly having a first male terminal assembly with a front wall; a second male connector assembly having a second male terminal assembly with a front wall; Fully assembled state S ＦＡ the first male terminal assembly and the second male terminal assembly are positioned within the outer housing, and the front walls of the first male terminal assembly and the second male terminal assembly (i) are substantially coplanar and (ii) are positioned substantially parallel to the extent of the bottom wall; Splice block system.

35. The first male terminal assembly is in a fully assembled state S ＦＡ 35. The splice block system of claim 34, further comprising a side wall disposed substantially perpendicular to the bottom wall.

36. The sidewall structure includes a sidewall disposed perpendicular to the bottom wall; The front wall of the first male terminal assembly is in a fully assembled state S ＦＡ 35. The splice block system of claim 34, wherein the outer housing is disposed substantially perpendicular to a side wall of the outer housing.

37. The sidewall structure includes a sidewall disposed perpendicular to the bottom wall; The first male terminal assembly is in a fully assembled state S ＦＡ 35. The splice block system of claim 34, further comprising a side wall disposed parallel to a side wall of the outer housing.

38. The first male terminal assembly includes a first sidewall and the second male terminal assembly includes a first sidewall; 35. The splice block system of claim 34, wherein the first side wall of the first male terminal assembly is coplanar with the first side wall of the second male terminal assembly.

39. 35. The splice block system of claim 34, wherein the first male terminal assembly includes a rear wall disposed substantially parallel to a bottom wall of the outer housing.

40. 35. The splice block system of claim 34, wherein the first male terminal assembly includes a connector plate disposed substantially parallel to a bottom wall of the outer housing.

41. 35. The splice block system of claim 34, wherein the first male terminal assembly includes: (i) a connector plate; and (ii) a rear wall coplanar with an extent of the connector plate and disposed substantially parallel to a bottom wall of the outer housing.

42. 35. The splice block system of claim 34, wherein the first male terminal assembly includes a rear wall substantially parallel to the front and bottom walls of the outer housing.

43. The splice block system of claim 34 , wherein the first male terminal assembly includes a male terminal body having a receiver configured to receive the spring member.

44. 44. The splice block system of claim 43, wherein the first male terminal assembly includes a front wall, the front wall being movable from (i) an open position configured to receive the spring member within the receiver to (ii) a closed position configured to secure the spring member within the receiver.

45. The first male terminal assembly includes: (i) a male terminal body having a rear wall; and (ii) a spring member having a rear wall; Male terminal assembly fully assembled state S ＦＡ 35. The splice block system of claim 34, wherein when in said position, a rear wall of said spring member is disposed adjacent a rear wall of said male terminal body.

46. The first male terminal assembly includes: (i) a male terminal body having a contact arm with a free end; and (ii) a spring member having a spring arm; Male terminal assembly fully assembled state S ＦＡ 35. The splice block system of claim 34, wherein when in the contact position, the free end of the contact arm abuts against a planar surface of the spring arm.

47. The first male terminal assembly includes: (i) a male terminal body having a contact arm with an inner surface; and (ii) a spring member having a spring arm with an outer surface; Male terminal assembly fully assembled state S ＦＡ 35. The splice block system of claim 34, wherein a gap is formed between an area of ​​an outer surface of the spring arm and an inner surface of the contact arm when the contact arm is at .

48. The first male terminal assembly includes: (i) a male terminal body having a contact arm formed on a side wall; and (ii) a spring member having a spring arm; 35. The splice block system of claim 34, wherein the electrical current does not have to flow through the sidewall to reach the contact arm.

49. 49. The splice block system of any one of claims 34-48, further comprising a mating assembly coupled to the removable cover and including a first female terminal assembly and a second female terminal assembly.

50. 50. The splice block system of claim 49, wherein the first female terminal assembly includes a sidewall disposed substantially perpendicular to the removable cover.

51. 50. The splice block system of claim 49, wherein the mating assembly includes an inner female housing assembly coupled to the removable cover.

52. The internal female housing assembly is (i) a first receiver having a cubical configuration and configured to receive a first female terminal assembly; (ii) a second receiver having a cubical configuration and configured to receive the second female terminal assembly; 52. The splice block system of claim 51, comprising: (iii) a third receiver having a cubical configuration and configured to receive the third female terminal assembly.

53. 50. The splice block system of claim 49, wherein the mating assembly includes a bridge, the bridge having a substantially planar configuration and configured to electrically interconnect the first and second terminal assemblies with one another.

54. 54. The splice block system of claim 53, wherein the mating assembly further comprises a non-conductive bridge housing positioned between the bridge and the removable cover.

55. The splice block system is in the disconnected state S ＤＣＯＮ to connection status S ＣＯＮ A binding force Fc is applied to the removable cover to move it to Connection status S ＣＯＮ 50. The splice block system of claim 49, wherein: (i) a range of the first male terminal assembly is positioned within the first female terminal assembly; and (ii) a range of the second male terminal assembly is positioned within the second female terminal assembly.

56. 56. The splice block system of claim 55, wherein the mating assembly includes a male compression means.

57. The splice block system is in the disconnected state S ＤＣＯＮ to connection status S ＣＯＮ 57. The splice block system of claim 56, wherein when moved to the male compression means compresses an area between the first male terminal assembly and the second male terminal assembly.

58. 57. The splice block system of claim 56, wherein the male compression means includes a compression surface, and an angle is formed between the compression surface and an outer surface of the mating assembly.

59. 60. The splice block system of claim 58, wherein the angle is between 1° and 10°.

60. Disconnected State S ＤＣＯＮ to connection status S ＣＯＮ 56. The splice block system of claim 55, wherein the coupling force Fc required to move to is less than 45 Newtons.

61. 56. The splice block system of claim 55, wherein coupling force Fc meets USCAR Class 2 connector specifications.

62. Disconnected State S ＤＣＯＮ to connection status S ＣＯＮ 56. The splice block system of claim 55, wherein the coupling force Fc required to move to is less than 75 Newtons.

63. 56. The splice block system of claim 55, wherein coupling force Fc meets USCAR Class 3 connector specifications.

64. 56. The splice block system of claim 55, wherein the coupling force Fc has (i) a first force component and (ii) a second force component different from the first force component.

65. 65. The splice block system of claim 64, wherein a force associated with a first force component of the coupling force Fc is greater than a force associated with a second force component of the coupling force Fc.

66. 65. The splice block system of claim 64, wherein a difference between the first force component and the second force component provides tactile feedback to a user, the tactile feedback notifying a user that each of the first and second male terminal assemblies is disposed within a respective first and second female terminal assemblies.

67. Connection status S ＣＯＮ the first female terminal assembly includes a sidewall disposed substantially parallel to a sidewall of the first male terminal assembly; 56. The splice block system of claim 55, wherein side walls of the first female terminal assembly and the first male terminal assembly are disposed perpendicular to the removable cover.

68. The first male terminal assembly includes: (i) a male terminal body having a contact arm; and (ii) a spring member having a spring arm; Connection status S ＣＯＮ 56. The splice block system of claim 55, wherein the spring arms of the spring member are configured to exert an outward spring biasing force on the contact arms of the first male terminal body.

69. 70. The splice block system of claim 68, wherein the spring bias force is directed substantially perpendicular to the coupling force Fc.

70. 70. The splice block system of claim 68, wherein the spring bias force is directed substantially parallel to the removable cover.

71. The first male terminal assembly includes: (i) a male terminal body having a contact arm; and (ii) a spring member having a spring arm with an anti-rotation protrusion; Connection status S ＣＯＮ 56. The splice block system of claim 55, wherein the anti-rotation projection of the spring arm is disposed adjacent an area of ​​the first male terminal body.

72. The first male terminal assembly includes: (i) a male terminal body having a contact arm; and (ii) a spring member having a spring arm; Connection status S ＣＯＮ 56. The splice block system of claim 55, wherein the contact arm of the first male terminal assembly is sandwiched between the spring arm of the spring member and an inner surface of the female terminal assembly.

73. Splice block system in disassembled state S ＤＡ From the fully assembled state S ＦＡ To move to the Ｐ The splice block system of claim 34 , wherein a is added to each of the first male terminal assembly and the second male terminal assembly.

74. Positioning force F Ｐ 74. The splice block system of claim 73, wherein the is substantially parallel to a bottom wall of the outer housing.

75. The sidewall structure includes a sidewall disposed perpendicular to the bottom wall; Positioning force F Ｐ 74. The splice block system of claim 73, wherein the is substantially perpendicular to a side wall of the outer housing.

76. The splice block system is in the disconnected state S ＤＣＯＮ to connection status S ＣＯＮ To move to the Ｐ a bonding force Fc directed substantially perpendicular to the removable cover is applied to the removable cover; Connection status S ＣＯＮ 74. The splice block system of claim 73, wherein: (i) a range of the first male terminal assembly is positioned within the first female terminal assembly; and (ii) a range of the second male terminal assembly is positioned within the second female terminal assembly.

77. The spring force is the positioning force F Ｐ 77. The splice block system of claim 76, wherein the splice block is oriented substantially parallel to the

78. The spring force is the positioning force F Ｐ 77. The splice block system of claim 76, wherein the splice block is oriented substantially perpendicular to the

79. 1. A splice block system for use in an electrical distribution system, comprising: an outer housing having a conductive cover; a mating assembly coupled to the cover; The mating assembly is (i) a first female terminal assembly; (ii) a second female terminal assembly; and (iii) a third female terminal assembly; and (iv) a bridge coupled to the first, second, and third female terminal assemblies and configured to electrically couple the first, second, and third female terminal assemblies to one another; (v) a non-conductive bridge housing positioned between the bridge and the cover and configured to substantially electrically isolate the bridge from the cover; Splice block system.

80. 80. The splice block system of claim 79, wherein the first female terminal assembly includes a sidewall disposed substantially perpendicular to the conductive cover.

81. The outer housing includes a sidewall.

80. The splice block system of claim 79, wherein the first female terminal assembly includes a sidewall disposed substantially parallel to the conductive cover when the conductive cover is coupled to the outer housing.

82. 80. The splice block system of claim 79, wherein the bridge has a substantially planar configuration.

83. 80. The splice block system of claim 79, wherein the mating assembly includes an inner female housing assembly coupled to the bridge housing.

84. The internal female housing assembly is (i) a first receiver having a cubical configuration and configured to receive a first female terminal assembly; (ii) a second receiver having a cubical configuration and configured to receive the second female terminal assembly; 84. The splice block system of claim 83, comprising: (iii) a third receiver having a cubical configuration, the third receiver configured to receive the third female terminal assembly.

85. 84. The splice block system of claim 83, wherein the internal female housing assembly includes a male compression means.

86. 86. The splice block system of claim 85, wherein the male compression means includes a compression surface, and an angle is formed between the compression surface and an exterior surface of the inner female housing assembly.

87. 87. The splice block system of claim 86, wherein the angle is between 1° and 10°.

88. moreover, a first male connector assembly having a first male terminal assembly; a second male connector assembly having a second male terminal assembly; 88. The splice block system of any one of claims 79 to 87, comprising a third male connector assembly having a third male terminal assembly.

89. 90. The splice block system of claim 88, wherein the first male terminal assembly includes a front wall disposed substantially parallel to the conductive cover.

90. 90. The splice block system of claim 88, wherein the first male terminal assembly includes a sidewall disposed substantially perpendicular to the conductive cover.

91. the first female terminal assembly includes a sidewall disposed substantially parallel to a sidewall of the first male terminal assembly; 90. The splice block system of claim 88, wherein a sidewall of the first female terminal assembly and the first male terminal assembly are disposed perpendicular to the conductive cover.

92. Splice block system in disassembled state S ＤＡ From the fully assembled state S ＦＡ To move to the Ｐ is added to each of the first male terminal assembly, the second male terminal assembly, and the third male terminal assembly, The splice block system is in the disconnected state S ＤＣＯＮ to connection status S ＣＯＮ To move to the Ｐ 90. The splice block system of claim 88, wherein the conductive cover is subjected to a coupling force Fc oriented substantially perpendicular to the conductive cover.

93. Connection status S ＣＯＮ 89. The splice block system of claim 88, wherein (i) a range of the first male terminal assembly is positioned within the first female terminal assembly, (ii) a range of the second male terminal assembly is positioned within the second female terminal assembly, and (iii) a range of the third male terminal assembly is positioned within the third female terminal assembly.

94. Disconnected State S ＤＣＯＮ to connection status S ＣＯＮ 89. The splice block system of claim 88, wherein the coupling force Fc required to move to is less than 45 Newtons.

95. 90. The splice block system of claim 88, wherein coupling force Fc meets USCAR Class 2 connector specifications.

96. Disconnected State S ＤＣＯＮ to connection status S ＣＯＮ 89. The splice block system of claim 88, wherein the coupling force Fc required to move to is less than 75 Newtons.

97. 90. The splice block system of claim 88, wherein coupling force Fc meets USCAR Class 3 connector specifications.

98. 90. The splice block system of claim 88, wherein the coupling force Fc has (i) a first force component and (ii) a second force component different from the first force component.

99. 100. The splice block system of claim 98, wherein a force associated with a first force component of the coupling force Fc is greater than a force associated with a second force component of the coupling force Fc.

100. 99. The splice block system of claim 98, wherein a difference between the first force component and the second force component provides tactile feedback to a user, the tactile feedback notifying a user that each of the first, second and third male terminal assemblies is disposed within a respective first, second and third female terminal assemblies.

101. 90. The splice block system of claim 88, wherein the first male terminal assembly includes a male terminal body having a receiver configured to receive the spring member.

102. 102. The splice block system of claim 101, wherein the first male terminal assembly includes a front wall, the front wall being movable from (i) an open position configured to receive the spring member within the receiver to (ii) a closed position configured to secure the spring member within the receiver.

103. The first male terminal assembly includes: (i) a male terminal body having a rear wall; and (ii) a spring member having a rear wall; Male terminal assembly fully assembled state S ＦＣ 89. The splice block system of claim 88, wherein when in said position, a rear wall of said spring member is disposed adjacent to a rear wall of said male terminal body.

104. The first male terminal assembly includes: (i) a male terminal body having a contact arm with a free end; and (ii) a spring member having a spring arm; Male terminal assembly fully assembled state S ＦＣ 90. The splice block system of claim 88, wherein the free end of the contact arm abuts against a planar surface of the spring arm when in the position indicated by arrow A1.

105. The first male terminal assembly includes: (i) a male terminal body having a contact arm with an inner surface; and (ii) a spring member having a spring arm with an outer surface; Male terminal assembly fully assembled state S ＦＣ 90. The splice block system of claim 88, wherein a gap is formed between an area of ​​an outer surface of the spring arm and an inner surface of the contact arm when the area of ​​the outer surface of the spring arm is at .

106. The first male terminal assembly includes: (i) a male terminal body having a contact arm; and (ii) a spring member having a spring arm; Connection status S ＣＯＮ 89. The splice block system of claim 88, wherein the spring arms of the spring member are configured to exert an outward spring biasing force on the contact arms of the first male terminal body.

107. The spring force is the positioning force F Ｐ 107. The splice block system of claim 106, wherein the splice block is oriented substantially parallel to the

108. The spring force is the positioning force F Ｐ 107. The splice block system of claim 106, wherein the splice block is oriented substantially perpendicular to the

109. 107. The splice block system of claim 106, wherein the spring bias force is directed substantially perpendicular to the coupling force Fc.

110. 107. The splice block system of claim 106, wherein the spring bias force is directed substantially parallel to the removable cover.

111. The first male terminal assembly includes: (i) a male terminal body having a contact arm; and (ii) a spring member having a spring arm with an anti-rotation protrusion; Connection status S ＣＯＮ 89. The splice block system of claim 88, wherein the anti-rotation protrusion of the spring arm is disposed adjacent an area of ​​the first male terminal body.

112. The first male terminal assembly includes: (i) a male terminal body having a contact arm formed on a side wall; and (ii) a spring member having a spring arm; 90. The splice block system of claim 88, wherein the current does not have to flow through the sidewall to reach the contact arm.

113. The first male terminal assembly includes: (i) a male terminal body having a contact arm; and (ii) a spring member having a spring arm; Connection status S ＣＯＮ 89. The splice block system of claim 88, wherein the contact arm of the first male terminal assembly is sandwiched between the spring arm of the spring member and an inner surface of the female terminal assembly.

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