High current terminal blade type sealed connection system

#The present invention relates generally to electrical connectors, more specifically a high current terminal blade connection system that is suitable for an automotive environment and is capable of handling electrical current in excess of 100 amperes continuous current, either alternating current or direct current.

#A problem frequently encountered in automotive electronics is a lack of power connection systems that are capable of handling in excess of 100 amps. Prior art connection systems that meet the required current carrying capacity are extremely expensive, bulky, and were not designed for an automotive application. Most of these connectors were intended for military applications, have too many parts, lack self-contained safety features, and are expensive and/or difficult to assemble.

#With the advent of hybrid electric vehicles, there is now a need for an electrical power connection system that is configured for an automotive environment and able to safely handle large power loads.

#The various advantages of the present invention will become apparent to one skilled in the art by reading the following specification and subjoining claims and by referencing the following drawings in which:

#FIG. 1 is a simplified perspective drawing of an embodiment of the presently claimed invention;

#FIG. 2 is a perspective drawing of the relationship of the female terminal, cable seal, and the terminal position assurance (TPA);

#In one embodiment of the presently disclosed invention, the high current terminal blade connection system 10 includes a male connector 12 and a female connector 14. In FIG. 1, a high current terminal blade connection system 10 is shown having a male connector 12 and a female connector 14 mated together in an interlocked fashion. A male connector 12 includes a male power terminal 16 with a male terminal blade 18 at the forward end of the male connector 12. Seal stop tabs 20 are visible on the location of the insulation crimp 22 of the female power terminal 32. The tabs 20 are formed to allow the cable seal 24 (See FIG. 2) to push against the terminal 32 and not slip over the insulation crimp. When the terminal position assurance [TPA] 26 is employed, FIG. 2, it pushes against the cable seal 24 and in turn pushes against the stop tabs 20 and forces the terminal 32 to seat in it's respective cavity.

#The female connector 14 in this embodiment has a U-shape female contact 31 to accommodate the male terminal blade 18 when received in the female power terminal cavity 30. The female power terminal 32 is located adjacent a forward end of the female connector 14 so that the forward ends of both the male and female connectors 12, 14 can mutually mate and the male terminal blade of the male power terminal 16 pass through the female power terminal cavity 30 and seats into the female power terminal 32 within a contact insert 34.

#FIG. 3 depicts a contact insert 34 with dimples 36. The dimples 36 are located on the contact insert 34 to provide additional support to the mating male terminal blade 18, thus enhancing the performance of the connection when the male and female connectors 12, 14 are interlocked. The benefit of this design is that the connection is firmly supported, thus reducing the tendency of the contact from rocking, which has been a factor in promoting contact corrosion. The dimples 36 also provide stability and additional contact points, which improve the electrical performance of the connection. The dimples 36 may be associated in pairs, one of each pair on either surface of the U-shaped female contact insert 34.