Abstract: An electrical connector and methods for minimizing arcing when the connector is connected or disconnected under load are disclosed. The invention provides an arc reduction circuit with one or more regulators, such as transistors, integrated into the connector housing that sense movement of the connector and shunt the current to an impedance circuit when a potential arc condition is sensed.

Abstract: A connector assembly (2) includes and arc prevention shunt (20) in one of two mating electrical connectors (10, 30). The shunt (20) engages a terminal (34) when the connectors (10) and (20) are in a partially mated configuration. If the terminal (34) is hot, current will pass from the shunt (20) to a relay coil (62) to close contacts (64) in a Form C relay (60). When the normally open switch contacts (64) are closed a bypass circuit (52) disconnects the terminals (14, 34) in the connectors (10, 30) so arcing will not occur when the connectors (10, 30) are mated or unmated under load. When the connectors (10, 30) are in the fully mated or fully unmated, the shunt (20) is electrically isolated from the terminals (14, 34).

Abstract: A terminal 20 for use in connecting a battery cable 9 to a rectangular blade 4 on a battery 2 includes a terminal body 22 and a spring member or multiple contact band 70. The spring member 70 is fabricated from a material that is more elastic than the terminal body 22 to reduce mating force, but still generate sufficient normal force to provide a good connection to the rectangular blade 4. The multiple contact spring band 70 has a plurality of spring beams in the form of twisted louvered spring beams 78 or curved spring beams 80. The spring member 70 is positioned within a receptacle section 30 of the terminal body 22 that includes two parallel walls 32, 46. The terminal body 22 also includes a wire termination section for attaching the terminal 20 to a battery cable 8. Inline and right angle versions of the terminals employ similar spring members 70.

Abstract: Arcs are prevented as electrical connectors are unmated by including a long and a short contact in an electrical connector with both contacts being connected along the same line between an electrical source and a load. The short contact comprises the lower resistance path between the source and the load and so carries most of the current when the connectors are fully mated. An electronic component, such as an FET or a positive temperature coefficient resistor is connected to the long contact. As the short contact is disconnected, the electronic component initially carries sufficient current to prevent arcing at the short contact. Current through the electronic component decays rapidly so that when the long contact is subsequently disconnected, the electrical energy in the short contact is reduced below an arcing threshold.

Abstract: A connector assembly (2) includes and arc prevention shunt (20) in one of two mating electrical connectors (10, 30). The shunt (20) engages a terminal (34) when the connectors (10) and (20) are in a partially mated configuration. If the terminal (34) is hot, current will pass from the shunt (20) to a relay coil (62) to close contacts (64) in a Form C relay (60). When the normally open switch contacts (64) are closed a bypass circuit (52) disconnects the terminals (14, 34) in the connectors (10, 30) so arcing will not occur when the connectors (10, 30) are mated or unmated under load. When the connectors (10, 30) are in the fully mated or fully unmated, the shunt (20) is electrically isolated from the terminals (14, 34).