Spring-actuated electrical connector for high-power applications

Abstract

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.

Claims

1. An electrical connector assembly for use in a high-power application, the connector assembly comprising: a first electrically conductive connector formed from a first material, the first connector having a side wall arrangement defining a receiver, the side wall arrangement having at least one side wall with (i) an aperture and (ii) a first contact beam extending from a first portion of the side wall, across an extent of the aperture, and towards a second portion of the side wall; an internal spring member formed from a second material and dimensioned to reside within the receiver of the first connector, the spring member having a first spring arm; a second electrically conductive connector with a receptacle dimensioned to receive a portion of both the first connector and the spring member residing within the receiver of the first connector to define a connected position; wherein in the connected position, the first spring arm of the spring member exerts an outwardly directed force on the first contact beam of the first connector to retain engagement between the first contact beam and an inner surface of the receptacle of the second connector.

2. The electrical connector assembly of claim 1, wherein the first contact beam includes a free-end that resides against an outer surface of the first spring arm when the spring member is positioned within the receiver of the first connector, and wherein a portion of the outwardly directed force exerted by the first spring arm is applied to said free-end of the first contact beam.

3. The electrical connector assembly of claim 2, wherein the free-end of the first contact beam is configured to be directed inward against an extent of the first spring arm when the electrical connector assembly is in the connected position.

4. The electrical connector assembly of claim 1, wherein the first connector includes a second contact beam and the spring member includes a second spring arm, and wherein in the connected position, the first spring arm exerts a first outwardly directed force on the first contact beam and the second spring arm exerts a second outwardly directed force on the second contact beam, and wherein the first outwardly directed force is oriented in a different direction than the second outwardly directed force.

5. The electrical connector assembly of claim 4, wherein the first connector includes a third contact beam, a fourth contact beam, and the spring member includes a third spring arm and a fourth spring arm, and wherein in the connected position, the third spring arm exerts a third outwardly directed force on the third contact beam and the fourth spring arm exerts a fourth outwardly directed force on the fourth contact beam, and wherein: (i) the first outwardly directed force is oriented substantially opposite the third outwardly directed force, and (ii) the second outwardly directed force is oriented substantially opposite the fourth outwardly directed force.

6. The electrical connector assembly of claim 1, wherein the outwardly directed force applied by the first spring arm on the first contact beam in the connected position is increased by thermal expansion during operation of the electrical connector assembly.

7. The electrical connector assembly of claim 1, wherein the outwardly directed force applied by the first spring arm on the first contact beam in the connected position is increased by residual material memory during operation of the electrical connector assembly.

8. The electrical connector assembly of claim 1, wherein the spring member includes a base that the first spring arm extends therefrom, and wherein an outer surface of the base is placed in contact with an inner surface of the first portion of the side wall when the spring member is positioned within the receiver of the first connector.

9. The electrical connector assembly of claim 1, further comprising an electrically non-conductive shroud that covers an extent of the first connector and includes a connector position assurance indicator.

10. An electrical connector assembly for use in a high-power application, the connector assembly comprising: a first electrically conductive connector formed from a first material, the first connector having a plurality of elongated contact beams arranged to define a receiver; an internal spring member formed from a second material, the spring member having a rearmost segment and a plurality of spring arms; and wherein when the spring member is inserted into the receiver of the first electrically conductive connector, (i) the rearmost segment of the internal spring member resides within the receiver of the first connector, and (ii) a spring arm of the plurality of spring arms is configured to provide a biasing force on a contact beam of the plurality of elongated contact beams under certain operating conditions of the electrical connector assembly.

11. The electrical connector assembly of claim 10, wherein a first elongated contact beam includes a free-end that resides against an outer surface of a first spring arm, and wherein an extent of the biasing force exerted by the spring arm is applied to said free-end of the contact beam.

12. The electrical connector assembly of claim 10, wherein a first elongated contact beam of the plurality of elongated contact beams is positioned on a first side of the receiver and a second elongated contact beam of the plurality of elongated contact beams is positioned on a second side of the receiver that is opposite to the first side of the receiver.

13. The electrical connector assembly of claim 12, wherein a third elongated contact beam of the plurality of elongated contact beams is positioned on a third side of the receiver and a fourth elongated contact beam of the plurality of elongated contact beams is positioned on a fourth side of the receiver that is substantially perpendicular to the first side of the receiver.

14. The electrical connector assembly of claim 10, wherein the plurality of elongated contact beams extend from a base of the first connector, and wherein said base forms an extent of the receiver.

15. The electrical connector assembly of claim 10, wherein the first connector includes a plurality of side walls, and wherein a side wall has at least one contact beam.

16. The electrical connector assembly of claim 10, wherein a residual material memory of the spring member will increase the biasing force on the plurality of elongated contact beams during operation of the electrical connector assembly.

17. The electrical connector assembly of claim 10, further comprising a shroud that includes a connector position assurance indicator.

18. The electrical connector assembly of claim 10, wherein the first material of the first connector includes copper and the second material of the spring member includes steel.

19. An electrical connector assembly for use in a high-power application, the connector assembly comprising: a first electrically conductive connector formed from a first material, the first connector having a contact beam; an internal spring member formed from a second material and configured to reside within an extent of the first connector, the spring member having at least one spring arm; a second electrically conductive connector with a receptacle dimensioned to receive a portion of both the first connector and the spring member to define a connected position; wherein in the connected position, the spring arm exerts an outwardly directed force on the contact beam to retain engagement between the contact beam and an inner surface of the receptacle of the second connector.

20. The electrical connector assembly of claim 19, wherein the first connector includes a second contact beam and the spring member includes a second spring arm, and wherein in the connected position, the second spring arm exerts an outwardly directed force on the second contact beam to retain engagement between the second contact beam and an inner surface of the receptacle of the second connector.

21. The electrical connector assembly of claim 19, wherein the contact beam includes a free-end that resides against an outer surface of the spring arm when the spring member is positioned within a receiver of the first connector, and wherein a portion of the outwardly directed force exerted by the spring arm is applied to said free-end of the contact beam.

22. The electrical connector assembly of claim 21, wherein the free-end of the contact beam is configured to be directed inward against an extent of the spring arm when the electrical connector assembly is in the connected position.

23. The electrical connector assembly of claim 19, wherein the outwardly directed force applied by the spring arm on the contact beam in the connected position is increased by thermal expansion during operation of the electrical connector assembly.

24. The electrical connector assembly of claim 19, wherein the outwardly directed force applied by the spring arm on the contact beam in the connected position is increased by residual material memory during operation of the electrical connector assembly.

25. The electrical connector assembly of claim 19, wherein the spring member includes a base that the spring arm extends therefrom, and wherein an outer surface of the base is placed in contact with an inner surface of the first connector when the spring member is positioned within the first connector.

26. The electrical connector assembly of claim 19, further comprising an electrically non-conductive shroud that covers an extent of the first connector and includes a connector position assurance indicator.

27. An electrical connector assembly for use in a high-power application, the connector assembly comprising: a first electrically conductive connector formed from a first material that includes copper, the first connector having a plurality of elongated contact beams arranged to define a receiver; an internal spring member formed from a second material that includes steel, the spring member having a plurality of spring arms; and wherein when the spring member is inserted into the receiver of the first electrically conductive connector, a spring arm of the plurality of spring arms is configured to provide a biasing force on a contact beam of the plurality of elongated contact beams under certain operating conditions of the electrical connector assembly.

28. The electrical connector assembly of claim 27, wherein a first elongated contact beam includes a free-end that resides against an outer surface of a first spring arm, and wherein an extent of the biasing force exerted by the spring arm is applied to said free-end of the contact beam.

29. The electrical connector assembly of claim 27, wherein a first elongated contact beam of the plurality of elongated contact beams is positioned on a first side of the receiver and a second elongated contact beam of the plurality of elongated contact beams is positioned on a second side of the receiver that is opposite to the first side of the receiver.

30. The electrical connector assembly of claim 29, wherein a third elongated contact beam of the plurality of elongated contact beams is positioned on a third side of the receiver and a fourth elongated contact beam of the plurality of elongated contact beams is positioned on a fourth side of the receiver that is substantially perpendicular to the first side of the receiver.

31. The electrical connector assembly of claim 27, wherein the plurality of elongated contact beams extend from a base of the first connector, and wherein said base forms an extent of the receiver.

32. The electrical connector assembly of claim 27, wherein a residual material memory of the spring member increases the biasing force on the plurality of elongated contact beams during operation of the electrical connector assembly.

33. The electrical connector assembly of claim 27, further comprising a shroud that includes a connector position assurance indicator.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention is illustrated with 44 drawings on 12 sheets.

(2) FIG. 1 is an isometric view of a male terminal showing the non-conductive plastic shroud and metallic tubular member.

(3) FIG. 2 is a top view of a male terminal.

(4) FIG. 3 is an isometric view of the female connector without a plastic shroud.

(5) FIG. 4 is an isometric view of the female connector, rotated approximately 90° from FIG. 3.

(6) FIG. 5 is an exploded isometric of the female connector.

(7) FIG. 6 is a lateral cut-away view of the female connector.

(8) FIG. 7 is a lateral view of the female connector.

(9) FIG. 8 is an end view of the female connector.

(10) FIG. 9 is an isometric view of an alternative embodiment of the female connector without a plastic shroud.

(11) FIG. 10 is an isometric view of an alternative embodiment of the female connector, rotated approximately 90° from FIG. 9.

(12) FIG. 11 is an exploded isometric of an alternative embodiment of the female connector.

(13) FIG. 12 is a lateral cut-away view of an alternative embodiment of the female connector.

(14) FIG. 13 is a lateral view of an alternative embodiment of the female connector.

(15) FIG. 14 is an end view of an alternative embodiment of the female connector.

(16) FIG. 15 is an isometric view of an alternative embodiment of the female connector.

(17) FIG. 16 is an isometric view of an alternative embodiment of the second connector.

(18) FIG. 17 is a top view of the alternative embodiment of the second connector and insulating shroud of FIG. 16.

(19) FIG. 18 is an isometric view of an alternative embodiment of the female connector.

(20) FIG. 19 is an isometric view of an alternative embodiment of the insulating shroud used with the female connector.

(21) FIG. 20 is a top view of an alternative embodiment of the insulating shroud.

(22) FIG. 21 is an end view of the female connector with an envelope of the non-conductive plastic shroud drawn as a dotted line.

(23) FIG. 22 is an isolated lateral view of the spring actuator of the female connector.

(24) FIG. 23 is a reverse end view of the female connector.

(25) FIG. 24 is a reverse end view of the female connector, with the insulating shroud in situ.

(26) FIG. 25 is an isometric view of an alternative embodiment of the female connector.

(27) FIG. 26 is an isometric view of an alternative embodiment of the female connector.

(28) FIG. 27 is a rotated isometric view of FIG. 25.

(29) FIG. 28 is a rotated isometric view of FIG. 26.

(30) FIG. 29 is a cut-away lateral view of an alternative embodiment of the female connector.

(31) FIG. 30 is a cut-away lateral view of an alternative embodiment of the female connector.

(32) FIG. 31 is a lateral exploded view of the contact element and spring actuator.

(33) FIG. 32 is an exploded view of the female connector with an alternator connector and cap.

(34) FIG. 33 is an isometric view of a male terminal for an alternator.

(35) FIG. 34 is an isometric view of the plastic shroud of a male terminal for an alternator.

(36) FIG. 35 is an isometric view of the male terminal.

(37) FIG. 36 is an isometric view of the metallic tubular member.

(38) FIG. 37 is a side view of the male terminal.

(39) FIG. 38 is an end view of the male connector.

(40) FIG. 39 is an isometric view of the male terminal metallic tubular member with an integral straight busbar.

(41) FIG. 40 is an isometric view of the male terminal metallic tubular member with an alternative embodiment and orientation of the integral busbar.

(42) FIG. 41 is an isometric view of the female connector implemented on an alternator connector.

(43) FIG. 42 is an alternative isometric view of the female connector implemented on an alternator connector.

(44) FIG. 43 is an isometric view of the present invention implemented on an alternator connector, with the alternator.

(45) FIG. 44 is an isometric view of the present invention implemented on an alternator connector, in situ on an alternator.

DETAILED DESCRIPTION OF THE DRAWINGS

(46) The following descriptions are not meant to limit the invention, but rather to add to the summary of invention, and illustrate the present invention, by offering and illustrating various embodiments of the present invention, a high-power, spring-actuated electrical connector. While embodiments of the invention are illustrated and described, the embodiments herein do not represent all possible forms of the invention. Rather, the descriptions, illustrations, and embodiments are intended to teach and inform without limiting the scope of the invention.

(47) FIGS. 3-4 show the female connector 20 of the present invention, a high-power, spring-actuated electrical connector. The female connector 20 includes a contact element 10 having a contact element 10 base 18, 19 having six sides 18 and six bent segments 19. The cross-section of the contact element 10 base is substantially hexagonal 18, 19. The contact element 10 has six contact beams 11. Each contact beam 11 has a substantially planar surface 12 terminating in a bent-termination portion 13. The end of the contact beam 11 distal from the bent-termination portion 13 is connected to the base 18. The thickness 14 and width of the planar surface 12 dictate the current carrying load of each contact beam 11. In use, the contact beams 11 form a large obtuse angle with the base 18, 19.

(48) The contact element 10 is an integral piece. The contact element 10 is made out of conductive metal, such as copper alloys C151 or C110. It is formed, bent, and folded into the correct shape. The contact element 10 has two planar spade elements 16, 17. The planar spade elements 16, 17 have a thickness 16, 17. The planar spade elements 16, 17 have a planar surface 15, 105. The planar spade elements 16 transitions 106 from the hexagonal base 18, 19. The transition 106 has a thickness 107.

(49) FIG. 5 further illustrates the female connector 20 by showing the spring actuator 30 that is inside the contact element 10. Still visible in the contact element 10 are the contact beams 11, the hexagonal base 18, 19, and the planar spade elements 16, 17. The planar surface 15, 105 and transition thickness 107 are also visible. The spring actuator 30 has a plurality of spring arms 31. The spring arms 31 have a substantially planar surface 32, a thickness 34, and a bent-termination portion 33, 333. The spring actuator 30 base is substantially hexagonal with six flat sides 38 and six bent portions 39. The spring actuator 30 is fabricated from spring steel. The spring arms 31 of the spring actuator 30 form a large obtuse angle with the spring actuator 30 base 38, 39.

(50) The spring actuator 30 fits inside the contact element 10. The spring actuator 30 spring arms 31 contact the inside planar surface 122 of the contact element 10 contact beams 11. The inside planar surface 122 of the contact beams 11 is obverse to the outside planar surface 12 of the contact beams 11. The bent-termination portion 13 of the contact element 10 allows the female connector 20 to be compressed as it is inserted into a connector block. The spring actuator 30 spring arms 31 will provide a consistent retention force against the inside surface 122 of the contact element 10 contact beams 11. In practice, it is advisable to use a minimum of four (4) contact beams 11 in any embodiment.

(51) FIGS. 6-7 show a lateral cutaway (FIG. 6) and a lateral view (FIG. 7). The relation of the planar spade elements 16, 17 to the contact beams 11 and bent-termination portion 13 is illustrated and evident. The spring actuator 30 spring arm 31 flat planar surface 32 and flat side 38 are shown in the cutaway. The relation of the six sides 18 of the hexagonal base 18, 19 to the planar surface 12 of the contact beams 11 is shown.

(52) FIG. 8 shows an end-view of the spring actuator 30 inside the contact element 10. The bent-termination portion 333, 33 of the spring actuator 30 push the bent-termination portion 13 of the contact element 10 outward.

(53) FIGS. 9-10 show an alternative embodiment of the present invention a high-power, spring-actuated electrical connector. The female connector 70 includes a contact element having a contact element 60 base having six sides 68 and bent portions 69. The contact element 60 base is substantially hexagonal 68, 69, 168. The contact element 60 has a six contact beams 61. Each contact beam 61 has a substantially planar surface 62 terminating in a bent-termination portion 63. The thickness 64 and surface area of the planar surface 62 dictate the current carrying load of each contact beam 61. The contact beams 61 form a large obtuse angle with the base 68, 69, 168. In this embodiment, the contact beams 61 have been reversed relative to the spade elements 66, 67. In this embodiment, there is flat portion 68 of the base that connects to the contact beams 61 and an additional flat portion 168 of the base near the bent-termination portion 63. The bent-termination portion 63 extends past the additional flat portion 168.

(54) The contact element 60 is an integral piece. The contact element 60 is made out of conductive metal, such as copper alloys C151 or C110. It is formed, bend, and folded into the correct shape. The contact element 10 has two planar spade elements 66, 67. The planar spade elements 66, 67 have a thickness 616, 67. The planar spade elements 66, 67 have a planar surface 65, 155. The planar spade elements 66 transitions 156 from the hexagonal base 68, 69, 168. The transition 156 has a thickness 171.

(55) FIG. 11 further illustrates the female connector 70 of the present invention by showing the spring actuator 80 that is inside the contact element 60. Still visible in the contact element 60 are the contact beams 61, the hexagonal base 168, and the planar spade elements 65, 66, 67, 155. The gap 200 caused by forming the contact element 60 out of a single piece of copper is also visible in this orientation. The spring actuator 80 has a plurality of spring arms 81. The spring arms 81 have a substantially planar surface 82 and a bent-termination portion 83. The spring actuator 80 base is substantially hexagonal with six flat sides 88 and five bent portions 89. The spring actuator 80 is fabricated from spring steel. The spring arms 81 of the spring actuator 80 form a large obtuse angle with the spring actuator 80 base 88, 89.

(56) The spring actuator 80 fits inside the contact element 60. The spring actuator 80 spring arms 81 contact the inside planar surface 222 of the contact element 60 contact beams 61. The bent-termination portion 63 of the contact element 60 allows the female connector 70 to be compressed as it is inserted into a connector block. The spring actuator 80 spring arms 81 will provide a consistent retention force against the inside surface 222 of the contact element 60 contact beams 61.

(57) FIGS. 12-13 show a lateral cutaway (FIG. 8) and a lateral view (FIG. 9). The relation of the planar spade elements 66, 67 to the contact beams 61 is illustrated. The spring actuator 80 spring arms 81 and bent-termination 83 are shown in the cutaway. The relation of the six sides 68 of the hexagonal base 68, 69, 168 to the planar surface 62 of the contact beams 61 is shown. The female connector 70 has, generally, a length 76 and a width 71. A ratio of length 76 to width 71 is the aspect ratio of the female connector 70.

(58) FIG. 14 shows an end-view of the spring actuator 80 inside the contact element 60. The bottom bent-termination 242 of the spring actuator 80 is visible.

(59) FIGS. 1-2 show the male terminal portion 1 of the present invention. The male terminal portion 1 of the present invention consists of a cylindrical plastic shroud 5; and a cylindrical stamped metallic terminal (“male terminal”) 6, 7, 8, 9, 102, 103, 104. The plastic shroud 5 is a cylinder with an outer surface 2, an inner surface 8, an upper edge 3 and a taper 4 connecting the inner cylindrical surface 8 and the upper edge 3. The plastic shroud 5 is made from high-temperature polymers, such as high-temperature polyamide (e.g., nylon 66). The male terminal has an outer cylindrical surface 104, an inner cylindrical surface 9, an upper edge 6, a taper 7 connecting the upper edge 6 and the inner cylindrical surface 9, and two fillets 102, 103.

(60) The female connector 20, 70 fits inside the male terminal portion 1. At elevated temperatures, the contact element 10, 60, and the spring actuator 30, 80, will tend to expand outwards due to metal memory and thermal expansion. This will increase the outward directed spring force exerted by the spring arms 31, 81 on the contact beams 11, 61. In turn, this will increase the contact force between the contact beams 11, 61 and the inner cylindrical surface 9 of the male terminal portion 1. As a result, the increased temperatures present in a motor vehicle engine compartment will increase, rather than decrease, the contact force of the connector.

(61) FIGS. 21-24 illustrate the interaction of the female connector 70 and the male terminal 1. The inner diameter 90 of the inner cylindrical surface 9 of the male terminal 1 contacts the contact element 60. The spring actuator 80 exerts outward force on the contact element 60 pushing the contact beams 61 of the contact element into the connector. The bent-termination portion 63 of the contact beams 61 are the part that contact the inner diameter 90. The upper edge 6 and taper 7, and fillets are oriented nearer the bent-termination portion 63 of the beams 61, in this embodiment.

(62) FIG. 15 shows another alternative embodiment of the first female connector 320 of the present invention, a high-power, spring-actuated electrical connector. The female connector 320 includes a contact element 310 base 350 having four sides 318 and four bent portions 319. The cross-section of the contact element 310 is substantially a square or rounded square with rectangular planar surfaces: the four side walls 318, the four rounded portions 319 extending between adjacent side walls 318, and the base 350. The contact element 310 has four contact beams 311. Each contact beam 311 has a substantially planar surface 312 terminating in a bent-termination portion 313. The contact beams 311 form extend at an angle to the base 350 and the side walls 318, and, as a result, the rounded termination end 313 is external to the side wall 318.

(63) The contact element 310 is an integral piece. The contact element 310 is fabricated from a conductive metal, such as copper alloys C151 or C110. It is formed, bent, pressed, and/or folded into the correct shape. The contact element 310 has two planar spade elements 316, 317. The planar spade elements 316, 317 have a planar surface 315. The planar spade elements 316, 317 transition from the base 350 and have a thickness 357. A spring actuator 330, 530, 630 as shown in FIG. 15, is interior to the contact element 310 within an internal receiver formed by the side walls 318 of the contact element 310, that extends from an open first end to a second, closed end at the base 350 of the first connector 320.

(64) FIGS. 16-17 show an alternative embodiment of the male terminal/connector 360 that mates with the first connector 320, shown in FIGS. 15 and 25-31, with a square cross-sectional base. In these drawings, the plastic shroud of the male terminal (or second connector 360) is omitted for clarity. The male terminal 360 has an outer surface 362, 361, an inner surface 365, an upper edge 363, and a taper 364 that connects the upper edge 363 to the inner surface 365. The female connector 320 fits inside the male terminal 360, thus the second connector 360 is cooperatively dimensioned to receive the female connector 320. The second connector 360, perhaps having differing overall dimensions, may be used with embodiments of the first connector 320, 520, 620 shown in FIGS. 15 and 25-31.

(65) FIG. 18 is another embodiment of the female connector 420 of the present invention, a high-power, spring-actuated electrical connector, with is similar to that shown in FIGS. 9-14, except with a different aspect ratio. The female connector 420 includes a contact element having a contact element 410 base having six sides 418 and six bent portions 419. The cross-section of the contact element 410 base is substantially hexagonal with rectangular planar surfaces 418, 419. The contact element 410 has a six contact beams 411. Each contact beam 411 has a substantially planar surface 412 terminating in a bent-termination portion 413. The contact beams 411 form a large obtuse angle with the base 418.

(66) The contact element 410 is an integral piece. The contact element 410 is fabricated from a conductive metal, such as copper alloys C151 or C110. It is formed, bend, pressed, and/or folded into the correct shape. The contact element 410 has two planar spade elements 416, 417. The planar spade elements 416, 417 have a thickness 416, 417. The planar spade elements 416, 417 have a planar surface 455. A spring actuator 430, with spring arms 431 is interior to the contact element 410. The female connector 420 has, generally, a length 470 and a width 471. A ratio of length 470 to width 471 is the aspect ratio of the female connector 420.

(67) FIGS. 19-20 show an alternative embodiment of the male terminal 460 that would mate with a female connector 420 with a hexagonal cross-sectional base. In these drawings, the plastic shroud of the male terminal portion is omitted for clarity. The male terminal 460 has an outer surface 462, an inner surface 461, an upper edge 463, and a taper 464 that connects the upper edge 463 to the inner surface 461. The female connector 420 fits inside the male terminal 460.

(68) FIGS. 25-28 show two additional alternative embodiments of a first, female connector 520, 620 with a square or substantially square cross-section. As shown in these figures, the embodiments have many elements in common: four side walls 518, 525, 618, 625 with an aperture 566, 666; four bent or rounded portions 519, 619 extending between a pair of adjacent side walls 518, 525, 618, 625; contact beams 511, 611 that have planar surfaces 512, 612 a curvilinear, bent-termination portion 513, 613 adjacent to a free end 568; a bottom plate 515; and a spring actuator 530, 630 positioned within the first connector 520, 620. These two alternative embodiments also have planar spade elements: 560, 515, 516, 517; and 660, 615, 616, 617. In one embodiment 520, the spade element 560, 515, 516, 517 is parallel with two of the four sides 518, 525. In the other embodiment 620, the spade element 660, 615, 616, 617 is orthogonal to all four sides 618, 625.

(69) FIGS. 29-30 are an isometric cutaway and a lateral cutaway of the first, female connector 520 with a square or substantially square cross-section, respectively. FIG. 31 is an isometric exploded view of the female connector 520, previously illustrated in FIGS. 25-28, with a square or substantially square cross-section. The spring actuator 530 sits inside an internal receiver 540 formed therein have a centerline 542 (see FIGS. 30 and 31) passing substantially through the center(s) thereof. The spring actuator 530 has spring arms 531 and a base portion 538 made of spring steel and/or stainless steel. The spring arms 531 have a flat planar surface 532 which exert outward force on the contact beams 511. As shown by the arrows in FIG. 29, a biasing force F exerted by the spring arms 531 is directed outward and away from the centerline 542 of the receiver 540 and a first connector 520. The contact beams 511 have a flat planar surface 512 and a curvilinear shoulder or bent portion 513 adjacent to the free end 568. The free end 568 of the contact beam 511 contacts the flat planar surface 532 of the corresponding spring arm 531. This allows the spring arms 531 to be coplanar with the base portion 538 of the spring actuator 530 so that they do not become overstressed during the fabrication process.

(70) The alternator terminal assembly 700 mates with the male terminal 703, as shown in FIG. 33-36. The male terminal 703 has a metallic, square tube 777 and a high temperature, non-conductive polymer shroud 711 with flange 709. The metallic, square tube 777 is electrically integral with the alternator busbar 708. The metallic square tube 777 is commonly made out of copper C110 or C151. The metallic square tube 777 has an outer surface composed of flat segments 769 and curved segments 768, an inner contact surface 710, a busbar 708, and an upper edge 770, distal from the busbar 708. The plastic shroud 711 has an inner surface 750, an outer surface 711, a flange 709, an upper edge 757 distal from the flange 709, and a mating protrusion 755. The mating protrusion 755 can be used to insure positive engagement between the female connector and the male terminal.

(71) FIGS. 37-38 show two angles of the male terminal 703 with a mating protrusion 755 highlighted.

(72) FIG. 32 shows the female connector 520 assembled into an alternator terminal assembly 700. A spade surface 515 (the reverse spade surface 566 is visible in FIG. 32) is ultrasonically welded or crimped to the wire 701. A cap 705 fabricated from high temperature polymers, such as high temperature polyamides, covers spade 566 of the female connector 520 and the wire weld. The rest of the female connector 520 fits into an alternator connector 702.

(73) FIG. 39-40 show two different embodiments of the metallic, square tube 778, 777. In one, the busbar 708 is parallel to the metallic tube 777. The busbar 708 is integral with the surface of the metallic tube 769. In the other embodiment, the busbar 779 is orthogonal to the surfaces 789, 788 of the metallic tube 778.

(74) FIGS. 41-42 show the female connector 520 in situ in an alternator terminal assembly 700. The cap 705 segment is joined to the alternator connector segment 702. The alternator connector segment has a plastic shroud 729 to prevent premature electrical contact. The beams 511 extend pass the plastic shroud 729, creating an electrical connection when mated with the male terminal 703. The alternator terminal assembly 700 has a connector position assurance indicator 720.

(75) FIGS. 43-44 show the alternator terminal assembly 700 in situ with an alternator 704. The male terminal 703 is integral to the alternator 704. The alternator terminal assembly 700 with the female connector 520 mates with the male terminal 703 as shown in FIG. 42. The connector position assurance indicator 720 shows whether the connector is fully engaged and locked.