Abstract: The seal spring of the present invention has a dual functionality. The seal spring provides both a sealing property and spring function in use within an electrical connector system, which is accomplished by its elastomeric qualities. The seal spring is preferably comprised of Silicone, EPDM rubber or materials and compositions that provide similar performance during use, or the like. The seal spring of the present invention is not limited or defined into a spring section or a seal section by its geometry. Shown is an implementation of the seal spring within an outer housing and connector assembly. The seal spring compresses and provides adequate spring force against a tab or tabs within the outer housing. The seal spring also functions as an interface seal and an environmental seal during use. The seal spring is, substantially, in its entirety, of a contiguous and continuous single construction. No part or section of the seal spring is made up of welded, soldered, or brazen part or section.

Abstract: A terminal spring on a female terminal that integrates a terminal spring spacer to underlying terminal bases of said terminal spring to aid in maintaining proper contact interface gap for receiving therein a corresponding male terminal. The terminal spring spacer is integrally, contiguously, or unitarily connected to said terminal spring as a single piece. The female terminal, onto which the terminal spring with the terminal spring spacer is joined, includes a pair of terminal bases, each having a contact zone, a transition zone, and a terminal (wire) zone. The contact zones and transition zones of the first and second terminal bases are substantially contained within the terminal spring. The terminal spring spacer effectively maintains a correct gap through an interface gap between front ends of the contact zones of the first and second terminal bases through another gap between transition zones of the first and second terminal bases for accommodating therein the corresponding male terminal.

Abstract: A tubular high current female terminal for mating with a male terminal having an outer terminal, and at least one core terminal. The outer terminal includes at least a mating portion and a termination portion. The core terminal includes a plurality of spring contacts, and preferably, latches for attaching thereof on an elongated opening of the outer terminal. The outer terminal is a seamless preformed tube that extends from the mating portion integrally extending to the termination portion as a single piece. A plurality of tubular high current female terminals may be joined together at termination portions thereof. Also, the tubular high current female terminal may have mating portions at opposing ends thereof, such that the male terminals respectively connected thereto extend at any desired angle. Furthermore, the mating portion may be a cylindric tube for mating with a cylindric male terminal, while the termination portion is attachable to an electrical cable.

Abstract: The seal spring of the present invention has a dual functionality. The seal spring provides both a sealing property and spring function in use within an electrical connector system, which is accomplished by its elastomeric qualities. The seal spring is preferably comprised of Silicone, EPDM rubber or materials and compositions that provide similar performance during use, or the like. The seal spring of the present invention is not limited or defined into a spring section or a seal section by its geometry. Shown is an implementation of the seal spring within a conductive female housing and connector assembly. The seal spring compresses and provides adequate spring force against a disk ferrule assembly, pressing the disk ferrule assembly, with a wire shield, against a conductive female outer housing, providing a grounding scheme for the connector assembly. The seal spring also seals against the female outer housing and a wire.

Abstract: An electrical connector having a housing for receiving therein at least one terminal; a hinged cover, operably coupled to the housing, for covering the terminal received by the housing; at least a hinge member operably coupled to the housing and the hinged cover; and an independent secondary terminal lock (ISL) within the hinged cover for locking the terminal within the housing when the hinged cover is at a closed position. The ISL blocks the terminal from being removed or dislodged from the housing. The housing and the hinged cover have a locking mechanism that retains and secures the hinged cover onto the housing, and thereby locks the terminal within the housing. Alternatively, the housing and the hinged cover have another locking mechanism that includes a substantially flexible member having an elongated slot and extending from a side portion of the housing for accommodating therein at least an elongated retention member extending from at least a side of the hinged cover.

Abstract: An electrical male terminal of this invention includes a clamp or crimp area, a main body, and a blade. Protruding members and support members of the main body act as overstress protection. A panel shield member protects a protruding guide member. In another embodiment of this invention, a protruding member extends from a first support member of the main body, and a cut-out portion at the lower portion of the main body accommodates therein the protruding member. Furthermore, in this another embodiment of the electrical male terminal of this invention, a protrusion extends from the unattached end portion of the lever member to protect the electrical male terminal from inadvertently falling out during use. The configuration or shape of the cross-section across the upper portion at the front portion of the main body and the support member at the front portion of the main body of the electrical male terminal is substantially U-shaped.

Abstract: A method for improving clearance and creepage in a male or female high voltage connector assembly using a male terminal position assurance (TPA) device. The high voltage connector assembly is suitable for high voltage electrical terminals. The method includes the steps of allowing a clearance and creepage or electrical path to extend from at least a high voltage electrical terminal to a conductive male outer housing, and or between another terminal using a male or a female TPA device. The TPA device is inserted in the high voltage connector assembly, whereby a clearance and creepage or electrical path extends from the high voltage electrical terminal along at least a surface of the TPA device and to the male outer housing of the high voltage connector assembly or from the high voltage electrical terminal to another high voltage electrical terminal in using the male and or female TPA device.

Abstract: An electrical male terminal of this invention includes a clamp or crimp area, a main body, and a blade. Protruding members and support members of the main body act as overstress protection. A panel shield member protects a protruding guide member. In another embodiment of this invention, a protruding member extends from a first support member of the main body, and a cut-out portion at the lower portion of the main body accommodates therein the protruding member. Furthermore, in this another embodiment of the electrical male terminal of this invention, a protrusion extends from the unattached end portion of the lever member to protect the electrical male terminal from inadvertently falling out during use. The configuration or shape of the cross-section across the upper portion at the front portion of the main body and the support member at the front portion of the main body of the electrical male terminal is substantially U-shaped.

Abstract: A manufacturing method for assembling a high voltage vertical disk ferrule, the ferrule being stamped and having a vertical disk-like structure, which is not necessarily round or does not necessarily have any roundness. The high voltage disk ferrule has an opening residing and traveling over the wire core and/or a wire braided shield, to which an end portion of the wire braided shield is affixed thereto the ferrule, or between two ferrules, such that a portion of the wire braided shield is flared and substantially perpendicular to the direction along which the wire core extends. The high voltage vertical disk ferrule slides over the core insulation, towards the outer insulation when the wire is pushed. The end portion/flared portion of the braided shield and the high voltage vertical disk ferrule, or the end portion/flared portion of the braided shield between at least two high voltage vertical disk ferrules are soldered, welded, or brazed together.

Abstract: The seal spring of the present invention has a dual functionality. The seal spring provides both a sealing property and spring function in use within an electrical connector system, which is accomplished by its elastomeric qualities. The seal spring is preferably comprised of Silicone, EPDM rubber or materials and compositions that provide similar performance during use, or the like. The seal spring of the present invention is not limited or defined into a spring section or a seal section by its geometry. Shown is an implementation of the seal spring within a conductive female housing and connector assembly. The seal spring compresses and provides adequate spring force against a disk ferrule assembly, pressing the disk ferrule assembly, with a wire shield, against a conductive female outer housing, providing a grounding scheme for the connector assembly. The seal spring also seals against the female outer housing and a wire.

Abstract: A shielded sealed header connector assembly having a detachable header housing, which is comprised of a outer shell and a metal shield member, and inner housing. The header housing is secured on a metal case with bolts and attached with an inner housing. The metal shield member, shields or seals the inner housing from EMI, external damage, either due to physical impact or from environmental contaminants. A method for detaching the header housing includes steps of unsecuring the header housing from the metal case by removing bolts and unlocking it from the inner housing while the inner housing maintains connection to a electrical device. A method for attaching a serviced, repaired, replaced or new header housing includes steps of attaching the header connector to the metal case with bolts; and locking the header connector to the inner housing, while maintaining the connection of the inner housing to the electrical device.

Abstract: 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.

Abstract: The connector assembly includes a terminal position assurance (TPA) device, and a seal retainer. A downwardly extending notch member of the seal retainer engages with a recess on an upper surface of an upper portion of the TPA device to form a cam linkage mechanism or a cam mechanical linkage for the TPA device and the seal retainer. The seal retainer, when pushed or inserted towards an outer housing, by way of the cam linkage mechanism with the TPA device, pushes the TPA device to one side such that the terminals within the outer housing remain unlocked. The seal retainer, when further pushed or inserted toward the outer housing, by way of the cam linkage mechanism, moves the TPA device laterally to an opposite side such that the TPA device blocks the terminals within the outer housing. A lower portion of the seal retainer is, at a pre-lock or full-lock position, engaged with mating locking members at a bottom portion of a terminal guidance member.

Abstract: A detachable outer shell, which is comprised of a header connector with a shield member, for a shielded device connector. The header connector with a shield member is detachably assembled, attached, or mounted onto a housing of a shielded device connector, while the shielded device preferably remains connected to an electrical device. A method for detaching the outer shell for the shielded device connector includes the steps of detaching the header connector with the shield member of the outer shell, which may require service, repair or replacement, from the housing of the shielded device; and disassembling or removing the header connector with the shield member of the outer shell from the housing of the shielded device connector, while maintaining connection of the shielded device to the electrical device.

Abstract: The seal spring of the present invention has a dual functionality. The seal spring provides both a sealing property and spring function in use within an electrical connector system, which is accomplished by its elastomeric qualities. The seal spring is preferably comprised of Silicone, EPDM rubber or materials and compositions that provide similar performance during use, or the like. The seal spring of the present invention is not limited or defined into a spring section or a seal section by its geometry. Shown is an implementation of the seal spring within an outer housing and connector assembly. The seal spring compresses and provides adequate spring force against a tab or tabs within the outer housing. The seal spring also functions as an interface seal and an environmental seal during use. The seal spring is, substantially, in its entirety, of a contiguous and continuous single construction. No part or section of the seal spring is made up of welded, soldered, or brazen part or section.

Abstract: An electrical female terminal for mating with a connector assembly generally including a main body, a two-bodied spring, and a wire fastening portion. A protrusion extends from an unattached end portion of the lever member, the protrusion having faces angled relative to each other to efficiently deflect the lever member upwards when the protrusion interacts with an internal protrusion of a housing or a connector assembly. A top portion of the retainer member of the electrical female terminal, located above the two-bodied spring, has a dimple portion. The terminal face or leading end portion of the electrical female terminal is prevented from damaging or cutting a silicone seal. The overstress feature of the tang member of the lever is improved upon by relocating and reshaping the protruding member thereof. The configuration or shape of the cross-section across the upper portion and the support member at the front end portion of the main body of the electrical female terminal is substantially U-shaped.

Abstract: An electrical male terminal of this invention includes a clamp or crimp area, a main body, and a blade. Protruding members and support members of the main body act as overstress protection. A panel shield member protects a protruding guide member. In another embodiment of this invention, a protruding member extends from a first support member of the main body, and a cut-out portion at the lower portion of the main body accommodates therein the protruding member to prevent the tang member fr©m inadvertently or accidentally rotating relative to the lower portion of the main body.

Abstract: A high voltage vertical disk ferrule, and method for assembling thereof, the ferrule being stamped and having a vertical disk-like structure, which is not necessarily round or does not necessarily have any roundness. The high voltage vertical disk ferrule has an opening residing and traveling over the wire core and/or a wire braided shield, to which an end portion of the wire braided shield is affixed to the ferrule, or between two ferrules, such that a portion of the wire braided shield is flared and substantially perpendicular to the direction along which the wire core extends. The high voltage vertical disk slides over the core insulation, and towards the outer insulation when the wire is pushed. The wire braided shield develops a natural spring force against the ferrule, and causes it to be accordioned, pleated, or folded against itself, and therefore pushes the vertical disk ferrule forward.

Abstract: The seal spring of the present invention has a dual functionality. The seal spring provides both a sealing property and spring function in use within an electrical connector system, which is accomplished by its elastomeric qualities The seal spring is preferably comprised of Silicone, EPDM rubber or materials and compositions that provide similar performance during use, or the like. The seal spring of the present invention is not limited or defined into a spring section or a seal section by its geometry. Shown is an implementation of the seal spring within a conductive female housing and connector assembly. The seal spring compresses and provides adequate spring force against a disk ferrule assembly, pressing the disk ferrule assembly, with a wire shield, against a conductive female outer housing, providing a grounding scheme for the connector assembly. The seal spring also seals against the female outer housing and a wire.