CONNECTOR SYSTEM FOR USE IN A POWER DISTRIBUTION SYSTEM

FIELD OF DISCLOSURE

The present disclosure relates to a connector system for use in a power distribution system which can be found in a motor vehicle, such as an automobile, bus or truck. In particular, the connector system includes features that increase the safety, durability and reliability of the connector system, while reducing the time needed to install the connector system in the power distribution system and the motor vehicle.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority from U.S. Provisional Patent No. 63/222,859, filed Jul. 16, 2021 and PCT/US2021/043686, filed Jul. 29, 2021, which is incorporated herein by reference in its entirety and made a part hereof.

BACKGROUND

Over the past several decades, the number of electrical components used in automobiles, and other on-road and off-road vehicles such as pick-up trucks, commercial vans and trucks, semi-trucks, motorcycles, all-terrain vehicles, and sports utility vehicles (collectively “motor vehicles”) has increased dramatically. Electrical components are used in motor vehicles for a variety of reasons, including but not limited to, monitoring, improving and/or controlling vehicle performance, emissions, safety and creates comforts to the occupants of the motor vehicles. Considerable time, resources, and energy have been expended to develop power distribution components that meet the varied needs and complexities of the motor vehicle market; however, conventional power distribution components suffer from a variety of shortcomings.

Motor vehicles are challenging electrical environments for both the electrical components and the connector assemblies due to a number of conditions, including but not limited to, space constraints that make initial installation difficult, harsh operating conditions, large ambient temperature ranges, prolonged vibration, heat loads, and longevity, all of which can lead to component and/or connector failure. For example, incorrectly installed connectors, which typically occur in the assembly plant, and dislodged connectors, which typically occur in the field, are two significant failure modes for the electrical components and motor vehicles. Each of these failure modes leads to significant repair and warranty costs. For example, the combined annual accrual for warranty by all of the automotive manufacturers and their direct suppliers is estimated to be between $50 billion and $150 billion, worldwide.

SUMMARY

The present disclosure relates to a connector system that provides a sealed and grounded electrical connection for a component of the power distribution system, such as a battery pack, that is compliant with industry standards and/or specifications set by a regulatory body, those required for a motor vehicle. The connector system is suitable for use with mechanically and electrically connecting components or devices in a power distribution system found in an airplane, motor vehicle, a military vehicle, a bus, a locomotive, a tractor, marine applications, or telecommunications hardware. Accordingly, the connector system is well-suited to electrically and mechanically connect components or devices that are installed in these high-stress applications vehicles to ensure reliable, long-term performance and operation of the components, devices and vehicles.

The connector system includes a female connector assembly with a female housing, a female terminal assembly that is inserted into the female housing using a first force, and a touch-proof member inserted into the female terminal assembly using a second force oriented opposite the first force. The touch-proof member prevents insertion of a foreign object into the female terminal assembly. In one version, the touch-proof member has a base and a touch-proof securing assembly with an arrangement of deformable retaining members that elastically deform from an original state to a deformed state during insertion of the touch-proof member within the female terminal assembly. The touch-proof member also has a touch-proof element with a first end wall, a second end wall, and a connecting wall extending between said first and second end walls. In another version, the touch-proof member includes an elastically deformable base having a first base portion and a second base portion that are separated by a recess, wherein the first base portion includes at least one retaining member that depends from said base portion and wherein the second base portion includes at least one retaining member that depends from said base portion. The touch-proof element extends from the elastically deformable base and has a first extent with a slot that is aligned with the recess that separates the first and second base portions. When the touch-proof member is inserted within the female terminal assembly, a foreign object distance of 5 mm or less is defined between the touch-proof element and a first wall of the female terminal assembly.

The connector system also includes a male connector assembly with a male terminal assembly, and a male housing assembly with a touch-proof element opening that receives an extent of the touch-proof member. The male terminal assembly includes a male terminal body with contact arms having a neck portion with a neck width and a body portion with a body width that is greater than the neck width. The male terminal assembly also includes a spring member that resides within a receiver of the male terminal body, wherein during operation of the power distribution system, spring arms of the spring member apply an outwardly directed biasing force on the contact arms to retain the male terminal assembly within the female terminal assembly.

The spring member also includes an arrangement of spring arms, wherein a first spring arm has a positioning projection extending from a free end of the first spring arm and a second spring arm lacks the positioning projection. In a seated state, the spring member resides within the spring receiver whereby the positioning projection of the first spring arm overlaps or wraps around an interior corner region of the first contact arm. The spring member further includes a third spring arm with a positioning projection extending from a free end of the third spring arm. In the seated state, the positioning projection of the third spring arm overlaps or wraps around an interior corner region of a third contact arm of the male terminal body. In the seated state, the engagement of the first and third spring arms with the first and third contact beams retains the spring member in the male terminal body and centers the spring member within the contact arms by limiting the amount the spring member can rotate within the male terminal body during operation of the power distribution system.

Additional structural and functional aspects and benefits of the connector system are disclosed in the Detailed Description section and the Figures.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings or figures, which are included to provide further understanding and are incorporated in and constitute a part of this specification, illustrate disclosed embodiments and together with the description serve to explain the principles of the disclosed embodiments. In the Figures, like reference numerals refer to the same or similar elements throughout the Figures. In the drawings:

FIG. 1 is a perspective view of a first embodiment of a connector system for use in a power distribution system;

FIG. 2 is an exploded view of the connector system of FIG. 1, where the connector system includes a male connector assembly and a female connector assembly;

FIG. 3 is a perspective view of the male connector assembly of FIG. 2 in a disassembled state, where the male connector assembly includes: (i) a male housing assembly, (ii) male terminal assemblies, each having a male terminal and a spring member, (iii) male shielding assemblies, and (vi) a male interlock (“MIL”);

FIG. 4 is a bottom perspective view of one of the male terminals of FIG. 3;

FIG. 5A is a first side view of the male terminal of FIG. 4;

FIG. 5B is a opposed second side view of the male terminal of FIG. 4;

FIG. 6A is a bottom view of the male terminal of FIG. 4;

FIG. 6B is a top view of the male terminal of FIG. 4;

FIG. 7A is a front view of the male terminal of FIG. 4;

FIG. 7B is a rear view of the male terminal of FIG. 4;

FIG. 8 is a perspective view of the spring member of FIG. 3;

FIG. 9A is a top view of the spring member of FIG. 7;

FIG. 9B is a bottom view of the spring member of FIG. 7;

FIG. 10 is a side view of the spring member of FIG. 7;

FIG. 11 is an end view of the spring member of FIG. 7;

FIG. 12 is a perspective view of the male terminal assemblies of FIG. 3 in a unseated state;

FIG. 13A is a bottom view of one of the male terminal assemblies of FIG. 3 in a seated state;

FIG. 13B is an end view of the male terminal assembly of FIG. 11;

FIG. 14A is a perspective view of the male terminal assemblies and male terminal holders of FIG. 3 in an uncoupled state;

FIG. 14B is a side view of the male terminal assembly and the male terminal holder of FIG. 13 in a coupled state;

FIG. 15 is a perspective cross-sectional view of the male terminal assembly and the male terminal holder taken along line 15-15 of FIG. 14B;

FIG. 16 is a cross-sectional view of the male terminal assembly and the male terminal holder taken along line 16-16 of FIG. 14B;

FIG. 17 is a perspective view of the male connector assembly of FIG. 3 in a first partially assembled state, where are separated from the male terminal assemblies, male terminal holders, and conductor leads;

FIG. 18 is a perspective view of the male shielding assemblies are not separated from and partially surround the male terminal assembly, the male terminal holder, and the conductor lead;

FIG. 19 is a side view of the male connector assembly in a second partially assembled state, where a primary locking member is partially coupled to the main housing member and a secondary locking member has been omitted;

FIG. 20 is a cross-sectional view of the male connector assembly taken along line 20-20 of FIG. 19;

FIG. 21 is a zoomed-in view of area A of the male connector assembly of FIG. 20 showing the accidental engagement assembly;

FIG. 22 is a bottom perspective view of the male connector assembly of FIG. 3 in a third partially assembled state, where the primary locking member is coupled to the main housing and a secondary locking member is in an unreceived state;

FIG. 23 is a bottom perspective view of the male connector assembly of FIG. 3 in an assembled state, where the primary locking member is coupled to the main housing member and a secondary locking member is in a received state;

FIG. 24 is a side view of the male connector assembly in the ready to engage/disengage state where the primary locking member is in an unlocked state;

FIG. 25 is a cross-sectional view of the male connector assembly taken along line 25-25 of FIG. 24;

FIG. 26 is a zoomed-in view of area B of the male connector assembly of FIG. 25 showing the accidental engagement assembly;

FIG. 27 is a bottom perspective view of the male connector assembly in an restrictive engagement state where the primary locking member is in a locked state;

FIG. 28 is a perspective view of the female connector assembly of FIG. 2 in a disassembled state, where the female connector assembly includes: (i) a female housing assembly, (ii) a touch-proof member, (iii) a female terminal assemblies, (iv) female shielding assemblies, and (v) a female interlock (“FIL”);

FIG. 29 is an end view of the female connector assembly of FIG. 28 in a first partially assembled state, where the FIL is in an un-received position and the touch-proof assembly is in an uninstalled position;

FIG. 30 is a cross-sectional view of the female connector assembly taken along line 30-30 of FIG. 29;

FIG. 31 is a perspective view of the female connector assembly of FIG. 28 in a second partially assembled state, where the FIL is in a received position and the touch-proof assembly is in the uninstalled position;

FIG. 32 is a perspective view of the touch-proof assembly of FIG. 28;

FIG. 33 is a side view of the touch-proof assembly of FIG. 32;

FIG. 34 is an end view of the touch-proof assembly of FIG. 32;

FIG. 35 is a top view of the touch-proof assembly of FIG. 32;

FIG. 36 is a bottom perspective view of the touch-proof assembly of FIG. 32;

FIG. 37 is a bottom view of the touch-proof assembly of FIG. 32;

FIG. 38 is a bottom view of the female connector assembly of FIG. 28 in the second partially assembled state;

FIG. 39 is a cross-sectional view of the female connector assembly taken along line 39-39 of FIG. 38;

FIG. 40 is a bottom view of the female connector assembly of FIG. 28 in the second partially assembled state;

FIG. 41 is a cross-sectional view of the female connector assembly taken along line 41-41 of FIG. 40;

FIG. 42 is an end view of the female terminal assembly and touch-proof assembly of FIG. 1, where the touch-proof assembly is in the uninstalled position;

FIG. 43 is a cross-sectional view of the female terminal assembly and touch-proof assembly taken along line 43-43 of FIG. 42;

FIG. 44 is an end view of the female connector assembly of FIG. 28 in the third partially assembled state, where the touch-proof assembly is in a partially installed position;

FIG. 45 is a cross-sectional view of the female connector assembly taken along line 45-45 of FIG. 44;

FIG. 46 is a perspective view of the female connector assembly of FIG. 28 in the assembled state;

FIG. 47 is a top view of the female connector assembly of FIG. 46;

FIG. 48 is a bottom view of the female connector assembly of FIG. 46;

FIG. 49 is a cross-sectional view of the female connector assembly taken along line 49-49 of FIG. 48;

FIG. 50 is a bottom perspective view of the female terminal assembly and touch-proof assembly in the installed position;

FIG. 51 is a side view of the female terminal assembly and touch-proof assembly of FIG. 50;

FIG. 52 is a cross-sectional view of the female terminal assembly and touch-proof assembly taken along line 52-52 of FIG. 51;

FIG. 53 is an end view of the female terminal assembly and touch-proof assembly of FIG. 50;

FIG. 54 is a cross-sectional view of the female terminal assembly and touch-proof assembly taken along line 54-54 of FIG. 53;

FIG. 55A is a bottom perspective view of the male connector assembly of FIG. 1 in the ready to engage/disengage state where the primary locking member is in a unlocked state;

FIG. 55B is a top view of the female connector assembly of FIG. 28 in the assembled state;

FIG. 56A is a side view of the connector system of FIG. 1 in a disconnected connected state, where the male connector assembly is in a ready to engage state and the male connector assembly is spaced away from the female connector assembly;

FIG. 56B is a cross-sectional view of the connector system taken along line 56B-56B of FIG. 56A;

FIG. 57 is a side view of the connector system of FIG. 1 in a partially connected state, where the male connector assembly is in a ready to engage state and the male connector assemblies are not fully seated within the female connector assemblies;

FIG. 58 is a cross-sectional view of the connector system taken along line 58-58 of FIG. 57;

FIG. 59 is a zoomed-in view of area C of the connector system of FIG. 58 showing the accidental engagement assembly;

FIG. 60 is a side view of the connector system of FIG. 1 in the partially connected state;

FIG. 61 is a cross-sectional view of the connector system taken along line 61-61 of FIG. 60;

FIG. 62 is a zoomed-in view of area D of the connector system of FIG. 61 showing the accidental engagement assembly;

FIG. 63 is a top view of the connector system of FIG. 1 in the partially connected state;

FIG. 64 is a cross-sectional view of the connector system taken along line 64-64 of FIG. 63;

FIG. 65 is a zoomed-in view of area E of the connector system of FIG. 64 showing the accidental disengagement assembly;

FIG. 66 is a zoomed-in view of area F of the connector system of FIG. 64 showing the CPA assembly;

FIG. 67 is a side view of the connector system of FIG. 1 in a connected state, where the male connector assemblies are fully seated in the female connector assemblies and the primary locking member is in an unlocked state;

FIG. 68 is a cross-sectional view of the connector system taken along line 68-68 of FIG. 67;

FIG. 69 is a zoomed-in view of area G of the connector system of FIG. 68 showing the accidental engagement assembly;

FIG. 70 is a side view of the connector system of FIG. 1 in the connected state;

FIG. 71 is a cross-sectional view of the connector system taken along line 71-71 of FIG. 70;

FIG. 72 is a zoomed-in view of area H of the connector system of FIG. 71 showing the accidental engagement assembly;

FIG. 73 is a top view of the connector system of FIG. 1 in the connected state;

FIG. 74 is a cross-sectional view of the connector system taken along line 74-74 of FIG. 73;

FIG. 75 is a zoomed-in view of area I of the connector system of FIG. 64 showing the bracing assembly;

FIG. 76 is a zoomed-in view of area J of the connector system of FIG. 64 showing the CPA assembly;

FIG. 77 is a side view of the connector system of FIG. 1 in a ready to use state, where the male connector assemblies are fully seated in the female connector assemblies and the primary locking member is in a locked state;

FIG. 78 is a cross-sectional view of the connector system taken along line 78-78 of FIG. 77;

FIG. 79 is a zoomed-in view of area K of the connector system of FIG. 68 showing the accidental engagement assembly;

FIG. 80 is a side view of the connector system of FIG. 1 in the ready to use state;

FIG. 81 is a cross-sectional view of the connector system taken along line 81-81 of FIG. 80;

FIG. 82 is a zoomed-in view of area L of the connector system of FIG. 81 showing the accidental engagement assembly;

FIG. 83 is a top view of the connector system of FIG. 1 in the ready to use state;

FIG. 84 is a cross-sectional view of the connector system taken along line 84-84 of FIG. 83;

FIG. 85 is a zoomed-in view of area M of the connector system of FIG. 84 showing the accidental disengagement assembly;

FIG. 86 is a zoomed-in view of area N of the connector system of FIG. 84 showing the CPA assembly;

FIG. 87 is a zoomed-in view of area O of the connector system of FIG. 84 showing the bracing assembly;

FIG. 88 is a side view of the connector system of FIG. 1 in the ready to use state;

FIG. 89 is a cross-sectional view of the connector system taken along line 89-89 of FIG. 88;

FIG. 90 is a side view of the connector system of FIG. 1 in the ready to use state;

FIG. 91 is a cross-sectional view of the connector system taken along line 91-91 of FIG. 90;

FIG. 92 is a bottom perspective view of the connector system of FIG. 1 in a connected state, where all components have been omitted except the male terminal assembly, female terminal assembly and the touch-proof assembly;

FIG. 93 is a side view of the male terminal assembly, female terminal assembly and the touch-proof assembly of FIG. 92;

FIG. 94 is a cross-sectional view of the male terminal assembly, female terminal assembly and the touch-proof assembly taken along line 94-94 of FIG. 93;

FIG. 95 is a side view of the male terminal assembly, female terminal assembly and the touch-proof assembly of FIG. 92;

FIG. 96 is a cross-sectional view of the male terminal assembly, female terminal assembly and the touch-proof assembly taken along line 96-96 of FIG. 95;

FIG. 97 is a side view of the connector system of FIG. 1 in a connected state, where the non-conductive components have been removed;

FIG. 98 is a cross-sectional view of the connector system taken along line 98-98 of FIG. 97;

FIG. 99A is a top view of the connector system of FIG. 1 in the ready to use state;

FIG. 99B is a cross-sectional view of the connector system taken along line 99B-99B of FIG. 99A;

FIG. 100 is a perspective view of a first embodiment of a power distribution system with a battery pack having at least one connector system;

FIG. 101 is a perspective view of a battery pack of FIG. 100 installed within a skateboard mounting platform of a vehicle;

FIG. 102 is a perspective view of a vehicle that includes the skateboard mounting platform of FIG. 101;

FIG. 103 is a perspective view of a passenger bus including a power distribution system having at least one connector system;

FIG. 104 is a perspective view of a ship including a power distribution system having at least one connector system;

FIG. 105 is a perspective view of a large ship including a power distribution system having at least one connector system;

FIG. 106 is a perspective view of a second embodiment of a connector system for use in a power distribution system;

FIG. 107 is an exploded view of the connector system of FIG. 106, where the connector system includes: (i) a male connector assembly with a male terminal assembly, and (ii) a female connector system;

FIG. 108 is an perspective view of the male terminal assembly of FIG. 107 in an unseated state;

FIG. 109 is a perspective view of the female connector assembly of FIG. 107 in a dissembled state;

FIG. 110 is a perspective view of the female connector assembly of FIG. 109 in a first partially assembled state, where a second embodiment of the touch-proof assembly is in an uninstalled position;

FIG. 111 is a top perspective view of the touch-proof assembly of FIG. 110;

FIG. 112 is a bottom perspective view of the touch-proof assembly of FIG. 111;

FIG. 113 is a perspective view of the touch-proof assembly of FIG. 111;

FIG. 114 is an end view of the touch-proof assembly of FIG. 111;

FIG. 115 is a bottom view of the touch-proof assembly of FIG. 111;

FIG. 116 is a top view of the touch-proof assembly of FIG. 111;

FIG. 117 is an end view of the female terminal assembly and the touch-proof assembly of FIG. 110 in an unengaged position;

FIG. 118 is a cross-sectional view of the female terminal assembly and the touch-proof assembly taken along line 118-118 of FIG. 117;

FIG. 119 is an end view of the female connector assembly of FIG. 109 in the second partially assembled state, where the touch-proof assembly is in partially installed position;

FIG. 120 is a cross-sectional view of the female connector assembly taken along line 120-120 of FIG. 119;

FIG. 121 is a top view of the female connector assembly of FIG. 109 in an assembled state;

FIG. 122 is a cross-sectional view of the female connector assembly taken along line 122-122 of FIG. 121;

FIG. 123 is an angled side view of the female connector assembly of FIG. 121;

FIG. 124 is a cross-sectional view of the female connector assembly taken along line 124-124 of FIG. 123;

FIG. 125 is a zoomed-in view of area P of the connector system of FIG. 124 showing the;

FIG. 126 is a perspective view of the female terminal assembly and the touch-proof assembly, where the touch-proof assembly is in a engaged position;

FIG. 127 is a bottom perspective view of the female terminal assembly and the touch-proof assembly of FIG. 126;

FIG. 128 is an end view of the female terminal assembly and the touch-proof assembly of FIG. 126;

FIG. 129 is a cross-sectional view of the female terminal assembly and the touch-proof assembly taken along line 129-129 of FIG. 128;

FIG. 130 is an angled side view of the female terminal assembly and the touch-proof assembly of FIG. 126;

FIG. 131 is a cross-sectional view of the female terminal assembly and the touch-proof assembly taken along line 131-131 of FIG. 130;

FIG. 132 is a top view of the connector system of FIG. 106 in a ready to use state;

FIG. 133 is a cross-sectional view of the connector system taken along line 133-133 of FIG. 132;

FIG. 134 is a side view of the connector system of FIG. 106 in a ready to use state, where all components have been omitted except for the male terminal assembly and female terminal assembly;

FIG. 135 is a cross-sectional view of the male terminal assembly and female terminal assembly taken along line 135-135 of FIG. 134;

FIG. 136 is a top perspective view of a third embodiment of a touch-proof assembly, which is configured for use with the second embodiment of the connector system;

FIG. 137 is a bottom perspective view of the touch-proof assembly of FIG. 136;

FIG. 138 is an end view of the touch-proof assembly of FIG. 136;

FIG. 139 is a bottom view of the touch-proof assembly of FIG. 136;

FIG. 140 is a top view of the touch-proof assembly of FIG. 136.

DETAILED DESCRIPTION

In the following detailed description, numerous specific details are set forth by way of examples in order to provide a thorough understanding of the relevant teachings. However, it should be apparent to those skilled in the art that the present teachings may be practiced without such details. In other instances, well-known methods, procedures, components, and/or circuitry have been described at a relatively high-level, without detail, in order to avoid unnecessarily obscuring aspects of the present teachings. In the Figures, like reference numerals refer to the same or similar elements throughout the Figures.

The Figures show two embodiments of a connector system 10, 1010 that includes a harness connector assembly or male connector assembly 200, 1200 and a component/device connector assembly or female connector assembly 600, 1600. Both versions of the connector system 10, 1010 include features integrated into both the male connector assembly 200, 1200 and the female connector assembly 600, 1600. In particular, the first embodiment of the connector system 10 generally includes the following features: (i) a retaining assembly 20 with a connector position assurance (“CPA”) assembly 80, (ii) an optional touch-proof assembly 40, (iii) an optional shielding assembly 60, and (iv) an optional interlock (“IL”) assembly 100. These features structurally and functionally interact to enable the connector system 10 to meet a variety of industry performance standards and regulations including: (a) certain aspects of USCAR (e.g., USCAR 12, USCAR 25, USCAR 38), (b) certain aspects of ISO (e.g., ISO 20076:2019 and ISO 20653:2013), (c) certain aspects of IEC (e.g., IEC 60529-2020), and (d) performance and installation requirements including T4/V4/S3/D2/M2, and Push-Click-Tug-Scan (PCTS).

The retaining assembly 20 of the connector system 10 is formed from a plurality of recesses and projections that structurally and functionally interact whereby the system 10 is secured and requires a predefined high force threshold (e.g., 500 Newtons of force): (a) move the male connector assembly 200 from a “ready to engage state” to an “restrictive engagement state” via an accidental engagement force F_AE, (b) move the system 10 from a “ready to use state” to a “connected” via an accidental disengagement force F_AD, and (c) remove the male connector assembly 200 from the female connector assembly 600 when the system 10 is in the “ready to use state” via an accidental engagement force F_DIS. The primary components of the retaining assembly 20 are: (i) a male retaining assembly 222, which includes a male accidental engagement assembly 336, an accidental disengagement assembly 347, a male bracing assembly 351, and a male CPA assembly 400, and (ii) female retaining assembly 622, which includes a female accidental engagement assembly 652, a female bracing assembly 648, and a female CPA assembly 700. While the CPA assembly 20 is part of the retaining assembly 20, the CPA assembly 80 also enables the system 10 to be PCTS compliant, which eliminates the need for air-assist tools (e.g, air guns) to connect the male terminal assembly 430 to the female terminal assembly 800 and enables the generation of a record showing proper installation of the system 10 for accounting and system management purposes. Overall, the retaining assembly 20 is beneficial because it: (i) reduces installation time by reducing the need for additional tools and ensuring the male connector assembly 200 is in a state that can be coupled to the female connector assembly 600, (ii) increases durability by reducing inadvertent disengagements of the system 10, and (iii) provides for accurate record keeping showing that a proper connection was made and when and where such connection was made in the assembly process.

The optional touch-proof assembly 40 enables the connector system 10 to meet industry regulations (e.g., USCAR 12, ISO 20076:2019 and ISO 20653:2013) because it protects against the inadvertent insertion of foreign objects into the female terminal assembly 800 that have a diameter over a predetermined size (e.g., 6 mm). These foreign objects can cause damage to the connector system 10 and/or the installer/operator and machines involved in the assembly of the power distribution system 5. The optional touch-proof assembly 40 includes a male touch-proof element opening 242 and a female touch-proof member 720. Unlike conventional connector systems that may have components that allow them to meet industry regulations, the touch-proof assembly 40 allows an installer or operator to add the female touch-proof member 720 after the female connector assembly 600 is installed within the environment, application, system, component, or device. This subsequent addition of the female touch-proof member 720 enables the touch-proof assembly 40 to provide significant benefits for the inventive connector system 10 over conventional connectors because: (i) the female touch-proof member 720 does not add weight to the system 10, if this component is not desired, (ii) the female touch-proof member 720 can be removed and/or replaced without tools or requiring the installer/operator to spend valuable time disassembling the entire system 10, (iii) the female touch-proof member 720 reduces maintenance cost, as it component can be easily removed and to provide access to the female terminal body 800, (iv) components of the system 10 can be manufactured at different times, shipped at different times and installed at different times, which may be beneficial if there is a shortage or delay in the supply chain manufacturing the touch-proof assembly 40, including the female touch-proof member 720, and (v) other benefits that are obvious to one of skill in the art based on the below disclosure and figures.

The optional shielding assembly 60 enables the connector system 10 to reduce electromagnetic noise that may otherwise be introduced into the motor vehicle and operating environment where the system 10 is installed. Reduction of the electromagnetic noise allows for additional mounting locations for the system 10 near or adjacent other electronics or components that are sensitive to electromagnetic noise, such as those under the hood of a motor vehicle. Finally, the optional interlock (“IL”) assembly 100 insures that current is not applied to the connector system 10 prior to the full engagement of the male connector assembly 200 with the female connector assembly 600. Additionally, unlike conventional connector systems that may have configurations that may provide an interlock assembly, the disclosed connector system 10 allows for an installer/operator to optionally add or remove the IL assembly 100 from the system 10. This selective addition or removal of the IL assembly 100 is beneficial over other disclosed system because: (i) it does not add weight to the system, if this component is not desired, (ii) reduces part numbers/stock keeping units (“SKU”) that a manufacturer defines and maintains, and (iii) other benefits that are obvious to one of skill in the art based on the below disclosure and figures.

The second embodiment of the connector system 1010 includes the following features: (i) CPA assembly 80, and (ii) optional touch-proof assembly 1040. These features structurally and functionally interact to enable the connector system 1010 to meet a variety of industry performance standards and regulations including: (a) certain aspects of USCAR (e.g., USCAR 12, USCAR 25, USCAR 38, ISO20653), (b) certain aspects of ISO (e.g., ISO20653), and (c) performance and installation requirements including T4/V4/S3/D2/M2, and Push-Click-Tug-Scan (PCTS). For the sake of brevity, features and functions of the second embodiment of the connector system 1010 that are similar to the features and functions of the first embodiment of the connector system 10. It should be understood that these omissions should not limit the disclosure of this application and instead the reader shall refer to the disclosure of similar structures that may be discussed within another section of this application or other applications that are incorporated herein by reference.

Unlike conventional connector systems that rely on ultrasonically welding portions of the female housing to one another in order to form an electrical connection between the female terminal assembly and the housing of a power distribution component with a capacitor assembly, the disclosed connector system 1010 provides a combination of projections, recesses, and openings that function together to mechanically join and seal the portions of the female housing 620 to one another. This is beneficial because it substantially increases the durability, operating performance and longevity of the system 1010. Additionally, the CPA assembly 80 and the optional touch-proof assembly 1040 enable the connector system 1010 to provide the same benefits that are provide by and discussed above in connection with the first embodiment of the connector system 10.

As depicted in the Figures, the connector systems 10, 1010 are designed to provide mechanical and electrical coupling of a conductor, lead or busbar to a component contained in a power distribution system 5. The connector system 10, 1010 and the power distribution system 5 may be installed within an application. As used herein, the term “application” means an airplane, motor vehicle (e.g., an automobile, bus, van, truck, or motorcycle), a military vehicle (e.g., tank, personnel carrier, heavy-duty truck, and troop transporter), a locomotive, a tractor, a boat, a submarine, a battery pack, a computer server, a 24-48 volt system, or applications or products that require high power, high current or high voltage. It should be understood that multiple connector systems 10, 1010 could be used in a single installation environment, application, product, component, or device. For example, multiple connector systems 10, 1010 may be used with a single component of the power distribution system 5. As another example, multiple connector systems 10, 1010 may be used within a first component of the power distribution system 5 and multiple connector systems 10, 1010 may be used within a second component of the same power distribution system 5, where that power distribution system 5 is installed in a single application, such as a motor vehicle.

While this disclosure includes a number of embodiments in many different forms, there is shown in the drawings and will herein be described in detail particular embodiments with the understanding that the present disclosure is to be considered as an exemplification of the principles of the disclosed methods and systems, and is not intended to limit the broad aspects of the disclosed concepts to the embodiments illustrated. As will be realized, the disclosed methods and systems are capable of other and different configurations and several details are capable of being modified all without departing from the scope of the disclosed methods and systems. For example, one or more of the following embodiments, in part or whole, may be combined consistently with the disclosed methods and systems. Accordingly, the drawings and detailed descriptions are to be regarded as illustrative in nature, not restrictive or limiting.

First Embodiment

As shown in FIGS. 1-98, the first embodiment of the connector system 10 includes male connector assembly 200 and a female connector assembly 600. Said male and female connector assemblies 200, 600 include the following features that are integrated in the assemblies 200, 600: (i) retaining assembly 20 that includes a male retaining assembly 222 and a female retaining assembly 622, (ii) connector position assurance (“CPA”) assembly 80 that includes a male CPA assembly 400 and a female CPA assembly 700, (iii) touch-proof assembly 40 that includes a male touch-proof receiver 242 and a female touch-proof member 720, (iv) shielding assembly 60 that includes a male shielding assembly 530 and a female shielding assembly 930, and (v) interlock (“IL”) assembly 100 that includes a male IL assembly 590 and a female IL assembly 980.

1. Male Connector Assembly

As shown in FIGS. 1-27, 55, 57-98, the connector system 10 includes male connector assembly 200. Said male connector assembly 200 includes: (i) a male housing assembly 220 with the male retaining assembly 222 having the male CPA assembly 400, (ii) the male terminal assembly 430, (iii) a male shielding assembly 530, and (iv) the male IL assembly 590. The male retaining assembly 222, which includes: (i) male accidental engagement assembly 336, which is formed from two accidental engagement portions 337a, 337b, (ii) accidental disengagement assembly 347, (iii) male bracing assembly 351, and male CPA assembly 400. As described below: (i) a first portion of the male accidental engagement assembly 377a includes: (a) an accidental engagement slots 294a, 294b, and (b) an accidental engagement depression 300a, 300b, (ii) a second portion of the male accidental engagement assembly 377b includes: (a) an accidental engagement recesses 331a, 331b, (b) an accidental engagement retainer 332a, 332b, and (c) an accidental engagement members 338a, 338b, (iii) an accidental disengagement assembly 347 includes a first disengagement projection 287 and a disengagement member 348 with a second disengagement projection 342, (iv) male bracing assembly 351 with bracing apertures 354, and (v) male CPA assembly 400 includes a deformable male CPA member 406.

A. Male Housing Assembly

As best shown in FIGS. 3 and 13-17, the male housing assembly 220 includes: (i) male terminal holder 230, (ii) shield insulator 260, (iii) main housing 280, (iv) a primary locking member 320, (v) a secondary locking member 360, (vi) an end cap 380, and (vii) seals 390, 392. Referring to FIGS. 13-15, the male terminal holder 230 is configured to receive the male terminal assembly 430, isolate the male shielding assembly 530 from the male terminal assembly 430, facilitate positioning and retaining the male terminal assembly 430 in the male connector assembly 200, and other functions that are obvious to one of skill in the art based on the below disclosure and figures. The male terminal holder 230 has an interior wall arrangement 232 that is bowl shaped and configured to snugly receive the male terminal assembly 430. Specifically, the interior wall arrangement 232 includes two side walls 234a, 234b, two end walls 236a, 236b, and a bottom wall 238. Contact arm apertures 240a, 240b are formed in an intermediate portion of the two side wall in order to allow the male terminal assembly 430 to make contact with the female terminal assembly 800, when the connector system 10 is in the connected state. As best shown in FIG. 16, the distance D₂between opposed outermost extents of the contact arms 494a-494h is greater than the distance D₁between opposed outermost surfaces of the side walls 234a, 234b. This configuration allows the contact arms 494a-494h to make contact with the female terminal assembly 800 without be obstructed by the side walls 234a, 234b. This configuration provides additional rigidity to the male terminal assembly 430 and limits the exposed amount of the male terminal assembly 430. However, due in part to the contact arm apertures 240a, 240b the entire male terminal assembly 430 is not encased by the male terminal holder 230.

It should be understood that the further the male terminal assembly 430 extends past the outer surface of the side walls 234a, 234b, there is a greater chance that male terminal assembly 430 will accidentally come into contact within a foreign object. Thus, the extent of the male terminal assembly 430 that extends past the outer surface of the side walls 234a, 234b needs to balance the ability to form a proper connection with the female terminal assembly 800. The design disclosed herein balances these factors and the extent of the male terminal assembly 430 extends beyond the outer surface of the side walls 234a, 234b by less than 2 mm and preferably less than 0.5 mm. In comparison to the length of the contact arm apertures 240a, 240b, the extent of the male terminal assembly 430 extends beyond the outer surface of the side walls 234a, 234b is less than 5% of the length and preferably less than 3% of the length. The bottom wall 238 of the interior wall arrangement 232 includes a touch-proof element opening 242, which is designed to receive an extent of the female touch-proof member 720, when the connector system 10 is in the connected state. In particular, the touch-proof element opening 242 mirrors the shape of the touch-proof element 720. Here, the touch-proof element 720 has an “I-shape” and thus the touch-proof element opening 242 also has an “I-shape.” As discussed below, other shapes of the touch-proof element 720 are contemplated by this disclosure and accordingly other shapes of the touch-proof element opening 242 are also contemplated by this disclosure.

The male terminal holder 230 also includes exterior wall arrangement 244 that: (i) surrounds the side and end walls 234a, 234b, 236a, 236b, (ii) is spaced away a receiver distance D₃away from the interior wall arrangement 232, and (iii) separates the male shielding assembly 530 from the male terminal assembly 430. Specifically, the receiver distance D₃is designed to receive an extent of the female terminal assembly 800, when the connector is in the connected state. However, receiver distance D₃is configured such that it are not large enough to accept the insertion of an assembler's finger, a probe, or another foreign object. For example, the receiver distance D₃may be less than 10 mm, preferably less than 6 mm, and most preferably less than 3.5 mm. The exterior wall arrangement 244 includes: (i) coupling openings 246a, 246b that are designed to receive an extent of the shield insulator 260, (ii) a plurality of projections 248 that secure an extent of the male shielding assembly 530 to the male terminal holder 230, (iii) an arrangement of recesses 250a-250d that are designed to receive an extent of the secondary locking member 360, and (iv) a first extent of a retaining lip 252a is positioned adjacent to the frontal edge of the male terminal connection plate 474. Each of these features will be discussed below in connection with other components of the connector system 10.

The male terminal holder 230 is configured to be placed in contact with both the shielding assembly 60 and the male terminal assembly 430; thus, it is desirable to form the male terminal holder 230 from a non-conductive material. It should be understood that the non-conductive material that is chosen should be able to sufficiently isolate the terminal assembly 430, even when a high current load is flowing through the terminal assembly 430. As discussed in other parts of this application, the male terminal holder 230 may be formed using any suitable method, such as injection molding techniques, 3D printing, cast, thermoformed, or any other similar technique. In other embodiments, the configuration of the interior wall arrangement 232 and the exterior wall arrangement 244 may have a different configuration to accommodate a different shaped male terminal assembly 430. For example, the interior wall arrangement 232 may be modified to include openings formed in the end walls 236a, 236b to accommodate a male terminal assembly 430 that includes contact arms 494a-494h that are positioned on all sides of the assembly 430 in order to be 360 degree compliant. Alternatively, the interior wall arrangement 232 may have a substantially circular, triangular, hexagonal configuration.

Still referring to FIGS. 13-17, the shield insulator 260 includes a cap 262 and a shroud 270, which are designed to mechanically interact with or engage with the male terminal holder 230. In particular, the cap 262 includes: (i) a horizontal portion, (ii) two vertical deformable projections 264a, 264b that extend downward from the horizontal portion, (iii) two securing elements 266a, 266b that extend from the vertical deformable projections 264a, 264b, (iv) a second extent of a retaining lip 252b, and (v) a securing recess 268. When the cap 262 is secured to the male terminal holder 230: (i) the securing elements 266a, 266b are positioned in the coupling openings 246a, 246b, and (ii) the vertical deformable projections 264a, 264b are removable positioned between the male terminal assembly 430 and the exterior wall arrangement 244. In this secured position, the male terminal assembly 430 is mechanically secured in the male terminal holder 230 and isolated from the shielding assembly 60.

The shroud 270 includes: (i) a rectangular arrangement of walls 272 that are designed to surround the male terminal connection plate 474 and an extent of the conductor 598, and (ii) coupling features 274 that secure the shroud 270 to the male terminal holder 230. Specifically, the coupling features 274 are designed to interact with the first and second extents of the retaining lip 252a, 252b in order to ensure that the cap 262 does not accidently become dislodged from the male terminal holder 230 and to separate the shielding assembly 60 from the male terminal connection plate 474. Like the male terminal holder 230, the shield insulator 260 is designed to be placed in contact with both the male terminal assembly 430 and the shielding assembly 60. Therefore, like the male terminal holder 230, it is desirable to form the shield insulator 260 from a non-conductive material. It should be understood that the non-conductive material that is chosen should be able to sufficiently isolate the terminal assembly 430, even when a high current load is flowing through the terminal assembly 430. As discussed in other parts of this application, the shield insulator 260 may be formed using any suitable method, such as injection molding techniques, 3D printing, cast, thermoformed, or any other similar technique.

The main or primary housing 280 is a complex structure that includes a number of projections, recesses, and openings to facilitate to functionalities associated with the male connector assembly 200. In particular, the main housing 280 can be broken down into two main parts, where: (i) the first part is a head or engaging portion 282, which is configured to receive a major extent of the male terminal assembly 430, and male terminal holder 230, and (ii) a second part is a body or supporting portion 310, which is configured to receive a minor extent of the male terminal assembly 430 and the conductor 598. The engaging portion 282 includes: (i) an upper arrangement of side walls 284, (ii) a top wall 286, (iii) a lower arrangement of side walls 288 that depend from the upper arrangement of side walls 284, (iv) a male CPA assembly 400. As best shown in FIGS. 65 and 85, the top wall 286 of the engaging portion 282 extends between the upper arrangement of side walls 284 and includes a first disengagement projection 287 that extends upward from the outer surface of the top wall 286. Said first disengagement projection 287 has a ramped or sloped curvilinear surface 290a and a forward angled flat surface 290b that forms an acute angle with the outer surface of the top wall 286, which function together to help ensure that the primary locking member 320 is not accidently unlocked. As best shown in FIG. 99B, the engaging portion 282 also includes two deformable male coupling projections 292a, 292b that extend rearward from the front wall of the upper arrangement of side walls 284. Said deformable male coupling projections 292a, 292b interact with the securing recess 268 formed in shield insulator 260 to secure the male terminal holder 230 and thereby securing the male terminal assembly 430 in the main housing 280.

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

The lower arrangement of side walls 288 includes: (i) two accidental engagement slots or engagement slots 294a, 294b, which are a part of the first portion 337a of the accidental engagement assembly 336, (ii) two positioning slots 296a, 296b, (iii) two stabilization slots 297a, 297b, (iv) a CPA slot 298, (v) accidental engagement depression or engagement depression 300a, 300b, which are a part of the first portion 337a of the accidental engagement assembly 336, and (iv) a rear lip 301. The accidental engagement slots 294a, 294b are formed in the side walls of the lower arrangement of side walls 288, extend along a majority if the height of the side walls 288, and are positioned between the rear wall of the lower arrangement of side walls 288 and the accidental engagement depression 300a, 300b. As will be described in great detail below, the accidental engagement slots 294a, 294b are configured to help secure the male connector assembly 200 to the female connector assembly 600, facilitate the movement of the locking member 320 from an unlocking state to a locked state, and prevent the male connector assembly from accidently moving from a ready to engage/disengage state to a restrictive engagement state. The accidental engagement depression 300a, 300b extends downward from the top edge of the side walls of the lower arrangement of side walls 288 and does not extend completely though the side walls of the lower arrangement of side walls 288. In particular, the accidental engagement depression 300a, 300b includes two extends, where: (i) the first extent is a sloped wall 302a, 302b extends forward from the frontal edge of the accidental engagement depression 300a, 300b, and (ii) the second extent is a flat wall 303a, 303b, offset or recessed from the side walls of the lower arrangement of side walls 288 more than 0.1 mm and preferably 0.75 mm, and is substantially parallel with the side walls of the lower arrangement of side walls 288. The accidental engagement depression 300a, 300b are configured to receive an extent of the primary locking member 320, when the primary locking member 320 is in a locked state.

The positioning slots 296a, 296b and stabilization slots 297a, 297b are positioned between the accidental engagement depression 300a, 300b and the CPA slot 298 and are designed to receive a substantial projection that helps stabilize the connection between the male connector assembly 200 and the female connector assembly 600. The CPA slot 298, which is included in the male CPA assembly 400, is formed in the front wall of the lower arrangement of side walls 288 and is designed to receive an extent of the female CPA assembly 700, when the system 10 is in the ready to use state. Surrounding the CPA slot 298 is a CPA sidewall arrangement 402, wherein said CPA sidewall arrangement 402 and the front wall of the lower arrangement of side walls 288 and upper arrangement of side walls 284 form the CPA receiver 404. The CPA receiver 404 is designed to house a deformable male CPA member 406. Said male CPA member 406 includes: (i) two lateral connecting members 408a, 408b, (ii) two vertical supporting member 410a, 410b that are coupled to the lateral connecting members 408a, 408b, (iii) a horizontal engaging member 412 that extends between the two lateral connecting members 408a, 408b, and (iv) a head or top user interaction structure 414. The lateral connecting members 408a, 408b extend away from the front wall of the lower arrangement of side walls 288 and towards the forwardmost point of the CPA sidewall arrangement 402. As such, the lateral connecting members 408a, 408b allow the male CPA member 406 to deform from a first or original positon to a second or deformed positon when the system 10 is being coupled together.

As will be herein and in PCT/US2020/049870, which is hereby incorporated by reference for all purposes, the head, top or user interaction structure 414 is designed such that the primary locking member 320 can interact with it to place the CPA assembly 80 in a locked position. In addition, the user interaction structure 414 is also designed to be accessible by the installer such that they can apply a force on the user interaction structure 414 to cause the elastically deformable male CPA member 406 to disengage with an extent of the female CPA assembly 700. The horizontal engaging member 412 is designed to interact with the extent of the female CPA assembly 700. Specifically, when the CPA assembly is in a locked position, the horizontal engaging member 412 prevents: (i) the male connector assembly 200 from being able to be coupled with the female connector assembly 600 or (ii) the male connector assembly 200 from accidently being disconnected from the female connector assembly 600. Finally, the CPA sidewall arrangement 402 protects the deformable male CPA member 406 and prevents said male CPA member 406 from accidently being damaged or disengaged from the female connector 600. It should also be understood that the configuration of the male CPA assembly 400, and in turn the CPA assembly 80, may include a different arrangement, combination, or number of components. For example, the CPA assembly 80 use magnetic forces, spring forces, require partial rotation, or require full rotation forces or a combination of these forces to place the CPA assembly 80 in a locked or unlocked position.

The rear lip 301 extends downward from the rearmost extent of the head or engaging portion 282. Thus, any structure that is positioned forward of the rear surface of said rear lip is contained in the engaging portion 282 of the main housing 280 and everything that is positioned rearward of the rear surface of said rear lip is contained in the supporting portion 310 of the main housing 280. The supporting portion 310 includes: (i) a wall arrangement 311 that forms a substantially rectangular body, (ii) a securing assembly 312 formed from a raised lip 313 and a plurality of locking projections 314a, 314b, and (iii) end cap coupling projections 315a-315d. The securing assembly 312 is designed to prevent the primary locking member 320 from being slid too far rearward or too far forward. In particular, the raised lip 312 prevents the primary locking member 320 from being slid too far rearward and the plurality of locking projections 314a, 314b from being slid too far forward. The supporting portion 310 of the main housing 280 includes a readable indicia 316 that is positioned adjacent to and forward form the raised lip 312. The indicia 316 is configured to be placed into two different configurations depending on the configuration of the connector system 10 and the CPA assembly 80, wherein one configuration the indicia 316 is unreadable by the recording system and the other configuration the indicia 316 is readable by the recording system. The indicia 316 may contain a serial number, part number, application information (e.g., vehicle identification number), component information (e.g., power distribution system) or device information (e.g., alternator). The indicia 316 may be a barcode (e.g., single or multi-dimensional barcode), quick response (QR) code, SnapTags, Microsoft Tags, Blipper, MaciCode, Data Matrix, Bokode, Aztec Code, CueCat, PDF417, Semacode, ShotCode, Touchatag, SPARQCode, SQR codes, RFID, NFC, Bluetooth, collection of shapes that can be read by the recording system, radio based device that can be read by the recording system, a collection of projections that can be read by the recording system, a collection of different color shapes, or a combination of the above. In other words, the indicia 316 may be any pattern, any color, have any texture, have a 2 dimensional configuration, or 3 dimensional configuration.

The primary locking member or first locking member or locking member 320 is positioned external to the main housing 280 and is configured to overlie: (i) the entire engaging portion 282, and (ii) a portion of the supporting portion 310. The primary locking member 320 is designed to be slidely engage with the main housing 280. This sliding engagement is designed to help prevent the connector system 10 from accidently: (a) move the male connector assembly 200 from the “ready to engage state” to the “restrictive engagement state,” (b) move the system 10 from the “ready to use state” to the “connected,” and (c) remove the male connector assembly 200 from the female connector assembly 600 when the system 10 is in the “ready to use state.” Specifically, the primary locking member 320 is designed to slide forward and back upon the application of a first force in a first plane, while the connector is designed to be coupled to the female connector assembly 600 upon the application of a second force in a second plane that is substantially perpendicular to the first plane. In other words, the first and second forces are not parallel to one another and instead are substantially perpendicular to each other. Stated another way, the first plane may be the X-Y plane and the second plane may be the Y-Z plane that is substantially perpendicular to the X-Y plane.

The primary locking member 320 includes: (i) an arrangement of side walls 322 that include an upper wall arrangement 324 and a lower wall arrangement 330, (ii) a second portion 337b of the accidental engagement assembly 336, (iii) a top wall 346 that is integrally formed with the upper wall arrangement 324, (iv) a bottom rail 350, (v) a rear connector coupling projection 352, and (vi) a locking CPA assembly 356. The upper wall arrangement 324 includes: (i) two side walls 325a, 325b with locking apertures 326, (ii) a front wall 325c with a CPA opening 327 formed there through. The locking apertures 326 interact with the locking projections 314a, 314b to ensure that the primary locking member 320 cannot be easily removed from the main housing 280. The CPA opening 327 is included in locking CPA assembly 356 and provides access to the male CPA member 406 and specifically the user interaction structure 414 of the male CPA assembly 400. As will be discussed below, the CPA opening 327 provides access to allow the user to depress the user interaction structure 414 forward and down in order to cause the horizontal engaging member 412 to move far enough forward from an extent of the female CPA assembly 700 to permit disengagement of the male CPA assembly 400 from the female CPA assembly 700.

Like the main housing 280, the outer surface of the lower wall arrangement 330 are positioned outside or beyond the outer surface of the upper wall arrangement 324. In other words, the distance between opposed outer surfaces of the lower wall arrangement 330 is greater than the distance between opposed outer surfaces of the upper wall arrangement 324. This arrangement substantially matches the arrangement of the lower arrangement of side walls 288 and upper arrangement of side wall 284. The lower wall arrangement 330 includes: (i) accidental engagement recesses or engagement recesses 331a, 331b, (ii) accidental engagement retainer or engagement retainer 332a, 332b, (iii) a locking CPA wall arrangement 333, (iv) a stabilization projections 334, and (v) a plurality of locking depressions 335 that are configured to align with the accidental engagement slots 294a, 294b, the positioning slots 296a, 296b, and the CPA slot 298. The locking CPA wall arrangement 333 is included in the locking CPA assembly 356 extends forward from the front wall of the lower wall arrangement 330 and is designed to interact with the CPA sidewall arrangement 402 to protect the male deformable male CPA member 406. As such, the locking CPA wall arrangement 333 is configured to be positioned outside of CPA sidewall arrangement 402 in certain operating positions. The stabilization projections 334 are received by an extent of the female connector assembly 600 and is designed to further enhance the connection between the male and female connector assemblies 200, 600, when the system 10 is in the ready to use state. Finally, like the accidental engagement slots 294a, 294b, the positioning slots 296a, 296b, and the CPA slot 298, the locking depressions 335 are configured to help secure the male connector assembly 200 to the female connector assembly 600 and facilitate the movement of the primary locking member 320 from an unlocking state to a locked state.

The accidental engagement recesses 331a, 331b and the accidental engagement retainer 332a, 332b are a part of the second portion 337b of the accidental engagement assembly 336 and are formed on the inner surface of the lower wall arrangement 330. The accidental engagement recesses 331a, 331b allows the accidental engagement member or engagement members 338a, 338b: (i) to be positioned between an extent of the male and female housings 220, 620, and (ii) to elastically deform under certain operating conditions (which will be discussed in greater detail below). Meanwhile, the accidental engagement retainer 332a, 332b is positioned in the accidental engagement recesses 331a, 331b and retains the accidental engagement members 338a, 338b within the lower wall arrangement 330. It should be understood that other configurations of the accidental engagement assembly 336 are contemplated by this disclosure, wherein these structures help ensure that the primary locking member 320 is not accidently engaged, locked, or moved forward prior to insuring the male terminal assemblies 430 into the female terminal assemblies 800.

The top wall 346 of the locking member 320 is integrally formed with and extends between the upper wall arrangement 324. The top wall 346 includes accidental disengagement member 348, which is a part of the accidental disengagement assembly 347 and is configured to prevent the locking member 320 from accidently being disengaged, unlocked, or moved rearward. In particular, the disengagement member 348 has been formed in the top wall 336 by removing material from said top wall 336 to form a pivot strip 339, a rear or locking cantilever segment 340b, and a forward or unlocking cantilever segment 340a. A second disengagement projection 342 is formed on the inside of the rear or unlocking cantilever segment 340b, where said disengagement projection 342 includes a ramped or sloped curvilinear surface 344a and a forward angled flat surface 344b that forms an acute angle with the inner surface of the top wall 346, which function together to help ensure that the locking member 320 is not accidently unlocked. As discussed in greater detail below, the pivot strip 339 allows the unlocking and locking cantilever segments 340a, 340b to angularly displaced inward or outward about a pivot point 346 formed at or near the pivot strip 339. It should be understood that other configurations of the accidental disengagement assembly 347 are contemplated by this disclosure, wherein these structures help ensure that the primary locking member 320 is not accidently disengaged, unlocked, or moved rearward after the connector system 10 is in a ready to use state.

The bottom rail 350 of the locking member 320 extends downward from a lower surface of the lower wall arrangement 330 and provides additional rigidity to the male connector assembly 200 and to help secure/stabilize the male connector assembly 200, when connected with the female connector assembly 600. The rear connector coupling projection 352 is positioned adjacent to the bottom rail 350, extends downward from the lower wall arrangement 330, includes a lower surface that is positioned below the bottom rail 350, and includes at least one and preferably two bracing apertures 354a, 354b that are a part of the male bracing assembly 351. Said bracing apertures 354a, 354b of the male bracing assembly 351 are configured to receive an extent of the female connector assembly 600, where the connector system 10 is under certain operating conditions (e.g., in the ready to use state).

As best shown in FIGS. 2-3, 17, and 22-23, the secondary locking member or terminal locking member 360 is designed to: (i) secure the male terminal holders 230 in the main housing 280, and (ii) prevent the locking member 320 from moving before the secondary locking member 360 is secured in a locked position. The secondary locking member 360 includes: (i) an IL assembly opening 362, (ii) an arrangement of projections 364 that are designed to interact with the arrangement of recesses 250a-250d of the male terminal holder 230, and (iii) at least one and preferably more than two deformable securing members 368a-368c that are configured to secure the secondary locking member 360 to the main housing 230. The IL assembly opening 362 is an opening that is formed in the secondary locking member 360 and is designed to receive an extent of the female IL assembly 980, when the connector system 10 is in a ready to use state. The arrangement of projections 364 includes at least one and preferably four projections 366a-366d, wherein each projection substantially surrounds a corner of the male terminal holder 230. Finally, the deformable securing members 368a-368c are positioned between the arrangement of projections 364 and are designed to interact with projections that are formed in the main housing 230 to secure the secondary locking member 360 to said housing 230. The securement of the secondary locking member 360 to the housing 230 helps support and secure the male terminal assemblies 430 in the proper position to facilitate their mating with the female terminal assemblies 800, when the connector system 10 is in the connected or ready to use state.

B. Male Terminal Assembly

FIGS. 3-14A show a first embodiment of the male terminal assembly 430, while FIGS. 107-108 show a second embodiment of a male terminal assembly. Referring specifically to the first embodiment, the male terminal assembly 430 includes a spring member 440d and a male terminal 470. A first embodiment of the spring member 440d is shown in FIGS. 8-11, while two other embodiments 440c are shown in FIG. 108. Additional disclosure about these embodiments is contained within PCT/US2021/033446, PCT/US2021/043686, PCT/US2021/057959, each of which is incorporated herein by reference. Returning to the first embodiment of the spring member 440d, said spring member 440d includes an arrangement of spring member side walls 442a-442b and a rear spring wall 444. The arrangement of spring member side walls 442a-442b include: (i) a first or arched spring section 448a-448h, and (ii) a second spring section or spring arm 452a-452h. The arched spring sections 448a-448h extend between the rear spring wall 444 and the spring arm 452a-452h and position the spring arm 452a-452h substantially perpendicular to the rear spring wall 444. In other words, the outer surface of the spring arm 452a-452h is substantially perpendicular to the outer surface of the rear spring wall 444.

The spring arms 452a-452h extend from the arched sections 448a-448h, away from the rear spring wall 444, and terminate at the free end 446. Said spring arms 452a-452h are not connected to one another and thus are separated by spring arm gaps 455a-455f. The gaps 455a-455f aid in omnidirectional expansion of the spring arms 452a-452h, which facilitates the mechanical coupling between the male terminal 470 and the female terminal assembly 800. In other embodiments, the spring arms 452a-452h may be coupled to other structures to restrict their omnidirectional expansion. The number and width of individual spring arms 452a-452h and openings may vary. In addition, the width of the individual spring arms 452a-452h (except for the positioning and retaining means 453) is typically equal to one another; however, in other embodiments one of the spring arms 452a-452h may be wider than other spring arms.

In contrast to the embodiments 440a, 440b that are shown in PCT/US2019/036010 and (which are incorporated herein by reference), the inventive spring member 440d includes at least one spring arm 452 that includes a positioning and retaining means 453. Said positioning and retaining means 453 are shown as a “J-shaped” positioning projection 454a-454d extending laterally from an edge of the spring arm 452a, 452d, 452e, 452h. Preferably, the positioning projections 454a-454d extend from a free end 446 of the spring arm 452a, 452d, 452e, 452h, as opposed to an intermediate edge of the spring arm 452a, 452d, 452e, 452h. Specifically, the positioning projections 454a-454d are configured to: (i) retain the spring member 440d in the male terminal body 472, and (ii) center the spring member 440d within the contact arms 494a-494h by limiting the amount the spring member 440d can rotate within said body 472, and in some instances eliminate any measurable rotation of the spring member 440d. In the version shown in FIGS. 8-16, the spring member 440d includes: (i) at least two regular, planar spring arms 452b, 452c, 452f, 452g that lack the positioning projections 454a-454d, and (ii) at least two irregular, non-planar spring arms 452a, 452d, 452e, 452h that include the positioning projections 454a-454d. In the Figures, the regular, planar spring arms 452b, 452c, 452f, 452g are positioned between the irregular, non-planar spring arms 452a, 452d, 452e, 452h and as such the regular, planar spring arms 452b, 452c, 452f, 452g can be considered intermediate spring arms and the irregular, non-planar spring arms 452a, 452d, 452e, 452h can be considered peripheral or exterior spring arms.

Unlike the spring arm disclosed in FIGS. 4-8 of PCT/US2018/019787, the free end 446 of the spring arms 452a, 452d, 452e, 452h do not have an inwardly curvilinear component. Instead, the spring arms 452a, 452d, 452e, 452h have a substantially planar outer surface (except for the positioning and retaining means 453). This configuration is beneficial because it ensures that the outwardly forces exerted by the inventive spring member 440d are applied substantially perpendicular to the free end 488 of the male terminal body 472. In contrast, the curvilinear components of the spring arms disclosed in FIGS. 4-8 of PCT/US2018/019787 do not apply a force in this manner. When the positioning and retaining means 453 is considered, then the outer four spring arms 452a, 452d, 452e, 452h are non-planar. Under this interpretation, the spring member 440d includes: (i) a curvilinear component that is not bent or angled inward towards the center of the connector and instead is directed away from the center of the connector, and (ii) a limited extent of the spring member 440d is positioned outside of the spring receiver 486. Moreover, a single spring arm 452a, 452d, 452e, 452h may be positioned between curvilinear components 448a-448h, 454a-454d that are positioned in two different planes.

In contrast to spring member 440c that is disclosed in PCT/US2021/033446 and in other PCT applications that are incorporated herein, the spring member 440d does not include four side walls and instead only include two side walls 442a-442b. This is because the disclosed male connector assembly 430 does not include contact arms on all four sides and thus is not 360 degree compliant. In addition, spring member 440d does not include a base section that extends between the arched section and the spring arms. In other words, the spring arm section gaps 455a-455f extend all the way to the rear wall 444. Another difference between these spring members 440a-440d is the fact that the inclusion of the curvilinear positioning projections 454a-454d causes the spring member side walls 442a-442b to no longer be planar. Finally, due to the positioning and retaining means 453 the spring 440d cannot be properly used in connection with other male terminal bodies that are disclosed in other PCT applications (e.g., PCT/US2019/036010 and PCT/US2020/049870).

In other embodiments, the spring member 440d may include at least one spring arm 452b, 452c, 452f, 452g and only two spring arm 452a, 452d, 452e, 452h with positioning projections 454 that are arranged on opposite sides of the spring member 440d, either in an opposed positional relationship or a diagonal positional relationship. This configuration may be beneficial because it limits the number of spring arms that need to be bent in a second direction. In other embodiments, the spring member 440d may include only a single irregular, non-planar spring arm in connection with the inclusion of a front or rear wall of the male terminal body 472. In this embodiment, the front or rear wall to stop the spring member from sliding in that direction while the single irregular, non-planar spring arm will keep this embodiment of the spring member from sliding in the direction opposite of the front or rear wall. In other embodiments, the positioning and retaining means 453 may be: (i) a projection(s) or tab(s) that extends from one or more of the free ends 446 of the spring arms 452a-452h and wraps around an appreciable portion of the curvilinear lower extent of the contact arms 494a-494h, namely overlapping or wrapping-around the interior corner region 493a-493d of the exterior contact arm 494a, 494d, 494e, 494h, (ii) projection(s) that do not extend from the spring arms 452a-452h, but instead extend from the rear spring wall 444 around an extent of the top male terminal body wall 480, (iii) projection(s) that are not positioned near the free end 446 of the spring arms 452a-452h, but instead are positioned near an upper extent of the spring arms 452a-452h and wrap around the neck portion 491a-491h of the contact arms 494a-494h, (iv) projections that extend from the rear spring wall 444 and are configured to be positioned between an inner surface of the top male terminal body wall 480 and a uppermost extent of the male terminal front wall 483, (v) any combination of these projections or tabs that have similar structural and functional attributes.

The spring member 440d is typically formed from a single piece of material (e.g., metal). Therefore, the spring member 440d is a one-piece spring member 440d or has integrally formed features. In particular, the following features are integrally formed: (i) the rear spring wall 444, (ii) the curvilinear sections 448a-448h, (iii) the spring arms 452a-452h, and (iii) the positioning projections 454a-454d. To integrally form these features, the spring member 440d is typically formed using a die forming process. The die forming process mechanically forces the spring member 440d into shape. As discussed in greater detail below and in PCT/US2019/036010, when the spring member 440d is formed from a flat sheet of metal, installed within the male terminal body 472 and connected to the female terminal assembly 800, and is subjected to elevated temperatures, the spring member 440d applies an outwardly directed spring thermal force Sm on the contact arms 494a-494h due in part to the fact that the spring member 440d attempts to return to a flat sheet. However, it should be understood that other types of forming the spring member 440d may be utilized, such as casting or using an additive manufacturing process (e.g., 3D printing). In other embodiments, the features of the spring member 440d may not be formed from a one-piece or be integrally formed, but instead formed from separate pieces that are welded together.

Referring to FIGS. 4-7B, the first embodiment of the male terminal 470 includes: (i) a male terminal body 472 and (ii) a male terminal connection plate 474. The male terminal connection plate 474 is configured to receive an extent of a conductor 598, a busbar, or any other type of an electrical connector. The conductor 598 is typically welded to the connection plate 474; however, other methods of connecting the conductor 598 to the connection plate 474 are contemplated by this disclosure. Referring now to the male terminal body 472, said male terminal body 472 has: (i) a top wall 480, (ii) a first side wall 482a, (iii) an opposed second side wall 482b, (iv) a front wall 483, and (v) a rear wall 484. The combination of these walls 480, 482a-482b, 483, and 484 forms a wall arrangement 479 that defines a spring receiver 486, which has a rectangular prism shape. The arrangement of the first and second side walls 482a-482b includes: (i) contact arms 494a-494h, where each contact arm 494a-494h has a first or neck portion 491a-491h and a second or body portion 492a-492h, (ii) a base sections 490a-490b that extends between the rear wall 484 and the contact arms 494a-494h, and (iii) a plurality of contact arm openings 496a-496h, where each contact arm opening 496a-496h has a first extent or neck gap 498a-498h and a second extent or a body gap 499a-499h. This configuration of features causes: (i) the lateral edges of each contact arm 494a-494h to have a non-linear edge, (ii) the lateral edges of the neck portion 491a-491h are parallel, but are not co-planar with the lateral edges of the body portion 492a-492h, (iii) the elongated boarders of the contact arm opening 496a-496h are non-linear, (iv) the contact arms 494a-494h to have non-uniform widths, and (v) the contact arm opening 496a-496h to have non-uniform widths.

The contact arms 494a-494h extend: (i) away from the top male terminal wall 480, and (ii) across an extent of the contact arm openings 496a-496h. This configuration is beneficial over the configuration of the terminals shown in FIGS. 9-15, 18, 21-31, 32, 41-42, 45-46, 48 and 50 in PCT/US2018/019787 because it allows for: (i) can be shorter in overall length, which means less metal material is needed for formation and the male terminal 470 can be installed in narrower, restrictive spaces, (ii) has a higher current carrying capacity, (iii) is easier to assemble, and (iv) other beneficial features that are disclosed herein or can be inferred by one of ordinary skill in the art from this disclosure.

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

The first or neck portion 491a-491h of the contact arm 494a-494h has a neck width W_N, while the second or body portion 492a-492h of the contact arm 494a-494h has a body width W_B. In the embodiment of the male terminal body 472 shown in the Figures, the neck width W_N(e.g., 1.9 mm) is not equal to the body width W_B(e.g., 3.2 mm). Specifically, the neck width W_Nis less than the body width W_B, preferably the neck width W_Nis at least 10% less than the body width W_B, more preferably the neck width W_Nis at least 20% less than the body width W_B, and most preferably the neck width W_Nis at least 40% less than the body width W_B. In other words, the neck width W_Nmay be approximately 60% of the body width W_B. This reduction in the neck width W_Nin comparison to the body width W_Breduces the force that is required to deflect or displace the contact arm 494a-494h inward and towards the center of the male terminal 470 when coupling the male terminal assembly 430 to the female terminal assembly 800. This is beneficial because it reduces the insertion force that is associated with the male terminal body 472, which is desirable in order to meet industry specifications (e.g., USCAR), reduce fatigue on the installer, and reduce installation times, while also reducing installation errors.

While the neck portion 491a-491h of the contact arm 494a-494h reduces the insertion force that is associated with the male terminal body 472, it also does not act as a current choke because the volume of the neck is larger than the volume of the contact arm 494a-494h that makes contact with the female terminal assembly 800. This is significant because the creation of a current choke by the neck portion 491a-491h would make this design less desirable then other designs that lacked a neck portion that created a current choke. Specifically, the volume of the neck is approximately 4.5 mm³(e.g., (length) 3 mm*(width) 1.9 mm*(thickness) 0.8 mm) and the volume of the contact area is approximately 2 mm³(e.g., (length) 0.8 mm*(width) 3.2 mm*(thickness) 0.8 mm). In other words, the volume of the contact area is 44% of the volume of the neck. Thus, the volume of the neck could be substantially reduced before creating a current choke. In other words, it may theoretically be possible to reduce the width of the neck to 0.9 mm, while keeping all other measurements the same, before the neck creates a theoretical current choke. It should be understood that in other embodiments, other measurements may be utilized and these are non-limiting.

By decreasing the insertion force associated with the male terminal body 472 of the male connector assembly 200, the designer has the ability to either: (i) maintain this reduced insertion force by using the same spring member 440d, or (ii) maintain an insertion force that is the same or similar to a male connector assembly 200 that utilizes a male terminal body that does not include contact arms that have a neck portion with a reduced width—namely, a male terminal body similar to the one disclosed in PCT/US2020/049870—by using a spring member that has a first biasing force that is larger than a second biasing force that is associated with spring member 440d. If the second option is selected where the designer desires to build a connector system 10 that has the same insertion force requirements that would be associated with a similar connector system that includes a contact arm that has linear edges, then the designer will reallocate the forces associated with the components that contribute to the insertion force such that a heaver reliance is placed on the spring member 440d and less reliance is place on the male terminal body 472. This heavier reliance on the internal spring member can be beneficial because the designer can easily change the properties of the connector system 10 without requiring alterations to the terminal body 472. For example, the designer can insert a stiffer spring member within the spring receiver 486 in order to increase the current capacity of the system 10. Or if there are specific customer requirements setting forth a target insertion force, the designer can simply select a spring member that meets these requirements without the need to redesign the male terminal body 472. This modularity and flexibility of the connector system 10 is a substantial improvement over the prior art, as reduce the number of product skus, increases the ability to meet customer requirements without retooling or redesigning the connector, and/or limits testing and other steps that would be required to utilize new/different connectors.

The first or neck portion 491a-491h of the contact arm 494a-494h has a neck length L_N, while the second or body portion 492a-492h of the contact arm 494a-494h has a body length L_B. In the embodiment of the male terminal body 472 shown in the Figures, the neck length L_N(e.g., 3 mm) is not equal to the body length L_B(e.g., 9.7 mm). Specifically, the neck length L_Nis less than the body length L_B, preferably the neck length L_Nis at least 10% less than the body length L_B, more preferably the neck length L_Nis at least 40% less than the body length L_B, and most preferably the neck length L_Nis at least 65% less than the body length L_B. The neck gap 498a-498h of the contact arm opening 496a-496h has a neck gap width W_NG, while the body gap 499a-499h of the contact arm opening 496a-496h has a body gap width W_BG. In the embodiment of the male terminal body 472 shown in the Figures, the neck gap width W_NG(e.g., 1.9 mm) is not equal to the body gap width W_BG(e.g., 0.6 mm). Specifically, the neck gap width W_NGis greater than the body gap width W_B, preferably the neck gap width W_NGis at greater 15% less than the body gap width W_BG, more preferably the neck gap width W_NGis at least 40% greater than the body gap width W_BG, and most preferably the neck gap width W_NGis at least 65% greater than the body gap width W_BG.

The neck gap 498a-498h of the contact arm opening 496a-496h has a neck gap length L_NG, while the body gap 499a-499h of the contact arm opening 496a-496h has a body gap legnth L_BG. In the embodiment of the male terminal body 472 shown in the Figures, the neck gap length L_NG(e.g., 3 mm) is not equal to the body gap length L_BG(e.g., 9.7 mm). Specifically, the neck gap length L_NGis less than the body gap length L_BG, preferably the neck gap length L_NGis at least 10% less than the body gap length L_BG, more preferably the neck gap length L_NGis at least 40% less than the body gap length L_BG, and most preferably the neck gap length L_NGis at least 65% less than the body gap length L_BG. The front wall 483 of the male terminal body 472 has a front wall length L_Fw (e.g., 4.5 mm), which is: (i) less than the length of the body length L_Bor body gap length L_BG, and (ii) greater than the neck width W_Nor neck gap width W_NG. In fact, the front wall length L_FW is: (i) approximately 35% of the length of the contact arm 494a-494h, (ii) approximately 45% of the length of the contact arm body length L_B, and (iii) approximately 1.5 times longer than the length of the contact arm neck length L_N. The reduced length of the front wall 483 is beneficial because it reduces the weight, expense of manufacturing, and cost of materials utilized in the male terminal assemblies 430. These benefits are a substantial improvement over the male terminal assemblies disclosed in PCT/US2019/036010 and PCT/US2020/049870.

Unlike the male terminal bodies disclosed in PCT/US2019/036010 and PCT/US2020/049870, the male terminal body 472 disclosed herein lacks a U-shaped side wall portion that surrounds the contact arms 494a-494h. This configuration reduces weight, expense of manufacturing, and cost of materials; however, it reduces the durability of the male terminal assembly 430. This reduction in durability is not a drawback to the disclosed system 10 because of the substantial male terminal holder 230 and other non-conductive members of the connector system 10. While the male terminal body 472 disclosed herein lacks the U-shaped side wall portion of PCT/US2019/036010, the male terminal body 472 includes terminal ends 488a-488h that are: (i) positioned within the spring receiver 486, (ii) have an inner surface that is co-planar with an inner surface of the base sections 490a-490b of the contact arms 494a-494h, and (iii) configured to be placed in contact the planar outer surface of the spring arms 452a-452d, when the spring member 440d is inserted into the spring receiver 486. This configuration is beneficial over the configuration shown in FIGS. 3-8 in PCT/US2018/019787 because the assembler of the male terminal assembly 430 does not have to apply a significant force in order to deform a majority of the contact arms 494a-494h outward to accept the spring member 440d. This required deformation can best be shown in FIG. 6 of PCT/US2018/019787 due to the slope of the contact arm and the fact the outer surface of the spring arm and the inner surface of the contact arm are adjacent to one another without a gap formed there between. In contrast to FIGS. 3-8 in PCT/US2018/019787, the present application shows a gap that is formed between the outer surfaces of the spring member 440d and the inner surface of the contact arms 494a-494h. Accordingly, very little force is required to insert the spring member 440d into the spring receiver 486 due to the fact the assembler does not have to force the contact arms 494a-494h to significantly deform during the insertion of the spring 440d.

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

The male terminal assembly 430 is assembled by moving the spring member 440d from an unseated state to a seated state. In particular, FIG. 10 shows the spring member 440d spaced away from the male terminal body 472 in an unseated state. The installer then applies an insertion force on the spring member 440d in order to place the spring member 440d in the spring receiver 486. The insertion force is applied on the spring member 440d until the rear spring wall 444 is positioned adjacent to the inner surface of the top male terminal wall 480, the free end 446 of the spring member 440d is substantially aligned with the free end 488 of the male terminal body 472, and a portion of the spring member 440d side walls 442a-442b is positioned adjacent to the male terminal side walls 482a-482b. In this position, the spring member 440d has moved from the unseated state to the seated state. In the seated state, which is best shown in FIGS. 11-16, the spring member 440d makes contact with three separate surfaces of the male terminal body 472, including contact between: (i) an outer surface of the spring member 440d and an inner surface of the male terminal body 472, (ii) an inner surface of the “J-shaped” positioning projections 454a and 454d of the spring member 440d and a first end surface of the contact arm 494a-494h of the male terminal body 472, which is an outer surface of contact arm 494a and 494h, and (iii) an inner surface of the “J-shaped” positioning projections 454b and 454c of the spring member 440d and a second end surface of the contact arm 494a-494h of the male terminal body 472, which is an outer surface of contact arm 494d and 494e. In this manner, each of the positioning projections 454a, 454b, 454c, 454c engages and wraps around an interior corner region 493a-493d (see FIGS. 12 and 13) of the exterior contact arm 494a, 494d, 494e, 494h of the male terminal body 472, but not the interior contact arms 494b, 494c, 494f, 494g. The engagement due to overlapping or wrapping-around the interior corner region 493a-493d by the positioning projections 454a, 454b, 454c, 454c ensures proper centering and retention of the spring member 440d within the spring receive 486 of the male terminal body 472 and is structurally and functionally different than the spring arms and male terminal assemblies disclosed in other PCT applications (e.g., PCT/US2019/036010 and PCT/US2020/049870) that are incorporated herein by reference.

As best shown in FIG. 11, a periphery of the interior lower edge of all spring arms 452a-452h are not equal and none of the peripheries of the interior lower edge of all spring arms 452a-452h are equal to the peripheries of the interior lower edge of the contact arms 494a-494h. Specifically, the periphery of the intermediate spring arms 452b-452c and 452f-452g is equal a first length (e.g., 2 mm), the periphery of the exterior spring arms 452a, 452d, 452e, 452h is equal a second length (e.g., 4.1 mm), and the periphery of the contact arms 494a-494h is equal to a third length (e.g., 5.3 mm). Here, the first length is less than the second length, and the second length is less than the third length. Unlike other male terminal assemblies, the first length (e.g., 2 mm) of the intermediate spring arms 452b-452c and 452f-452g is not equal to the third length (e.g., 5.3 mm) of the periphery of the contact arms 494a-494h. Also, the spring arm width W_S(e.g., 2 mm) of the intermediate spring arms 452b-452c and 452f-452g is not equal to the body width W_B(e.g., 3.2 mm) or neck width W_N(e.g., 1.9 mm) of the contact arms 494a-494h. As shown here, the spring arm width W_Sis 62.5% of the contact arm body width W_B. Meanwhile, the spring arm width W_Sis just a little larger than the contact arm neck width W_N. While other widths and other ratios of widths are contemplated by this disclosure, alterations of these widths/ratios of widths will likely impact the insertion force of the connector system 10 and thus need to be closely considered when make any changes thereto.

The first embodiment of the male terminal assembly 430 shows a male terminal 470 that is not 360° compliant because the outer surface of the contact arms 494a-494h are designed to only make contact with two opposed side wall of the female terminal receiver 814 and not all four side walls of the female terminal receiver 814. As such, the spring biasing force S_BFis only applied in two directions and not all four directions. It should be understood that some of the embodiments of the male terminal assemblies 430 may be 360 degree compliant because the outer surface of the contact arms 494a-494h are designed to make contact with all four side walls of the female terminal receiver 814.

The male terminal 470, including the contact arms 494a-494h, may be formed from a first material such as copper, a highly-conductive copper alloy (e.g., C151 or C110), aluminum, and/or another suitable electrically conductive material. The first material preferably has an electrical conductivity of more than 80% of IACS (International Annealed Copper Standard, i.e., the empirically derived standard value for the electrical conductivity of commercially available copper). For example, C151 typically has 95% of the conductivity of standard, pure copper compliant with IACS. Likewise, C110 has a conductivity of 101% IACS. In certain operating environments or technical applications, it may be preferable to select C151 because it has anti-corrosive properties desirable for high-stress and/or harsh weather applications. The first material for the male terminal 470 is C151 and is reported, per ASTM B747 standard, to have a modulus of elasticity (Young's modulus) of approximately 115-125 gigaPascals (GPa) at room temperature and a coefficient of terminal expansion (CTE) of 17.6 ppm/degree Celsius (from 20-300 degrees Celsius) and 17.0 ppm/degree Celsius (from 20-200 degrees Celsius).

The spring member 440a, 440b, 440d may be formed from a second material such as spring steel, stainless steel (e.g., 301SS, ¼ hard), and/or another suitable material having greater stiffness (e.g., as measured by Young's modulus) and resilience than the first material of the male terminal 470. The second material preferably has an electrical conductivity that is less than the electrical conductivity of the first material. The second material also has a Young's modulus that may be approximately 193 GPa at room temperature and a coefficient of terminal expansion (CTE) of approximately 17.8 ppm/degree Celsius (from 0-315 degrees Celsius) and 16.9 ppm/degree Celsius (from 0-100 degrees Celsius).

Based on the above exemplary embodiment, the Young's modulus and the CTE of the spring member 440d is greater than the Young's modulus and the CTE of the male terminal 470. Thus, when the male terminal 470 is used in a high power application that subjects the system 10 to repeated thermal cycling with elevated temperatures (e.g., approximately 150° Celsius) then: (i) the male terminal 470 become malleable and loses some mechanical resilience, i.e., the copper material in the male terminal 470 softens and (ii) the spring member 440d does not become as malleable or lose as much mechanical stiffness in comparison to the male terminal 470. Thus, when utilizing a spring member 440d that is mechanically cold forced into shape (e.g., utilizing a die forming process) and the spring member 440d is subjected to elevated temperatures, the spring member 440d will attempt to at least return to its uncompressed state, which occurs prior to insertion of the male terminals assembly 430 within the female terminal assembly 800, and preferably to its original flat state, which occurs prior to the formation of the spring member 440d. In doing so, the spring member 440d will apply a generally outward directed thermal spring force S_TFon the free end 488 of the male terminal 470. This thermal spring force S_TFis dependent upon local temperature conditions, including high and/or low temperatures, in the environment where the system 10 is installed. Accordingly, the combination of the spring biasing force S_BFand the thermal spring force S_TFprovides a resultant biasing force S_RBFthat ensures that the outer surface of the contact arms 494a-494h are forced into contact with the inner surface of the female terminal assembly 800 when the male terminal 470 is inserted into the female terminal assembly 800 and during operation of the system 10 to ensure an electrical and mechanical connection. Additionally, with repeated thermal cycling events, the male terminal assembly 430 will not decrease the outwardly directed resultant spring forces S_RBFthat are applied to the female terminal assembly 800 during repeated operation of the system 10. It should be understood that additional details about the male terminal 470 and the spring 440d are discussed within PCT/US2019/036010, PCT/US2019/036070, PCT/US2019/036127, PCT/US2021/043686, PCT/US2021/043788, and PCT/US2021/057959, each of which is incorporated herein by reference.

C. Male Shielding Assembly

As best shown in FIGS. 17-18 and 97-99B, the shielding assembly 60 includes male shielding assembly 530 that resides within the male housing assembly 220 and is designed to interact with the female shielding assembly 930 in order to reduce the electromagnetic interference (“EMI”) noise emitted by the male connector assembly 200. The male shielding assembly 530 is comprised of: (i) a male terminal body shield 532, (ii) a male connection plate shield 538, (iii) a bottom shield 542, (vi) a shielding cap 546, and (v) a shielding connector 556. Each of these components are coupled together to form an electrical path that is connected to the cable shields and partially surround the male terminal assembly 430. The male terminal body shield 532 is configured to be positioned adjacent to the exterior wall arrangement 244 of the male terminal holder 230 and the cap 262 of the shield insulator 260 and interact with male connection plate shield 538 and the bottom shield 542. The male terminal body shield 532 has: (i) two opposed side walls 534a, 534b, where three deformable coupling members 536a-536c are formed in one side wall 534a, three deformable coupling member 536d-536f are formed in the opposed side wall 534b, (ii) a front wall 534c, with two deformable coupling members 536g-536h are formed in the front wall 534c, and (iii) a top wall 534d with divot that matches the securing recess 268 formed in the cap 262. The bottom shield 542 has an arrangement of walls 544 that form a bowl shaped receiver that is configured to partially surround male connector plate 474, be positioned adjacent to an extent of the male terminal holder 230, and interact with the male terminal body shield 532 and the male connection plate shield 538. The bottom shield 542 includes one deformable coupling member 536i which extend from the bottom wall of the arrangement of walls 544. The combination of the male terminal body shield 532 and bottom shield 542 provide nine deformable coupling member 536d-536i (e.g., six on the sides of the terminal assemblies 430, two in front of the terminal assemblies 430, and one in the rear of the of the terminal assemblies 430). It should be understood that other numbers of shield coupling member 536a-536i, which form the shield coupling assembly 535, are contemplated by this disclosure included between one shield coupling member and fifty shield coupling members.

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

As shown in FIGS. 14A and 14B, a force is applied on the male terminal assemblies 430 to position said male terminal assemblies 430 in the male terminal holders 230 in order to move the combination of components from the uncoupled state to the coupled state. Once the male terminal assemblies 430 are positioned within the male terminal holders 230, a force can be applied on the cap 262 of the shield insulator 260 to couple the caps 262 to the male terminal holders 230 and secure the male terminal assemblies 430. Next, an upwardly force is applied to the bottom shield 542 in order to position said bottom shield 542 around a lower extent of the male terminal holder 230. After the bottom shield 542 is installed, then a downwardly directed force is applied on the male terminal body shield 532 to position said male terminal body shield 532 in contact with: (i) an extent of the male terminal holder 230, (ii) an extent of the cap 262, (iii) an extent of the bottom shield 542. In this configuration, the shield coupling member 536a-536i form nine contact points (e.g., six on the sides of the terminal assemblies 430, two in front of the terminal assemblies 430, and one in the rear of the of the terminal assemblies 430) that are designed to make contact with the female shielding assembly 930, when the system 10 is in the ready to use state.

Once the bottom shield 542 and the male terminal body shield 532 are properly positioned around the male terminal assembly 430, a force is applied to the male connection plate shield 538 in order to cause the forward and rear connection elements 542a, 542b to make contact with the bottom shield 542 and the male terminal body shield 532. Next, a conductor 598 is welded to the male connection plate 474 and then the shielding cap 546 is coupled to the bottom shield 542 and the male terminal body shield 532. Finally, the shielding cap 546 is connected to the shielding connector 556, which is crimped to conductor's shield.

D. Male Interlock Assembly

As shown and discussed in greater detail in PCT/US2021/043686, the male interlock or MIL 590, which is a part of the IL assembly 100, is design help prevent arcing from occurring during the mating of the connector assembly 200, 600. To achieve this, the IL assembly 100 prevents electrical current from being applied to a portion of the connector system 10, namely—the female connector assembly 600—prior to the connector system being placed in the connected state. This functionality is achieved using an interlock circuitry, which may include: (i) components of a battery distribution system, which include a sense module and a disconnect controller, and (ii) a disconnect switch. The sense module is coupled to the FIL receiver 982 and detects when the circuit is closed by the insertion of the MIL jumper 592. When the circuit is closed, the sense module sends a signal to the disconnect controller to close the disconnect switch. When the disconnect switch is closed, electrical current can flow from the power supply through the switch to the connector system 10. Alternatively, when the MIL jumper 592 is not inserted into the FIL receiver 982, the sense module sends a signal to the disconnect controller to open the disconnect switch. When the disconnect switch is open, electrical current cannot flow from the power supply through the switch to the connector system 10. For sake of clarity, a chart showing the operation of these components is shown in FIG. 74B of PCT/US2021/043686 and other examples of interlock circuits are disclosed in U.S. Pat. Nos. 7,084,361, 7,508,097, 7,586,722, 8,466,586, 9,327,601, 9,533,639 or 9,851,387, each of which is fully incorporated herein by reference.

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

E. Assembly of the Male Connector Assembly

As shown in FIG. 3, the male connector assembly 200 is in a disassembled state. As described above and shown in FIGS. 12-13B, the first step in assembling the male connector assembly 200 is moving the male terminal assembly 430 from an unseated state to a seated state by positioning the spring member 440d in the spring receiver 486 of the male terminal body 472. As shown in FIG. 14A, the second step in assembling the male connector assembly 200 is moving the male terminal assembly 430 from an uncoupled state to a coupled state by positioning the male terminal assembly 430 in the male terminal holder 230. As shown in FIGS. 14B-17, the next step in assembling the male connector assembly 200 is finishing the assembling the non-conductive elements that surround the male terminal assembly 430. In particular, this step involves coupling the shield insulator 260 to the male terminal holder 230. Once this step is complete, the male connector assembly 200 is in the first partially assembled state.

To move the male connector assembly 200 from the first partially assembled state to the second partially assembled state: (i) the male shielding assembly 530 is installed around the non-conductive elements of the male terminal assembly 430 in the manner described above, (ii) the combination of the male terminal assembly 430, housing members 230, 260, and shielding assembly 530 are inserted into the main housing 280, and (iii) the primary locking member 320 is partially coupled to the main housing 280 by applying a rearwardly directed force on said primary locking member 320, as shown in FIGS. 19-21.

The application of the rearwardly directed force on said primary locking member 320 will cause the primary locking member 320 to default into the locked state or forward state. In order to move the primary locking member 320 from this locked state, the installer applies a downward directed pivoting force F_Pon the forward or unlocking cantilever segment 340a in order to cause the rear or locking cantilever segment 340a to pivot around the pivot strip 339 in order to move a lowermost extent of the second disengagement projection 342 above the uppermost extent of the first disengagement projection 287. While applying the downward directed force on the forward or unlocking cantilever segment 340a, the installer also applies a rearwardly directed unlocking force F_ULon the primary locking member 320 in order to move the second disengagement projection 342 rearward of the first disengagement projection 287. In this state, the locking member 320 is in the rearward state or unlocked state. The required downward directed pivoting force F_Pis less than 25 Newtons of force, while the required unlocking force F_ULis less than 25 Newtons of force. To move the male connector assembly 200 from the second partially assembled state to the third partially assembled state, the secondary locking member 360 is positioned in the main housing 280, but is not coupled thereto (i.e., the secondary locking member 360 is in the unreceived state). To move the male connector assembly 200 from the third partially assembled state to the assembled state, an upwardly directed force is applied to the secondary locking member 360 to move it from the unreceived state to the received state (see FIGS. 22-23).

2. Female Connector Assembly

FIGS. 28-31 and 38-99B provide various views of the female connector assembly 600. The female connector assembly 600 includes: (i) a female housing 620 with a female CPA assembly 700, (ii) a female touch-proof member 720, (iii) a female terminal assembly 800, (iv) female shielding assembly 930, and (v) a female IL assembly 980.

A. Female Housing Assembly

As best shown in FIG. 28, the female housing assembly 620 includes: (i) female terminal holder 630, (ii) main housing 640, and (vii) a seals 998. The female terminal holder 630 is configured to receive the 630 terminal assembly 800, isolate the female shielding assembly 930 from the female terminal assembly 800, facilitate positioning and retaining the female terminal assembly 800 in the female connector assembly 600, and other functions that are obvious to one of skill in the art based on the below disclosure and figures. The female terminal holder 630 has an arrangement of walls 632 with terminal holding projections 634 and terminal holding recesses 636, where the outer surface of the projections substantially match the outer surface of the end walls of the female terminal assemblies 800 and the terminal holding recesses 636 receive an extent of the side walls of the female terminal assemblies 800. The female terminal holder 630 is configured to be placed in contact with both the shielding assembly 60 and the female terminal assembly 800; thus, it is desirable to form the female terminal holder 630 from a non-conductive material. It should be understood that the non-conductive material that is chosen should be able to sufficiently isolate the female terminal assembly 800, even when a high current load is flowing through the terminal assembly 800. As discussed in other parts of this application, the female terminal holder 630 may be formed using any suitable method, such as injection molding techniques, 3D printing, cast, thermoformed, or any other similar technique.

The female main housing 640 includes: (i) a base wall 642, (ii) an arrangement of internal walls 644, (iii) an arrangement of external walls 646, (iv) female bracing assembly 648, (v) an arrangement of terminal securing projections 670, (vi) a FIL retainer 674, and (vii) the female CPA assembly 700. As shown in FIGS. 28-31, the base wall 642 is designed to be positioned adjacent to an extent of a component 8 contained in the power distribution system and facilitate the coupling of the female terminal assemblies 800 to said component. As such, the base wall 642 has a substantial thickness to help ensure proper mounting and has four connector openings 654a-654d formed therethrough. Said connector openings 654a-654d are designed to receive an extent of elongated couplers that are configured to secure the female connector assembly 200 to the component.

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

It should be understood that in other embodiments, the sloped or angled configuration of the internal segment 664 may not be constant, the dimensions may be different, and the internal segment 664 may be continuous within the housing 620. It should also be understood that the internal segment 664 is typically formed from the same material that the rest of the female housing 640 is formed from, such as polymer (e.g., nylon or plastic). Utilizing a polymer material is beneficial because there is less friction between the metal contact arms 494a-494h and the polymer material of the internal segment 664 in comparison to the friction between either: (i) the metal contact arms 494a-494h and an alternative internal segment 664 made from metal, or (ii) the metal contact arms 494a-494h and the metal female terminal assembly 800. In alternative embodiments, a coating, liner or other materials may be used to line or coat the internal segment 664 to reduce the friction with the contact arms 494a-494h.

The arrangement of external walls 646 also extend upward from the base wall 642 and surrounds the arrangement of internal walls 644. The arrangement of external walls 646 includes two side walls 650a, 650b that include: (i) the female accidental engagement assembly 652 with an accidental engagement projections 654a, 654b, (ii) positioning structures 656a, 656b, and (iii) stabilization projections 658a, 658b. As discussed in greater detail below and when the male connector assembly 800 is connected to the female connector assembly 600, the accidental engagement projections 654a, 654b are configured to be received by the accidental engagement slots 294a, 294b, the positioning structures 656a, 656b are configured to be received by the positioning slots 296a, 296b, and (iii) the stabilization projection 658a, 658b are configured to be received by the stabilization slots 297a, 297b. The female bracing assembly 648 extend rearward from the base wall 642 and include two bracing projections 649a, 649b. The bracing projections 649a, 649b are configured to fit within the two bracing apertures 354, when the primary locking member 320 is in a locked state.

The arrangement of terminal securing projections 670 includes a plurality of terminal securing projections 672a-672c, which are configured to be positioned under an extent of the female terminal assembly 800 to secure said female terminal assembly 800 within the female main housing 640. Also formed on a bottom extent of the base wall 642 is the FIL retainer 674. Said FIL retainer 674 is a deformable FIL projection 676 that allows the FIL to optionally be added to the system 10. This is beneficial over other disclosed system because: (i) it does not add weight to the system, if this component is not desired, (ii) reduces part numbers/SKUs that a manufacture maintains, and (iii) other benefits that are obvious to one of skill in the art based on the below disclosure and figures. The female CPA assembly 700 includes a female coupling member 702 that is coupled to the external walls 646 of the main housing 640 and includes a CPA body 704 and a CPA retaining member 706 that extends from the CPA body 704. The CPA body 704 and CPA retaining member 706 are configured to be positioned in the CPA slot 298 formed in the male connector assembly 200, when the male connector assembly 800 is connected to the female connector assembly 600.

As described above, the optional touch-proof assembly 40 includes a male touch-proof element opening 242 and a female touch-proof member 720. Said touch-proof assembly 40 is designed to: (i) help ensure that foreign objects cannot come into contact with the female terminal assembly 800 when the female connection assembly 600 is not coupled to the male connector assembly 200 and (ii) stabilize the connection between the male terminal assembly 430 and the female terminal assembly 800. To accomplish both of these tasks, the female touch-proof member 720 includes: (i) the touch-proof securing assembly 762 and (ii) the touch-proof element 780. The touch-proof securing assembly 762 is best shown in FIGS. 28-45 and includes: (i) an arrangement of deformable retaining members 764 with a first end deformable retaining member 768a and a second end deformable retaining member 768b, and (ii) a base portion 776. The first and second end deformable retaining members 768a, 768b extend downward from the base portion 776 and include a body 770a, 770b, a protrusion 772a, 772b, and a sloped rear wall 774a, 774b. It should be understood that each of these structures aid in allowing the female touch-proof member 720 to be installed after the female connector system 600 is coupled to the component.

As will be described in greater detail below, the arrangement of deformable retaining members 764 have: (i) an original state or undeformed state when the touch-proof member 720 is in an uninstalled or installed state, and (ii) an unoriginal state or deformed state when the touch-proof member 720 is in a partially installed. Because the arrangement of deformable retaining members 764 are a part of the touch-proof securing assembly 762 and the touch-proof securing assembly 762 is a part of the touch-proof member 720, the states from the arrangement of deformable retaining members 764 apply to the touch-proof securing assembly 762 and touch-proof member 720. In other words, the when the arrangement of deformable retaining members 764: (i) is in the original state, the touch-proof securing assembly 762 and touch-proof member 720 are also in the original state, and (ii) is in the deformed state, the touch-proof securing assembly 762 and touch-proof member 72 are also in the deformed state. The base portion 776 has a substantially rectangular shape that substantially matches the shape of the female terminal receiver and includes: (i) openings formed therethrough to allow for the coupling of said member 720 and reduce weight, (ii) downwardly depending projections that are designed to support the base portion 776 and ensure that said base portion 776 is offset from the lowermost extent of the receiver.

The touch-proof element 780 includes three integrally formed walls 782 that extend upward from the base portion 776, where said walls 782 include: (i) a first end wall 784a, (ii) a second end wall 784b, and (iii) a connecting wall or paddle wall 786 that is positioned between the end walls 748a, 748b. The combination of end walls 748a, 748b and connecting wall 786 form an “I-shaped” projection. In other words, the touch-proof element 780 has a I-shaped cross-sectional configuration. Said “I-shaped” projection provides substantial benefits over previous versions of the touch-proof post that is disclosed in PCT applications that are incorporated herein because the end walls 748a, 748b provide additional rigidity to the connecting wall or paddle wall 786. Without this additional rigidity, a foreign object can displace the connecting wall or paddle wall 786 and thus the touch-proof post fails to provide the desired functionality and in turn causes the connector system to fail various industry regulations. Alternative ways of adding additional rigidity to the connecting wall or paddle 786 have been contemplated, but each alternative has issues that makes it less desirable to utilize. For example, one way of providing additional rigidity would be to increase the thickness of the connecting wall or paddle wall 786. However, increasing the thickness of the connecting wall or paddle wall 786 is not desirable because it can interfere with the compression of the spring member 440d, when the connector system 10 is in the connected state or the ready to use state. Another way of providing additional rigidity would be to use a different material that has a higher stiffness. However, this is not desirable because it increases the cost of the touch-proof post and complexity associated with manufacturing said touch-proof post. Another way of providing additional rigidity would be to use include supporting walls that help couple the connecting wall or paddle wall 786 to the base portion 776. However, this is not desirable because said additional support walls will likely interfere with the connecting of the male connector assembly 200 with the female connector assembly 600. In addition to the above examples, it should be understood that the “I-shaped” design of the touch-proof element 780 may be replaced with other shapes such as a triangular prism, a pentagonal prism, a hexagonal prism, octagonal prism, sphere, a cone, a tetrahedron, a cuboid, a dodecahedron, an icosahedron, an octahedron, or an ellipsoid.

B. Female Terminal Assembly

FIGS. 28, 41-45, 49-53, 55B, 56B58, 61, 68, 71, 78, 81, 91-99B depict various views of the female terminal assemblies 800. The female terminal assemblies 800 includes: (i) a female terminal body 810 and (ii) a female terminal connection plate 816. The connection plate 816 is directly connected to the female terminal body 810 and is configured to be coupled to a structure (e.g., a radiator fan) outside of the connector system 10. The female terminal body 810 is comprised of: (i) an arrangement of female terminal walls 812a-812d that are coupled to one another to form a substantially rectangular shape, and (ii) a rear wall 813 that is positioned substantially perpendicular to the walls 812a-812d. Specifically, one female terminal side wall 812a of the arrangement of female terminal walls 812a-812d is: (i) substantially parallel with another one female terminal side wall 812c of the arrangement of female terminal walls 812a-812d and (ii) substantially perpendicular to two female terminal end wall 812b, 812d of the arrangement of female terminal walls 812a-812d. The female terminal body 810 defines a female terminal receiver 814. The female terminal receiver 814 is designed and configured to be coupled, both electrically and mechanically, to an extent of the male terminal 470, when the male terminal 470 is inserted into the female terminal receiver 814.

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

C. Female Shielding Assembly

The shielding assembly 60 also includes female shielding assembly 930 that resides within the female housing assembly 620 and is designed to interact with the male shielding assembly 530 in order to reduce the electromagnetic interference (“EMI”) noise emitted by the male connector assembly 200. The female shielding assembly 930 is comprised of a female terminal body shield 932 with component coupling elements 940 that are designed to interact with an extent of a component 8 contained in the power distribution system. The female terminal body shield 932 is formed from an arrangement of side walls 934 that form a substantially rectangular tubular component. Said component coupling elements 940 extend downward from the lower edge of the an arrangement of side walls 934 are deformable, such that they can be deformed inward when the female connector assembly 600 is coupled to the component in order to make sufficient contact with the extent of a component 8. It should be understood that other configurations, elements, and components are contemplated by this disclosure, which function together to connect the integrated conductor shield to a structure that surrounds a majority of the female terminal assembly 800. Further, it should be understood that inclusion of the female shielding assembly 930 is optional and can be omitted, if desired. The female shielding assembly 930 is formed from a conductive material, such as metal. Other conductive materials (e.g., conductive plastics) that may be utilized are disclosed within PCT/US2020/013757, which is incorporated herein by reference.

D. Female Interlock Assembly

As discussed above and disclosed in PCT/US2021/043686, the female interlock or FIL 980, which is a part of the IL assembly 100, is design help prevent arcing from occurring during the mating of the connector assembly 200, 600. As shown in the Figures, the FIL 980 is a receiving structure 982 formed in a non-conductive housing 984. In particular, the receiving structure 982 includes two receivers 986a, 986b. Said housing 984 can be optionally added to the system 10 by securing it to the housing assembly 620 via the deformable FIL projection 676. Said receivers 986a, 986b include conductive elements 988a, 988b that are coupled to the IL circuit, which was described above. The conductive elements 988a, 988b are designed to receive the connecting elements 594a, 594b of the MIL 590 during certain operating conditions, which thereby to short and connect the wires that connect to the FIL 980 and closes the circuit to allow current to flow between the male and female terminal assemblies 430, 800.

E. Assembly of the Female Connector Assembly

As shown in FIG. 28, the female connector assembly 600 is in a disassembled state. As shown in FIGS. 30, the first step in assembling the female connector assembly 600 accomplished by: (i) assembling the female terminal assembly 800 with the female terminal holder 630, (ii) applying a female terminal coupling force FFTC in a first or upwardly direction on the combination of the female terminal holder 630 and the female terminal assembly 800 in a first direction in order to cause the arrangement of terminal securing projections 670 to secure said combination (i.e., 630, 800) to the female housing assembly 620, and (iii) coupling the female shielding assembly 930 to the female housing assembly 620. Once the above steps are completed, the connector assembly 600 is in the first partially assembled state. In this first partially assembled state, all major components of the connector assembly 600 are installed except for the FIL 980 and the female touch-proof member 720, where (i) the FIL 980 is spaced a part from the housing 620 and in the un-received positon, and (ii) the female touch-proof member 720 is spaced a part from the housing 620 and in the uninstalled positon. At this point, the installer can decide whether they include the FIL 980 or omit it from the system 10. If the installer can decides to omit the FIL 980, then the connector assembly 600 skips the second partially assembled state and moves directly to the third partially assembled state.

If the installer decides to include the FIL 980, then an FIL force F_FILin the first or upwardly direction is applied to the FIL 980 in order to insert said FIL 980 into the FIL opening in the main body 640 and secure the FIL 980 in said opening using the FIL retainer 674. Once the FIL 980 is coupled to the main body 640, the connector assembly 600 has moved from the first partially assembled state to the second partially assembled state. In this state, the FIL 980 is coupled to the main body 640 via the FIL retainer 674 and as such the FIL 980 is in the received position. To move the connector assembly 600 to the third partially assembled state, a TPM force F_TPMin a second or downwardly direction is applied on the female touch-proof member 720 to move said female touch-proof member 720 from a separated and uninstalled state to a partially installed position. In this position, the sloped rear wall 774a, 774b of the first and second end deformable retaining members 768a, 768b are engaged with the rear wall 813 of the terminal assembly 800. The continued application of the downwardly directed force on the female touch-proof member 720 causes the first and second end deformable retaining members 768a, 768b to continue to elastically deform outward or away from the center of the female touch-proof member 720.

Once the first and second end deformable retaining members 768a, 768b have elastically deformed enough (e.g., each member has deformed more than predetermined amount −0.7 mm) to allow the protrusion 772a, 772b to pass by the rear wall 813 of the terminal assembly 800, the first and second end deformable retaining members 768a, 768b can return to their non-deformed or original state; thereby coupling the touch-proof member 720 within the female terminal assembly 800. In other words, the touch-proof member 720 is coupled to the female terminal assembly 800 when the first and second end deformable retaining members 768a, 768b are in their non-deformed or original state and the protrusion 772a, 772b are positioned below the rear wall of the terminal assembly 800. When the components are in this positional relationship, the female connector assembly 600 is in assembled state. As discussed above, the female terminal coupling force FFTC and the FIL force F_FILare in the first direction, while the TPM force F_TPMis in a second and opposite direction. In other words, the female terminal assembly 800 is configured to be inserted within the female housing 620 using a force (e.g., female terminal coupling force) that is directed in a first direction (e.g., upward) and touch-proof member 720 is configured to be inserted within the female terminal assembly 800 using a force (e.g., TPM force) that is directed in a second direction (e.g., downward), and wherein said first direction (e.g., upward) is opposite of the second direction (e.g., downward). The above method is beneficial because it can be added to the system 10 after the system 10 is use. The directional insertion of the touch-proof member 720 disclosed herein provides substantial benefits over previous designs of elements that: (i) are designed to restrict the insertion of foreign objects into the female terminal assembly 800, and (ii) are inserted into the housing assembly 220 in the same direction as the female terminal assembly 800. In particular, the directional insertion of the disclosed the touch-proof member 720 enables this component to be an optional component that can be added after the component side connector assembly 600 is installed in the component or part (i.e., post-installation). In contrast, the FIL 980 is an optional component that can only be added pre-installation of the component side connector assembly 600. Other structures to allow for the post-installation of the touch-proof member 720 are contemplated by this disclosure.

As discussed above, rear wall 813 of the female terminal assembly 800 has: (i) an internal terminal length L_ITof (e.g., 25 mm) that spans the inner distance between opposed end walls 812b, 812d, (ii) a rear wall length L_Rw (e.g., 17.5 mm) that spans the distance between the outermost edges of the rear wall 813, (iii) an original protrusion length Lop (e.g., 16.5 mm) that extends between the first and second protrusions 772a, 772b of the arrangement of deformable retaining members 764, when the female touch-proof member 720 is in the original state, and (iv) an deformed protrusion length L_DP(e.g., 17.6 mm) that extends between the first and second protrusions 772a, 772b of the arrangement of deformable retaining members 764, when the female touch-proof member 720 is in the deformed state. It should be understood that: (i) the original protrusion length is less than the deformed protrusion length, (ii) the deformed protrusion length is greater than the rear wall length, and (iii) the deformed protrusion length is less than the internal terminal length. Specifically, the deformed protrusion length is about: (i) 0.5% larger than the original protrusion length, (ii) approximately the same or just larger than the rear wall length, and (iii) is approximately 30% smaller than the internal terminal length.

As such, a securement gap 820 is formed between the outer edge of the rear wall 813 and the inner surface if the end wall 812b, 812d. When the touch-proof member 720 is inserted into the female terminal receiver 814, the original protrusion length of the first and second protrusions 772a, 772b expanse to the deformed protrusion length in order to allow the first and second protrusions 772a, 772b to clear the rear wall length. Once the first and second protrusions 772a, 772b clear the rear wall length and are inserted into the securement gap 820 of the female terminal assembly 800, the deformed protrusion length of the first and second protrusions 772a, 772b is reduced to the original protrusion length; whereby positioning an extent of the first and second protrusions 772a, 772b below the rear wall 813 of the female terminal assembly 800.

Once the female touch-proof member 720 is in the installed state, the distance between the inner surface of the female terminal assembly 800 and the outer surface of the female touch-proof member 720 varies due to the configuration of the female touch-proof member 720. For example, the distance between the end surface of the end walls 748a, 748b of the touch-proof element 780 and the inner surface of the end walls 812b, 812d is approximately a D_TPEend distance (e.g., 2.5 mm in FIG. 54), the distance between the outer surface of the connecting wall 786 of the touch-proof element 780 and the inner surface of the side walls 812a, 812b is approximately a D_TPSside distance (e.g., 4.1 mm in FIG. 52), and the distance between the side surface of the end walls 748a, 748b of the touch-proof element 780 and the inner surface of the side walls 812a, 812b is approximately a D_TPSEedge distance (e.g., 3.5 mm in FIG. 52). While these distances vary, each of the above distances are below the distances provided in various industry regulations (e.g., ISO 20076:2019, ISO 20653:2013, USCAR 12, Revision 5, and IEC 60529-2020). Thus, the inclusion of the touch-proof member 720 allows the female connector assembly 600 to pass or be compliant with each of these standards (e.g., ISO 20076:2019, ISO 20653:2013, USCAR 12, Revision 5, and IEC 60529-2020).

3. Assembly of the Connector System

Once the male and female connector assemblies 200, 600 are in their assembled states (as shown in FIGS. 55A and 55B), the system 10 can move from a disassembled state (FIGS. 56A-56B) to a partially connected state (FIGS. 57-64) to a connected state (FIGS. 67-74) to a ready to use state (FIGS. 77-84, 88-91). In the disconnected state, the male connector assembly 200 is spaced a part of the female connector assembly 600. In this disconnected state, the male connector assembly 200 has been assembled and can be in either: (i) ready to engage state or (ii) restrictive engagement state.

In the ready to engage state, the primary locking member 320 is moved rearward until: (i) the accidental engagement members 338a, 338b are positioned in the accidental engagement slots 294a, 294b, as shown in FIGS. 24-26, and (ii) the second disengagement projection 342 is positioned rearward of the first disengagement projection 287. Once the male connector assembly 200 is placed in the ready to engage state, an accidental engagement force F_AEthat is over a predefined accidental engagement amount (e.g., 500 Newtons of force) would need to be applied on the primary locking member 320 to move the primary locking member 320 from the unlocked state or rearward state to the locked state or forward state. In particular, this accidental engagement force F_AEwould have to be significant enough to force the accidental engagement members 338a, 338b from their positon in the accidental engagement slots 294a, 294b. The locking force F_L(which will be described below) is less than the accidental engagement force F_AE, preferable locking force F_Lis at least 10 times less than the accidental engagement force F_AE, and most preferable locking force F_Lis twenty times less than the accidental engagement force F_AE. The predefined accidental engagement amount is large to help ensure that the primary locking member 320 is not accidently engaged prior to installation. This helps reduce installation times, but the installer does not have to trouble shoot why the connector may not be able to mate due to the positional relationship of the primary locking member 320.

If the accidental engagement force F_AEis applied to the primary locking member 320 in an amount that is over a predefined accidental engagement amount, then accidental engagement members 338a, 338b would be forced from their positon in the accidental engagement slots 294a, 294b and the male connector assembly 200 would be moved from the ready to engage/disengage state to the restrictive engagement state (i.e., the primary locking member 320 would be in the locked state). In this restrictive engagement state, the accidental engagement members 338a, 338b are positioned forward of the edge of the accidental engagement slots 294a, 294b and the second disengagement projection 342 is positioned forward of the first disengagement projection 287. The male connector assembly 200 that is shown in FIG. 14 is in this restrictive engagement state, wherein the male connector assembly 200 cannot be mated with the female connector assembly 600 due to the positional relationship of the primary locking member 320. For example, the male bracing assembly 351 and female bracing assembly 648, which together form the bracing assembly 349 would prevent the connector assemblies 200, 600 from mating with one another.

If the male connector assembly 200 is moved from the ready to engage state to the restrictive engagement state, it is possible to return the connector to the ready to engage state by applying a downward directed pivoting force F_Pon the forward or unlocking cantilever segment 340a in order to cause the rear or locking cantilever segment 340a to pivot around the pivot strip 339 in order to move a lowermost extent of the second disengagement projection 342 above the uppermost extent of the first disengagement projection 287. While applying the downward directed force on the forward or unlocking cantilever segment 340a, the installer also applies a rearwardly directed unlocking force F_ULon the primary locking member 320 in order to move the second disengagement projection 342 rearward of the first disengagement projection 287. As stated above, the required downward directed pivoting force F_Pis less than 25 Newtons of force, while the required unlocking force F_ULis less than 25 Newtons of force. However, due to the accidental engagement of the primary locking member 320, the connector assembly 200 should be inspected prior to its use.

A. Partially Connected State

Assuming that the male connector assembly 200 is in the ready to engage/disengage state, the installer can start to apply a downwardly directed connecting force F_Con the male connector assembly 200 in order to move the system 10 from the disconnected state to the partially connected state. In this partially connected state, the following structures are in the positions: (i) the accidental engagement projections 654a, 654b are aligned with and are partially received by the accidental engagement slots 294a, 294b, (ii) the stabilization projections 658a, 658b are aligned with and are partially received by the stabilization slots 297a, 297b, (iii) touch-proof element 780 is aligned with and partially received by touch-proof element opening 242, (iv) the CPA body 704 is aligned with and are partially received by the CPA slot 298 and the horizontal engaging member 412 of the male deformable male CPA member 406 is positioned above the CPA retaining member 706, (v) MIL 590 is not electrically connected to FIL 980 or in other words the male IL jumper 592 is not received by the female IL receiver 982, whereby allowing current cannot flow between the male and female terminal assemblies 200, 600, (vi) the contact arms 494a-494h are starting to engage with contact arm displacement means 663 (i.e., internal segment 664 of the upper portion of the side walls 660a, 660b).

To move the system 10 from the partially connected state towards the connected state, the installer continues to apply the downwardly directed connecting force F_C. This downwardly directed connecting force F_C: (i) causes the accidental engagement projections 654a, 654b to be substantially received by the accidental engagement slots 294a, 294b, whereby said accidental engagement projections 654a, 654b displace the accidental engagement members 338a, 338b out of the accidental engagement slots 294a, 294b and into the accidental engagement recesses 331a, 331b formed in the lower wall arrangement 330 of the primary locking member 320, (ii) the stabilization projections 658a, 658b are substantially received by the stabilization slots 297a, 297b, (iii) the positioning structures 656a, 656b are substantially received by the positioning slots 296a, 296b, (iv) the CPA body 704 is substantially received by the CPA slot 298 and the CPA retaining member 706 elastically displaces the male deformable male CPA member 406 into a deformed positon, where: (a) the horizontal engaging member 412 of the male deformable male CPA member 406 is displaced towards the front of the system 10, and (b) the user interaction structure 414 of the male deformable male CPA member 406 is displaced towards the rear of the system 10, (v) touch-proof element 780 is received by touch-proof element opening 242, (vi) MIL 590 is not electrically connected to FIL 980 or in other words the male IL jumper 592 is not received by the female IL receiver 982, whereby allowing current cannot flow between the male and female terminal assemblies 200, 600, and (vii) the contact arms 494a-494h are displace towards the center of each terminal assembly 430 by the contact arm displacement means 662 (i.e., internal segment 664 of the upper portion of the side walls 660a, 660b).

B. Connected State

The system 10 is in the connected state when the male terminal assemblies 430 are received in the female terminal receivers 814 and thus the installer can stop applying the downwardly directed connecting force F_C. In the connected state: (i) the accidental engagement projections 654a, 654b are received by the accidental engagement slots 294a, 294b, whereby said accidental engagement projections 654a, 654b displace the accidental engagement members 338a, 338b out of the accidental engagement slots 294a, 294b and into the accidental engagement recesses 331a, 331b formed in the lower wall arrangement 330 of the primary locking member 320, (ii) the stabilization projections 658a, 658b are received by the stabilization slots 297a, 297b, (iii) the positioning structures 656a, 656b are received by the positioning slots 296a, 296b, (iv) the CPA body 704 is received by the CPA slot 298, male deformable male CPA member 406 has returned to its original position, and the horizontal engaging member 412 of the male deformable male CPA member 406 is positioned below the CPA retaining member 706, (v) touch-proof element 780 is received by touch-proof element opening 242, (vi) MIL 590 is electrically connected to FIL 980 or in other words the male IL jumper 592 is received by the female IL receiver 982, whereby allowing current to flow between the male and female terminal assemblies 200, 600, and (vii) the contact arms 494a-494h are displace towards the center of each terminal assembly 430 and in contact with the inner surface of the side walls 812a, 812c of the female terminal assembly 800.

Referring specifically to the male and female terminal assemblies 430, 800, the combination of outer surfaces of the contact arms 494a-494h form a rectangle that has a width that is slightly larger (e.g., between 0.1% and 15%) than the width of the rectangle that is associated with the female terminal assembly 800. When the slightly larger male terminal assembly 430 is inserted into the slightly smaller female terminal receiver 814, the outer surface of the contact arms 494a-494h are forced towards the center of the male terminal assembly 430. Because the outer surface of the contact arms 494a-494h is forced towards the center of the male terminal assembly 430, the free end 446 of the spring member 440d are also forced towards the center of the male terminal assembly 430. The spring 440d resists this inward displacement by providing a spring biasing force S_BF. This spring biasing force S_BFis generally directed outward against the free ends 488 of the male terminal 470. In other words, this spring biasing force S_BFprovides an outwardly directed biasing force, a wedging function, or shimmering effect against the contact arms 494a-494h thereby holding the outer surfaces of the contact arms 494a-494h in engagement with the female terminal assembly 800.

In this connected state, the primary locking member 230 remains in the unlocked position, whereby the second disengagement projection 342 is positioned rearward of the first disengagement projection 287 and bracing projections 649a, 649b are not positioned in the bracing apertures 354. To note, said downwardly directed connecting force F_Crequires less than 100 Newtons of force, preferably less than 76 Newtons of force to meet class 3 of USCAR 25, and more preferably less than 46 Newtons of force to meet class 2 of USCAR 25. Also, it should be noted that this system 10 provides substantial benefits over prior connector systems due to is large current carry capacity without requiring a lever assist that aids in the mating of the male and female connector assemblies 200, 600.

To move the system 10 from the connected state towards the ready to use state, the installer starts to apply the forwardly directed locking force F_Lon the primary locking member 320. This forwardly directed locking force F_L(which is substantially perpendicular to the downwardly directed coupling force F_C) causes the primary locking member 320 to move forward, whereby: (i) the accidental engagement members 338a, 338b are substantially displaced into the accidental engagement depression 300a, 300b, (ii) the bracing projections 649a, 649b are substantially positioned in the bracing apertures 354, (iii) the ramped or sloped curvilinear surface 344a of the second disengagement projection 342 interacts with the ramped or sloped curvilinear surface 290a first disengagement projection 287 in order to: (a) upwardly displace via an engagement force FE the rear or locking cantilever segment 340a about the pivot strip 339 to cause the lowermost extent of the second disengagement projection 342 to be positioned above the uppermost extent of the first disengagement projection 287, and (b) downwardly displace the forward or unlocking cantilever segment 340a about the pivot strip 339.

C. Ready To Use State

The system 10 is in the ready to use state when the primary locking member 320 is in the locked state and thus the installer can stop applying the forwardly directed locking force F_L. In the ready to use state: (i) the accidental engagement members 338a, 338b are displaced from the accidental engagement recesses 331a, 331b and positioned in the accidental engagement depression 300a, 300b, (ii) the bracing projections 649a, 649b are positioned in the bracing apertures 354, (iii) an extent of the primary locking member 320 is positioned adjacent to the user interaction structure 414 of the male deformable male CPA member 406 in order to prevent said male deformable male CPA member 406 from elastically deforming, (iv) the second disengagement projection 342 is positioned forward of the first disengagement projection 287, whereby the forward angled flat surface 344b of the second disengagement projection 342 is positioned forward of the forward angled flat surface 290b of the first disengagement projection 287, and (v) the indicia 316 that is disposed on the main housing 280 is viewable/readable by an installer and/or a machine.

To read the indicia 316, the installer positions the indicia reading device above the connector system 10 and points the indicia reading device 4 downwards such that it scans the top portion of the connector system 10. This downwards scanning direction is: (i) in the same general direction as the connecting force F_Cthat is applied to the male connector assembly 200 in order to connect the male connector assembly 200 to the female connector assembly 600, and/or (ii) is substantially perpendicular to the spring biasing force F_SBthat is applied by the spring member 440d on the contact arm 494a-494h of the male terminal body 472. The information that is obtained from the indicia (i.e., QR code) 316 includes: (i) connector type, (ii) materials contained within the connector, (iii) company that manufactured the connector, (iv) when the connector was manufactured, and (v) where the connector was manufactured. Once the indicia 316 is read, the indicia reading device informs the installer that the connector system 10 is in the ready to use and thus the primary locking member 320 is in the locked position.

Once the system 10 is placed in the ready to use state, an accidental disengagement force F_ADthat is over a predefined accidental disengagement amount (e.g., 500 Newtons of force) would need to be applied on the primary locking member 320 to move the primary locking member 320 from the locked state or forward state to the unlocked state or rearward state. In particular, this accidental disengagement force F_ADwould have to be significant enough to force the second disengagement projection 342 rearward of the first disengagement projection 287, which is prevented by the interaction between the forward angled flat surface 344b of the second disengagement projection 342 and the forward angled flat surface 290b of the first disengagement projection 287. The predefined accidental disengagement amount is large to help ensure that the primary locking member 320 is not accidently disengaged after installation, which helps reduce possible connection failures. If the accidental disengagement force F_ADis applied to the primary locking member 320 in an amount that is over a predefined accidental disengagement amount, then the connector system 10 would be moved from the ready to use state to the connected state and the male connector assembly 200 would be moved to the ready to disengage state (i.e., the primary locking member 320 would be in the unlocked state).

D. Connected State

Once the system 10 is placed in the ready to use state, the system 10 can be moved to the connected state by applying a downward directed pivoting force F_Pon the forward or unlocking cantilever segment 340a in order to cause the rear or locking cantilever segment 340a to pivot around the pivot strip 339 in order to move a lowermost extent of the second disengagement projection 342 above the uppermost extent of the first disengagement projection 287. While applying the downward directed pivoting force F_Pon the forward or unlocking cantilever segment 340a, the installer also applies a rearwardly directed unlocking force F_ULon the primary locking member 320 in order to move the second disengagement projection 342 rearward of the first disengagement projection 287. Said rearwardly directed unlocking force F_ULcauses: (i) the accidental engagement members 338a, 338b to be: (a) displaced from the accidental engagement depression 300a, 300b due to the interaction between said accidental engagement members 338a, 338b and the sloped wall 302a, 302b, and (b) positioned within the accidental engagement recesses 331a, 331b, (ii) removes the bracing projections 649a, 649b from the bracing apertures 354, and (iii) removes the extent of the primary locking member 320 from being positioned adjacent to the user interaction structure 414 of the male deformable male CPA member 406. As stated above, the required downward directed pivoting force F_Pis less than 25 Newtons of force, while the required unlocking force F_ULis less than 25 Newtons of force. It should be noted that if installer does not properly apply the downward directed pivoting force F_P, then the second disengagement projection 342 will interact with the first disengagement projection 287; whereby preventing the unlocking of the primary locking member 320 unless the installer applies the accidental disengagement force F_ADin an amount that is greater than 500 Newtons. As such, the unlocking force F_ULis less than the accidental disengagement force F_AD, preferable unlocking force F_ULis at least 10 times less than the accidental disengagement force F_AD, and most preferable unlocking force F_ULis twenty times less than the accidental disengagement force F_AD.

E. Disconnected State

Once the system 10 is placed in the connected state, system 10 can be moved to the disconnected state by applying: (i) a rearward CPA force F_CPAon the user interaction structure 414 of the male deformable male CPA member 406 is displaced towards the rear of the system 10, whereby causing the horizontal engaging member 412 of the male deformable male CPA member 406 is displaced towards the front of the system 10, and (ii) a upwardly directed disconnecting force F_DISon the male connector assembly 200.

Second Embodiment

As shown in FIGS. 106-135, the second embodiment of the connector system 1010 includes multiple components that are designed to electrically and mechanically connect one device or component to another device or component within a power distribution system 5. For sake of brevity, the above disclosure in connection with connector assembly 10 will not be repeated below. However, it should be understood that the disclosure related to the male terminal assembly 430 and the female terminal assembly 800 applies in equal force to male terminal assembly 1430 and the female terminal assembly 1800. Additionally, all other structures (e.g., busbar 1700 and capacitor assembly 1750) that are not disclosed in this application are fully disclosed in PCT/US2021/033446, which is incorporated herein by reference. It should be understood that like numbers like numbers represent like structures. For example, the disclosure from PCT/US2021/033446 that relates to busbar 700 applies in equal force to busbar 1700 disclosed herein. Moreover, it is to be understood that any one or more features of the connector assembly 10 can be used in conjunction with those disclosed regarding the connector assembly 1010, and that any one or more features of the connector assembly 1010 can be used in conjunction with those disclosed regarding the connector assembly 10. For example, any features of the touch-proof member 720 or touch-proof member 2942 can be used in conjunction with those disclosed regarding the touch-proof member 1942, and any features of the touch-proof member 1942 can be used in conjunction with those disclosed regarding the touch-proof member 720 or touch-proof member 2942.

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

The primary differences between the connector system disclosed in PCT/US2021/033446 and the connector system 1010 disclosed herein is the alteration of: (i) the female housing 1610 (e.g., the lower female housing 1612 and an upper female housing 1650), and (ii) a second embodiment of the touch-proof member 1942. Specifically, the lower housing member has been altered to: (i) fit within the upper female housing 1650, (ii) include an arrangement of coupling projections 1634 that extend from an outer surface of the lower arrangement of side walls 1626, and (iii) omits the two mounting areas 1646a, 1646b and openings 1647a, 1647b formed there through. The arrangement of coupling projections 1634 includes a plurality of pyramidal shaped structures 1636a-1636f. Said pyramidal shaped structures 1636a-1636f are configured to be received by the arrangement of apertures 1680 formed in the upper wall 1678 of the upper adaptor housing 1650. In particular, said arrangement of apertures 1680 includes a plurality of oval shaped openings 1682a-1682f that are configured to receive the pyramidal shaped structures 1636a-1636f, when the lower female housing 1612 is coupled to the upper female housing 1650. In addition to the arrangements of apertures 1680, the upper female housing 1650 has been modified to include the mounting areas 1684a, 1684b. Said mounting areas 1684a, 1684b include openings 1686a, 1686b formed there through that are designed to receive elongated fasteners that secure the housing 1610 (and the female connector assembly 600) to the component 8.

The alterations to the housing 1610 that are shown and described above provide improvements over the housing 610 that is disclosed in PCT/US2021/033446 because the housing 1610 disclosed herein: (i) does not rely only on ultrasonic welding of the lower female housing 1612 and an upper female housing 1650 in order to maintain a sealed connector 600; instead, the disclosed housing 1610: (a) utilizes a mechanical method (i.e., the arrangement of coupling projections 1634 and arrangements of apertures 1680) of securing the upper female housing 1650 to the lower female housing 1612, and (b) utilizes a mechanical method (i.e., the elongated fasteners through the mounting areas 1684a, 1684b of the upper female housing 1650) of directly securing the upper female housing 1650 to the component 8, which seals the lower female housing 1612 within the upper female housing 1650, and (ii) increases the thickness of the bottom wall to prevent bowing or separation from the component 8. Other alterations between these housing designs may be obvious to one of skill in the art and said alterations may provide additional benefits that may also be obvious to one of skill in the art.

The touch-proof member 1942 shown in FIGS. 106-135 provide substantial improvements over a third embodiment of the touch-proof member 2942, which is disclosed in FIGS. 136-140. In particular, these improvements include better securement of the member 1942 in the female terminal assembly 1800, and less force being required to insert said touch-proof member 1942 into the female terminal assembly 1800. The optional touch-proof assembly 1040 includes a male touch-proof element opening 1242 and a female touch-proof member 1942. Said touch-proof assembly 1040 is designed to: (i) help ensure that foreign objects cannot come into contact with the female terminal assembly 1800 when the female connection assembly 1600 is not coupled to the male connector assembly 1200 and (ii) stabilize the connection between the male terminal assembly 1430 and the female terminal assembly 1800. To accomplish both of these tasks, the female touch-proof member 1942 includes: (i) the touch-proof securing assembly 1944 and (ii) the touch-proof element 1960. The touch-proof securing assembly 1944 and includes an arrangement of deformable retaining members 1946 with: (i) a first base portion 1948a having a first retaining member 1950a, and a second retaining member 1950b, (ii) a second base portion 1948b having a third retaining member 1950c, and a fourth retaining member 1950d, and (iii) a touch-proof recess 1951 that extends between the first base portion 1948a and the second base portion 1948b. The retaining members 1950a-1950d depend or extend downward from their base portion 1948a, 1948b and include a body 1952a-1952d, a protrusion 1954a-1954d, and a sloped rear wall 1956a-1956d. It should be understood that each of these structures aid in allowing the female touch-proof member 1942 to be installed after the female connector system 600 is coupled to the component.

The arrangement of deformable retaining members 1946 have: (i) an original state or undeformed state when the touch-proof member 1942 is in an uninstalled or installed state, and (ii) an unoriginal state or deformed state when the touch-proof member 1942 is in a partially installed. In the an original state or undeformed state, the touch-proof recess 1951 has a first original width and in the unoriginal state or deformed state the touch-proof recess 1951 has a second compressed width, wherein the first original width is greater than the second compressed width. Because the arrangement of deformable retaining members 1946 are a part of the touch-proof securing assembly 1944 and the touch-proof securing assembly 1944 is a part of the touch-proof member 1942, the states from the arrangement of deformable retaining members 1946 apply to the touch-proof securing assembly 1944 and touch-proof member 1942. In other words, the when the arrangement of deformable retaining members 1946: (i) is in the original state, the touch-proof securing assembly 1944 and touch-proof member 1942 are also in the original state, and (ii) is in the deformed state, the touch-proof securing assembly 1944 and touch-proof member 1942 are also in the deformed state.

The first and second base portion 1948a, 1948b have a substantially rectangular shape, wherein the combined outer periphery of the base portions 1948a, 1948b and the touch-proof recess 1951 substantially match the shape of the female terminal receiver 1814. In addition to the arrangement of deformable retaining members 1946 that depend downward from the base portions 1948a, 1948b, the touch-proof member 1942 also includes downwardly depending support projections 1958a, 1958b that are designed to support the base portions 1948a, 1948b and ensure that said base portions 1948a, 1948a are offset from the lowermost extent of the female terminal receiver 1814. Extending upward (i.e., opposite from the arrangement of deformable retaining members 1946 and support projections 1958a, 1958b) from the base portions 1948a, 1948b is the touch-proof element 1960 that includes a first extent 1961a and a second extent 1962b. The first extent 1961a extends from both of the base portions 1948a, 1948b and has a substantially solid perimeter except for the slot 1953 formed through the first extent 1961a. The slot 1953 reduces the rigidity of the first extent 1961a and is cooperatively positioned or aligned with the recess 1951. The slot 1953 and the recess 1951 permit the first extent 1961a to act as a living hinge to facilitate elastic deformation of the first and second base portion 1948a, 1948b during insertion of the touch-proof member 1942 within the female terminal assembly 1800.

The second extent 1961b extends from the first extent 1961a and includes three integrally formed walls 1962, where said walls 1962 include: (i) a first end wall 1964a, (ii) a second end wall 1964b, and (iii) a connecting wall 1966 that is positioned between the end walls 1964a, 1964b, defines grooves between the end walls 1964a, 1964b, and is aligned with the recess 1951 and slot 1953. The combination of end walls 1964a, 1964b and connecting wall 1966 provide the second extent 1961b with “I-shaped” sectional configuration. In this configuration, the slot 1953 does not extend into second extent 1961b of the element 1960 that is formed from walls 1962 to help ensure that the touch-proof element 1960 is rigid enough to meet the required industry standards. It should be understood that in other embodiments the touch-proof member 1942 may replace the recess 1951 and slot 1953 with: (i) two recesses that are perpendicular to one another, whereby the base portion is formed in quarters, (ii) two slots that are perpendicular to one another, whereby the touch-proof element is formed in quarters, (iii) a combination of the above, where both the base portion and touch-proof element are formed in quarters, or (iv) forming the base portion and/or the touch-proof element into any number (e.g., one to ten) different segments or portions in order to: (i) increase or decrease the force need to insert the touch-proof member 1942 in the female terminal receiver 1814, and (ii) increase or decrease the force need displace the touch-proof element 1960 using a foreign object.

The female terminal assembly 1800 and the touch-proof member 1942 have: (i) an internal terminal length L_ITof (e.g., 20 mm) that spans the inner distance between opposed end walls 1812b, 1812d, (ii) an original protrusion length Lop (e.g., 22 mm) that extends between the first and third retaining members 1950a, 1950c of the arrangement of deformable retaining members 1946, when the female touch-proof member 1942 is in the original state, and (iv) an deformed protrusion length L_DP(e.g., less than 20 mm) that extends between the first and third retaining members 1950a, 1950c of the arrangement of deformable retaining members 764, when the female touch-proof member 1942 is in the deformed state. It should be understood that: (i) the original protrusion length is greater than the deformed protrusion length, and (ii) the deformed protrusion length is greater than the internal terminal length. While the first and second deformable retaining member 768a of the first embodiment of the female touch-proof member 720 are expanded away from one another in their deformed state, the first and third retaining members 1950a, 1950c are compressed towards one another in their deformed state. When the female touch-proof member 1942 is inserted into the female terminal receiver 1814, the original protrusion length of the first and third retaining members 1950a, 1950c compresses to the deformed protrusion length in order to allow the first and third retaining members 1950a, 1950c to be inserted to the female terminal receiver 1814. Once the first and third retaining members 1950a, 1950c clear the length of the side wall 1812a-1812d and are inserted into the securement openings 1970 of the female terminal assembly 1800, the deformed protrusion length of the first and third retaining members 1950a, 1950c is expanded to the original protrusion length; whereby positioning an extent of the protrusions 1954a-1954d below the ide wall 1812a-1812d of the female terminal assembly 1800.

Once the female touch-proof member 1942 is in the installed state, the distance between the inner surface of the female terminal assembly 1800 and the outer surface of the female touch-proof member 1942 varies due to the configuration of the female touch-proof member 1942. For example, the distance between the end surface of the end wall 1964a, 1964b of the touch-proof element 1942 and the inner surface of the end walls 1812b, 1812d is approximately a D_TPEend distance (e.g., 4.85 mm), the distance between the outer surface of the connecting wall 1966 of the touch-proof element 1942 and the inner surface of the side walls 1812a, 1812b is approximately a D_TPSside distance (e.g., 6.85 mm). While these distances vary, each of the above distances are below the distances provided in various industry regulations (e.g., ISO 20076:2019, ISO 20653:2013, USCAR 12, Revision 5, and IEC 60529-2020). Thus, the inclusion of the touch-proof member 1942 allows the female connector assembly 1600 to pass or be compliant with each of these standards (e.g., ISO 20076:2019, ISO 20653:2013, USCAR 12, Revision 5, and IEC 60529-2020).

Third Embodiment

FIGS. 136-140 show a third embodiment of a touch-proof member 2942. It should be understood that this third embodiment of the touch-proof member 2942 is configured to be utilized with the second embodiment of the connector system 1010. As such, the figures and associated disclosure related to the second embodiment 1010 are not repeated for this third embodiment of the touch-proof member 2942. The omission of these figures and associated disclosure should not limit this third embodiment in any way and instead a reader should refer back to the figures and disclosure set forth above in connection with the second embodiment of the connector system 1010. Additionally, it should also be understood that certain disclosure related to the second embodiment of a touch-proof member 1942 has not been repeated here for the third embodiment of a touch-proof member 2942. Instead, it should be understood that like numbers like numbers represent like structures. For example, the disclosure from retaining member 1950a applies in equal force to retaining member 2950a. Moreover, it is to be understood that any one or more features of the touch-proof member 720 or touch-proof member 1942 can be used in conjunction with those disclosed regarding the touch-proof member 2942, and that any one or more features of the touch-proof member 2942 can be used in conjunction with those disclosed regarding the touch-proof member 720 or touch-proof member 1942. The primary difference between the second embodiment of the touch-proof member 1942 and the third embodiment of the touch-proof member 2942 is: (i) the touch-proof recess is omitted, and (ii) first extent of the touch-proof element 2960 is also omitted. As such, the walls 2962 extend directed from the base portion 2948. Because this embodiment cannot rely on collapsing the touch-proof recess 1951 in order to allow the touch-proof member 2942 to move from the original state or undeformed state to the unoriginal state or deformed state, this functionality is provided by retaining members 2950a-2950d. Nevertheless, this third embodiment of the touch-proof member 2942 provides the same overall functions as described above in the second embodiment of the touch-proof member 1942.

The system 10, 1010 is a T4/V4/S3/D2/M2, wherein the system 10, 1010 meets and exceeds: (i) T4 is exposure of the system 100 to 150° C., (ii) V4 is severe vibration, (iii) S1 is sealed high-pressure spray, (iv) D2 is 200 k mile durability, and (v) M2 is less than 45 Newtons of force is required to connect the male terminal assembly 430, 1430 to the female terminal assembly 800, 1800. The terminal assemblies 430, 1430 shown in the following figures are rated to carry at 55° C. rise over ambient (RoA) or 80° C. with a derating of 80%, where FIGS. 1-99B can carry 365 amps with a 100 mm²conductor, while FIGS. 106-135 can carry 245 amps with a 50 mm²conductor, 280 amps with a 75 mm²conductor, 330 amps with a 100 mm²conductor. Additionally, other performance specifications of the system 10 disclosed herein will be obvious to one of skill in the art.

While the figures and disclosure contained herein discuss two different embodiments of the connector system 10, 1010 it should be understood that these are only exemplary embodiments and that other embodiments are possible. For example, any number of male terminal assemblies 430, 1430 may be positioned within a single male housing assembly 220, 1220. Specifically, the male housing assembly 220, 1220 may be configured to contain multiple (e.g., between 3-30, preferably between 3-8, and most preferably between 3-4) male terminal assemblies 430, 1430. The female terminal assembly 800, 1800 may be reconfigured to accept these multiple male terminal assemblies into a single female terminal assembly 800, 1800. Alternatively, the female terminal assembly 800, 1800 may be reconfigured to include multiple female terminal assemblies 800, 1800, where each female terminal assembly 800, 1800 receives a single male terminal assemblies 430, 1430. In other words, the system disclosed herein may include: (i) any number of male terminal assemblies 430, 1430 and (ii) a number of female terminal assemblies 800, 1800 that is equal to or less than the number of male terminal assemblies 430, 1430. Also, it should be understood that, if multiple male terminal assemblies 430, 1430 are utilized, the male terminal assemblies 430, 1430 may have the same shape, similar shapes, or different shapes.

Moreover, it should also be understood that the male terminal assemblies 430, 1430 may have any number of contact arms 494, 1494 (e.g., between 2-100, preferably between 2-50, and most preferably between 2-8) and any number of spring arms 452, 1452 (e.g., between 2-100, preferably between 2-50, and most preferably between 2-8). As discussed above, the number of contact arms 494, 1494 may not equal the number of spring arms 452, 1452, the width of the spring arms 452, 1452 may be equal to or larger than the width of the contact arms 494, 1494, or the width of each spring arms 452, 1452 or each contact arms 494, 1494 may vary from the width of other spring arms 452, 1452 or contact arms 494, 1494 contained in the same terminal assembly 430, 1430. For example, there may be more contact arms 494, 1494 then spring arms 452, 1452. Alternatively, there may be less contact arms 494, 1494 then spring arms 452, 1452.

MATERIALS AND DISCLOSURE THAT ARE INCORPORATED BY REFERENCE

PCT Application Nos. PCT/US2021/057959, PCT/US2021/047180, PCT/US2021/043788, PCT/US2021/043686, PCT/US2021/033446, PCT/US2020/049870, PCT/US2020/050018, PCT/US2020/014484, PCT/US2020/013757, PCT/US2019/036127, PCT/US2019/036070, PCT/US2019/036010, and PCT/US2018/019787, U.S. patent application Ser. No. 16/194,891 and U.S. Provisional Application 63/222,859, each of which is fully incorporated herein by reference and made a part hereof.

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

ISO Specifications, including Road vehicles—Test methods and performance requirements for voltage class B connectors (ISO 20076:2019) and Road Vehicles—Degrees Of Protection (IP Code)—Protection Of Electrical Equipment Against Foreign Objects, Water And Access (ISO 20653:2013)

IEC Specifications, including Degrees of Protection Provided by Enclosures (IP Code) (IEC 60529-2020), each of which is fully incorporated herein by reference and made a part hereof.

SAE Specifications, including: J1742_201003 entitled, “Connections for High Voltage On-Board Vehicle Electrical Wiring Harnesses—Test Methods and General Performance Requirements,” last revised in March 2010, each of which is fully incorporated herein by reference and made a part hereof.

ASTM Specifications, including: (i) D4935-18, entitled “Standard Test Method for Measuring the Electromagnetic Shielding Effectiveness of Planar Materials,” and (ii) ASTM D257, entitled “Standard Test Methods for DC Resistance or Conductance of Insulating Materials,” each of which are fully incorporated herein by reference and made a part hereof.

DIN Specification, including Connectors for electronic equipment—Tests and measurements—Part 5-2: Current-carrying capacity tests; Test 5b: Current-temperature derating (IEC 60512-5-2:2002), each of which are fully incorporated herein by reference and made a part hereof.

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

Other standards, including American National Standards Institute standards that correspond or have counterparts to the above listed standards, and Federal Test Standard 101C and 4046, each of which is fully incorporated herein by reference and made a part hereof.

While some implementations have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the disclosure; and the scope of protection is only limited by the scope of the accompanying claims. For example, the overall shape of the of the components described above may be changed to: a triangular prism, a pentagonal prism, a hexagonal prism, octagonal prism, sphere, a cone, a tetrahedron, a cuboid, a dodecahedron, an icosahedron, an octahedron, a ellipsoid, or any other similar shape.

It should be understood that the following terms used herein shall generally mean the following: “High power” shall mean (i) voltage between 20 volts to 600 volts regardless of current or (ii) at any current greater than or equal to 80 amps regardless of voltage. “High current” shall mean current greater than or equal to 80 amps regardless of voltage. “High voltage” shall mean a voltage between 20 volts to 600 volts regardless of current.

Headings and subheadings, if any, are used for convenience only and are not limiting. The word exemplary is used to mean serving as an example or illustration. To the extent that the term includes, have, or the like is used, such term is intended to be inclusive in a manner similar to the term comprise as comprise is interpreted when employed as a transitional word in a claim. Relational terms such as first and second and the like may be used to distinguish one entity or action from another without necessarily requiring or implying any actual such relationship or order between such entities or actions.

Phrases such as an aspect, the aspect, another aspect, some aspects, one or more aspects, an implementation, the implementation, another implementation, some implementations, one or more implementations, an embodiment, the embodiment, another embodiment, some embodiments, one or more embodiments, a configuration, the configuration, another configuration, some configurations, one or more configurations, the subject technology, the disclosure, the present disclosure, other variations thereof and alike are for convenience and do not imply that a disclosure relating to such phrase(s) is essential to the subject technology or that such disclosure applies to all configurations of the subject technology. A disclosure relating to such phrase(s) may apply to all configurations, or one or more configurations. A disclosure relating to such phrase(s) may provide one or more examples. A phrase such as an aspect or some aspects may refer to one or more aspects and vice versa, and this applies similarly to other foregoing phrases.

Numerous modifications to the present disclosure will be apparent to those skilled in the art in view of the foregoing description. Preferred embodiments of this disclosure are described herein, including the best mode known to the inventors for carrying out the disclosure. It should be understood that the illustrated embodiments are exemplary only, and should not be taken as limiting the scope of the disclosure.

	Number	Date	Country
Parent	PCT/US2021/043686	Jul 2021	WO
Child	18579204		US

CONNECTOR SYSTEM FOR USE IN A POWER DISTRIBUTION SYSTEM

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