Abstract: A shielded electrical connector assembly includes an electromagnetic shield integrally formed from a single sheet of conductive material. The shield has a main wall and four side walls surrounding the main wall. The shield defines an opening opposite the main wall having an opening perimeter that is greater than or equal to a main wall perimeter. One of the four side walls defines at least one side wall opening that is configured to receive a shielded wire cable. A method of manufacturing the shielded electrical connector assembly includes the steps of providing a single planar sheet of conductive material, providing a die and a punch, forming the sheet into a cupped shape having a main wall and four side walls surrounding the main wall using the die and the punch, and forming a side wall opening in one of the four side walls.

Abstract: A single-piece high voltage (HV) terminal frame includes a top wall, a bottom wall, and a side wall extending between the top wall and the bottom wall. The top wall includes a first top wall layer and an adjacently located second top wall layer. The side wall includes a first side wall layer and an adjacently located second side wall layer. The bottom wall includes a first bottom wall layer and an adjacently located second bottom wall layer. A single-layer contact spring extends from the first top wall layer, wherein the single-layer contact spring is bent to extend into a space located between the top wall and the bottom wall.

Abstract: A single-piece high voltage (HV) terminal frame includes a top wall, a bottom wall, and a side wall extending between the top wall and the bottom wall. The top wall includes a first top wall layer and an adjacently located second top wall layer. The side wall includes a first side wall layer and an adjacently located second side wall layer. The bottom wall includes a first bottom wall layer and an adjacently located second bottom wall layer. A single-layer contact spring extends from the first top wall layer, wherein the single-layer contact spring is bent to extend into a space located between the top wall and the bottom wall.

Abstract: A shielded electrical connector assembly includes an electromagnetic shield integrally formed from a single sheet of conductive material. The shield has a main wall and four side walls surrounding the main wall. The shield defines an opening opposite the main wall having an opening perimeter that is greater than or equal to a main wall perimeter. One of the four side walls defines at least one side wall opening that is configured to receive a shielded wire cable. A method of manufacturing the shielded electrical connector assembly includes the steps of providing a single planar sheet of conductive material, providing a die and a punch, forming the sheet into a cupped shape having a main wall and four side walls surrounding the main wall using the die and the punch, and forming a side wall opening in one of the four side walls.

Abstract: An electrical connector having one or more pairs of opposing contact arms extending from a body portion and configured to receive a mating connector. A spring clamp member is positioned over the opposing contact arms to increase a compressive force of the contact arms on the mating connector. The contact arms include stabilizing features to limit lateral, longitudinal, and/or rotational movement of the spring clamp member relative to the contact arms. The contact arms may be formed of a material having a high electrical connectivity and the spring clamp member may be formed of a different material having a higher relaxation temperature than the contact arm material. The mating connector may include be a male blade type terminal.

Abstract: An electrical connector having one or more pairs of opposing contact arms extending from a body portion and configured to receive a mating connector. A spring clamp member is positioned over the opposing contact arms to increase a compressive force of the contact arms on the mating connector. The contact arms include stabilizing features to limit lateral, longitudinal, and/or rotational movement of the spring clamp member relative to the contact arms. The contact arms may be formed of a material having a high electrical connectivity and the spring clamp member may be formed of a different material having a higher relaxation temperature than the contact arm material. The mating connector may include be a male blade type terminal.