Delphi Technologies, Inc.

Mark D McCall

James D Daugherty

Shao Chung Hsieh

William L Stein, Sr

Paul S Lam

Robert C Beer

John M Chupak

Raymond J Blasko

Nicole L Liptak

Thomas Andrew Volpone

John L Wicks

Andreas Sikora

Christopher E Schaefer

Raymond Arnold Maga

Michael C Wolczak

Daniel R Rester

Rick Loutzenhiser

A low insertion force female terminal that is configured to make electrical contact with a male pin. The terminal includes a spring portion configured to be deflected by the pin as the pin is inserted into the terminal. The spring portion is also configured to urge a contact feature formed into the spring portion toward the pin to make electrical contact with the pin. The contact feature is characterized by an asymmetrical shape configured so a leading-edge ramp angle of the contact feature is less than a trailing-edge ramp angle of the contact feature. The asymmetrical shape reduces the peak insertion force for the terminal when compared to terminal designs that have symmetrically shaped contact features with similar dimensions.

Low insertion force terminal

A terminal is used in an electrical connector and receives a matable contact member. The terminal has a receptacle contact section has a bottom wall, an upper wall, and a primary and a secondary spring beam, or member. The primary member extends from a bottom wall and is bent back into the receptacle contact section. The primary member has an upper surface facing the upper wall and a lower surface opposite the upper surface. The primary member includes a free end that is spaced from the upper wall a distance less than a thickness of the matable contact member. The secondary member is formed from the bottom wall that extends into the contact section and includes a free end disposed beneath the lower surface of the primary member in an overlapping, spaced relationship thereto remote from the free end of the primary member.

Dual contact beam terminal

A ganged electrical connection system includes an arrangement having a spring including a plurality of engagement portions. A plurality of first connectors is receivably coupled in a plurality of receptacles in the arrangement and a plurality of second connectors is matable to the coupled first connectors along mating axes. The plurality of coupled first connectors have floatable movement in the plurality of receptacles. The floatable movement is in at least an axial direction in relation to the plurality of receptacles and the axial positional mating tolerance variation of each second connector in the plurality of second connectors in relation to each first connector in the plurality of coupled first connectors that manifests at each receptacle in the plurality of receptacles is assimilated by each respective spring engagement portion when the plurality of second connectors mate to the plurality of coupled first connectors.

Electrical connection system having dielectric spring to absorb axial positional mating tolerance variation for multiple connectors

A ganged electrical connection system includes a plurality of first connectors matable to a plurality of second connectors along mating axes, and a connector position assurance (CPA) member. The CPA member includes a plurality of tabs and a plurality of release fingers. The plurality of first connectors include a plurality of lock arms and the plurality of second connectors include a plurality of inclined ramps. The plurality of tabs receive the plurality of lock arms and the plurality of inclined ramps deflectingly engage said plurality of release fingers to allow movement of the CPA member in to a position of the CPA member, that when disposed in the position, keeps the plurality of second connectors from unmating from the plurality of coupled first connectors. Methods of fabricating an electrical connection system and a ganged electrical connection system that include the CPA member are also presented.

Bi-directional CPA member to prevent unmating of multiple connectors

A ganged electrical connection system includes an arrangement defining a plurality of receptacles. A plurality of first connectors is receivably coupled in the plurality of receptacles. A plurality of second connectors is matable to the plurality of coupled first connectors of the arrangement along mating axes. Positional mating tolerance variation associated with the plurality of second connectors in relation to the plurality of coupled first connectors manifested at the plurality of receptacles when the plurality of second connectors are mated to the plurality of coupled first connectors is absorbed by the arrangement. The plurality of the plurality of second connectors mate with the plurality of coupled first connectors in a single unimpeded, uninterrupted mating connection. A ganged electrical system for an electric-type vehicle is also presented.

Electrical connection system that absorbs multi-connector positional mating tolerance variation

A shorting clip terminal connector assembly electrically shorts together terminals in a first connector body dependent on connection status of a first and a second connector body. A shorting clip terminal disposed in a shorting clip terminal cavity in the first connector body receives a protrusion disposed on the second connector body. When the second connector body is mated with the first connector body, the protrusion engages a lift element of the shorting clip terminal in the shorting clip terminal cavity thereon and urges the lift element to lift contact elements of the shorting clip terminal away from the terminals in the shorting clip terminal cavity enabling insertion of protrusion side walls intermediate the contact elements and the terminals in the shorting clip terminal cavity. The contact elements of the shorting clip terminal do not make electrical contact with the terminals and the protrusion side walls further shield the contact elements from making electrical contact with the terminals.

Shorting clip terminal connector assembly including protrusion shield

A connection position assurance retainer may include mechanisms for retaining connectors. For example, a female connector and a male connector may be mated and retained. Male and female terminals, the female terminal including a terminal insert, may also be provided.

Electrical connection system

A low profile electrical connector assembly has terminals attached to insulated electric cables that are disposed in topless slots of a connector base. Each terminal has two longitudinally spaced retention slots. The connector base has two transverse grooves that extend through sidewalls of the topless slots to provide terminal retainers that engage the forward retention slots to retain the terminals in a longitudinal direction. The connector base has a third transverse groove that extends through the sidewalls of the topless slots with selected sidewalls having undercuts for retaining a bottomless connector cover. The connector cover has a face plate that has a plurality of apertures that align with the topless slots, a lower ledge, and a depending lock bar. The lock bar is disposed in the third transverse groove and extends through the rearward retention slots to further retain the terminals in the longitudinal direction. The depending lock bar has a lip engaging the undercuts and the lower ledge of the cover is located in a bottom face groove of the connector base to hold the connector cover down on the topless slots. The connector cover is held in an assembled position by engaging portions of the face plate and the connector base.

Low profile electrical connector assembly and terminal therefor

A high current terminal blade connection system adapted for automotive environments, which provides environmental sealing includes a female connector and a male connector. The male connector includes a male power terminal having a contact blade and a means for connecting a power cable thereto. The female connector includes a female power terminal with a terminal blade seat for contactibly receiving the contact blade of the respective male power terminal. A contact insert is inserted within the female terminal and is the direct receiver of the male terminal contact blade. The contact insert includes dimples to provide stability and additional contact points to improve the electrical performance of the connection, and contact vanes to accept the mating male terminal blade for an in-line and right angle direction termination with the mating terminal blade. This design allows one female terminal and one contact insert for two different mating directions, thus eliminating the need for any additional parts.

High current terminal blade type sealed connection system

A slide contact electrical connector preferably for an oxygen sensor is assembled in such a way as to protect the precious metal surface of multiple contact pads of an edge card . The edge card is encased by a ceramic capsule . Trailing portions of terminals are laterally inserted into longitudinally extending channels of a core being radially and axially locked in place. The terminals extend forward from the core and are positioned about the trailing end of the edge card from a longitudinal direction. A collar compresses the terminals against the edge card from a lateral direction thereby making the electrical contact. A shield encircles the capsule , collar , terminals and core thereby protecting the electrical connection integrity. A seal is disposed at a trailing end of the shield penetrated by a plurality of insulated electrical wires

Slide contact electrical connector

An improved IDC trim resistor connector assembly made up of a generally open top cup shape connector with side wall slots and an interior first array of terminal posts arranged for passage therethrough of a first lead wire of sensor circuitry. A first stamped metal IDC terminal is push-on mounted on the terminal posts for IDC cradling and electrically and mechanically receiving and connecting to the first lead wire. A conventional trim resistor substrate is loose mounted but accurately positioned on the connector bottom wall and has an &ldquo;E&rdquo; pattern of resistive material adapted for center leg laser trimming to calibrate the associated sensor circuitry. A first IDC terminal spring leg overlap contacts one side leg of the trim resistor E-pattern and thereby spring clamps the resistor substrate. A cover is snap-latch mounted on the connector and has an access opening to enable laser trimming of the trim resistor after cover installation. One end of a second lead wire is received in a second IDC metal terminal in turn mounted on a second array of connector-interior terminal posts and also having a spring leg overlap electrically contacting and clamping the other E-pattern side leg. Spring barbs on the terminals anchor the same once fully inserted downwardly onto the terminal posts. Connector locking tangs and cover locking ears provide snap-on retention of the cover on the connector, and press-in/keeper internal cover projections cause push-down assembly of the lead wires as the cover is latched onto the connector. Cover locking tangs and cap latching ears provide snap-together locking of a cap on the cover when the cap is pushed down on the cover to seal the access opening after completion of laser trimming and in-filling of the covered container with sealant. In a second embodiment a crimp-type terminal, also provided with a spring clamping leg, is fastened to the second lead wire and has a barbed mounting strap clasping a modified second terminal post array when fully installed thereon.

Trim resistor connector and sensor system

An electrical connector assembly having mateable male and female connector members includes a separate slide clip component that is received in a channel of the male connector and is provided with attachment features for mounting the assembly to support structure. The slide clip and channel include mateable detent and bump lock projection features that engage when the slide clip is fully installed in the channel to lock the slide clip against removal.

Electrical connector having slide clip attachment

A high power connection system adapted for automotive environments which provides environmental and EMI shielding includes a female connector, a male connector, and a panel mount. The female connector includes a female connector base and a snap fitted female connector cover. The male connector includes a male connector base and a snap fitted male connector cover. The female connector base has at least one female power terminal cavity for seatably receiving a respective female power terminal. The male connector base has at least one male power terminal cavity for seatably receiving a respective male power terminal. The female connector is covered by a cover seal and a conductive shroud. A pair of lock arms protrude outward from the front end of the male connector base, pass through the panel mount and interface with a lever of a lever rotatably connected to the shroud to thereby mechanically assist mating of the male and female connectors. Safety terminals in the male and female connectors provide a last-to-connect-first-to-break connection with an HVIL circuit.

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Hubbard, OH, United States of America

Mark D McCall