A method of making an electrical connector which includes an insulative housing having a tongue with two opposite surfaces and plural contacts with contacting portions exposed to the two opposite surfaces of the tongue is characterized by the steps of: forming the plurality of contacts from a single contact carrier to have one group of contacts thereof each with a respective contacting portion connected to a first carrier strip and the other group of contacts thereof each with a respective contacting portion connected to a second carrier strip situated beside the first carrier strip; insert-molding the plurality of contacts with an insulator to form the insulative housing while exposing front ends of the plurality of contacts; and severing the first carrier strip and the second carrier strip from the front ends of the plurality of contacts.

A method of making an electrical connector which includes an insulative housing having a tongue with two opposite surfaces and plural contacts with contacting portions exposed to the two opposite surfaces of the tongue is characterized by the steps of: forming the plurality of contacts from a single contact carrier to have one group of contacts thereof each with a respective contacting portion connected to a first carrier strip and the other group of contacts thereof each with a respective contacting portion connected to a second carrier strip situated beside the first carrier strip; insert-molding the plurality of contacts with an insulator to form the insulative housing while exposing front ends of the plurality of contacts; and severing the first carrier strip and the second carrier strip from the front ends of the plurality of contacts.

An electrical connector assembly for electrically and mechanically connecting a component to a power source is disclosed. The connector assembly includes a male terminal with side walls defining a receiver. The side wall includes a contact arm that extends across an aperture in the side wall. The assembly also includes an internal spring member dimensioned to reside within the receiver of the male terminal. The spring member has at least one spring arm that extends from a base portion. The assembly further includes a female terminal with a receptacle dimensioned to receive both the male terminal and the spring member residing within the receiver of the male connector to define a connected position. In the connected position, the spring arm exerts an outwardly directed biasing force on the contact arm of the male terminal to outwardly displace it into engagement with an inner surface of the receptacle to ensure connectivity.

An electrical connector system for electrically and mechanically connecting with a component in a motor vehicle is disclosed. The connector system includes a motor vehicle component and a male connector assembly with a male housing that receives a male terminal. This terminal includes a receiver and side walls with a contact arm that extends across an aperture in the side wall. An internal spring member with at least one spring arm resides within the male terminal receiver. A female connector assembly includes a female terminal with a receptacle that receives both the male terminal and the spring member. A female housing receives the female terminal and an extent of the male connector assembly. When the connector system moves from the partially assembled state to a connected position for connection of the vehicle component, the male connector assembly is inserted into female housing, the contact arm is brought into sliding engagement with an angled internal segment of the female housing, and the contact arm is inwardly displaced as the contact arm slidingly engages with the angled internal segment.

An electrical connector system for electrically and mechanically connecting with a component in a motor vehicle is disclosed. The connector system includes a motor vehicle component and a male connector assembly with a male housing that receives a male terminal. This terminal includes a receiver and side walls with a contact arm that extends across an aperture in the side wall. An internal spring member with at least one spring arm resides within the male terminal receiver. A female connector assembly includes a female terminal with a receptacle that receives both the male terminal and the spring member. A female housing receives the female terminal and an extent of the male connector assembly. When the connector system moves from the partially assembled state to a connected position for connection of the vehicle component, the male connector assembly is inserted into female housing, the contact arm is brought into sliding engagement with an angled internal segment of the female housing, and the contact arm is inwardly displaced as the contact arm slidingly engages with the angled internal segment.

A power connector socket includes a main body and a lamella cage. The main body includes a socket, an opening at a side portion of the socket, and a chamber inside the socket. The lamella cage passes through the socket. The lamella cage includes a ring portion and contact lamellae. The contact lamellae outwardly extend from a side portion of the ring portion and are annularly arranged. The ring portion is in an inner side of the chamber. One of two ends of each of the contact lamellae includes a fixed end formed on the ring portion, a free end outwardly extends from the other end of each of the contact lamellae, and the free ends are positioned at a portion of the main body adjacent to the opening.

A power connector socket includes a main body and a lamella cage. The main body includes a socket, an opening at a side portion of the socket, and a chamber inside the socket. The lamella cage passes through the socket. The lamella cage includes a ring portion and contact lamellae. The contact lamellae outwardly extend from a side portion of the ring portion and are annularly arranged. The ring portion is in an inner side of the chamber. One of two ends of each of the contact lamellae includes a fixed end formed on the ring portion, a free end outwardly extends from the other end of each of the contact lamellae, and the free ends are positioned at a portion of the main body adjacent to the opening.

A connector assembly for an electrical connection, the connector assembly includes a plug and a socket. The plug includes a connector and a frame. The connector has a solid core conductor, the solid core conductor has an end portion. The frame surrounds the solid core conductor except for the end portion. The end portion is deformed to overlap the frame. The socket includes a socket conductor and a receiving portion into which the plug engages. The end portion directly contacts the socket conductor to form an electrical contact and causes the frame to deflect and provide a bias to force the end portion and the socket conductor into direct contact with one another.

A connector assembly for an electrical connection, the connector assembly includes a plug and a socket. The plug includes a connector and a frame. The connector has a solid core conductor, the solid core conductor has an end portion. The frame surrounds the solid core conductor except for the end portion. The end portion is deformed to overlap the frame. The socket includes a socket conductor and a receiving portion into which the plug engages. The end portion directly contacts the socket conductor to form an electrical contact and causes the frame to deflect and provide a bias to force the end portion and the socket conductor into direct contact with one another.

A housing part for an electrical connector includes a housing wall adjacent to an opening. The housing wall has a front edge with a chamfer on a side of the housing wall. The chamfer extends away from the front edge by a distance that varies along the front edge.