Abstract: An electrical connector system for electrically and mechanically connecting with a component in a motor vehicle is disclosed. The connector system includes a motor vehicle component and a male connector assembly with a male housing that receives a male terminal. This terminal includes a receiver and side walls with a contact arm that extends across an aperture in the side wall. An internal spring member with at least one spring arm resides within the male terminal receiver. A female connector assembly includes a female terminal with a receptacle that receives both the male terminal and the spring member. A female housing receives the female terminal and an extent of the male connector assembly.

Abstract: 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.

Abstract: An electrical connector assembly for electrically and mechanically connecting a component to a power source is disclosed. The connector assembly includes a male terminal with side walls defining a receiver. The side wall includes a contact arm that extends across an aperture in the side wall. The assembly also includes an internal spring member dimensioned to reside within the receiver of the male terminal. The spring member has at least one spring arm that extends from a base portion. The assembly further includes a female terminal with a receptacle dimensioned to receive both the male terminal and the spring member residing within the receiver of the male connector to define a connected position. In the connected position, the spring arm exerts an outwardly directed biasing force on the contact arm of the male terminal to outwardly displace it into engagement with an inner surface of the receptacle to ensure connectivity.

Abstract: 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.

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.

Abstract: The present invention is a wireless HVIL system and method using RFID-enabled Electrical Connector with connector position assurance (“CPA”) features. Each RFID-enabled Electrical Connector has an RFID tag that is only readable after the CPA features of the RFID-enabled Electrical Connector have been fully deployed. If a CPA feature has not been fully deployed, electrically conductive material will obscure the RFID tag so that it cannot be read. At least one RFID reader is distributed so that all of the RFID tags are within its effective range. When system power is cycled on, the at least one RFID reader emits a digital pulse and reads all of the non-obscured RFID tags. If the at least one RFID reader detects all of the expected RFID tags, an HVIL processor will shut an HVIL switch, and power will be supplied to all HV devices.

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.

Abstract: The present invention is an RFID-enabled electrical connector with connector position assurance (“CPA”) features. The RFID tag is only readable after the CPA features have been fully deployed. The electrical connector is comprised of at least two parts, a socket and a plug. In the illustrated embodiment, a connector housing is positioned between the socket and plug, with both the socket and plug connecting to the connector housing. Until the CPA feature has been fully deployed, the RFID tag is covered by an electrically conductive material, preferably an electrically conductive plastic. The RFID tag can only be properly read after the CPA feature has been fully deployed. To prevent signal leakage, the RFID tag can alternately be placed inside a five-sided box fabricated from electrically conductive material, preferably electrically conductive plastic.

Abstract: The present invention is a wireless HVIL system and method using RFID-enabled Electrical Connector with connector position assurance (“CPA”) features. Each RFID-enabled Electrical Connector has an RFID tag that is only readable after the CPA features of the RFID-enabled Electrical Connector have been fully deployed. If a CPA feature has not been fully deployed, electrically conductive material will obscure the RFID tag so that it cannot be read. At least one RFID reader is distributed so that all of the RFID tags are within its effective range. When system power is cycled on, the at least one RFID reader emits a digital pulse and reads all of the non-obscured RFID tags. If the at least one RFID reader detects all of the expected RFID tags, an HVIL processor will shut an HVIL switch, and power will be supplied to all HV devices.

Abstract: A shielded electrical connector system for electrically and mechanically connecting a component to a power source is disclosed. The connector system includes a male connector assembly with a male terminal, a non-conductive internal male housing that receives the male terminal, and a conductive external male housing that receives an extent of the internal male housing. This terminal includes a receiver and side walls with a contact arm that extends across an aperture in the side wall. An internal spring member with at least one spring arm resides within the male terminal receiver. A female connector assembly includes a female terminal with a receptacle that receives both the male terminal and the spring member. A non-conductive internal female housing receives the female terminal and an extent of the male connector assembly.

Abstract: An electrical connector assembly for electrically and mechanically connecting a component to a power source is disclosed. The connector assembly includes a male terminal with side walls defining a receiver. The side wall includes a contact arm that extends across an aperture in the side wall. The assembly also includes an internal spring member dimensioned to reside within the receiver of the male terminal. The spring member has at least one spring arm that extends from a base portion. The assembly further includes a female terminal with a receptacle dimensioned to receive both the male terminal and the spring member residing within the receiver of the male connector to define a connected position. In the connected position, the spring arm exerts an outwardly directed biasing force on the contact arm of the male terminal to outwardly displace it into engagement with an inner surface of the receptacle to ensure connectivity.

Abstract: An electrical connector system for electrically and mechanically connecting with a component in a motor vehicle is disclosed. The connector system includes a motor vehicle component and a male connector assembly with a male housing that receives a male terminal. This terminal includes a receiver and side walls with a contact arm that extends across an aperture in the side wall. An internal spring member with at least one spring arm resides within the male terminal receiver. A female connector assembly includes a female terminal with a receptacle that receives both the male terminal and the spring member. A female housing receives the female terminal and an extent of the male connector assembly.

Abstract: This invention is a method for making a bipolar plate by selecting at least one resin from the group consisting of acrylonitrile butadiene styrene (ABS), polyphenylsulfone, a polymer resistant to sulfuric acid, and combinations of any thereof. The method may include adding conductive fibers in an amount of from about 20% to about 50% by volume, to the bipolar plate.

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.

Abstract: 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.

Abstract: A bipolar plate can include at least one resin selected from the group consisting of acrylonitrile butadiene styrene (ABS), polyphenylsulfone, a polymer resistant to sulfuric acid, and combinations of any thereof. The bipolar plate can further include conductive fibers comprise amount of from about 20% to about 50% by volume.

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.

Abstract: This invention is a method for making a bipolar plate by selecting at least one resin from the group consisting of acrylonitrile butadiene styrene (ABS), polyphenylsulfone, a polymer resistant to sulfuric acid, and combinations of any thereof. The method may include adding conductive fibers in an amount of from about 20% to about 50% by volume, to the bipolar plate.

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.

Abstract: The present invention is a high-power, spring-actuated connector device. The device has a male terminal and a female connector. The male terminal has a metallic tubular member that provides a contact surface for the female connector. The female connector fits inside the male terminal, when making an electrical connection. The female connector has a contact element, with a plurality of contact beams. A spring actuator is nested inside the contact element. The spring has spring arms that map, one-to-one, to the contact beams. The spring-actuator spring arms force the contact beams into electrical contact with the inner surface of the metallic tubular member of the male terminal. Thermal expansion and residual material memory create a more secure connection in this configuration.