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 from inadvertently or accidentally rotating relative to the lower portion of the main body.

Abstract: A method for improving clearance and creepage in a high voltage connector assembly using a female terminal position assurance (TPA) device. The female housing in this invention is highly suitable for high voltage electrical terminals, which are larger terminals. The female TPA device in this invention includes two frontward extending members, while the female housing includes a front portion for terminals to reside. With the above-described characteristics of this invention, the creepage and the clearance of an electrical path between one terminal to another terminal are advantageously increased. The electrical path one of the a electric high voltage electrical terminal to another high voltage electrical terminal extending along the front portion of the female housing and between the front downward extending members of the frontward extending members of the female TPA device.

Abstract: An electrical male terminal of this invention includes a clamp or crimp area, a main body, and a blade. A tang member having a lever member, locks with a connector assembly. Protruding members and support members of the main body act as overstress protection. The main body includes a tapered portion, a protruding guide member, and a panel shield member to guide the electrical male terminal, the panel shield member protecting the protruding guide member. The polarity of the electrical male terminal is such that the upper portion of the main body in the upper portion of the connector assembly is narrower than the lower portion of the main body in the lower portion of the connector assembly. Also, this invention includes methods for securing a wire or cable with the electrical male terminal, using a pair of wire-insulation clamping tabs or insulation crimp wing portions, and a pair of wire-clamping tabs or core crimp wing portions.

Abstract: An Insulation Displacement Contact Compliant connector system (IDCC) which includes a housing, header pins, and a Printed Circuit Board (PCB). Each header pin has at least a single barb to be retained into the housing. Each pin has a blade for contacting a wire. A compliant feature on the pin retains itself into holes in the PCB. The housing has a negative space similarly shaped to the pin. The housing includes a strain relief which provides a lead-in for a wire. When the system is fully assembled, the pins reside in the housing, and exit through the housing and into and through respective holes in the PCB. A wire can be inserted into the housing once the pins reside in the housing. There are several options for the assembly process including a) a pin-to-housing insertion process; b) a housing assembly-to-PCB process or a connector-to-PCB process; and c) a wired housing assembly-to-PCB assembly process or a wire harness-to-PCB assembly process.

Abstract: A connector position assurance device having multiple features for assuring a full coupling and locking of a female housing with a male housing in a connector system, such that the female housing and male housing are placed into a fully coupled and locked position when the connector position assurance device is moved from a pre-lock position to a full-lock position. When the connector position assurance device is at a full-lock position, a first member on the connector position assurance penetrates a window formed on the female housing, and at least one ledge extending from the connector position assurance device prevents a flexible member of the female housing from being moved downward, providing assurance that the female and male housings are fully coupled and locked together.

Abstract: An Insulation Displacement Contact Compliant connector system (IDCC) which includes a housing, header pins, and a Printed Circuit Board (PCB). Each header pin has at least a single barb to be retained into the housing. Each pin has a blade for contacting a wire. A compliant feature on the pin retains itself into holes in the PCB. The housing has a negative space similarly shaped to the pin. The housing includes a strain relief which provides a lead-in for a wire. When the system is fully assembled, the pins reside in the housing, and exit through the housing and into and through respective holes in the PCB. A wire can be inserted into the housing once the pins reside in the housing. There are several options for the assembly process including a) a pin-to-housing insertion process; b) a housing assembly-to-PCB process or a connector-to-PCB process; and c) a wired housing assembly-to-PCB assembly process or a wire harness-to-PCB assembly process.

Abstract: A connector position assurance (CPA) member for assuring the engagement of a female housing with a male housing. The CPA member includes arms designed to stably and securely fit with apertures formed by the female housing. Also, the female housing includes a connector latch which engages with the CPA member and which used to securely hold together the female housing and the male housing.

Abstract: Method of operating a connector latch used to securely hold together a connector apparatus, wherein the connector apparatus has at least a first housing and a second housing which can be mated together. Initially, after the connector latch is manufactured, the connector latch is in an undeflected position. After manufacture, the connector latch is subjected to a pre-mating deflection process, in order to deflect the connector latch into a preloaded position. After the pre-mating deflection process has been completed, the connector latch is locked in the preloaded position. The preloaded connector latch provides a number of desirable characteristics, including at least an extra loud “click” sound when the connecting latch is operated to mate the first housing with the second housing.

Abstract: An electromagnetic interference (EMI) grounding protection method for a connector assembly using a conductive housing. The method includes the steps of: conducting the EMI generated by a source towards a metallic braided shield, the metallic braided shield being secured and mounted onto the conductive housing by a metallic clamp; conducting the EMI from the metallic braided shield to the metallic clamp and to the conductive housing, the conductive plastic housing being mounted onto a metallic device by at least a metallic bolt and the bolt being accommodated within a corresponding metallic compression limiter; and thereafter, conducting the EMI: (1) from the conductive housing through the metallic compression limiters and through their respective bolts, and ultimately to the metallic device, and (2) from the conductive housing directly through conductive pads thereof, and ultimately to the metallic device.

Abstract: A low profile high voltage connector, having a minimal height and meeting high voltage requirements and a method of assembling thereof, includes a male housing and a female housing, and further includes a terminal position assurance (TPA) device and a connector position assurance (CPA) device, the TPA device ensuring that a terminal, housed within the female housing, provides a secondary lock, so as to ensure that the terminal is secured or locked within the female housing. The CPA device assures that the male and female housings remain locked and inseparable from each other. The terminal is housed within the female housing in such a way as to have the female housing, engaged within the male housing, to meet a minimal height requirement. Each of the TPA device and the CPA device functions in a pre-lock position or a full-lock position when engaging with the low profile high voltage connector.

Abstract: A dual row low profile high voltage connector, having a minimal height and meeting high voltage requirements and a method of assembling thereof, includes a male housing and a female housing, and further includes a terminal position assurance (TPA) device and a connector position assurance (CPA) device, the TPA device ensuring that a terminal, housed within the female housing, provides a secondary lock, so as to ensure that the terminal is secured or locked within the female housing. The CPA device assures that the male and female housings remain locked. The terminal is housed within the female housing to meet a minimal height requirement and having dual rows of terminals inserted therein the female. The TPA device and the CPA device function in pre-lock or full-lock positions. A method also improves clearance and creepage by allowing a clearance or electrical path to extend around an inserted TPA between terminals.

Abstract: An electrical male terminal of this invention includes a clamp or crimp area, a main body, and a blade. A tang member having a lever member, locks with a connector assembly. Protruding members and support members of the main body act as overstress protection. The main body includes a tapered portion, a protruding guide member, and a panel shield member to guide the electrical male terminal, the panel shield member protecting the protruding guide member. The polarity of the electrical male terminal is such that the upper portion of the main body in the upper portion of the connector assembly is narrower than the lower portion of the main body in the lower portion of the connector assembly. Also, this invention includes methods for securing a wire or cable with the electrical male terminal, using a pair of wire-insulation clamping tabs or insulation crimp wing portions, and a pair of wire-clamping tabs or core crimp wing portions.

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. The two-bodied spring includes two members to provide spring force to impinge upon and mate the terminal with a male pin or male terminal, or further “blade-like” object. A guide member directs and “self-corrects” the insertion of a male pin or male terminal, or further “blade-like” object into the electrical female terminal. The main body further includes a tang member with overstress protection which fastens and locks the terminal within a connector housing. The main body has support members at either end thereof. The terminal has a polarity defined by the main body and for proper mating with a corresponding housing. The electrical female terminal also may accommodate a TPA device within a space above the wire fastening portion and located behind the main body.

Abstract: An electromagnetic interference (EMI) grounding protection method for a connector assembly using a multi-directional conductive housing.

Abstract: A dual contact Insulation Displacement Contact (IDC) header pin comprised of an upper section, a lead-in section, and a retention section. The upper section of the pin has at a plurality of pin barbs to allow it to be retained into a housing. The side walls and back of the upper portion create a C-shape to the upper portion. Each IDC header pin has two blades to contact a wire and displace the insulation thereof. The lead-in section serves to lead the IDC header pin into a housing and prevent stubbing of the pin during insertion. The retention section of the pin has a plurality of rib-like projections allowing the pin to be retained into respective holes in a PCB by applying normal force and an interference fit. An embodiment is open, with front protrusions on the upper section, and another embodiment is closed, having two front walls on the upper section.

Abstract: A connector assembly for connecting to a device which, when in operation, experiences reduced or suppressed EMI. The EMI flow path, generated by, e.g., at least a battery cable assembly or the like, housed within at least a male connector assembly or a female connector assembly, is conducted through at least an electrically conductive housing and an electrically conductive seal.

Abstract: A male terminal position assurance (TPA) device for a male connector assembly, preferably for a high voltage connector assembly. The male TPA has a substantially wing-like shaped upper member that respectively locks terminals inside a male inner housing, and further has a flexible arm member, in a lower member thereof, that locks the male TPA device in the male inner housing. The male TPA device does not lock inside the male inner housing if it detects that the corresponding terminal has not been fully inserted or installed into the male inner housing. The male inner housing includes a primarily lock for locking the terminal, while the male TPA device, when in full-lock position, provides for a secondary lock for locking the terminal inside the inner housing. When in the full-lock position inside the male inner housing, the male TPA device assures that the necessary retention forces are provided to ensure that the terminal remains fully locked within the male connector assembly.

Abstract: A high voltage connector, connected to a device, that experiences a reduced electromagnetic interference (EMI), avoids galvanic corrosion of dissimilar metals within or without a fluid environment, and provides an effective electrical ground system. The connector includes an outer housing assembly, an inner housing mounted inside the outer housing, a set of cable reinforcement retainer assemblies secured inside the inner housing, a back cover through which the cables respectively slide along and covers a central opening of the outer housing, a braided shield covering the cables, and a clamp that connects the shield onto the outer housing.

Abstract: Method of operating a connector latch used to securely hold together a connector apparatus, wherein the connector apparatus has at least a first housing and a second housing which can be mated together. Initially, after the connector latch is manufactured, the connector latch is in an undeflected position. After manufacture, the connector latch is subjected to a pre-mating deflection process, in order to deflect the connector latch into a preloaded position. After the pre-mating deflection process has been completed, the connector latch is locked in the preloaded position. The preloaded connector latch provides a number of desirable characteristics, including at least an extra loud “click” sound when the connecting latch is operated to mate the first housing with the second housing.