High voltage electrical terminal with compliant contact insert

An electrical connector assembly, comprising:

• a generally planar first terminal;
• a U-shaped retainer having a first side wall attached to terminal, a second side wall separated from and substantially parallel to the first side wall, and an end wall interconnecting the first side wall and the second side wall, wherein the terminal is arranged intermediate the first side wall and the second side wall;
• a resilient spring disposed intermediate the second side wall and the terminal and attached to the second side wall;
• a contact insert separate and distinct from the resilient spring that is disposed intermediate the spring and the terminal, the contact insert defining an array of paired negative and positive protrusions, the negative protrusions being welded directly to the terminal;
• and
• a planar mating terminal inserted into a gap between the spring and the contact insert, the spring being configured to exert a normal connection force mating terminal and establish electrical contact points between the terminal and the mating terminal through the array of paired negative and positive protrusions of the contact insert.

A method of manufacturing an electrical connector assembly, comprising:

• providing a generally planar terminal;
• attaching a U-shaped retainer to the terminal;
• arranging a resilient spring intermediate the terminal and the retainer;
• forming a contact insert from a flat sheet of material to define an array of paired negative and positive protrusions, the contact insert being separate and distinct from the resilient spring;
• welding the negative protrusions of the contact insert to the terminal;
• arranging the contact insert between the spring and the terminal;
• inserting a planar mating terminal into a gap between the spring and the contact insert;
• exerting a normal connection force provided by the spring on the array of paired negative and positive protrusions;
• and
• establishing electrical contact points between the terminal and the mating terminal through the array of paired negative and positive protrusions.