Electrical connector system having a male terminal assembly with compression limiting means

Abstract

An electrical connector system having a male connector assembly and a female connector assembly is disclosed. The male connector assembly includes a male housing assembly and a male terminal assembly, which includes a spring member having at least one contact arm having a large curved shape and an openable and closable jacket enclosing a substantial portion of the male terminal and the spring member. The male terminal assembly also includes compression limiting means to prevent the contact arm from being excessively deformed inward by an external force. It is desirable to prevent excessive compression of the contact arm, as such excessive compression may damage the contact arm and / or the spring member. The female connector assembly includes a female housing assembly configured not only to receive the female terminal assembly but also to receive a portion of the male terminal assembly in the connected state of the electrical connector system in operation.

Claims

[Claim 1] An electrical connector assembly for use in a power distribution assembly, wherein the connector assembly is A male connector assembly comprising a male housing assembly and a male terminal assembly, the male connector assembly comprises, A male terminal body including a receptacle and at least one contact arm having a bent portion that defines the apex of the contact arm, A spring member having at least one spring arm configured to be located below the contact arm, A jacket that can be opened and closed, To prevent damage to the male terminal assembly, the means includes a means for limiting excessive compression of the at least one contact arm by external force, Fully assembled state S FA In this, (i) the spring member is positioned within the receptacle of the male terminal body, the spring arm is positioned below the contact arm, and (ii) the majority of the male terminal body and the spring member are located within the jacket. Electrical connector assembly. [Claim 2] An electrical connector assembly according to claim 1, wherein the openable and closable jacket has a contact arm opening, the opening being flanked on both sides by at least one flexible projection. [Claim 3] An electrical connector assembly according to claim 2, in a fully assembled state S FA The electrical connector assembly wherein the apex of the contact arm extends upward from the upper edge of the flexible projection. [Claim 4] An electrical connector assembly according to claim 2, wherein the outer surface of the flexible projection is substantially parallel to the contact surface of the contact arm. [Claim 5] An electrical connector assembly according to claim 1, wherein the at least one spring arm includes a bent portion formed by an upward inclination range of the spring arm and a downward inclination range of the spring arm. [Claim 6] An electrical connector assembly according to claim 5, wherein the internal angle of the bent portion of at least one spring arm is defined between the inner surface of the upward inclined range and the inner surface of the downward inclined range, and the internal angle is between 60 degrees and 120 degrees. [Claim 7] An electrical connector assembly according to claim 6, wherein the inner angle of the bent portion of at least one spring arm is between 75 degrees and 105 degrees. [Claim 8] An electrical connector assembly according to claim 6, wherein the inner angle of the bent portion of at least one spring arm is 80 degrees. [Claim 9] An electrical connector assembly according to claim 6, wherein the inner angle of the bent portion of the at least one spring arm is a remarkably acute angle. [Claim 10] An electrical connector assembly according to claim 1, wherein the at least one spring arm of the spring member is a first spring arm comprising both a straight portion having a first width and a folded portion having a second width, wherein the first width is greater than the second width. [Claim 11] An electrical connector assembly according to claim 10, wherein the spring member includes a second spring arm having a folded portion having a third width, the third width being greater than the second width of the first spring arm. [Claim 12] An electrical connector assembly according to claim 1, wherein the male terminal body includes a wall configuration having an internal spring wall with an anti-rotation projection, and the anti-rotation projection is configured to be positioned within an anti-rotation recess formed in the spring member. [Claim 13] An electrical connector assembly according to claim 12, wherein the anti-rotation recess is formed between a pair of spring arms of the spring member. [Claim 14] An electrical connector assembly according to claim 1, wherein the terminal assembly is in a fully assembled state S FA An electrical connector assembly in which, when the at least one contact arm includes a free end that does not contact the flat outer surface of the spring arm. [Claim 15] An electrical connector assembly according to claim 1, wherein the receptacle of the male terminal body is in a receiving preparation position P R When in this position, it has a first frontal dimension, and the receptacle has the male terminal body in the ready-to-use position P U An electrical connector assembly having a second front dimension, which is smaller than the first front dimension, when in the position described above. [Claim 16] An electrical connector assembly according to claim 15, wherein the spring member comprises two opposing spring arms having bent portions defining the vertices of the spring arms, the external dimensions of the spring member are defined between the vertices of the spring arms, and the external dimensions of the spring member are greater than the second frontal dimensions of the receptacle of the male terminal body. [Claim 17] An electrical connector assembly according to claim 1, wherein the male terminal body includes a base having an outer surface, and the at least one contact arm includes a linear range having an outer surface that is coplanar with the outer surface of the base. [Claim 18] An electrical connector assembly according to claim 1, further comprising a female connector assembly including a female housing assembly and a female terminal assembly. [Claim 19] An electrical connector assembly according to claim 18, wherein the male connector assembly and the female connector assembly are in a connected state S C An electrical connector assembly in which the male terminal body, the spring member, and the front portion of the jacket are operably coupled and housed within the female terminal assembly. [Claim 20] An electrical connector assembly used in a vehicle's power distribution assembly, wherein the connector assembly is A male connector assembly comprising a male housing assembly and a male terminal assembly, The aforementioned male terminal assembly is A male terminal body having a receptacle, a base, and at least one contact arm extending from the base, A spring member having at least one spring arm configured to be positioned below the contact arm, Compression limiting means configured to limit excessive compression of the at least one contact arm and the at least one spring arm, A jacket that can be opened and closed, The system includes compression limiting means configured to limit excessive compression of the contact arm and the spring arm, Complete bond state S FC An electrical connector assembly wherein (i) the spring member is located within the receptacle of the male terminal body, the spring arm is located below the contact arm, (ii) the majority of the male terminal body and the spring member are housed within a jacket, and (iii) the spring member, the male terminal body and the jacket are located within a male housing assembly. [Claim 21] An electrical connector assembly according to claim 20, wherein the openable and closable jacket has a contact arm opening, the opening being flanked on both sides by at least one flexible projection. [Claim 22] An electrical connector assembly according to claim 21, in a fully assembled state S FA The electrical connector assembly wherein the apex of the contact arm extends upward from the upper edge of the flexible projection. [Claim 23] An electrical connector assembly according to claim 21, wherein the outer surface of the flexible projection is substantially parallel to the contact surface of the contact arm. [Claim 24] An electrical connector assembly according to claim 21, wherein the at least one spring arm includes a bent portion formed by an upward inclination range of the spring arm and a downward inclination range of the spring arm. [Claim 25] An electrical connector assembly according to claim 24, wherein the internal angle of the bent portion of at least one spring arm is defined between the inner surface of the upward inclined range and the inner surface of the downward inclined range, and the internal angle is between 60 degrees and 120 degrees. [Claim 26] An electrical connector assembly according to claim 25, wherein the inner angle of the bent portion of at least one spring arm is between 75 degrees and 105 degrees. [Claim 27] An electrical connector assembly according to claim 25, wherein the inner angle of the bent portion of at least one spring arm is 80 degrees. [Claim 28] An electrical connector assembly according to claim 25, wherein the inner angle of the bent portion of at least one spring arm is a remarkably acute angle. [Claim 29] An electrical connector assembly according to claim 21, wherein the at least one spring arm of the spring member is a first spring arm comprising both a straight portion having a first width and a folded portion having a second width, wherein the first width is greater than the second width. [Claim 30] An electrical connector assembly according to claim 29, wherein the spring member includes a second spring arm having a folded portion having a third width, the third width being greater than the second width of the first spring arm. [Claim 31] An electrical connector assembly according to claim 21, wherein the male terminal body includes a wall configuration having an internal spring wall with an anti-rotation projection, and the anti-rotation projection is configured to be positioned within an anti-rotation recess formed in the spring member. [Claim 32] An electrical connector assembly according to claim 31, wherein the anti-rotation recess is formed between a pair of spring arms of the spring member. [Claim 33] The electrical connector assembly according to claim 32, wherein the terminal assembly is in a fully engaged state S FC at which time the at least one contact arm includes a free end that does not abut against the flat outer surface of the spring arm, the electrical connector assembly. [Claim 34] An electrical connector assembly according to claim 21, wherein the receptacle of the male terminal body is in a receiving preparation position P R When in this position, it has a first frontal dimension, and the receptacle has the male terminal body in the ready-to-use position P U An electrical connector assembly having a second front dimension, which is smaller than the first front dimension, when in the position described above. [Claim 35] An electrical connector assembly according to claim 34, wherein the spring member comprises two opposing spring arms having bent portions defining the vertices of the spring arms, the external dimensions of the spring member are defined between the vertices of the spring arms, and the external dimensions of the spring member are greater than the second frontal dimensions of the receptacle of the male terminal body. [Claim 36] An electrical connector assembly according to claim 21, wherein the base includes a base having an outer surface, and the at least one contact arm includes a linear range having an outer surface that is coplanar with the outer surface of the base. [Claim 37] An electrical connector assembly according to claim 21, further comprising a female connector assembly including a female housing assembly and a female terminal assembly. [Claim 38] An electrical connector assembly according to claim 22, wherein the male connector assembly and the female connector assembly are in a connected state S C An electrical connector assembly in which the male terminal body, the spring member, and the front portion of the jacket are operably coupled and housed within the female terminal assembly. [Claim 39] An electrical connector assembly according to claim 20, wherein the male terminal body includes a plurality of contact arms, the spring member includes a plurality of spring arms, the number of contact arms is equal to the number of spring arms, and the fully coupled state S FC Here is an electrical connector assembly where a single spring arm is located below a single contact arm. [Claim 40] An electrical connector assembly used in a power distribution assembly, wherein the connector assembly is A male connector assembly comprising a male housing assembly and a male terminal assembly, The aforementioned male terminal assembly is A male terminal body having a receptacle, a base, and a contact arm extending from the base, (i) A primary spring arm located below the contact arm and having a front portion having an overcompression range, and (ii) a spring member including a pair of secondary spring arms located to the side of the primary spring arm and having upper edges positioned at a distance from the overcompression range of the primary spring arm, Fully assembled state S FA Then, (i) the spring member is located inside the receptacle of the male terminal body, the primary spring arm is located below the contact arm, and (ii) external force F E When the force F is applied to the contact arm, the contact arm and the primary spring arm are compressed inward, and (iii) an external force F is applied to them as well. E When applied to the contact arm, further inward compression of the primary spring arm is suppressed by the overcompression range that brings the primary spring arm into contact with the upper edge of the secondary spring arm, thereby preventing excessive compression of the male terminal assembly, in an electrical connector assembly. [Claim 41] An electrical connector assembly according to claim 40, further comprising the openable and closable jacket, in a fully assembled state S FA An electrical connector assembly in which the male terminal body and most of the spring member are housed within a jacket, the openable jacket having a contact arm opening, the opening being flanked on both sides by at least one flexible projection. [Claim 42] An electrical connector assembly according to claim 41, wherein the contact arm has a bent portion that defines the apex of the contact arm, and in a fully assembled state S FA The electrical connector assembly wherein the apex of the contact arm extends upward from the upper edge of the flexible projection. [Claim 43] An electrical connector assembly according to claim 41, wherein the outer surface of the flexible projection is substantially parallel to the contact surface of the contact arm. [Claim 44] An electrical connector assembly according to claim 40, wherein the primary spring arm includes a bent portion formed by an upward inclination range of the primary spring arm and a downward inclination range of the primary spring arm. [Claim 45] An electrical connector assembly according to claim 44, wherein the inner angle of the bent portion of the primary spring arm is defined between the inner surface of the upward inclined range and the inner surface of the downward inclined range, and the inner angle is between 60 degrees and 120 degrees. [Claim 46] An electrical connector assembly according to claim 45, wherein the inner angle of the bent portion of the primary spring arm is between 75 degrees and 105 degrees. [Claim 47] An electrical connector assembly according to claim 45, wherein the inner angle of the bent portion of the primary spring arm is 80 degrees. [Claim 48] An electrical connector assembly according to claim 45, wherein the inner angle of the bent portion of the primary spring arm is a remarkably acute angle. [Claim 49] An electrical connector assembly according to claim 40, wherein the primary spring arm has both a straight portion having a first width and a folded portion having a second width, the first width being greater than the second width. [Claim 50] An electrical connector assembly according to claim 40, wherein the male terminal body includes a wall configuration having an internal spring wall with an anti-rotation projection, and the anti-rotation projection is configured to be positioned within an anti-rotation recess formed in the spring member. [Claim 51] An electrical connector assembly according to claim 50, wherein the anti-rotation recess is formed between the primary spring arm and one of the secondary spring arms of the spring member. [Claim 52] An electrical connector assembly according to claim 40, wherein the receptacle of the male terminal body is in a receiving preparation position P R When in this position, it has a first frontal dimension, and the receptacle has the male terminal body in the ready-to-use position P U An electrical connector assembly having a second front dimension, which is smaller than the first front dimension, when in the position described above. [Claim 53] An electrical connector assembly according to claim 52, wherein the spring member includes a pair of primary spring arms, each primary spring arm having a bend defining the apex of the spring arm, the external dimensions of the primary spring member are defined between the apex of the spring arm, and the external dimensions of the primary spring member are greater than the second frontal dimensions of the receptacle of the male terminal body. [Claim 54] An electrical connector assembly according to claim 52, wherein each secondary spring arm has a bent portion defining the vertex of the spring arm, the external dimensions of the secondary spring member are defined between the vertices of the spring arm, and the external dimensions of the secondary spring member are greater than the second frontal dimensions of the receptacle of the male terminal body. [Claim 55] An electrical connector assembly according to claim 53, wherein each secondary spring arm has a bent portion defining a spring arm vertex, the external dimensions of the secondary spring member are defined between the spring arm vertices, and the external dimensions of the secondary spring member are substantially equal to the second frontal dimension. [Claim 56] An electrical connector assembly according to claim 40, wherein the base of the male terminal body has an outer surface, and the contact arm of the male terminal body includes a linear range having an outer surface that is coplanar with the outer surface of the base. [Claim 57] An electrical connector assembly according to claim 40, wherein the male terminal body includes a support rib extending from the base, the length of which the support rib is shorter than the length of the contact arm of the male terminal body. [Claim 58] An electrical connector assembly according to claim 40, wherein the overcompression range includes a pair of flanges extending outward from the free end of the primary spring arm. [Claim 59] An electrical connector assembly according to claim 40, wherein each of the secondary spring arms includes a projection having one of the upper edges positioned at a distance from the overcompression range of the primary spring arm, the projection being located forward of and beyond the overcompression range of the primary spring arm. [Claim 60] An electrical connector assembly according to claim 59, further comprising an openable and closable jacket, in a fully assembled state S FA The electrical connector assembly wherein the projection range of the secondary spring arm of the spring member is housed within an opening formed in the openable and closable jacket. [Claim 61] An electrical connector assembly according to claim 40, wherein the male terminal body includes a plurality of contact arms, the spring member includes a plurality of primary spring arms and a plurality of secondary spring arms, the number of contact arms is equal to the total number of primary and secondary spring arms, and in a fully assembled state S FA Here is an electrical connector assembly where a single spring arm is located below a single contact arm. [Claim 62] An electrical connector assembly according to claim 40, further comprising a female connector assembly including a female housing assembly and a female terminal assembly. [Claim 63] An electrical connector assembly according to claim 62, wherein the male connector assembly and the female connector assembly are in a connected state S C An electrical connector assembly in which the male terminal body, the spring member, and the jacket are operably coupled, with the respective forward ranges of the male terminal body, the spring member, and the jacket being received within the female terminal assembly. [Claim 64] An electrical connector assembly used in a power distribution assembly, wherein the connector assembly is A male connector assembly comprising a male housing assembly and a male terminal assembly, The aforementioned male terminal assembly is A male terminal body having a receptacle, a base, and at least one contact arm extending from the base, A spring member having at least one spring arm configured to be located below the contact arm, wherein the at least one spring arm includes a spring member having a front portion having a jacket projection range, and A jacket with a spring arm opening that can be opened and closed. Fully assembled state S FA Then, (i) the spring member is positioned within the receptacle of the male terminal body, the primary spring arm is positioned below the contact arm, (ii) most of the male terminal body and the spring member are housed within the jacket, and (iii) an external force F is applied to the contact arm. E When (iv) an additional external force F is applied, both the contact arm and the primary spring arm are displaced inward, and (iv) an additional external force F is applied. E An electrical connector assembly in which, when applied to the contact arm, direct contact between the inner surface of the jacket projection range of at least one spring arm and the inner compression edge of the spring arm opening limits further inward displacement of the primary spring arm, thereby preventing excessive displacement of the male terminal assembly. [Claim 65] An electrical connector assembly according to claim 64, wherein the jacket projection range includes an inner surface, and the inner surface is in direct contact with the inner compression edge of the spring arm opening to prevent damage to the male terminal assembly. [Claim 66] An electrical connector assembly according to claim 65, wherein the jacket projection range defines the foremost part of the spring member. [Claim 67] An electrical connector assembly according to claim 64, wherein the at least one spring arm includes a bend formed by an upward inclination range of the primary spring arm and a downward inclination range of the primary spring arm. [Claim 68] An electrical connector assembly according to claim 67, wherein the inner angle of the bent portion of the primary spring arm is defined between the inner surface of the upward inclined range and the inner surface of the downward inclined range, and the inner angle is between 60 degrees and 120 degrees. [Claim 69] An electrical connector assembly according to claim 68, wherein the inner angle of the bent portion of the primary spring arm is between 75 degrees and 105 degrees. [Claim 70] An electrical connector assembly according to claim 68, wherein the inner angle of the bent portion of the primary spring arm is 80 degrees. [Claim 71] An electrical connector assembly according to claim 68, wherein the inner angle of the bent portion of the primary spring arm is a remarkably acute angle. [Claim 72] An electrical connector assembly according to claim 64, wherein the primary spring arm has both a straight portion having a first width and a folded portion having a second width, the first width being greater than the second width. [Claim 73] An electrical connector assembly according to claim 64, wherein the male terminal body includes a wall configuration having an internal spring wall with an anti-rotation projection, and the anti-rotation projection is configured to be positioned within an anti-rotation recess formed in the spring member. [Claim 74] An electrical connector assembly according to claim 73, wherein the anti-rotation recess is formed between a pair of spring arms of the spring member. [Claim 75] An electrical connector assembly according to claim 64, wherein the receptacle of the male terminal body is in a receiving preparation position P R When in this position, it has a first frontal dimension, and the receptacle has the male terminal body in the ready-to-use position P U An electrical connector assembly having a second front dimension, which is smaller than the first front dimension, when in the position described above. [Claim 76] An electrical connector assembly according to claim 75, wherein the at least one spring arm of the spring member includes a pair of primary spring arms, each primary spring arm having a bend defining the top of the spring arm, the external dimensions of the primary spring member are defined between the tops of the spring arms, and the external dimensions of the primary spring member are greater than the second frontal dimensions of the receptacle of the male terminal body. [Claim 77] An electrical connector assembly according to claim 75, wherein the at least one spring arm of the spring member further comprises a pair of secondary spring arms, each secondary spring arm having a bend defining the top of the spring arm, the external dimensions of the secondary spring member being defined by the distance between the vertices of the spring arms, and the external dimensions of the secondary spring member being greater than the second frontal dimensions of the receptacle of the male terminal body. [Claim 78] An electrical connector assembly according to claim 75, wherein the at least one spring arm of the spring member further comprises a pair of secondary spring arms, each secondary spring arm having a bend defining the top of the spring arm, the distance between the tops of the spring arms defines the external dimensions of the secondary spring member, and the external dimensions of the secondary spring member are substantially equal to the dimensions of the secondary outer spring member. [Claim 79] An electrical connector assembly according to claim 64, wherein the base of the male terminal body has an outer surface, and the contact arm of the male terminal body includes a linear range having an outer surface that is coplanar with the outer surface of the base. [Claim 80] An electrical connector assembly according to claim 64, wherein the male terminal body includes a support rib extending from the base, the length of which the support rib is shorter than the length of the contact arm of the male terminal body. [Claim 81] An electrical connector assembly according to claim 64, wherein the at least one spring arm includes a first spring arm including the jacket projection range and a second spring arm having a front portion including an overcompression range, the first spring arm having an upper edge positioned on the side of the second spring arm and at a distance from the overcompression range. [Claim 82] An electrical connector assembly according to claim 81, wherein the overcompression range includes a pair of flanges extending outward from the free end of the secondary spring arm. [Claim 83] An electrical connector assembly according to claim 81, wherein the jacket projection range of the first spring arm is located forward of and beyond the overcompression range of the second spring arm. [Claim 84] An electrical connector assembly according to claim 64, wherein the male terminal body includes a plurality of contact arms, the spring member includes a plurality of spring arms, the number of contact arms is equal to the number of spring arms, and in a fully assembled state S FA Here is an electrical connector assembly where a single spring arm is located below a single contact arm. [Claim 85] An electrical connector assembly according to claim 64, further comprising a female connector assembly including a female housing assembly and a female terminal assembly. [Claim 86] An electrical connector assembly according to claim 85, wherein the male connector assembly and the female connector assembly are in a connected state S C An electrical connector assembly in which the male terminal body, the spring member, and the jacket are operably coupled, with the respective forward ranges of the male terminal body, the spring member, and the jacket being received within the female terminal assembly. [Claim 87] An electrical connector assembly according to claim 64, wherein the at least one spring arm of the spring member includes (i) a first pair of spring arms having a front portion having a jacket projection range and arranged opposite to each other, and (ii) a second pair of spring arms having a front portion having an overcompression range and arranged opposite to each other, An electrical connector assembly in which the first pair of spring arms are aligned with the second pair of spring arms at a 90-degree angle.

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