Electrical connector assembly with spring and shifter

Abstract

Various implementations of an electrical connector assembly include a male and female terminal assembly. The male terminal assembly includes a male terminal body including at least one contact arm, a spring including at least one spring arm applying an outwardly directed biasing force on the at least one contact arm, and a shifter including an outer frame. The shifter is movable between a pre-set and a full-set position. The female terminal assembly includes a female terminal body dimensioned to receive a portion of the male terminal body and a touch proof post. A portion of the touch proof post is configured to move the shifter from the pre-set position to the full-set position. In the pre-set position, the at least one contact arm is spaced apart from the female terminal body, and in the full-set position, the at least one contact arm is biased against the female terminal body.

Description

ELECTRICAL CONNECTOR ASSEMBLY WITH SPRING AND SHIFTERCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. Provisional Patent Application No. 63 / 532,265 filed August 11, 2023, and U.S. Provisional Patent Application No. 63 / 581,406 filed September 8, 2023, each of which is incorporated by reference in its entirety.BACKGROUND

[0002] High-power electrical connectors are commonly found in industrial equipment, power distribution systems, and heavy machinery (e.g., in automobile applications). High-power electrical connectors often include male and female terminals used for secure and robust electrical connections. The male terminals typically feature pins or prongs that fit securely into corresponding receptacles or sockets defined by the female terminal. Examples of high-power electrical connectors include high power lock box (HPLB) connectors.

[0003] The connection reliability of high-power electrical connectors may be affected by a variety of factors such as vibration of the base equipment, repeated connection cycling, and environmental factors. For example, in high heat applications, the metal terminals (e.g., the pins or prongs of the male component) may expand and potentially weaken connections.Additionally, a deliberate application of force is used to mate the male and female terminals together and ensure a tight fit. However, problems occur when the applied or insertion force is too low (such that the contact force between the terminals is insufficient) or too high (such that a user cannot easily connect the terminals together).SUMMARY

[0004] According to various implementations, an electrical connector assembly is disclosed. The electrical connector assembly includes a male terminal assembly and a female terminal assembly. The male terminal assembly includes a male terminal body, a spring, and a shifter. The male terminal body defines a receiver and includes at least one contact arm. The spring is disposed within the receiver of the male terminal body. The spring includes at least one spring arm applying an outwardly directed biasing force on the at least one contact arm of the male terminal body. The shifter includes an outer frame defining an opening. The shifter is movable between a pre-set position and a full-set position. The female terminal assembly includes a female terminal body and a touch proof post. The female terminal body defines a femaleterminal receiver dimensioned to receive a portion of the male terminal body. The touch proof post is coupled to the female terminal body. The touch proof post includes a base plate, at least one insulative post extending from the base plate beyond a front edge of the female terminal body, and at least one lock arm extending from the base plate and spaced apart from the at least one insulative post. A portion of the touch proof post is configured to abut and engage with a portion of the shifter to move the shifter from the pre-set position to the full-set position. In the pre-set position, the at least one contact arm is spaced apart from the female terminal body, and in the full-set position, the at least one contact arm is biased against the female terminal body.

[0005] In some implementations, in the pre-set position, the outer frame of the shifter retains a free end of the at least one contact arm in a first position and, in the full-set position, the free end of the at least one contact arm moves to a second position that is radially outward from the first position.

[0006] In some implementations, in the pre-set position, the outer frame of the shifter retains a free end of the at least one spring arm in a first position and, in the full-set position, the free end of the at least one spring arm moves to a second position that is radially outward from the first position.

[0007] In some implementations, the shifter of the male terminal assembly further includes at least one support leg, a central locking portion, and a connecting arm. The at least one support leg extends from the outer frame in a first direction substantially perpendicular to a first plane defined by the outer frame of the shifter. The central locking portion extends in the first direction between a first end of the central locking portion adjacent the opening of the shifter and a second end of the central locking portion opposite and spaced apart from the first end of the central locking portion along a central longitudinal axis thereof, the first end of the central locking portion including a deflector surface. The connecting arm extending between the at least one support leg and the second end of the central locking portion.

[0008] In some implementations, the touch proof post further includes at least one pushing surface coupled to the at least one insulative post, and the shifter further includes at least one pushing surface coupled to the at least one support leg. The portion of the touch proof post that is configured to abut and engage with the at least one pushing surface of the shifter includes the at least one pushing surface of the touch proof post.

[0009] In some implementations, the at least one lock arm of the touch proof post includes a free end having a first ramped surface configured to engage with the deflector surface of the central locking portion of the shifter to (i) deflect the at least one lock arm radially outward and(ii) situate the free end of the at least one lock arm of the touch proof post in a locking space defined by the central locking portion of the shifter.

[0010] In some implementations, the free end of the at least one lock arm of the touch proof post further includes a second surface adjacent the first ramped surface. The second surface of the at least one lock arm of the touch proof post engages with a pulling surface of the central locking portion of the shifter to move the shifter from the full-set position to the pre-set position.

[0011] In some implementations, a chamfered edge of the outer frame of the shifter facilitates movement of the free end of the at least one contact arm radially inward to be retained by the outer frame in the pre-set position.

[0012] In some implementations, inserting the male terminal body into the female terminal receiver causes the shifter to move along a central longitudinal axis of the male terminal body.

[0013] According to various implementations, an electrical connector assembly including a male terminal assembly is disclosed. The male terminal assembly includes a male terminal body, a spring, and a shifter. The male terminal body defines a receiver and including at least one contact arm. The spring is disposed within the receiver of the male terminal body, the spring including a spring base and at least one spring arm extending from the spring base. The at least one spring arm applies an outwardly directed biasing force on the at least one contact arm of the male terminal body. The shifter includes an outer frame defining an opening. The shifter is movable between (i) a pre-set position wherein a free end of the at least one contact arm is disposed in a first position, and (ii) a full-set position wherein the free end of the at least one contact arm is disposed in a second position. The first position is radially inward of the second position.

[0014] In some implementations, in the pre-set position, the free end of the at least one contact arm is retained radially inward by the outer frame of the shifter.

[0015] In some implementations, the shifter is closer to the spring base of the spring in the full- set position.

[0016] In some implementations, the electrical connector assembly further includes a male terminal retainer. The male terminal retainer includes a base and at least one side wall extending from the base of the male terminal retainer. The base and the at least one side wall of the male terminal retainer define a male terminal retainer receiver. In the pre-set position, at least a portion of the shifter is disposed within the male terminal retainer receiver, and the base of the male terminal retainer prevents movement of the shifter in a direction away from the spring base.

[0017] In some implementations, the at least one contact arm of the male terminal body includes: a first portion extending at a radially outward angle, an outer surface of the first portion of the at least one contact arm defining a contact surface configured to engage with a female terminal body; an intermediate portion extending substantially radially inward from the first portion; and a second portion extending at a radially outward angle from the intermediate portion and including the free end of the at least one contact arm.

[0018] In some implementations, the intermediate portion and the second portion of the at least one contact arm define a resting space within which the outer frame of the shifter is disposed in the full-set position.

[0019] In some implementations, the free end of the at least one spring arm contacts an inner surface of the first portion of the at least one contact arm.

[0020] According to various implementations, an electrical connector assembly including a female terminal assembly is disclosed. The female terminal assembly includes a female terminal body and a touch proof post. The female terminal body defines a female terminal receiver dimensioned to receive a portion of a male terminal body. The touch proof post is coupled to the female terminal body. The touch proof post includes a base plate and at least one insulative post extending from the base plate beyond a front edge of the female terminal body. At least one lock arm extends from the base plate and spaced apart from the at least one insulative post.

[0021] In some implementations, the female terminal body further defines a first coupling opening and a second coupling opening. The female terminal assembly further includes a post retainer coupled to the female terminal body and the touch proof post. The post retainer includes at least one side wall defining a cavity and at least one coupling protrusion extending radially outward from the at least one side wall. The at least one coupling protrusion of the post retainer extends through the first coupling opening to couple the post retainer to the female terminal body. A portion of the base plate of the touch proof post and a portion of the post retainer each extend through the second coupling opening to align the touch proof post with the post retainer.

[0022] In some implementations, the at least one lock arm includes a first lock arm and a second lock arm spaced apart from the first lock arm to define a locking area therebetween, each of the first lock arm and the second lock arm being capable of deflecting radially outward from the locking area.

[0023] In some implementations, the at least one insulative post includes a plurality of insulative posts disposed radially outward relative to the at least one lock arm.

[0024] The drawings are merely exemplary and certain features may be used singularly or in combination with other features. The drawings are not necessarily drawn to scale.

[0025] Additional advantages will be set forth in part in the description which follows or may be learned by practice. The advantages will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive, as claimed.BRIEF DESCRIPTION OF THE DRAWINGS

[0026] FIG. 1 shows an electrical connector assembly in a disconnected position, according to one implementation.

[0027] FIG. 2 shows the electrical connector assembly of FIG. 1 in a connected position.

[0028] FIG. 3 shows a cross-sectional view of the electrical connector assembly of FIG. 1 along line 3-3, along with an inset detailed view of a portion of the male terminal assembly and a portion of the female terminal assembly.

[0029] FIG. 4 shows an exploded view of the male terminal assembly of the electrical connector assembly of FIG. 1.

[0030] FIG. 5 shows an isometric view of the male terminal assembly of FIG. 4.

[0031] FIG. 6 shows a side view of the male terminal assembly of FIG. 4.

[0032] FIG. 7 shows a top view of the male terminal assembly of FIG. 4.

[0033] FIG. 8 shows a front view of the male terminal assembly of FIG. 4.

[0034] FIGS. 9A-9E show the spring shown in FIGS. 4-8.

[0035] FIGS. 10A-10F show the shifter shown in FIGS. 4-8.

[0036] FIGS. 11-15 show different views of the female terminal assembly shown in FIGS. 1-3.

[0037] FIGS. 16-19 show views of the male and female terminal assemblies shown in FIGS. 1- 3 in a connected and full-set position.

[0038] FIGS. 20A, 20B, 21 A, and 21B show a set of cross-sectional views of the electrical connector assembly shown in FIGS. 1-3 along line 3-3, showing the progress of the insertion of the male terminal body into the female terminal receiver.

[0039] FIG. 22 shows an additional assembly view of the male and female terminal assemblies shown in FIGS. 1-3.

[0040] FIG. 23 shows an exploded view showing the interaction between the shifter and the touch proof post of the terminal assemblies shown in FIGS. 1-3.

[0041] FIG. 24 shows an assembly view showing the interaction between the spring and the touch proof post of the terminal assemblies shown in FIGS. 1-3.

[0042] FIG. 25 shows a partial cut-away view of a fully assembled male and female terminal assembly shown in FIGS. 1-3.

[0043] FIGS. 26A-26C show cross-sectional side views of known electrical terminal assemblies.

[0044] FIGS. 27 and 28 show an electrical connector assembly, according to another implementation.

[0045] FIG. 29 shows the spring shown in FIGS. 27-28.

[0046] FIGS. 30A-30F show the shifter shown in FIGS. 27-28.

[0047] FIGS. 31A-31H show the touch proof post shown in FIGS. 27-28.

[0048] FIG. 32 shows an isometric view of one implementation of an electrical connector assembly in a fully assembled and connected position.

[0049] FIG. 33 shows an exploded view of the electrical connector assembly of FIG. 32.

[0050] FIG. 34 shows a top view of the electrical connector assembly of FIG. 32.

[0051] FIG. 35 shows a side view of the electrical connector assembly of FIG. 32.

[0052] FIG. 36 shows a front view of the electrical connector assembly of FIG. 32.

[0053] FIG. 37 shows a back view of the electrical connector assembly of FIG. 32.

[0054] FIG. 38 shows a cross-sectional view of the electrical connector assembly along line38-38 in FIG. 37.

[0055] FIG. 39 shows a cross-sectional view of the electrical connector assembly along line39-39 in FIG. 36.

[0056] FIG. 40 shows an isometric detail view of the cross-sectional view shown in FIG. 38.

[0057] FIG. 41 shows the cross-sectional view of the electrical connector assembly shown in FIG. 38 with the outer components (e.g., housings) removed.

[0058] FIG. 42 shows an isometric view of the cross-sectional view of FIG. 41.

[0059] FIG. 43 shows a cross-sectional view of the male and female terminal bodies and adjacent elements along line 43-43 in FIG. 41.

[0060] FIG. 44 shows the isometric view of the cross-sectional view of FIG. 43.

[0061] FIG. 45 shows an isometric view of the male terminal assembly of the electrical connector assembly of FIG. 32, according to one implementation.

[0062] FIG. 46 shows the male terminal assembly of FIG. 45 without the male housing assembly.

[0063] FIG. 47 shows a back view of the male terminal assembly of FIG. 45.

[0064] FIG. 48 shows a front view of the male terminal assembly of FIG. 45.

[0065] FIG. 49 shows a side view of the male terminal assembly of FIG. 45.

[0066] FIG. 50 shows a cross-sectional view of the male terminal assembly along line 50-50 in FIG. 48.

[0067] FIG. 51 and FIG. 52 show different views of the male terminal body, the spring, and the shifter in a full-set position.

[0068] FIG. 53 shows the male terminal body in an open configuration adjacent the spring.

[0069] FIG. 54 shows the male terminal body in a closed configuration with the spring disposed within the receiver of the male terminal body.

[0070] FIG. 55 shows an isometric view of a shifter, according to one implementation.

[0071] FIG. 56 shows a front view of the shifter of FIG. 55.

[0072] FIG. 57 shows a side view of the shifter of FIG. 55.

[0073] FIG. 58 shows a different side view of the shifter of FIG. 55.

[0074] FIG. 59 shows another implementation of the male terminal body wherein the contact arm and the side wall have a different configuration.

[0075] FIG. 60 shows another implementation of the male terminal body wherein the contact arm has a necked portion adjacent the side wall.

[0076] FIG. 61 shows a front view of the female terminal assembly with the shifter shown in FIGS. 32 and 33.

[0077] FIG. 62 shows the female terminal assembly and the shifter of FIG. 61 from an isometric view.

[0078] FIG. 63 shows an isometric view of the female terminal assembly shown in FIG. 32.

[0079] FIG. 64 shows a different isometric view of the female terminal assembly of FIG. 63.

[0080] FIG. 65 shows a front view of the female terminal assembly of FIG. 63.

[0081] FIG. 66 shows a cross-sectional view of the female terminal assembly of FIG. 63 along line 66-66.

[0082] FIG. 67 shows a cross-sectional view of the female terminal assembly of FIG. 63 along line 67-67.

[0083] FIG. 68 shows an isometric view of a touch proof post shown in FIGS. 32-33.

[0084] FIG. 69 shows a side view of the touch proof post of FIG. 68.

[0085] FIG. 70 shows a top view of the touch proof post of FIG. 68.

[0086] FIG. 71 shows a different side view of the touch proof post of FIG. 68.

[0087] FIG. 72 shows a cross-sectional view of the electrical connector assembly of FIG. 39 in the disconnected position with the shifter in the pre-set position.

[0088] FIG. 73 shows the cross-sectional view of FIG. 72 wherein the touch proof post of the female terminal assembly engages with the shifter of the male terminal assembly.

[0089] FIG. 74 shows the cross-sectional view of FIG. 72 wherein the electrical connector assembly is in the connected position and the shifter is in the full-set position.

[0090] FIG. 75 shows an isometric view of the shifter and the touch proof post shown in FIGS. 32-33 in the full-set position.

[0091] FIG. 76 shows a cross-sectional view of the assembly of FIG. 75 along line 76-76.

[0092] FIG. 77 shows another implementation of a touch proof post.

[0093] FIG. 78 shows another implementation of a shifter.

[0094] Various objects, aspects, features, and advantages of the disclosure will become more apparent and better understood by referring to the detailed description taken in conjunction with the accompanying drawings, in which like reference characters identify corresponding elements throughout. In the drawings, like reference numbers generally indicate identical, functionally similar, and / or structurally similar elements.DETAILED DESCRIPTION

[0095] Various implementations of an electrical connector assembly include a male terminal assembly and a female terminal assembly. The male terminal assembly is movable relative to the female terminal assembly between (1) a disconnected, separated, or decoupled position and (2) a connected, engaged, or coupled position.

[0096] The male terminal assembly includes a male terminal body including one or more contact arms, a spring (e.g., a U-shaped spring or an internal spring member), and a shifter. The one or more contact arms extend radially outward from a portion of the male terminal body (e.g., a side wall). When assembled, the spring and the shifter are at least partially disposed inside a receiver defined by the male terminal body of the male terminal assembly. The spring includes one or more spring arms that are biased radially outward. Each arm has an outer surface that abuts an inner surface of a respective contact arm, such that outward radial movement of each spring arm causes outward radial movement of the respective contact arm.

[0097] The shifter includes an outer frame that at least partially surrounds (i) a free end of each spring arm or (ii) a free end of each contact arm. The shifter is configured to compress and retain the free ends (or tips) of the one or more spring arms or one or more contact arms radially inward, which defines a pre-set position. In the pre-set and disconnected position, the one or more contact arms are spaced apart from a female terminal body of the female terminal assembly.

[0098] When the shifter is moved axially relative to the spring and towards a spring base of the spring, the free ends of each of the one or more spring arms and / or one or more contact arms disengage from the outer frame of the shifter. When each of the free ends of the one or more spring arms and / or one or more contact arms are disengaged from the outer frame of the shifter, the shifter is in the full-set position. In the full-set position, the one or more spring arms and / or one or more the contact arms are free to expand radially outward. The one or more contact arms have contact portion (e.g., a point or surface most radially outward on the outer surface of the one or more contact arms) disposed on a contact plane. For example, the contact plane may be spaced apart radially outward from a plane that includes the side wall. In some implementations, the contact portion is an apex.

[0099] The female terminal assembly includes a female terminal body defining a female terminal receiver that is sized to receive a portion of the male terminal assembly. The femaleterminal assembly further includes a touch proof post (TPP) disposed within the female terminal receiver. The TPP extends from a base plate. The TPP is configured to engage with the shifter to move the shifter from the pre-set position to the full-set position.

[0100] When the male terminal assembly is in the disconnected position, the male terminal assembly is not inserted into the female terminal assembly. In the disconnected position, the shifter is in the pre-set position. When the shifter is in the pre-set position, the male terminal assembly, including the male terminal body with the one or more contact arms, the spring, and the shifter, move in tandem with each other. Once the male terminal assembly is moved axially into the female terminal assembly a first distance, a portion of the shifter abuts a portion of the touch proof post, which causes axial movement of the shifter relative to the male terminal body. As the male terminal assembly is further pushed into the female terminal assembly to a second distance that is inward of the first distance, the free ends of the one or more spring arms or one or more the contact arms move past the outer frame of the shifter and expand radially outward. The outer surface of each of the one or more contact arms thus moves radially outward to contact an inner conductive surface of the female terminal body. Thus, when the shifter is in the full-set position and the male terminal assembly is disposed within the receiver of the female terminal assembly, the one or more contact arms mechanically and electrically connect to the female terminal body of the female terminal assembly, which is referred to herein as the connected position.Example Device and Assembly #1

[0101] FIGS. 1-3 show an electrical connector assembly 1000, according to one implementation. The assembly shown in FIGS. 1-3 includes a male terminal assembly 1100 and a female terminal assembly 1600 along with related electrical components (e.g., output wire assembly and connector plates).Male Terminal Assembly

[0102] FIGS. 4-8 contain different views of the male terminal assembly 1100 shown in FIGS. 1-3. The male terminal assembly 1100 shown in FIGS. 4-8 includes a male terminal body 1200 having a square cross-sectional shape with eight contact arms 1202 - two on each of the four sides of the male terminal body 1200. However, in other implementations, a different number of contact arms may be included in the male terminal body (e.g., 1, 2, 3, 4, 5, 6, 7, 9, 10, 12, 15, 20, or more contact arms). In other implementations, the contact arms may be differently arranged (e.g., only 1 contact arm per side, 3 contact arms per side, 4 contact arms per side, or a firstnumber of contact arms on a first side that is different from a second number of contact arms on a second side of the male terminal body).

[0103] As shown in the exploded view of FIG. 4, the male terminal assembly 1100 includes a male terminal body 1200, a spring 1300, and a shifter 1400. The male terminal body 1200 may be integrally formed as a single piece (e.g., formed by progressive stamping) or formed from two or more pieces and coupled together to form a single part (e.g., welded). The male terminal body 1200 comprises an electrically conductive material (e.g., copper, aluminum, or any other selected conductive material). The male terminal body 1200 includes a connector plate 1212, a rear wall 1204, at least one side wall 1206, and a front cover 1240. The connector plate 1212 is for coupling to an electrical connection point or wire and is disposed on a first end 1201 of the male terminal body 1200. The rear wall 1204 extends from the connector plate 1212. The at least one side wall 1206 includes four sidewalls 1206a-1206d that extend from either the connection plate 1212 or the rear wall 1204 towards a second end 1203 of the male terminal body 1200 opposite of the first end 1201 along a central longitudinal axis 1205. The front cover 1240 is disposed on the second end 1203 of the male terminal body 1200 and partially encloses the second end 1203 of the male terminal body 1200. The front cover 1240 also defines a center opening 1242.Together, the front cover 1240, sidewalls 1206a-1206d, and rear wall 1204 define a receiver 1208.

[0104] The contact arms 1202 are formed as a part of side walls 1206 (e.g., pressed or partially cut out from each sidewall 1206a-1206d). Each contact arm 1202 is coupled to the sidewall 1206 at a fixed end 1216 of the contact arm 1202 and extends radially outward from the fixed end 1216. A free end 1224 of the contact arm 1202 is spaced apart from the fixed end 1216 in a longitudinal direction. In some implementations, the free end of the contact arm is biased radially inward toward the male terminal cavity. In the implementation shown in FIG. 4, two contact arms 1202 are formed on each side wall 1206, creating a total of eight contact arms 1202a-1202h. The contact portion of the contact arms 1202 is an apex 1218 disposed on a contact plane that is radially spaced apart outwardly from a plane that includes the sidewall 1206.

[0105] Although FIG. 4 shows the spring 1300 and the shifter 1400 as separate from the male terminal body 1200, once assembled, the spring 1300 and the shifter 1400 are disposed inside of the receiver 1208 of the male terminal body 1200. For example, the spring 1300 and the shifter 1400 are inserted into the male terminal body 1200 through the open second end 1203 before the front cover 1240 is bent to partially enclose the receiver 1208. The spring 1300 comprisesstainless steel. However, in other implementations, the spring may include other rigid materials (e.g., metals).

[0106] The spring 1300 is shown in FIGS. 9A-9E. Specifically, FIG. 9 A shows an isometric view, FIG. 9B shows a side view, FIG. 9C shows a front view, FIG. 9D shows another side view, and FIG. 9E shows a back view of the spring 1300. The spring 1300 includes a spring base 1304 and at least one spring arm 1302 that extends away from the spring base 1304 in a first direction. The first direction has at least a component that is substantially parallel to the central longitudinal axis 1205. Each of the spring arms 1302 include a free end 1310. The spring 1300 is inserted into the receiver 1208 of the male terminal body 1200 such that the free ends 1310 of each of the spring arms 1302 are closer to the second end 1203 of the male terminal body 1200 (adjacent to the front cover 1240). The spring 1300 shown in FIGS. 4-9 includes four sides, and each side has two spring arms 1302. Thus, the number and arrangement of the spring arms 1302a-1302h correspond to the number and arrangement of the contact arms 1202a-1202h. However, in other implementations, the number of spring arms may be different from the number of contact arms.

[0107] Each spring arm 1302a-1302h is biased radially outward from the central longitudinal axis 1205 extending through the spring base 1304. Each spring arm 1302 abuts an inner surface 1230 of a corresponding contact arm 1202. Each spring arm 1302 includes a first portion 1306 that includes a fixed end and a second portion 1308 that includes a free end 1310. The free end and the fixed end of the spring arm 1302 are opposite and spaced apart from each other along a longitudinal axis of the spring arm 1302. The first portion 1306 of each spring arm 1302 extends from the spring base 1304 in the first direction. The second portion 1308 of each spring arm 1302 extends from the first portion 1306 of the spring arm 1302. At least a portion of the second portion 1308 of the spring arm 1302 is concave shaped portion when viewed from an outer surface of the spring 1300, as shown in FIG. 9B. For example, an apex of the concave shaped portion of the spring arm 1302 is radially inward of the first portion 1306 and the free end 1310 of the spring arm 1302.

[0108] The spring arms 1302c, 1302d, 1302g, 1302h further includes a tab 1312 that extends perpendicularly to the central longitudinal axis 1205. The tab 1312 extends from the first portion 1306 of the spring arm 1302 in a direction away from an adjacent spring arm 1302 within the same plane of the respective spring arm 1302. For example, the tab 1312 of the spring arm 1302h extends away from the corresponding spring arm 1302g, and the tab 1312 of the spring arm 1302g extends away from the corresponding spring arm 1302h. The tabs 1312 provide overstressprotection for the spring 1300 when the spring 1300 is being pushed axially relative to the shifter 1400. The tabs 1312 may also provide alignment of the spring 1300 within the receiver 1208 and prevent rotation of the spring 1300 within the receiver 1208.

[0109] The shifter 1400 is shown in FIGS. 10A-10F. Specifically, FIG. 10A shows an isometric view, FIG. 10B shows another isometric view, FIG. 10C shows a front view on the base plate side, FIG. 10D shows a top view, FIG. 10E shows a back view on the outer frame side, and FIG. 10F shows a side view. The shifter 1400 includes a base plate 1420 defining a central opening 1422 (e.g., an H-shaped opening). At least one protrusion 1424 (e.g., two protrusions 1424 in the shifter 1400 shown in FIGS. 10A-10E) extends partially into the central opening 1422. The shifter 1400 further includes an outer frame 1402. The outer frame 1402 defines an opening 1404, which is a square shaped opening. The base plate 1420 is coupled to the outer frame 1402 via connecting arms 1418. The shifter 1400 includes four connecting arms 1418 - one for each corner of the outer frame 1402.

[0110] The inner surface(s) 1403 of the square shaped outer frame 1402 face towards and define the opening 1404 of the shifter 1400. The opening 1404 is sized to engage the free ends 1310 of the spring arms 1302 and compress the spring arms 1302 radially inward. However, in other implementations, the opening of the shifter is sized and configured to retain the free ends of the contact arms of the male terminal body radially inward.

[0111] The various elements of the shifter 1400 are dimensioned and configured to accommodate the spring arms 1302. For example, the first portion 1306 of the spring arms 1302 extends over and outside of the base plate 1420 without interfering with the connecting arms 1418. The second portion 1308 of the spring arms 1302 extends within the opening 1404 defined by the outer frame 1402. Thus, in the pre-set position, the free end 1310 of each spring arm 1302a-1302h abuts inner surface(s) 1403 of the outer frame 1402 of the shifter 1400 to be retained radially inward. However, in the full-set position, the concave shaped portion of the second portion 1308 of the spring arm 1302 abuts the inner surface(s) 1403 of the outer frame 1402. The shifter 1400 comprises an electrically insulated material (e.g., nylon or other any non- conductive plastic material).

[0112] In other implementations of the male terminal assembly, various elements may have different shapes, numbers, and / or orientations. In some implementations, the male terminal body includes a shape other than a square (e.g., a round, rectangular, or low-profile shaped terminal body). In some implementations, the spring includes a shape other than a square, corresponding to an alternative shape of the male terminal body (e.g., a round, rectangular, or low-profileshaped spring). In some implementations, the shifter includes a shape other than a square, corresponding to an alternative shape of the male terminal body (e.g., a round, rectangular, or low-profile shaped shifter). In some implementations, the male terminal body includes fewer than eight contact arms (e.g., 1, 2, 3, 4, 5, 6, or 7 contact arms). In some implementations, the male terminal body includes more than eight contact arms (e.g., 9, 10, 11, 12, 13, 14, 15, 20, or more contact arms). In some implementations, the spring includes fewer than eight spring arms (e.g., 1, 2, 3, 4, 5, 6, or 7 spring arms). In some implementations, the spring includes more than eight spring arms (e.g., 9, 10, 11, 12, 13, 14, 15, 20, or more spring arms). In some implementations, the shifter is shaped to accommodate an alternative number of spring arms of the spring. In some implementations, the surfaces of the male terminal assembly and the female terminal assembly may include ramped surfaces to facilitate movement engagement (e.g., the free ends of the spring arms may include ramped surfaces). In some implementations, surfaces and corners between surfaces of the spring, shifter, and / or male terminal body include rounds, chamfers, and / or ramps to facilitate the sliding of elements passed one another (e.g., see Example Device and Assembly #2 and FIGS. 27 - 31H).

[0113] Assembly and Manufacture of the Male Terminal Assembly

[0114] After production and prior to assembly, the male terminal body 1200 of the male terminal assembly 1100 includes an open second end 1203. For example, the front cover 1240 of the male terminal body 1200 is parallel to the connector plate 1212 rather than bent to a position parallel to the rear wall 1204 to close the receiver 1208.

[0115] First, the spring arms 1302 are compressed radially inward by a machine automation process and / or device. For example, a sleeve may extend from the spring base 1304 and encapsulate a portion of the spring arms 1302 before compressing the spring arms 1302 radially inward. Then, once the spring arms 1302 are compressed, the shifter 1400 is installed onto the spring arms 1302. The shifter 1400 is installed such that the free ends 1310 of the spring arms 1302 are aligned with (or, in some implementations, engaged with) the inner surface(s) 1403 of the outer frame 1402 of the shifter 1400. Once the free ends 1310 of the spring arms 1302 are aligned with (or engaged with) the shifter 1400, the sleeve is released or removed from the spring arms 1302. The free ends 1310 of the spring arms 1302 then expand radially outward to engage with the inner surface 1403 (or, in some implementations, a cutout / channel of the inner surface) of the shifter 1400. The shifter 1400 retains the free ends 1310 of the spring arms 1302 in this position, which defines the pre-set position.

[0116] Once the spring 1300 and the shifter 1400 are in the pre-set position, they are installed into the receiver 1208 of the male terminal body 1200 via the open second end 1203 of the male terminal body 1200. Once the spring base 1304 is adjacent to the rear wall 1204 of the male terminal body 1200, and the outer frame 1402 of the spring shifter 1400 is fully disposed within the receiver 1208, the front cover front cover 1240 of the male terminal body 1200 is bent to close the receiver 1208. Once the front cover 1240 is bent closed, the male terminal assembly 1100 is fully manufactured and assembled in the pre-set position (see FIGS. 5-8).Female Terminal Assembly

[0117] FIGS. 11-15 contain different views of the female terminal assembly 1600 shown in FIGS. 1-3. Specifically, FIG. 11 is an exploded view of each component, FIG. 12 is an isometric view of the assembly, and FIGS. 13-15 are top, side, and front views of the assembly. The female terminal assembly 1600 shown in FIGS. 11-15 is a square-shaped female terminal body 1700 configured to accept a square shaped male assembly (e.g., the male terminal assembly 1100).

[0118] As shown in the exploded view of FIG. 11, the female terminal assembly 1600 includes a female terminal body 1700 including at least one side wall 1704 defining a female terminal receiver 1702 that is sized to receive at least a portion of the male terminal assembly 1100. The female terminal assembly 1600 further includes a touch proof post 1800 disposed within the female terminal receiver 1702. The female terminal body 1700 comprises an electrically conductive material (e.g., copper, aluminum, or any other selected conductive material). The inner conductive surface 1706 of the at least one side wall 1704 forms a conductive perimeter to accept the contact arm 1202 of the male terminal body 1200. Two contact arms 1202 may contact each side of the at least one side wall 1704 of the square-shaped female terminal body 1700 (e.g., in the connected position, creating an electrical connection therebetween).

[0119] The touch proof post 1800 is centrally located within the female terminal receiver 1702. The touch proof post 1800 includes a base plate 1802 and an insulative post 1820 that extends from the base plate 1802. The touch proof post 1800 is sized to pass through the center opening 1242 of the front cover 1240 of the male terminal body 1200. In the exemplary implementation shown in FIG. 11, the insulative post 1820 includes an X-shaped profile having four beams, which accommodates various elements of the male terminal assembly 1100. For example, the concave shaped portion of the second portion 1308 of the spring arms 1302 does not interfere with the insulative post 1820 when the insulative post 1820 is inserted into the receiver 1208 of the male terminal body 1200 of the male terminal assembly 1100. The insulative post 1820comprises a non-conductive material (e.g., nylon or any other non-conductive plastic material). Additionally, the insulative post 1820 provides a “touch proof’ functionality, preventing a user from touching the electrically conductive square-shaped female terminal body 1700.

[0120] The insulative post 1820 includes a free end 1818 spaced apart from the base plate 1802. As shown in FIG. 11, each beam of the insulative post 1820 further includes a groove or cut-out that defines a shoulder 1830 axially spaced between the base plate 1802 and the free end 1818. The shoulders 1830 are configured to abut the at least one protrusion 1424 of the shifter 1400 when the male terminal assembly 1100 and the female terminal assembly 1600 move from the disconnected position to the connected position. In the implementation shown in FIG. 11 , the groove has a triangular cross-sectional shape, but other cross-sectional shapes may be implemented (e.g., square, rectangular, or semi-circle). The shoulder 1830 is located at a first distance from the free end 1818 of the insulative post 1820 corresponding to a distance necessary for the male terminal assembly 1100, including the male terminal body 1200, the spring 1300, and the shifter 1400, to move in tandem into the female terminal receiver 1702 of the squareshaped female terminal body 1700 before a complete electrical connection is made.

[0121] In other implementations of the female terminal assembly, various elements may have different shapes, numbers, or orientations. In some implementations, the female terminal body includes a shape other than a square (e.g., a round, rectangular, or low-profile shaped terminal body). In some implementations, the shape of the square-shaped female terminal body, the female terminal receiver 1702, the at least one side wall 1704, and the conductive perimeter formed therein correspond to an alternative shape of the male terminal assembly (e.g., a round, rectangular, or low-profile shaped sidewall, female terminal receiver, and conductive perimeter formed therein). In some implementations, surfaces and corners between surfaces of the female terminal assembly, including the sidewall and the touch proof post, include rounds, chamfers, and / or ramps to facilitate the sliding of elements passed one another.Connected Position

[0122] FIGS. 16-19 contain views of the male and female terminal assemblies 1100, 1600 in the connected position. As shown in the cross-sectional views of FIG. 17 and FIG. 19, the protrusions 1424 of the shifter 1400 have engaged with the shoulders 1830 of the insulative post 1820 to initiate axial movement of the shifter 1400 towards the rear wall 1204 of the male terminal body 1200. As a result, the free ends 1310 of the spring arms 1302 of the spring 1300 have extended axially beyond the outer frame 1402 of the shifter 1400, expanding the spring arms 1302 radially outward. Furthermore, the contact arms 1202 of the male terminal body 1200have been pushed radially outward by the spring arms 1302 to contact the inner conductive surface 1706 of the female terminal body 1700.

[0123] As a more detailed example, FIGS. 20A, 20B, 21 A, and 2 IB contain a set of cross- sectional views showing the progress of the insertion of the male terminal body 1200 into the female terminal assembly 1600. Before the male terminal body 1200 is inserted into the female terminal receiver 1702 of the female terminal assembly 1600, the shifter 1400 of the male terminal assembly 1600 is in the pre-set position. In the pre-set position, the outer frame 1402 of the shifter 1400 retains the free ends 1310 of the spring arms 1302 radially inward, resulting in the contact arm 1202 being retained radially inward since they are configured to follow radial movement of the spring arms 1302, as shown in FIGS. 20A and 20B. When in the pre-set position, the apex 1218 of opposing contact arms 1202 (e.g., contact arms 1202a and 1202f on opposite sides of the central longitudinal axis 1205) are spaced apart from each other a distance DI and the free ends 1310 of opposing spring arms 1302 (e.g., spring arms 1302a and 1302f on opposite sides of the central longitudinal axis 1205) are spaced apart from each other a distance D3. The first portion 1306 of the spring arms 1302 in FIGS. 20A and 20B is oriented at an angle A with respect to the central longitudinal axis 1205 of the male terminal body 1200 (e.g., an angle greater than 0° and less than 45°) due to the compressive retaining force of the shifter 1400 on the spring arms 1302.

[0124] In FIGS. 20A and 20B, the portion of male terminal body 1200 (still in the pre-set position) has been inserted into the female terminal receiver 1702, which is defined by the inner conductive surface 1706 of the at least one side wall 1704. The at least one side wall 1704 includes opposing inner conductive surfaces 1706 (e.g., on opposite sides of the central longitudinal axis 1205) spaced apart from each other a distance D2 that is greater than the distance DI between apexes 1218 of opposing contact arm 1202. The apexes 1218 of opposing contact arms 1202 are adjacent to, but not fully engaged with, the inner conductive surface(s) 1706 of the female terminal body 1700. In other words, there is a small space or gap between the apex 1218 of opposing contact arms 1202 and the inner conductive surface 1706 of the at least one side wall 1704, which results in a reduced insertion force when the male terminal assembly 1100 is being connected to the female terminal assembly 1600. The spring arms 1302 remain retained by the shifter 1400, preventing the spring 1300 from expanding and pushing the contact arms 1202 radially outwards towards the inner conductive surface 1706 of the at least one side wall 1704 of the female terminal body 1700. In FIGS. 20A and 20B, the protrusions 1424 of the shifter 1400 are adjacent to the shoulders 1830 of the touch proof post 1800. However, the maleterminal body 1200 has not moved far enough inside the female terminal receiver 1702 for the protrusions 1424 and the shoulders 1830 to engage.

[0125] Once the male terminal body 1200 (still in the pre-set position) is inserted further axially into the female terminal receiver 1702, the protrusions 1424 of the shifter 1400 abut the shoulders 1830 of the touch proof post 1800, which stops movement of the shifter 1400 relative to the touch proof post 1800 and initiates movement of the shifter 1400 relative to the male terminal body 1200.

[0126] As the male terminal body 1200 is pushed axially further into the female terminal receiver 1702 to a second distance, the free ends 1310 of the spring arms 1302 of the spring 1300 move past the outer frame 1402 of the shifter 1400 in a direction away from the spring base 1304, which allows the spring arms 1302 to be released from their compressed, or pre-set, position. Once released, the spring arms 1302 expand radially outward to the full-set position as shown in FIGS. 21 A and 21B, where free ends 1310 of opposing spring arms 1302 are spaced apart from each other a distance D3’, which is greater than the distance D3 between free ends 1310 of opposing spring arms 1302 when the male terminal body 1200 is in the pre-set position.

[0127] The released spring arms 1302 in turn force the contact arms 1202 to move radially outward to the full-set position, where apexes 1218 of opposing contact arms 1202 are spaced apart from each other a distance DI’, which is greater than the distance DI between apexes 1218 of opposing contact arms 1202 when the male terminal assembly 1100 is in the pre-set position. When the contact arms 1202 are moved radially outward to the full-set position, the apexes 1218 of contact arms 1202 are fully engaged with the inner conductive surface 1706 of the female terminal body 1700. This results in a mechanical and electrical coupling between the male terminal body 1200 and the female terminal body 1700, shown in FIGS. 21 A and 2 IB.

[0128] Now released and in the full-set (and connected) position, the first portion 1306 of the spring arms 1302 in FIGS. 21A and 21B are substantially parallel to the central longitudinal axis 1205. Additionally, the full-set position in FIGS. 21A and 21B shows that the shifter 1400 has moved axially within the receiver 1208 towards the rear wall 1204 of the male terminal body 1200.

[0129] In the cross-sectional model of FIGS. 21 A and 21 B, the contact arms 1202 and the inner conductive surface 1706 of the female terminal body 1700 show an overlap. However, this overlap is an artifact of the modeling program depicting the images of FIGS. 21 A and 2 IB. In reality, the apexes 1218 of the contact arms 1202 contacts the inner conductive surface 1706 of the female terminal body 1700 with a certain contact (normal) force.

[0130] In use, the male terminal assembly 1100 and the female terminal assembly 1600 shown in the figures and described herein provide for a more reliable electrical connection. For example, existing electrical terminal systems may include contact arms biased radially inward that “squeeze” a male terminal body (e.g., box and blade terminal systems). Vibrational forces and / or heat produced during use expand the metal contact arms which can reduce the terminal contact (normal) force of such terminal systems. However, implementations of the assemblies described herein have spring arms that bias contact arms radially outward towards a female terminal body (e.g., the assemblies of FIGS. 1-21B). Thus, when experiencing heat expansion and / or vibrational forces, the spring arms expand to improve the contact force between the contact arms and inner surface of the female terminal body of the female terminal assembly.

[0131] Furthermore, the shifter allows for (i) a lower insertion force between the male and female terminal assemblies and (ii) a smoother transition from the disconnected position to the connected position (and from the pre-set position to the full-set position). In known systems, such as shown in FIGS. 26A-26C, the assembly does not include a shifter nor a touch proof post. In known systems, such as shown in FIGS. 26A-26C, the free ends of the spring arms disposed 180 degrees apart from each other (opposing each other) extend away from each other a first distance in the disconnected position. The distance between those free ends is reduced when the spring is in the connected position. Correspondingly, the apexes (or contact portions) of the contact arms disposed 180 degrees apart from each other extend away from each other a first distance in the disconnected position, and the distance between those contact portions is reduced when the contact arms are in the connected position. This connection requires the compression of the spring and the contact arms as the male terminal assembly is being inserted into the female terminal receiver, adding to the insertion force required. Plastic ramps are included externally to the female terminal receiver to guide the male contact arms and free ends of the spring arms into their compressed configurations in the connected position, which requires additional material for the female terminal assembly.

[0132] According to the implementations described above (e.g., shown and described in FIGS. 1-25), the distance between oppositely aligned free ends of the spring arms and contact arms is less in the pre-set position and / or the disconnected position than in the full-set position and / or the connected position (e.g., distances DI and D3 in the pre-set position are less than distances DI’ and D3’ in the full-set position). This pre-compressed arrangement in the pre-set position allows the male terminal body 1200 to be inserted into the female terminal body 1700 with less or no insertion force until the shifter 1400 engages the touch proof post 1800. The insertion forcerequired to slide the spring 1300 past the shifter 1400 after the shifter 1400 has engaged the touch proof post 1800 is less than the insertion force required in known systems.Implementations of the resulting electrical connector assembly avoids spikes in the insertion force when sliding the male terminal assembly into the female terminal receiver.Detailed Views and Assemblies

[0133] FIGS. 22-25 provide additional exploded views and assembly views of the male and / or female terminal assemblies 1100, 1600. For example, FIG. 22 shows the spring 1300, shifter 1400, and male terminal body 1200 of the male terminal assembly 1100 separated from each other and arranged around the touch proof post 1800 of the female terminal assembly 1600. FIG. 23 shows the interaction between the shifter 1400 and the touch proof post 1800. FIG. 24 shows the interaction between the spring 1300 and the touch proof post 1800. FIG. 25 shows a partial cut-away view of a fully assembled male and female terminal assembly in the connected position.Example Device and Assembly #2

[0134] FIGS. 27 - 31H show an electrical connector assembly 2000 according to another implementation. The electrical connector assembly 2000 of FIGS. 27 - 31H includes a male terminal assembly 2100 and a female terminal assembly 2600 that are substantially similar to the male terminal body 1200 and the female terminal assembly 1600 of the electrical connector assembly 1000 shown in FIGS. 1 - 3 except as described below.

[0135] FIG. 27 shows a side cross-sectional view of the electrical connector assembly 2000 in the connected position with the shifter 2400 in the full-set position. FIG. 28 shows a detailed section view of the cross-sectional view of FIG. 27.

[0136] A side view of the spring 2300 of the male terminal assembly 2100 is shown in FIG. 29. In this example implementation, the free end 2310 of the spring arms 2302 each include a rounded leading edge 2314 adjacent a ramped surface 2316. The rounded leading edge 2314 is on the radially outward surface of the free end 2310 of each spring arm 2302. In contrast to the sharp corner shown in FIG. 9B, the spring 2300 in FIG. 29 includes a free end 2310 of a spring arm 2302 having the rounded leading edge 2314 (e.g., having a radius of curvature of 0.1 to 0.3 mm) on the side that engages with the shifter 2400. In other implementations, the rounded leading edge is formed with a differently shaped curvature with a different radius (or radii) of curvature than that shown. In other implementations, the rounded leading edge is instead a chamfered leading edge.

[0137] The shifter 2400 of the male terminal assembly 2100 is shown in FIGS. 30A-30F.Specifically, FIGS. 30A and 30B show isometric views, FIG. 30C shows a front view, FIG. 30D shows a side view, FIG. 30E shows a back view, and FIG. 30F shows a cross-sectional view of the shifter 2400 as taken along the line F-F in FIG. 30B. The shifter 2400 in FIGS. 30A-30F includes rounded edges on all of the outside edges of the outer frame 2402 and the base plate 2420 - in contrast to the sharp edges of the shifter 1400 shown in FIGS. 10A-10F. For example, the protrusions 2424 on the shifter 2400 include rounded edges having a radius of curvature of 0.1 to 0.3mm to smoothly engage with and slide past the surfaces of the touch proof post 2800.

[0138] The inner surface 2403 of each side of the outer frame 2402 of the shifter 2400 shown in FIGS. 30A-30F defines a cutout or channel 2430. Each channel 2430 extends along a portion of the inner surface 2403 of each side. The ends of each channel 2430 are defined on the same side such that each channel 2430 does not connect with any other channels 2430. The channel 2430 has a curved floor having a radius that is configured to engage with the rounded leading edge 2314 of the spring 2300.

[0139] The shifter 2400 also includes a ramped surface 2432 on the second side of the outer frame 2402. The ramped surface 2432 extends from the front surface on the second side of the outer frame 2402 to the inner surface 2403 of the outer frame 2402, forming an angle of greater than 90° and less than 180° therebetween. The ramped surface 2432 extends all the way around the inner surface 2403 to connect each of the four sides. The ramped surface 2432 of the shifter 2400 is shaped to engage with a corresponding distal ramped surface 2316 of the free end 2310 of the spring arm 2302 adjacent the rounded leading edge 2314.

[0140] The touch-proof post 2800 of the female terminal assembly 2600 of the electrical connector assembly 2000 is shown in FIGS. 31 A - 31H. Specifically, FIG. 31A and FIG. 3 IB show isometric views, FIG. 31C shows a side view, FIG. 3 ID shows a front view, FIG. 3 IE shows a top view, FIG. 31F shows a detail isometric view, FIG. 31G shows a isometric view with a cross-sectional plane, and FIG. 31H shows a cross-sectional view along the plane of FIG. 31G.

[0141] In contrast to the touch proof post 1800 of the electrical connector assembly 1000 of FIGS. 1-3, the touch proof post 2800 in FIGS. 31A-31H includes snap fit beams 2850 extending from a central portion of the X-shaped insulative post 2820. The snap fit beams 2850a and 2850b are spaced apart and opposed to each other relative to a central longitudinal axis 2805 of the touch proof post 2800.

[0142] Each of the snap-fit beams 2850a, 2850b includes a snap-fit protrusion 2852 having ramped surfaces on axial sides of the protrusion 2852. The snap-fit protrusion 2852 is disposed between a plane that includes a free end 2818 of the touch proof post 2800 and a plane that includes the shoulder 2830, wherein the planes are axially spaced apart from each other. The ramped surfaces of the snap-fit protrusion 2852 include an entrance surface 2854 and a retraction surface 2856. The entrance surface 2854 is closer to the free end 2818 of the insulative post 2820 and is formed at a first angle of greater than 0° and less than 90° with respect to the central longitudinal axis 2805 of the touch proof post 2800. The retraction surface 2856 is closer to the shoulder 2830 of the touch proof post 2800 and is formed at a second angle of greater than 0° and less than 90° with respect to the central longitudinal axis 2805 of the touch proof post 2800. In some implementations, the first and second angles are different. In other implementations, the first and second angles are the same.

[0143] Each of the opposing snap-fit beams 2850a, 2850b are configured to flex radially inwardly towards each other about their fixed proximal ends. For example, when the protrusions 2424 of the shifter 2400 contacts the entrance surface 2854, the snap-fit beams 2850 may be forced radially inwardly to accommodate the protrusion 2424 of the shifter 2400.

[0144] A shifter protrusion cavity 2860 is defined in the area of the touch proof post 2800 between the retraction surface 2856 and the shoulder 2830. In the full-set position, the protrusions 2424 of the shifter 2400 sit within the spring shifter protrusion cavity 2860 of the touch proof post 2800.

[0145] In use, the male and female terminal assemblies 2100, 2600 of this example connect in a manner substantially similar to the electrical connector assembly 1000 of FIGS. 1-3 except as noted below. In the disconnected position, with the shifter 2400 in the pre-set position, the rounded leading edge 2314 of the spring 2300 is engaged with the cutout or channel 2430 on the inner surface 2403 of the outer frame 2402 of the shifter 2400 on each of the four sides. In the pre-set position, the rounded leading edges 2314 of the free ends 2310 of the spring arms 2302 are compressed radially inward by the inner surface 2403 of the outer frame 2402 of the shifter 2400. Therefore, the contact arms 2202 are also maintained in their radially inward position in the pre-set position.

[0146] To engage the male terminal assembly 2100 with the female terminal assembly 2600, the male terminal assembly 2100 is moved in a first axial direction a first distance into the female terminal receiver 2702, which causes the protrusions 2424 of the shifter 2400 to abut the entrance surface 2854 of the snap-fit beams 2850 of the insulative post 2820. The rounded edgesof the protrusions 2424 engage with the ramped entrance surface 2854 to flex each of the snap-fit beams 2850 inwardly toward each other. The inward flexing of the snap-fit beams 2850 allows the protrusions 2424 of the shifter 2400 to slide past the snap-fit protrusions 2852 until the protrusions 2424 of the shifter 2400 sit within the shifter protrusion cavity 2860.

[0147] Once the protrusions 2424 of the shifter 2400 are disposed within the shifter protrusion cavity 2860, the shifter 2400 is moved a second distance in the first axial direction until the protrusions 2424 abut the shoulder 2830 of the touch proof post 2800, which initiates movement of the shifter 2400 in the first axial direction with respect with respect to the male terminal body 2200 and stops the axial movement of the shifter 2400 in the first axial direction with respect to the touch proof post 2800.

[0148] As the male terminal body 2200 is further pushed into the female terminal receiver 2702 to a third distance in the first axial direction, the rounded leading edges 2314 of the spring 2300 move out of the channel 2430 of the shifter 2400 and past the outer frame 2402. Once free from the shifter 2400, the spring arms 2302 expand radially outward from each other into the connected position and the full-set position. In the full-set position, the outer surface of the spring arms 2302 pushes the contact arms 2202 radially outwardly to engage with the female terminal body 2700, completing the electrical connection between the male and female terminal assemblies 2100, 2600.

[0149] To disconnect the male and female terminal assemblies 2100, 2600 (i.e., move from the connected position to the disconnected position and from the full-set position to the pre-set position), the male terminal body 2200 is removed from the female terminal receiver 2702 in a second axial direction that is opposite of the first axial direction. By moving the male terminal body 2200 in second axial direction, the spring 2300 moves in the second axial direction until the distal ramped surface 2316 of the free end 2310 of the spring arm 2302 (that is adjacent to the rounded leading edge 2314) abuts the ramped surface 2432 of the outer frame 2402 of the shifter 2400. The ramped surfaces of these two elements facilitate compression of the free ends 2310 of the spring arms 2302 towards each other when the spring 2300 is moved in the second axial direction. The ramped surfaces slide past each other until the free ends 2310 of the spring arms 2302 clear the ramped surface 2432 of the outer frame 2402 of the 2400 and abut the inner surface 2403 of the outer frame 2402 of the shifter 2400, thereby compressing the spring arms 2302 radially inward.

[0150] The male terminal body 2200 is further moved outward in the second axial direction until the rounded leading edges 2314 of each spring arm 2302 engage with the channels 2430defined by the inner surfaces 2403 of the outer frame 2402 of the spring shifter 2400, firmly coupling the spring 2300 and shifter 2400 together. As the spring arms 2302 are compressed, the respective contact arms 2202 move radially inward away from the female terminal body 2700, such that the apexes of the contact arms 2202 disengage from the inner surface of the female terminal sidewall, thereby electrically disconnecting the male terminal assembly 2100 from the female terminal assembly 2600. However, the male and female terminal assemblies 2100, 2600 remain mechanically coupled (e.g., via the non-conductive touch proof post and shifter, and / or via a housing element) until the male terminal assembly 2100 is fully pulled out from the female terminal receiver 2702.

[0151] Next, the male terminal assembly 2100 is moved further in the second axial direction until the protrusions 2424 of the shifter 2400 abut the retraction surface 2856 of the snap-fit beams 2850 of the touch proof post 2800. The rounded edges of the protrusions 2424 engage with the ramped retraction surface 2856 to flex each of the snap-fit beams 2850 inwardly toward each other. The bending of the snap-fit beams 2850 allows the protrusions 2424 to slide past the snap-fit protrusions 2852 until the protrusions 2424 of the shifter 2400 are no longer engaged with or contained by the touch proof post 2800. At this point, the male terminal assembly 2100 is mechanically separated from the female terminal assembly 2600. The connection and disconnection of the male and female terminal assemblies 2100, 2600 may be repeated as needed.Example Device and Assembly #3

[0152] FIGS. 32-58 and 61-76 show various views of an electrical connector assembly 3000 and the components thereof, according to various implementations. The basic operation of the electrical connector assembly 3000 is similar to that of the electrical connector assemblies 1000, 2000 described with reference to FIGS. 1-31G. For example, the electrical connector assembly 3000 includes both a male terminal assembly 3100 and a female terminal assembly 3600. The male terminal assembly 3100 is mechanically and electrically couplable to the female terminal assembly 3600. The electrical connector assembly 3000 includes a male housing assembly 3102 couplable to a corresponding female housing assembly 3602.

[0153] In general, the electrical connector assembly 3000 includes a shifter 3400 that is moveable between a pre-set position and a full-set position. Similar to the shifters 1400, 2400 of the electrical connector assemblies 1000, 2000, a touch-proof post 3800 on the female terminal assembly 3600 moves the shifter 3400 from the pre-set position to the full-set position. In the pre-set position, the shifter 3400 retains a portion of the male terminal assembly 3100 (e.g.,contact arms 3202 of a male terminal body 3200). In the full-set position, the shifter 3400 does not retain the portion of the male terminal assembly 3100, which allows the male terminal assembly 3100 to make electrical and mechanical contact with a female terminal body 3700 of the female terminal assembly 3600 when the male terminal assembly 3100 is in the connected position with the female terminal assembly 3600. Moving the electrical connector assembly 3000 from the disconnected position to the connected position also involves moving the shifter 3400 of the male terminal assembly 3100 from the pre-set position to the full-set position

[0154] As further described herein, the electrical connector assembly 3000 ensures that the male terminal assembly 3100 remains in the pre-set position during transportation and system assembly (e.g., when coupling a male connector plate to a local wire and / or battery pack). The electrical connector assembly 3000 also has a low insertion force. For example, the electrical connector assembly 3000 can provide an insertion force that meets USCAR standards for connector-to-connector insertion force (e.g., less than 75 Newtons). In some implementations, the electrical connector assemblies of the present disclosure provide an insertion force in the range of 15 to 75 Newtons (e.g., 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, or 75 Newtons).

[0155] FIG. 32 shows an isometric view of the electrical connector assembly 3000 in a fully assembled or connected position. FIG. 33 shows an exploded view of the electrical connector assembly 3000. FIG. 34 shows a top view, and FIG. 35 shows a side view, of the electrical connector assembly 3000. FIG. 36 shows a front view, and FIG. 37 shows a back view, of the electrical connector assembly 3000. FIG. 38 shows a cross-sectional view of the electrical connector assembly 3000 along line 38-38 in FIG. 37. FIG. 39 shows a cross-sectional view of the electrical connector assembly along line 39-39 in FIG. 36. Both FIG. 38 and FIG, 39 show the internal elements of the electrical connector assembly 3000, including the interactions between the male terminal assembly 3100 and the female terminal assembly 3600.

[0156] FIG. 40 shows an isometric detail view of the cross-sectional view of FIG. 38. FIG. 41 shows a view of the electrical connector assembly 3000 with the external components (e.g., housings) removed. FIG. 41 is a cross-sectional view that shows the interaction between the male and female terminal bodies 3200, 3700 and adjacent elements. FIG. 42 is an isometric view of the cross-sectional view of FIG. 41.

[0157] FIG. 43 shows a cross-sectional view of the male and female terminal bodies 3200, 3700 and adjacent elements along the line 43-43 in FIG. 41. FIG. 44 shows the cross-sectional view of FIG. 43 at an angle to better view some of the internal elements.Male Terminal Assembly

[0158] FIG. 45 shows an isometric view of the male terminal assembly 3100, and FIG. 46 shows the same view without the male housing assembly 3102. FIG. 47 shows a back view, and FIG. 48 shows a front view, of the male terminal assembly 3100 without the male housing assembly 3102. FIG. 49 shows a side view of the male terminal assembly 3100. FIG. 50 shows a cross-sectional view along line 50-50 in FIG. 48.

[0159] The male terminal assembly 3100 includes the male housing assembly 3102, a male terminal body 3200, a spring 3300, a shifter 3400, and male terminal retainer 3500. FIGS. 51 and 52 show only the male terminal body 3200, the spring 3300, and the shifter 3400 in a full-set position. FIGS. 53 and 54 show only the male terminal body 3200 and the spring 3300, including the assembly thereof.

[0160] The male terminal body 3200 includes a rear wall 3204 and at least one side wall 3206. As shown, the at least one side wall 3206 includes four side walls 3206a, 3206b, 3206c, and 3206d. The side walls 3206a-3206d are arranged in a square cross-sectional shape (e.g., side wall 3206a is parallel to and spaced apart from side wall 3206c, while side walls 3206b and 3206d are perpendicular to both side walls 3206a and 3206c). However, in other implementations, the at least one side wall has a different overall cross-sectional shape (e.g., a rectangular or a round cross-sectional shape).

[0161] The male terminal body 3200 defines a receiver 3208. The receiver 3208 may be defined between the side walls 3206a-3206d and the rear wall 3204. A central longitudinal axis 3210 of the male terminal body 3200 extends through the rear wall 3204 and the receiver 3208.

[0162] The rear wall 3204 is coupled to a connector plate 3212. Additionally, the side wall 3206c is coupled to another portion of the connector plate 3212. During assembly, both portions of the connector plate 3212 are coupled together via a tox 3214 (e.g., a weld or a rivet-like weld). Although the connector plate 3212 of the male terminal body 3200 (and the similar connector plates of the male terminal bodies 1200, 2220 elsewhere described), includes two portions coupled together (e.g., via a tox), in other implementations, the connector plate of this disclosure may only include one portion or may include more than two portions coupled together.

[0163] The male terminal body 3200 includes at least one contact arm 3202. As shown, the male terminal body 3200 includes eight contact arms, 3202a, 3202b, 3202c, 3202d, 3202e, 3202f, 3202g, and 3202h. The first set of contact arms 3202a and 3202b extend from the first side wall 3206a. The second set of contact arms 3202c and 3202d extend from the second side wall 3206b. The third set of contact arms 3202e and 3202f extend from the third side wall 3206c. The fourth set of contact arms 3202g and 3202h extend from the fourth side wall 3206d.

[0164] Although eight total contact arms 3202 are shown, in other implementations, a different number of contact arms may be present (e.g., 1, 2, 3, 4, 5, 6, 7, 9, 10, 11, 12, 15, 20, 25, 30, 35, 40, or more contact arms). Although the contact arms 3202 are shown with two contact arms 3202 per side of the male terminal body 3200, in other implementations, a different arrangement of contact arms may be present (e.g., 1 contact arm per side, 3 contact arms per side, 4 contact arms per side, 5 contact arms per side, or more contact arms per side). In other implementations, a circular or cylindrical male terminal body is provided having a single wall with a number of contact arms defined by or extending from the side wall. In other implementations, a rectangular or rectangular prism male terminal body is provided having a first number of contact arms on a first side of the male terminal body and a second number of contact arms on a second side of the male terminal body (e.g., anywhere from 0 to 10 contact arms on a first side and anywhere from 0 to 10 contact arms on a second side, and any combination in between). In some implementations, the contact arms extend directly from a rear wall (e.g., no side wall or side portion is present). In some implementations, the fixed end of the contact arm includes a cut-out adjacent to the side wall (see, e.g., FIG. 59 showing a varied depth of the cut-out, and FIG. 60 showing a varied width of the cut-out).

[0165] Each contact arm 3202 includes a first portion 3216 extending radially outward from the corresponding side wall 3206. The first portion 3216 includes an apex 3218 that is spaced apart from the central longitudinal axis 3210 on the first portion 3216 of the contact arm 3202. The apex 3218 is configured to contact the female terminal body when the male terminal body 3200 and the female terminal body are in the connected position.

[0166] The contact arm 3202 further includes an intermediate portion 3220 extending substantially radially inward from the first portion 3216. The intermediate portion 3220 may extend perpendicular to the central longitudinal axis 3210. The contact arm 3202 further includes a second portion 3222 extending at a radially outward angle from the intermediate portion 3220. The second portion 3222 includes a free end 3224 of the contact arm 3202.

[0167] A width of the intermediate portion 3220 tapers between the first portion 3216 to the second portion 3222. A width of the second portion 3222 is less than a width of the first portion 3216 of the contact arm 3202. Each width is measured in a direction perpendicular to the central longitudinal axis 3210 and parallel to the corresponding side wall 3206. For example, the width of the first portion 3216 of the first contact arm 3202a adjacent to the first side wall 3206a is measured in a direction along the first side wall 3206a perpendicular to the second side wall 3206b. The width of the second portion 3222 of the first contact arm 3202a is measured in thesame direction that is less than the width of the first portion 3216. In other implementations, the contact arm includes a necked-portion having a smaller width adjacent to the side wall (e.g., a necked-portion providing enhanced bending capabilities for the contact arm, see FIG. 60). The necked portion shown in FIG. 60 is on the fixed end of the contact arm adjacent the side wall. In some implementations, fewer than all of the contact arms have a narrowing width (e.g., some contact arms may have a uniform width along their entire length).

[0168] The contact arm 3202 includes an outer surface 3228 and an inner surface 3230. The outer surface 3228 is disposed radially outward with respect to the inner surface 3230. A resting space 3226 is defined by and in between the intermediate portion 3220 and the second portion 3222 on the outer surface 3228 side of the contact arm 3202. The resting space 3226 is configured and shaped to house a portion of the shifter 3400 in the full-set position, as further described below.

[0169] The spring 3300 is disposed within the receiver 3208 of the male terminal body 3200. For example, the receiver 3208 of the male terminal body 3200 is dimensioned to receive the spring 3300. As shown in FIG. 53, during assembly of the male terminal body 3200 (e.g., after a step in a progressive stamping operation), the male terminal body 3200 is “open” to allow installation of the spring 3300 in the receiver 3208. In FIG. 54, the spring 3300 is fully installed within the male terminal body 3200, which is “closed” around the spring 3300. A portion of the at least one side wall 3206 and / or the rear wall 3204 of the male terminal body 3200 may be welded (e.g., spot-welded) to permanently close the male terminal body 3200 and hold the spring 3300 within the receiver 3208.

[0170] The spring 3300 includes a spring base 3304 and at least one spring arm 3302 extending from the spring base 3304. As shown, the spring 3300 includes the same number of spring arms 3302 as the number of contact arms 3202 of the male terminal body 3200. For example, a first spring arm 3302a corresponds to the first contact arm 3202a. However, in other implementations, the spring may include a number of spring arms larger or smaller than that of the contact arms. At least a portion of each of the spring arms 3302a-3302h is disposed radially inward from at least a portion of the corresponding contact arm 3202a-3202h.

[0171] Each spring arm 3302 includes a first portion 3306 extending from the spring base 3304. The first portion 3306 extends substantially perpendicularly from the spring base 3304. However, in other implementations, the first portion of the spring arm may extend radially outwardly or radially inwardly from the spring base. Each spring arm 3302 further includes a second portion 3308 extending at a radially outward angle from the first portion 3306 (e.g., awayfrom the central longitudinal axis 3210). However, in other implementations, the entire spring arm may be perpendicular to the rear wall - or the entire spring arm may extend radially outwardly - along the entire length of the spring arm.

[0172] The second portion 3308 of the spring arm 3302 includes a free end 3310. The free end 3310 of the spring arm 3302 abuts the inner surface 3230 of the contact arm 3202 of the male terminal body 3200. The spring arm 3302 applies an outwardly directed biasing force on the contact arm 3202 of the male terminal body 3200. Each of the spring arms 3302a-3302h apply an equal portion of the outwardly directed biasing force on each of the contact arms 3202a-3202h.

[0173] The male terminal assembly 3100 further includes a shifter 3400. FIGS. 55-58 show various views of the shifter 3400, and FIGS. 51-52 show the shifter 3400 in place on the male terminal body 3200 and the spring 3300 in the full-set position.

[0174] The shifter 3400 includes an outer frame 3402 defining an opening 3404, at least one support leg 3410, at least one connecting arm 3418, and a central locking portion 3420. The outer frame 3402 and the corresponding opening 3404 are aligned with a central longitudinal axis 3406 of the shifter 3400 (e.g., which may be colinear with the longitudinal axis 3210 of the male terminal body 3200 when the shifter 3400 is disposed within the receiver 3208 of the male terminal body 3200). The outer frame 3402 includes a chamfered edge 3408 (e.g., a rounded or chamfered edge about the periphery of the opening 3404).

[0175] The at least one support leg 3410 includes a first support leg 3410a and a second support leg 3410b. Each support leg 3410 extends from the outer frame 3402 in the first direction substantially parallel to the central longitudinal axis 3406 (e.g., perpendicular to a first plane defined by the outer frame 3402). The at least one support leg 3410 includes a first end 3412 adjacent and coupled to the outer frame 3402 and a second end 3414 opposite and spaced apart from the first end 3412 in the first direction.

[0176] The at least one connecting arm 3418 includes a first connecting arm 3418a and a second connecting arm 3418b. The first connecting arm 3418a, having a curved or S-type shape, is coupled to and extends radially inward from the second end 3414 of the first support leg 3410a. The second connecting arm 3418b is coupled to and extends radially inward from the second end 3414 of the second support leg 3410b. However, in other implementations, the at least one connecting arm 3418 is coupled to and extends from a different portion of the at least one support leg 3410.

[0177] The central locking portion 3420 extends in the first direction substantially parallel to the central longitudinal axis 3406. The central locking portion 3420 includes a first end 3422 adjacent to the opening 3404 of the shifter 3400. The central locking portion 3420 includes a second end 3424 opposite and spaced apart from the first end 3422 in the first direction. The second end 3424 of the central locking portion 3420 is coupled to each of the first connecting arm 3418a and the second connecting arm 3418b.

[0178] The central locking portion 3420 includes a first lock leg 3426a and a second lock leg 3426b. The first lock leg 3426a is coupled to the first connecting arm 3418a on the second end 3424 of the central locking portion 3420. The second lock leg 3426b is coupled to the second connecting arm 3418b on the second end 3424 of the central locking portion 3420. A locking space 3428 is defined between the first lock leg 3426a and the second lock leg 3426b. Each of the first lock leg 3426a and the second lock leg 3426b are connected to each other on the first end 3422 of the central locking portion 3420. The locking space 3428 is further defined by at least one pulling surface 3440 arranged substantially perpendicular to the central longitudinal axis 3406 and adjacent to the first lock leg 3426a and the second lock leg 3426b.

[0179] The central locking portion 3420 includes a deflector surface 3430 on the first end 3422 adjacent to where the first and second lock legs 3426a, 3426b are connected to each other. The deflector surface 3430 includes a first side 3430a and a second side 3430b each arranged to align with the locking space 3428. A distance between the first side 3430a and the second side 3430b of the deflector surface 3430 gradually increases from the first end 3422 of the central locking portion 3420 towards the second end 3424 of the central locking portion 3420.

[0180] The central locking portion 3420 further includes a pushing surface 3438 on the first end 3422 of the at least one pulling surface 3440 adjacent to the deflector surface 3430. The pushing surface 3438 is disposed in between the first side 3430a and the second side 3430b of the deflector surface 3430. The pushing surface 3438 is substantially perpendicular to the central longitudinal axis 3406 and is configured to abut a portion of the touch proof post 3800.

[0181] The shifter 3400 is movable between (i) a pre-set position wherein the free end 3224 of the at least one contact arm 3202 is disposed in a first position, and (ii) a full-set position wherein the free end 3224 of the at least one contact arm 3202 is disposed in a second position, wherein the first position is radially inward of the second position (e.g., closer to the longitudinal axis 3210 in the first position).

[0182] In the pre-set position, the free end 3224 of the contact arm 3202 is retained radially inwardly by the outer frame 3402 of the shifter 3400. For example, FIG. 72 shows the pre-setposition wherein the free end 3224 of each of the at least one contact arm 3202 is retained radially inwardly by the outer frame 3402 of the shifter 3400. As further described below, the contact arm 3202, including the apex 3218, is spaced apart from the female terminal body 3700 in the pre-set position.

[0183] In the full-set position, as shown in FIGS. 38-42, 50-52, and 74, the shifter 3400 is moved relative to the male terminal body 3200 in a direction towards the rear wall 3204 of the male terminal body 3200. The outer frame 3402 no longer retains the free ends 3224 of the contact arms 3202 in the full-set position. Instead, the outer frame 3402 of the shifter 3400 is disposed in the resting space 3226 of the contact arm 3202, and the free end 3224 of the contact arm 3202 is free to expand radially outwardly with respect to the pre-set position. The movement of the contact arms 3202 outwardly is due at least in part to the outwardly directed spring force from the spring arms 3302 of the spring 3300 disposed within the receiver 3208 of the male terminal body 3200. In other implementations, the outer frame of the shifter may retain free ends of the spring arms, such as in the electrical connector assembly 1000.

[0184] The shifter 3400 is also moveable from the full-set position back to the pre-set position by moving the shifter 3400 with respect to the male terminal body 3200 (e.g., away from the rear wall 3204 of the male terminal body 3200). The chamfered edge 3408 of the outer frame 3402 facilitates movement of the shifter 3400 from the full-set position to the pre-set position by providing a surface along which the outer surface 3228 of the contact arm 3202 can slide until the free end 3224 of the contact arm 3202 is retained by the outer frame 3402 of the shifter 3400.

[0185] The male terminal assembly 3100 further includes a male terminal retainer 3500, as shown in FIGS. 46-50. The male terminal retainer 3500 comprises an insulative or non- conductive material. The male terminal retainer 3500 generally provides a mechanical connection between the male terminal body 3200 and the male housing assembly 3102 while providing support and placement to elements of the male terminal assembly 3100. Additionally, the male terminal assembly 3100 prevents unintended movement of the shifter 3400 during handling, assembly, and subsequent operations.

[0186] The male terminal retainer 3500 includes a base 3502 and at least one side wall 3504 extending from the base 3502. The base 3502 defines a central opening 3516. The base 3502 and the at least one side wall 3504 define a male terminal retainer receiver 3506 dimensioned to receive the male terminal body 3200. The at least one side wall 3504 includes four side walls that match the shape of the male terminal body 3200 (e.g., a square cross-sectional shape, or, in other implementations, a rectangular or circular cross-sectional shape).

[0187] Each side wall of the at least one side wall 3504 defines a side wall opening 3508. As shown in FIGS. 46, 49, and 50, each contact arm 3202 extends through the side wall opening 3508. Specifically, the apex 3218 of each contact arm 3202 extends through the side wall opening 3508 to ensure that electrical connection between the male terminal body 3200 and the female terminal body 3700 remains possible with the insulative male terminal retainer 3500 in place.

[0188] The male terminal retainer 3500 further includes a housing 3510 integrally formed with the at least one side wall 3504 and extending away from the base 3502. The housing 3510 further defines the male terminal retainer receiver 3506 through which the male terminal body 3200 is disposed during assembly. The housing 3510 also defines a connector plate receiver 3512 sized to receive and retain the connector plate 3212 of the male terminal body 3200.

[0189] The base 3502 of the male terminal retainer 3500 prevents movement of the shifter 3400 in a direction away from the spring base 3304 of the spring 3300 and / or away from the rear wall 3204 of the male terminal body 3200. Once assembled and in the pre-set position, the outer frame 3402 of the shifter 3400 is adjacent to an inner surface of the base 3502 of the male terminal retainer 3500. For example, as shown in FIG. 72, the outer frame 3402 of the shifter 3400 may abut the inner surface of the base 3502 of the male terminal retainer 3500 so that shifter 3400 cannot move away from the rear wall 3204 of the male terminal body 3200. Thus, during transportation, assembly, and handling, the shifter 3400 cannot inadvertently move from the pre-set position to a disengaged position away from the rear wall 3204 of the male terminal body 3200. For example, without the male terminal retainer 3500, the shifter 3400 may shift forward of the ends of the contact arms 3202, thus being disengaged with the contact arms 3202.

[0190] The electrical connector assembly 3000 includes a male-side wire 3002. The male-side wire 3002 may be a customer-side wire that is installed onto the electrical connector assembly 3000 after delivery. For example, the male-side wire 3002 may be welded to the connector plate 3212 of the male terminal body 3200. Similarly, the electrical connector assembly 3000 includes a female connector terminal 3006 that is coupled to the female terminal body (e.g., a connector plate thereof).

[0191] The male housing assembly 3102 generally houses and insulates the male terminal body 3200 and the spring 3300 from an external environment. The male housing assembly 3102 includes a male-side wire housing 3104 that covers the male-side wire 3002. The male housing assembly 3102 further includes a first male housing 3106 that couples to the male-side wirehousing 3104. The first male housing 3106 includes a first coupling portion 3108 that couples to a housing coupling 3514 of the male terminal retainer 3500.

[0192] The first male housing 3106 defines a connector position assembly retainer 3110. The connector position assurance (CPA) retainer 3110 is configured to receive a connector position assurance (CPA) device 3112. The CPA device 3112 couples to both the first male housing 3106 and the female housing assembly 3602.Female Terminal Assembly

[0193] The female terminal assembly 3600 includes a female housing assembly 3602, a female terminal body 3700, a touch proof post 3800, and a post retainer 3900. FIGS. 61-62 show the female terminal assembly 3600 without the female housing assembly 3602 but with the shifter 3400 of the male terminal assembly 3100. Thus, the interaction between the shifter 3400 and the touch proof post 3800 is visible in FIGS. 61-62. FIGS. 63-67 show various views of the female terminal assembly 3600 without the female housing assembly 3602. FIGS. 68-71 show various views of the touch proof post 3800.

[0194] The female terminal body 3700 defines a female terminal receiver 3702 dimensioned to receive a portion of the male terminal body 3200 (e.g., the contact arms 3202). The female terminal body 3700 includes at least one side wall 3704 defining the female terminal receiver 3702. The at least one side wall 3704 has a cross-sectional shape matching that of the male terminal body 3200 (e.g., a square cross-sectional shape as shown, or, in other implementations, rectangular or circular cross-sectional shape).

[0195] The female terminal body 3700 further includes a connector plate 3708 coupled to the at least one side wall 3704. The connector plate 3708 extends away from the portion of the female terminal body 3700 and the at least one side wall 3704 that defines the female terminal receiver 3702. The connector plate 3708 is configured to couple to a terminal (e.g., a battery terminal or conductive wire) to transfer electricity between the terminal and the female terminal body 3700.

[0196] Each side wall 3704 of the female terminal body 3700 includes an inner conductive surface 3706. In the connected position and the full-set position, the contact arms 3202 of the male terminal body contact the inner conductive surface 3706 of the female terminal body 3700.

[0197] The at least one side wall 3704 and the female terminal receiver 3702 defined therein include a front edge 3710 (e.g., a front edge on an end of the female terminal body 3700 oppositefrom the connector plate 3708). The front edge 3710 of the at least one side wall 3704 includes a chamfered edge (e.g., a rounded or chamfered periphery of the female terminal receiver 3702).

[0198] The female terminal body 3700 defines a plurality of openings extending through the at least one side wall 3704 (e.g., coupling openings). For example, one of the at least one side walls 3704 (e.g., the side wall 3704c shown in FIG. 64 and colinear with the connector plate 3708) defines a first coupling opening 3712 and a second coupling opening 3714. In other implementations, more than two coupling openings are defined in the female terminal body, or less than two coupling openings are defined in the female terminal body. The at least one side wall 3704 further defines at least one coupling slot 3716, as further described below.

[0199] The touch proof post 3800 is coupled to the female terminal body 3700 (e.g., via one or more of the first coupling opening 3712 or the at least one coupling slot 3716). The touch proof post 3800 includes a base plate 3802 and a base block 3804 aligned with a central longitudinal axis 3805 of the touch proof post 3800. For example, the base plate 3802 includes a back surface 3806 and a front surface 3808 opposite from the back surface 3806. The base block 3804 extends from a central portion of the front surface 3808 of the base plate 3802 (e.g., aligned with the central longitudinal axis 3805). The base block 3804 has a substantially square shape, but, in other implementations, the base block may have a different shape (e.g., rectangular, circular, irregular, etc.). In other implementations, the back block is not included in the touch proof post.

[0200] The base plate 3802 further includes a first coupling protrusion 3810 configured to fit within the first coupling opening 3712 of the female terminal body 3700. The base plate 3802 further includes a second coupling protrusion 3812 configured to fit within the at least one coupling slot 3716 of the female terminal body 3700. Thus, each of the first coupling protrusion 3810 and the second coupling protrusion 3812 of the base plate 3802 are configured to fit and align the touch proof post 3800 with the female terminal body 3700. The base plate 3802 further includes a notch 3814 configured to engage with a portion of the post retainer 3900.

[0201] The touch proof post 3800 further includes at least one insulative post 3820 extending from the base block 3804 in a direction parallel to the central longitudinal axis 3805. The touch proof post 3800 shown includes four insulative posts 3820a-3820d. Each of the insulative posts 3820a-3820d are arranged on or adjacent the corners of the base block 3804. However, in other implementations, the insulative posts extend from a different portion of the base block and / or the base plate. In other implementations, the touch proof post includes a different number of insulative posts (e.g., 1, 2, 3, 5, 6, 7, 8, 9, 10, 12, 15, or 20 insulative posts).

[0202] When assembled, a free end 3818 of each of the at least one insulative posts 3820 extends beyond the front edge 3710 of the female terminal body 3700. During assembly and operation, the at least one insulative post 3820 creates a mechanical interference that prevents a user from accidentally touching the conductive female terminal body 3700.

[0203] The touch proof post 3800 further includes at least one lock arm 3830 extending from the base block 3804 (or, in other implementations, from the base plate) in a direction substantially perpendicular to the central longitudinal axis 3805. As shown, the touch proof post 3800 includes a first lock arm 3830a and a second lock arm 3830b spaced apart from each other. A locking area 3832 is defined between the first lock arm 3830a and the second lock arm 3830b. Each of the at least one lock arm 3830 is disposed radially inward relative to the at least one insulative post 3820. However, in other implementations, the at least one insulative post and the at least one lock arm have a different arrangement (e.g., the lock arms are disposed radially outward of the insulative posts; at least one lock arm is disposed radially outward and at least one lock arm disposed radially inward of at least one insulative post; or at least one insulative post is radially spaced apart from the central longitudinal axis a distance equal to that of at least one lock arm).

[0204] Each of the first lock arm 3830a and the second lock arm 3830b include a free end 3834. The free end 3834 of each of the first lock arm 3830a and the second lock arm 3830b may be deflected radially outward from the locking area 3832.

[0205] The free end 3834 of the at least one lock arm 3830 includes a first ramped surface 3836 oriented substantially towards the locking area 3832 and the central longitudinal axis 3805. The free end 3834 of the at least one lock arm 3830 includes a second surface 3838 adjacent the first ramped surface 3836, the second surface 3838 oriented substantially parallel to the base plate 3802 in a direction substantially perpendicular to the central longitudinal axis 3805.

[0206] The first ramped surface 3836 is configured to engage with the deflector surface 3430 of the central locking portion 3420 of the shifter 3400 (e.g., when moving from the pre-set position to the full-set position). The second surface 3838 is configured to engage with the at least one pulling surface 3440 of the central locking portion 3420 of the shifter 3400 (e.g., when moving from the full-set position to the pre-set position).

[0207] The post retainer 3900 of the female terminal assembly 3600 assists in supporting the touch proof post 3800 and coupling the various elements of the female terminal assembly 3600 together (e.g., the female housing assembly 3602 and the female terminal body 3700). The post retainer 3900 also provides error prevention during assembly (e.g., a poke-yoke feature) bypreventing incorrect installation / assembly of the touch proof post 3800 with the female terminal body 3700.

[0208] The post retainer 3900 includes at least one side wall 3902 and at least one rear wall 3904 defining a cavity 3906. At least one coupling protrusion extends radially outward from the at least one side wall 3902 of the post retainer 3900. In the post retainer 3900 shown, a first coupling protrusion 3908a extends from one side of the post retainer 3900. The first coupling protrusion 3908a is configured to engage with and extend into the second coupling opening 3714 of the female terminal body 3700. Furthermore, a second coupling protrusion 3908b on a second side opposite of the first coupling protrusion 3908a is configured to engage with a portion of the female housing assembly 3602. Each of the first and second coupling protrusions 3908a and 3908b are snap-fit or cantilevered protrusions. However, in other implementations, they may be stationary protrusions. A third coupling protrusion 3908c extends through the first coupling opening 3712 of the female terminal body 3700 along with the first coupling protrusion 3810 of the touch proof post 3800. In other implementations, a greater or a fewer number of protrusions, couplings, and alignment holes are present in the female terminal assembly.

[0209] The female housing assembly 3602 generally houses and insulates female terminal body 3700 from an external environment. The female housing assembly 3602 includes a coupling portion 3604 that engages with the male housing assembly 3102 and the connector position assurance (CPA) device 3112. The female housing assembly 3602 further includes a front edge 3606 which encapsulates the front edge 3710 of the female terminal body 3700.

[0210] In use, the male terminal assembly 3100 is mechanically and electrically coupled to the female terminal assembly 3600 from a disconnected position to a connected position. The configuration of elements in each of the male terminal assembly 3100 and the female terminal assembly 3600 provide a low insertion force connection process. For example, the electrical connector assembly 3000 can move from the disconnected position to the connected position (i) without exceeding USCAR standards for insertion force, and (ii) while providing adequate connective feedback and assurance to a user.

[0211] Moving the electrical connector assembly 3000 from the disconnected position to the connected position also involves moving the shifter 3400 of the male terminal assembly 3100 from the pre-set position to the full-set position. For example, when the male terminal assembly 3100 is manufactured, assembled, and delivered, the shifter 3400 is in the pre-set position, and it remains in that position until the male terminal assembly 3100 engages with and connects to a female terminal assembly 3600.

[0212] FIG. 72 shows a disconnected position of the male terminal assembly 3100 and the female terminal assembly 3600 wherein the shifter 3400 is in the pre-set position with the outer frame 3402 retaining the contact arms 3202 radially inward. Each of the male terminal assembly 3100 and the female terminal assembly 3600 are axially aligned. As shown, a portion of the female housing assembly 3602, the free end 3818 of the at least one insulative post 3820, and the front edge 3710 of the female terminal body 3700 are each adjacent to, but not yet engaged with, the male terminal assembly 3100. The shifter 3400 is shown within the male terminal retainer receiver 3506 of the male terminal retainer 3500 adjacent to the base 3502. The central opening 3516 is oriented towards the free end 3818 of the at least one insulative post 3820. The first end 3422 of the central locking portion 3420, including the first side 3430a and the second side 3430b of the deflector surface 3430, is adjacent to the central opening 3516.

[0213] FIG. 73 shows the beginning of the insertion process, wherein the female terminal assembly 3600 and the male terminal assembly 3100 are moved closer relative to each other and begin to engage. A portion of the female housing assembly 3602 is now within the male housing assembly 3102 (e.g., the first male housing 3106). The free end 3818 of the at least one insulative post 3820 extends through the central opening 3516 of the male terminal retainer 3500 and into the receiver 3208 of the male terminal body 3200. The elements of the electrical connector assembly 3000 are dimensioned such that the at least one insulative post 3820 does not interfere with the male terminal body 3200, the spring 3300, or the shifter 3400 except as desired (e.g., engaging the pushing surface 3438 with the base block 3804).

[0214] In FIG. 73, the first ramped surface 3836 on the free end 3834 of the each of the first lock arm 3830a and the second lock arm 3830b of the touch proof post 3800 abut the first side 3430a and the second side 3430b, respectively, of the deflector surface 3430 of the central locking portion 3420 of the shifter 3400. As the touch proof post 3800 moves further relative to the male terminal body 3200 (e.g., towards the rear wall 3204 of the 3200), the deflector surface 3430 of the shifter 3400 pushes the free ends 3834 of the first and second lock arms 3830a, 3830b apart from each other.

[0215] Thus, the first and second lock arms 3830a, 3830b of the touch proof post 3800 move away from each other until they can pass by the deflector surface 3430 (e.g., until the distance between the first and second lock arms 3830a, 3830b exceeds the width of the central locking portion 3420 adjacent to the locking space 3428). In some implementations, as the free ends 3834 of the first and second lock arms 3830a, 3830b move apart from each other, the shifter 3400 also begins to move towards the rear wall 3204 of the male terminal body 3200.

[0216] Once the free ends 3834 of the first and second lock arms 3830a, 3830b move passed the deflector surface 3430, the free ends 3834 of first and second lock arms 3830a, 3830b move back towards each other to be disposed within the locking space 3428 of the shifter 3400. (e.g., as shown in FIG. 74). Once free ends 3834 of first and second lock arms 3830a, 3830b are disposed within the locking space 3428 of the shifter 3400, the touch proof post 3800 may continue to move relative to the shifter 3400 until the base block 3804 and the pushing surface 3438 of the central locking portion 3420 abut each other. The base block 3804 of the touch proof post 3800 may push on the pushing surface 3438 of the shifter 3400 to continue moving the shifter 3400 from the pre-set position to the full-set position.

[0217] FIG. 75 shows the shifter 3400 and the touch proof post 3800 wherein the base plate 3802 of the touch proof post 3800 abuts the pushing surface 3438 of the shifter 3400. FIG. 76 shows a cross-sectional view of FIG. 75 through the central longitudinal axis 3805. As shown in FIGS. 75 and 76, the pushing surface 3438 of the central locking portion 3420 of the shifter 3400 is configured to abut the base block 3804 of the touch proof post 3800. The condition shown in FIG. 76 is the maximum that the touch proof post 3800 can move longitudinally with respect to the shifter 3400 since the pushing surface 3438 effectively stops the progress of the touch proof post 3800.

[0218] FIG. 74, as well as FIGS. 38-40 and others, show the shifter 3400 in the full-set position. The outer frame 3402 is disposed within the resting space 3226 of the contact arm 3202. The contact arm 3202 (e.g., the contact arms 3202a-3202h), now free from the outer frame 3402 of the shifter 3400, extend radially outward to a second position. The spring arms 3302 exert an outwardly directed force on each of the contact arms 3202 as well. The contact arms 3202 (e.g., the apex 3218) abuts and is biased against the inner conductive surface 3706 of the female terminal body 3700, creating an electrical connection between the female terminal body 3700 and the male terminal body 3200. Additionally, in the full-set position, the male housing assembly 3102 couples to the female housing assembly 3602 (e.g., with the connector position assurance device 3112).

[0219] The electrical connector assembly 3000 can also be moved from the connected position to the disconnected position, wherein the shifter 3400 therein moves from the full-set position to the pre-set position. In this operation, the male terminal assembly 3100 and the female terminal assembly 3600 are pulled apart from each other to electrically and mechanically disconnect the two assemblies. This process may be visualized, for example, viewing FIGS. 74, 73, and 72 in that order.

[0220] As the female terminal assembly 3600 begins to pull apart from the male terminal assembly 3100, free ends 3834 of the first and second lock arms 3830a, 3830b of the touch proof post 3800 are still disposed within the locking space 3428. The second surface 3838 of each of the first and second lock arms 3830a, 3830b of the touch proof post 3800 abuts the at least one pulling surface 3440 of the central locking portion 3420 of the shifter 3400. The second surface 3838 of the touch proof post 3800 then pulls the shifter 3400, via the at least one pulling surface 3440, away from the rear wall 3204 of the male terminal body 3200.

[0221] As the shifter 3400 is pulled away from the rear wall 3204 of the male terminal body 3200, the outer frame 3402 of the shifter 3400 begins to engage with the second portion 3222 of the contact arm 3202, pushing the free end 3224 of the contact arm 3202 radially inward. The free end 3224 of the contact arm 3202 slides over the chamfered edge 3408 of the outer frame 3402 until the free ends 3224 of the contact arms 3202 are fully retained within the outer frame 3402 of the shifter 3400. The apex 3218 of the contact arm 3202 has then moved radially inward to mechanically and electrically disengage from the female terminal body 3700.

[0222] Once the outer frame 3402 of the shifter 3400 reaches the base 3502 of the male terminal retainer 3500, the second surface 3838 of the touch proof post 3800 is prevented from pulling the shifter 3400 any further. Instead, the rounded edge between the second surface 3838 and the first ramped surface 3836 of each of the first and second lock arms 3830a, 3830b facilitates radial expansion of the first and second lock arms 3830a, 3830b away from each other. Once the first and second lock arms 3830a, 3830b are spaced apart by a width greater than that of the deflector surface 3430 of the central locking portion 3420, the second surface 3838 disengages from the at least one pulling surface 3440.

[0223] In some implementations, as the touch proof post 3800 and the remainder of the female terminal assembly 3600 is removed from the male terminal assembly 3100, the first ramped surface 3836 on the free end 3834 of the each of the first lock arm 3830a and the second lock arm 3830b of the touch proof post 3800 re-engage with and abut the first side 3430a and the second side 3430b, respectively, of the deflector surface 3430 of the central locking portion 3420 of the shifter 3400. The female terminal assembly 3600 is then free to disengage with the male terminal assembly 3100, and the electrical connector assembly 3000 returns to the disconnected position. Because the shifter 3400 returns to the pre-set position, the electrical connector assembly 3000 may be re-used and / or re-connected.

[0224] FIG. 77 shows an alternative implementation of the touch proof post, and the FIG. 78 shows an alternative implementation of the shifter, each similar to that of FIGS. 75-76, wherein like reference numbers denote like elements.

[0225] The touch proof post 3800a of FIG. 77 is substantially similar to the touch proof post 3800 of FIGS. 68-71, except as described below. The touch proof post 3800a does not include a base block extending between both of the lock arms 3830a, 3830b and the at least one insulative post 3820. Instead, locking area 3832 between the lock arms 3830a, 3830b extends to the base plate 3802.

[0226] Because the touch proof post 3800a does not have a base block, the touch proof post 3800a lacks a central surface that can engage with the pushing surface of the corresponding shifter 3400a. However, the touch proof post 3800a includes a base projection 3850a that extends radially outward from one of the insulative posts 3820 along the front surface 3808 of the base plate 3802. Similarly, a base projection 3850b extends radially outward from another one of the insulative posts 3820 on a side opposite from the base projection 3850a with respect to the central longitudinal axis 3805. Each of the base projections 3850a, 3850b include a pushing surface 3852a, 3852b that is substantially perpendicular to the central longitudinal axis 3805 and that is substantially parallel to the front surface 3808 of the base plate 3802. The base projections 3850a, 3850b may extend from the base plate 3802 a distance similar to that of the base block 3804 in the touch proof post 3800.

[0227] In other implementations, the pushing surfaces 3852a, 3852b of the touch proof post extend from a different portion of the touch proof post 3800a (e.g., both projections on the same side, only a single projection, a projection of a different shape, or any of various other combinations). The pushing surfaces 3852a, 3852b are configured to align with pushing surfaces 3452a, 3452b of the shifter 3400a of FIG. 78 (e.g., when moving from the pre-set position to the full- set position).

[0228] The shifter 3400a of FIG. 78 is substantially similar to the shifter 3400 of FIGS. 55-58, except as described below. The corresponding shifter 3400a includes pushing surfaces 3452a, 3452b that extend radially inward from the base plate 3802. The pushing surface 3452a is supported by the first support leg 3410a, and the pushing surface 3452b is supported by the second support leg 3410b. However, in other implementations, only one pushing surface is present, or a pushing surface may extend from a different portion of the outer frame.

[0229] The pushing surfaces 3452a, 3452b are aligned with a first plane of the outer frame3402 such that the pushing surface 3438 of the central locking portion 3420 is not colinear firstplane (e.g., set back from the outer frame 3402). However, in other implementations, the pushing surface of the central locking portion and the pushing surface of the outer frame may be colinear and / or aligned in the first plane.

[0230] The pushing surfaces 3452a, 3452b are configured to abut the pushing surfaces 3852a, 3852b of the touch proof post 3800a when moving from the pre-set position to the full-set position. In particular, the pushing surfaces 3452a, 3452b engage with the pushing surfaces 3852a, 3852b during and / or after the free ends 3818 of the first and second lock arms 3830a, 3830b move into locking space 3428 defined between the first lock leg 3426a and the second lock leg 3426b. Notably, the locking space 3428 of the shifter 3400a is split by a central locking surface 3456 against which a portion of the free ends 3818 of the first and second lock arms 3830a, 3830b may rest. However, the locking space 3428 of the shifter 3400a does not change the overall function as compared to shifter 3400.

[0231] Because the pushing surfaces 3452a, 3452b of the shifter 3400a face (or are substantially parallel to) the pushing surfaces 3852a, 3852b of the touch proof post 3800a, mechanical force is translated easily between the two. Movement of the touch proof post 3800a further towards the rear wall 3204 of the male terminal body 3200 causes the pushing surfaces 3852a, 3852b of the touch proof post 3800a to push on the pushing surfaces 3452a, 3452b of the shifter 3400a, moving the shifter 3400a further back towards the rear wall 3204 of the male terminal body 3200 along with the touch proof post 3800a. Thus, the shifter 3400a is moved from the pre-set position into the full-set position.Configuration of Certain Implementations

[0232] The construction and arrangement of the systems and methods as shown in the various implementations are illustrative only. Although only a few implementations have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes, and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.). For example, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. Accordingly, all such modifications are intended to be included within the scope of the present disclosure. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative implementations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the implementations without departing from the scope of the present disclosure.

[0233] As used in the specification and the appended claims, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” one particular value, and / or to “about” another particular value. When such a range is expressed, another implementation includes from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another implementation. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

[0234] “Optional” or “optionally” means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

[0235] Throughout the description and claims of this specification, the word “comprise” and variations of the word, such as “comprising” and “comprises,” means “including but not limited to,” and is not intended to exclude, for example, other additives, components, integers or steps. “Exemplary” means “an example of’ and is not intended to convey an indication of a preferred or ideal implementation. “Such as” is not used in a restrictive sense, but for explanatory purposes.

[0236] Disclosed are components that can be used to perform the disclosed methods and systems. These and other components are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, etc. of these components are disclosed that while specific reference of each various individual and collective combinations and permutation of these may not be explicitly disclosed, each is specifically contemplated and described herein, for all methods and systems. This applies to all aspects of this application including, but not limited to, steps in disclosed methods. Thus, if there are a variety of additional steps that can be performed it is understood that each of these additional steps can be performed with any specific implementation or combination of implementations of the disclosed methods.EXEMPLARY ASPECTS

[0237] In view of the described systems and methods, herein below are described certain, more particularly described aspects of the disclosures. These particularly recited aspects should not, however, be interpreted to have any limiting effect on any different claims containing different or more general teachings described herein, or that the “particular” aspects are somehow limited in some way other than the inherent meanings of the language literally used therein.

[0238] Example 1. An electrical connector assembly comprising: a male terminal assembly comprising: a male terminal body defining a receiver and comprising at least one contact arm; a spring disposed within the receiver of the male terminal body, the spring comprising at least one spring arm applying an outwardly directed biasing force on the at least one contact arm of the male terminal body; and a shifter comprising an outer frame defining an opening, the shifter being movable between a pre-set position and a full-set position; and a female terminal assembly comprising: a female terminal body defining a female terminal receiver dimensioned to receive a portion of the male terminal body; and a touch proof post coupled to the female terminal body, the touch proof post comprising: a base plate, at least one insulative post extending from the base plate beyond a front edge of the female terminal body, and at least one lock arm extending from the base plate and spaced apart from the at least one insulative post, wherein a portion of the touch proof post is configured to abut and engage with a portion of the shifter to move the shifter from the pre-set position to the full-set position, wherein in the pre-set position, the at least one contact arm is spaced apart from the female terminal body, and in the full-set position, the at least one contact arm is biased against the female terminal body.

[0239] Example 2. The electrical connector assembly according to example 1, wherein, in the pre-set position, the outer frame of the shifter retains a free end of the at least one contact arm in a first position and, in the full-set position, the free end of the at least one contact arm moves to a second position that is radially outward from the first position.

[0240] Example 3. The electrical connector assembly of any of examples 1-2, wherein, in the pre-set position, the outer frame of the shifter retains a free end of the at least one spring arm in a first position and, in the full-set position, the free end of the at least one spring arm moves to a second position that is radially outward from the first position.

[0241] Example 4. The electrical connector assembly of any of examples 1-3, wherein the shifter of the male terminal assembly further comprises: at least one support leg extending from the outer frame in a first direction substantially perpendicular to a first plane defined by the outer frame of the shifter; a central locking portion extending in the first direction between a first end of the central locking portion adjacent the opening of the shifter and a second end of the central locking portion opposite and spaced apart from the first end of the central locking portion along a central longitudinal axis thereof, the first end of the central locking portion including adeflector surface; and a connecting arm extending between the at least one support leg and the second end of the central locking portion.

[0242] Example 5. The electrical connector assembly of any of examples 1-4, wherein the touch proof post further comprises at least one pushing surface coupled to the at least one insulative post, and the shifter further comprises at least one pushing surface coupled to the at least one support leg, wherein the portion of the touch proof post that is configured to abut and engage with the at least one pushing surface of the shifter comprises the at least one pushing surface of the touch proof post.

[0243] Example 6. The electrical connector assembly of any of examples 1-5, wherein the at least one lock arm of the touch proof post comprises a free end having a first ramped surface configured to engage with the deflector surface of the central locking portion of the shifter to (i) deflect the at least one lock arm radially outward and (ii) situate the free end of the at least one lock arm of the touch proof post in a locking space defined by the central locking portion of the shifter.

[0244] Example 7. The electrical connector assembly of any of examples 1-6, wherein: the free end of the at least one lock arm of the touch proof post further comprises a second surface adjacent the first ramped surface, and the second surface of the at least one lock arm of the touch proof post engages with a pulling surface of the central locking portion of the shifter to move the shifter from the full-set position to the pre-set position.

[0245] Example 8. The electrical connector assembly of any of examples 1-7, wherein a chamfered edge of the outer frame of the shifter facilitates movement of the free end of the at least one contact arm radially inward to be retained by the outer frame in the pre-set position.

[0246] Example 9. The electrical connector assembly of any of examples 1-8, wherein inserting the male terminal body into the female terminal receiver causes the shifter to move along a central longitudinal axis of the male terminal body.

[0247] Example 10. An electrical connector assembly comprising: a male terminal assembly comprising: a male terminal body defining a receiver and comprising at least one contact arm; a spring disposed within the receiver of the male terminal body, the spring comprising a spring base and at least one spring arm extending from the spring base, the at least one spring arm applying an outwardly directed biasing force on the at least one contact arm of the male terminal body; and a shifter comprising an outer frame defining an opening, the shifter being movable between (i) a pre-set position wherein a free end of the atleast one contact arm is disposed in a first position, and (ii) a full-set position wherein the free end of the at least one contact arm is disposed in a second position, wherein the first position is radially inward of the second position.

[0248] Example 11. The electrical connector assembly of example 10, wherein, in the pre-set position, the free end of the at least one contact arm is retained radially inward by the outer frame of the shifter.

[0249] Example 12. The electrical connector assembly of any of examples 10-11, wherein the shifter is closer to the spring base of the spring in the full-set position.

[0250] Example 13. The electrical connector assembly of any of examples 10-12, further comprising: a male terminal retainer comprising: a base; and at least one side wall extending from the base of the male terminal retainer, the base and the at least one side wall of the male terminal retainer defining a male terminal retainer receiver; wherein, in the pre-set position, at least a portion of the shifter is disposed within the male terminal retainer receiver, and the base of the male terminal retainer prevents movement of the shifter in a direction away from the spring base.

[0251] Example 14. The electrical connector assembly of any of examples 10-13, wherein the at least one contact arm of the male terminal body comprises: a first portion extending at a radially outward angle, an outer surface of the first portion of the at least one contact arm defining a contact surface configured to engage with a female terminal body; an intermediate portion extending substantially radially inward from the first portion; and a second portion extending at a radially outward angle from the intermediate portion and including the free end of the at least one contact arm.

[0252] Example 15. The electrical connector assembly of any of examples 10-14, wherein the intermediate portion and the second portion of the at least one contact arm define a resting space within which the outer frame of the shifter is disposed in the full- set position.

[0253] Example 16. The electrical connector assembly of any of examples 10-15, wherein the free end of the at least one spring arm contacts an inner surface of the first portion of the at least one contact arm.

[0254] Example 17. An electrical connector assembly comprising: a female terminal assembly comprising: a female terminal body with a female terminal receiver dimensioned to receive a portion of a male terminal body; and a touch proof post coupled to the female terminal body, the touch proof post comprising: a base plate, at least oneinsulative post extending from the base plate beyond a front edge of the female terminal body, and at least one lock arm extending from the base plate and spaced apart from the at least one insulative post.

[0255] Example 18. The electrical connector assembly of example 17, wherein the female terminal body further defines a first coupling opening and a second coupling opening, the female terminal assembly further comprises a post retainer coupled to the female terminal body and the touch proof post, the post retainer comprising at least one side wall defining a cavity and at least one coupling protrusion extending radially outward from the at least one side wall, wherein the at least one coupling protrusion of the post retainer extends through the first coupling opening to couple the post retainer to the female terminal body, and a portion of the base plate of the touch proof post and a portion of the post retainer each extend through the second coupling opening to align the touch proof post with the post retainer.

[0256] Example 19. The electrical connector assembly of any of examples 17-18, wherein the at least one lock arm comprises a first lock arm and a second lock arm spaced apart from the first lock arm to define a locking area therebetween, each of the first lock arm and the second lock arm being capable of deflecting radially outward from the locking area.

[0257] Example 20. The electrical connector assembly of any of examples 17-19, wherein the at least one insulative post comprises a plurality of insulative posts disposed radially outward relative to the at least one lock arm.

[0258] In view of the many possible aspects to which the principles of the disclosed disclosure can be applied, it should be recognized that the illustrated aspects are only preferred examples of the disclosure and should not be taken as limiting the scope of the disclosure. Rather, the scope of the disclosure is defined by the following claims. We, therefore, claim as our disclosure all that comes within the scope and spirit of these claims.

Claims

CLAIMS1. An electrical connector assembly comprising: a male terminal assembly comprising: a male terminal body defining a receiver and comprising at least one contact arm; a spring disposed within the receiver of the male terminal body, the spring comprising at least one spring arm applying an outwardly directed biasing force on the at least one contact arm of the male terminal body; and a shifter comprising an outer frame defining an opening, the shifter being movable between a pre-set position and a full-set position; and a female terminal assembly comprising: a female terminal body defining a female terminal receiver dimensioned to receive a portion of the male terminal body; and a touch proof post coupled to the female terminal body, the touch proof post comprising: a base plate, at least one insulative post extending from the base plate beyond a front edge of the female terminal body, and at least one lock arm extending from the base plate and spaced apart from the at least one insulative post, wherein a portion of the touch proof post is configured to abut and engage with a portion of the shifter to move the shifter from the pre-set position to the full-set position, wherein in the pre-set position, the at least one contact arm is spaced apart from the female terminal body, and in the full-set position, the at least one contact arm is biased against the female terminal body.

2. The electrical connector assembly of claim 1, wherein, in the pre-set position, the outer frame of the shifter retains a free end of the at least one contact arm in a first position and, in the full-set position, the free end of the at least one contact arm moves to a second position that is radially outward from the first position.

3. The electrical connector assembly of claim 1, wherein, in the pre-set position, the outer frame of the shifter retains a free end of the at least one spring arm in a first position and, in the full-set position, the free end of the at least one spring arm moves to a second position that is radially outward from the first position.

4. The electrical connector assembly of claim 1 , wherein the shifter of the male terminal assembly further comprises: at least one support leg extending from the outer frame in a first direction substantially perpendicular to a first plane defined by the outer frame of the shifter; a central locking portion extending in the first direction between a first end of the central locking portion adjacent the opening of the shifter and a second end of the central locking portion opposite and spaced apart from the first end of the central locking portion along a central longitudinal axis thereof, the first end of the central locking portion including a deflector surface; and a connecting arm extending between the at least one support leg and the second end of the central locking portion.

5. The electrical connector assembly of claim 4, wherein the touch proof post further comprises at least one pushing surface coupled to the at least one insulative post, and the shifter further comprises at least one pushing surface coupled to the at least one support leg, wherein the portion of the touch proof post that is configured to abut and engage with the at least one pushing surface of the shifter comprises the at least one pushing surface of the touch proof post.

6. The electrical connector assembly of claim 4, wherein the at least one lock arm of the touch proof post comprises a free end having a first ramped surface configured to engage with the deflector surface of the central locking portion of the shifter to (i) deflect the at least one lock arm radially outward and (ii) situate the free end of the at least one lock arm of the touch proof post in a locking space defined by the central locking portion of the shifter.

7. The electrical connector assembly of claim 6, wherein: the free end of the at least one lock arm of the touch proof post further comprises a second surface adjacent the first ramped surface, and the second surface of the at least one lock arm of the touch proof post engages with a pulling surface of the central locking portion of the shifter to move the shifter from the full-set position to the pre-set position.

8. The electrical connector assembly of claim 7, wherein a chamfered edge of the outer frame of the shifter facilitates movement of the free end of the at least one contact arm radially inward to be retained by the outer frame in the pre-set position.

9. The electrical connector assembly of claim 1, wherein inserting the male terminal body into the female terminal receiver causes the shifter to move along a central longitudinal axis of the male terminal body.

10. An electrical connector assembly comprising: a male terminal assembly comprising: a male terminal body defining a receiver and comprising at least one contact arm; a spring disposed within the receiver of the male terminal body, the spring comprising a spring base and at least one spring arm extending from the spring base, the at least one spring arm applying an outwardly directed biasing force on the at least one contact arm of the male terminal body; and a shifter comprising an outer frame defining an opening, the shifter being movable between (i) a pre-set position wherein a free end of the at least one contact arm is disposed in a first position, and (ii) a full-set position wherein the free end of the at least one contact arm is disposed in a second position, wherein the first position is radially inward of the second position.

11. The electrical connector assembly of claim 10, wherein, in the pre-set position, the free end of the at least one contact arm is retained radially inward by the outer frame of the shifter.

12. The electrical connector assembly of claim 10, wherein the shifter is closer to the spring base of the spring in the full-set position.

13. The electrical connector assembly of claim 10, further comprising: a male terminal retainer comprising: a base; and at least one side wall extending from the base of the male terminal retainer, the base and the at least one side wall of the male terminal retainer defining a male terminal retainer receiver;wherein, in the pre-set position, at least a portion of the shifter is disposed within the male terminal retainer receiver, and the base of the male terminal retainer prevents movement of the shifter in a direction away from the spring base.

14. The electrical connector assembly of claim 10, wherein the at least one contact arm of the male terminal body comprises: a first portion extending at a radially outward angle, an outer surface of the first portion of the at least one contact arm defining a contact surface configured to engage with a female terminal body; an intermediate portion extending substantially radially inward from the first portion; and a second portion extending at a radially outward angle from the intermediate portion and including the free end of the at least one contact arm.

15. The electrical connector assembly of claim 14, wherein the intermediate portion and the second portion of the at least one contact arm define a resting space within which the outer frame of the shifter is disposed in the full-set position.

16. The electrical connector assembly of claim 14, wherein the free end of the at least one spring arm contacts an inner surface of the first portion of the at least one contact arm.

17. An electrical connector assembly comprising: a female terminal assembly comprising: a female terminal body with a female terminal receiver dimensioned to receive a portion of a male terminal body; and a touch proof post coupled to the female terminal body, the touch proof post comprising: a base plate, at least one insulative post extending from the base plate beyond a front edge of the female terminal body, and at least one lock arm extending from the base plate and spaced apart from the at least one insulative post.

18. The electrical connector assembly of claim 17, wherein the female terminal body further defines a first coupling opening and a second coupling opening, the female terminal assembly further comprises a post retainer coupled to the female terminal body and the touch proof post, the post retainer comprising at least one side walldefining a cavity and at least one coupling protrusion extending radially outward from the at least one side wall, wherein the at least one coupling protrusion of the post retainer extends through the first coupling opening to couple the post retainer to the female terminal body, and a portion of the base plate of the touch proof post and a portion of the post retainer each extend through the second coupling opening to align the touch proof post with the post retainer.

19. The electrical connector assembly of claim 17, wherein the at least one lock arm comprises a first lock arm and a second lock arm spaced apart from the first lock arm to define a locking area therebetween, each of the first lock arm and the second lock arm being capable of deflecting radially outward from the locking area.

20. The electrical connector assembly of claim 17, wherein the at least one insulative post comprises a plurality of insulative posts disposed radially outward relative to the at least one lock arm.

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