Cylindrical stamped electrical power terminal

A power terminal for an electrical connector, the terminal having an insertion axis and comprising:

• a metal sheet comprising:
• a base comprising a portion of the sheet formed around the insertion axis;
• a mounting contact coupled to the base;
• a plurality of deflectable beams extending from the base parallel to the insertion axis, wherein:
• the plurality of deflectable beams is 8 to 16 deflectable beams;
• each deflectable beam of the plurality of deflectable beams extends from the base to a cantilevered end opposite the base;
• a ratio a length of each deflectable beam to a thickness of the metal sheet is between 27:1 and 8:1;
• a ratio a length of each deflectable beam to a width of each deflectable beam is between 12:1 and 4:1;
• each deflectable beam of the plurality of deflectable beams comprises a mating contact at the cantilevered end of the deflectable beam;
• each deflectable beam of the plurality of deflectable beams comprises plating on the mating contact;
• the plurality of deflectable beams are arranged around the insertion axis;
• and
• the mating contact of each deflectable beam faces the insertion axis,
• wherein each of the plurality of deflectable beams is configured to generate a contact force of about 0.1 to 1.0 N applied to the plating on the mating contact of the deflectable beam when the terminal is mated with a radial interference between 0.1 to 0.175 mm to a complementary power terminal.

An electrical power system comprising:

• a first electrical connector comprising a first power terminal, the first terminal comprising a first stamped metal sheet formed around a first insertion axis, the first metal sheet comprising:
• a first base;
• a hollow portion comprising a portion of the first metal sheet formed around the first insertion axis;
• a first mounting contact coupled to the first base;
• a first mating contact on an exterior portion of the hollow portion,
• a second electrical connector comprising a second power terminal, the second terminal configured to mate with the first power terminal, the second terminal comprising a second metal sheet formed around a second insertion axis, the second metal sheet comprising:
• a second base comprising a portion of the second metal sheet formed around the second insertion axis;
• a second mounting contact coupled to the second base;
• a plurality of deflectable beams extending from the second base, wherein:
• each deflectable beam of the plurality of deflectable beams comprises a second mating contact;
• the plurality of deflectable beams are arranged in a circle around the second insertion axis;
• and
• the second mating contact of each deflectable beam faces the second insertion axis,
• wherein the first terminal and the second terminal have a radial interference between 0.1 to 0.175 mm when mated;
• wherein each deflectable beam of the plurality of deflectable beams of the second terminal comprises plating on the second mating contact;
• and
• wherein when the first power terminal is mated to the second power terminal, the radial interference of the first terminal and the second terminal generates, for each of the plurality of deflectable beams, a contact force of about 0.1 to 1.0 N applied to plating on the second mating contact of the deflectable beam.