In various embodiments, compact connector designs may be provided that have reduced board pitch (e.g., 1.80 mm, 1.50 mm, 1.27 mm, etc.), but are still capable of accommodating large electrical conductors (e.g., 1.4 mm, 1.1 mm, 0.9 mm, etc.). In this manner, PCB footprint may be reduced (e.g., by 50% when a staggered connector configuration is used), while adequate current carrying capacity may be maintained (e.g., 2 A, 3 A, 4 A, etc.). Additionally, or alternatively, one or more other advantages may be achieved, such as ruggedness (e.g., vibration endurance), error proofing, configuration flexibility, ease of manufacturing, ease of assembly, and/or lowered costs.

In various embodiments, compact connector designs may be provided that have reduced board pitch (e.g., 1.80 mm, 1.50 mm, 1.27 mm, etc.), but are still capable of accommodating large electrical conductors (e.g., 1.4 mm, 1.1 mm, 0.9 mm, etc.). In this manner, PCB footprint may be reduced (e.g., by 50% when a staggered connector configuration is used), while adequate current carrying capacity may be maintained (e.g., 2 A, 3 A, 4 A, etc.). Additionally, or alternatively, one or more other advantages may be achieved, such as ruggedness (e.g., vibration endurance), error proofing, configuration flexibility, ease of manufacturing, ease of assembly, and/or lowered costs.

The invention relates to a socket contact element for establishing an electrically conductive connection including a crimp section for establishing an electrically conductive connection to a line and a contact box for establishing a detachable electrically conductive connection to a contact box plug, wherein the socket contact element is constructed in one piece and includes a plurality of integrally implemented functions based on geometrical designs. Furthermore, the invention relates to a sheet-shaped semifinished product for producing a socket contact element and the production method by forming.

A power coupler includes an input end assembly and an output end assembly separably coupled to the input end assembly. The input end assembly includes an input end base including a slot, a sealing cover arranged at the input end base, an input conductive member arranged at the input end base and connected to an external power supply, and a self-locking structure. The sealing cover is movable between a closing position to cover a slot port of the slot and an opening position to at least partially open the slot port. The self-locking structure is switchable between a locked state to limit the sealing cover from moving towards the opening position and an unlocked state to not limit the sealing cover. The output end assembly includes an output conductive member configured to extend into the slot and be connected to the input conductive member.

A power coupler includes an input end assembly and an output end assembly separably coupled to the input end assembly. The input end assembly includes an input end base including a slot, a sealing cover arranged at the input end base, an input conductive member arranged at the input end base and connected to an external power supply, and a self-locking structure. The sealing cover is movable between a closing position to cover a slot port of the slot and an opening position to at least partially open the slot port. The self-locking structure is switchable between a locked state to limit the sealing cover from moving towards the opening position and an unlocked state to not limit the sealing cover. The output end assembly includes an output conductive member configured to extend into the slot and be connected to the input conductive member.

The present disclosure provides embodiments of direct current (DC) power connectors and methods to manufacture the same. More specifically, the present disclosure provides a connector plug with improved power capacity and structural rigidity. The connector plug includes an inner body and an outer body coupled to transmit power through the DC power connector, wherein the inner body is concentrically arranged within the outer body, and an insulating barrel that is coupled between the inner body and the outer body to electrically isolate the inner body from the outer body. The inner body and outer body comprise a base metal or metal alloy having an electrical conductivity ranging between 30% International Annealed Copper Standard (IACS) and greater than or equal to 99% IACS. In addition, the inner body, outer body and insulating barrel comprise an interlocking feature, which increases the structural rigidity of the connector plug and prevents disassembly when the inner body, outer body and insulated barrel are assembled together.

The present disclosure provides embodiments of direct current (DC) power connectors and methods to manufacture the same. More specifically, the present disclosure provides a connector plug with improved power capacity and structural rigidity. The connector plug includes an inner body and an outer body coupled to transmit power through the DC power connector, wherein the inner body is concentrically arranged within the outer body, and an insulating barrel that is coupled between the inner body and the outer body to electrically isolate the inner body from the outer body. The inner body and outer body comprise a base metal or metal alloy having an electrical conductivity ranging between 30% International Annealed Copper Standard (IACS) and greater than or equal to 99% IACS. In addition, the inner body, outer body and insulating barrel comprise an interlocking feature, which increases the structural rigidity of the connector plug and prevents disassembly when the inner body, outer body and insulated barrel are assembled together.

A header assembly includes a header housing having a header cavity. The header assembly includes header signal contacts received in corresponding signal contact channels having mating ends arranged in the header cavity for mating with the receptacle assembly. The header assembly includes header ground contacts received in corresponding ground contact channels. Each header ground contact includes shield walls forming a shield cavity receiving header signal contacts to provide electrical shielding for the header signal contacts. The shield walls include an end wall extending between first and second side walls. Each header ground contact includes a mating protrusion that extends outward relative to the shield cavity from the corresponding shield wall. The mating protrusion is configured to engage a conductive insert of the receptacle assembly used to electrically common each of the header ground contacts.

A header assembly includes a header housing having a header cavity. The header assembly includes header signal contacts received in corresponding signal contact channels having mating ends arranged in the header cavity for mating with the receptacle assembly. The header assembly includes header ground contacts received in corresponding ground contact channels. Each header ground contact includes shield walls forming a shield cavity receiving header signal contacts to provide electrical shielding for the header signal contacts. The shield walls include an end wall extending between first and second side walls. Each header ground contact includes a mating protrusion that extends outward relative to the shield cavity from the corresponding shield wall. The mating protrusion is configured to engage a conductive insert of the receptacle assembly used to electrically common each of the header ground contacts.

A low insertion force contact terminal which has a conductor mating portion, a securing portion and a substrate mating portion. The conductor mating portion is configured to terminate a conductor therein. The securing portion is configured to secure the terminal in a terminal receiving cavity of a housing. The substrate mating portion extends from the securing portion. The substrate mating portion has at least two sections which have curved portions thereon. At least one embossment is provided on a first section of the at least two sections or a second section of the at least two sections. The curved portions of the at least two sections move independently, which allows the curved portions to exert a low normal force on walls of through holes of a substrate to which the contact terminal is mated. The low normal force is sufficient to provide a stable electrical connection.