The present invention relates to a contact finger alignment arrangement (100) to facilitate electrical connections in a switchgear cubicle (102), said contact finger alignment arrangement (100) comprising a first contact finger (104-1) and a second contact finger (104-2) extending parallel to a longitudinal axis (106), each of said contact fingers (104-1,104-2) having a front end (108) defining a contact receiving portion to facilitate longitudinal insertion of a contact arm (114) fixed to said cubicle (102), a coupling portion (118) for mechanically coupling the first contact finger (104-1) and the second contact finger (104-2), and a rear end (112). The rear end (112) of each of said contact fingers (104-1,104-2) is provided with a conical hole (120) converging towards said longitudinal axis (106) for receiving an alignment pin (122) projected through the conical hole (120) of said first contact finger (104-1) to the second contact finger (104-2) such that the resilient rotational motion of the contact fingers (104-1,104-2) is executed in a restricted manner.

A contact arm assembly includes a contact arm defining a central axis and having a first end configured for electrical connection with a pole of a circuit breaker and a second end having a distal end defining a shoulder and an engagement that protrudes from the contact arm proximal to the shoulder. A plurality of contact fingers are mounted circumferentially on the second end of the contact arm and configured to electrically engage a primary circuit contact. Each contact finger has a body with a depression that receives the engagement for electrical contact.

A contact arm assembly includes a contact arm defining a central axis and having a first end configured for electrical connection with a pole of a circuit breaker and a second end having a distal end defining a shoulder and an engagement that protrudes from the contact arm proximal to the shoulder. A plurality of contact fingers are mounted circumferentially on the second end of the contact arm and configured to electrically engage a primary circuit contact. Each contact finger has a body with a depression that receives the engagement for electrical contact.

The present invention provides an electrical connector assembly for use in a high-power application, such as with motor vehicle electronics, that exposes the connector assembly to elevated temperatures and thermal cycling. The connector assembly includes a first electrically conductive connector formed from a first material, an internal spring member formed from a second material residing within the first connector, and a second electrically conductive connector with a receptacle dimensioned to receive both the first connector and the spring member to define a connected position, wherein the connector assembly withstands the elevated temperatures and thermal cycling resulting from the high-power application. To maintain the first and second connectors in the connected position, the spring arm of the spring member exerts an outwardly directed force on the contact beam of the first connector to outwardly displace the contact beam into engagement with an inner surface of the receptacle of the second connector.

The present invention provides an electrical connector assembly for use in a high-power application, such as with motor vehicle electronics, that exposes the connector assembly to elevated temperatures and thermal cycling. The connector assembly includes a first electrically conductive connector formed from a first material, an internal spring member formed from a second material residing within the first connector, and a second electrically conductive connector with a receptacle dimensioned to receive both the first connector and the spring member to define a connected position, wherein the connector assembly withstands the elevated temperatures and thermal cycling resulting from the high-power application. To maintain the first and second connectors in the connected position, the spring arm of the spring member exerts an outwardly directed force on the contact beam of the first connector to outwardly displace the contact beam into engagement with an inner surface of the receptacle of the second connector.

A spring-actuated electrical connector assembly for electrically and mechanically connecting a device to a power source in high-power, high-voltage applications is disclosed. The connector assembly includes a first connector with an internal receiver, a plurality of side walls, and at least one contact beam. The contact beam integrally extends to an outer surface of the side wall and includes a free end that extends inward of the outer surface of the side wall. An internal spring member is dimensioned to reside within the receiver of the first connector. This assembly also includes a second electrically conductive connector with a receptacle dimensioned to receive both the first connector and the spring member to define a connected position during operation of the device. In the connected position, at least one spring arm of the spring member exerts an outwardly directed force on the contact beam of the first connector to outwardly displace the contact beam into engagement with the second connector.

A spring-actuated electrical connector assembly for electrically and mechanically connecting a device to a power source in high-power, high-voltage applications is disclosed. The connector assembly includes a first connector with an internal receiver, a plurality of side walls, and at least one contact beam. The contact beam integrally extends to an outer surface of the side wall and includes a free end that extends inward of the outer surface of the side wall. An internal spring member is dimensioned to reside within the receiver of the first connector. This assembly also includes a second electrically conductive connector with a receptacle dimensioned to receive both the first connector and the spring member to define a connected position during operation of the device. In the connected position, at least one spring arm of the spring member exerts an outwardly directed force on the contact beam of the first connector to outwardly displace the contact beam into engagement with the second connector.

A power terminal includes a contact portion, a connection portion, and an intermediate portion. The contact and intermediate portions include conductive layers stacked along a direction corresponding to their respective thicknesses. The contact portion includes a main top surface and at least one contact area protruding from the main top surface. Each layer in the contact portion includes at least one first embossed region, the at least one first embossed region of each layer being registered with the at least one first embossed region of an adjacent layer, and the at least one first embossed region of a top layer forming the at least one contact area. A set of power terminals including a plurality of such a power terminal and a connector including such a power terminal are also disclosed.

A power connector system having a right-angle type plug connector or a straight type plug connector engageable with a header connector. The right-angle type plug connector is a plug connector having a mating direction, which is 90 degrees from the centerline of the cables exiting from the plug connector. The straight type plug connector is a plug connector having a mating direction, which is parallel to the centerline of the cables exiting the back of the plug connector. The header connector holds at least a female receiving terminal or receptacle made of a high electrical conductivity material. The female receiving terminal or receptacle includes fingers that extend parallel to each other, and are spaced apart from each other, and further includes a reinforcing spring member. The plug connector holds at least a male rectangular tab terminal, the male rectangular tab terminal having a short edge and a long edge. The female receiving terminal of the header connector may mate with either the short edge or the long edge of the male rectangular tab terminal of the plug connector. The other end of the male rectangular tab terminal includes a wire or a cable attached thereto via welding, mechanical crimp, or the like.

An electrical contact sleeve includes a contact spring extending in a longitudinal direction from a base to an end of the electrical contact sleeve on a connector side. The contact spring has a recess and a plurality of spring legs adjoining the recess in a circumferential direction. The spring legs unite to form a free end of the contact spring.