High current electrical connector system and methods thereof

An electrical connection system comprising:

• a first cable contact with a first mating surface and a first retaining surface;
• a second cable contact with a second mating surface and a second retaining surface;
• a first housing which defines a first passage for the first cable contact, a second passage for mating with a portion of the second cable contact, and a first opening which extends to one end of the first passage;
• a second housing which defines a third passage for the second cable contact, a fourth passage for mating with a portion of the first cable contact, and a second opening which extends to one end of the third passage, wherein a portion of the first housing with the second passage detachably mates with a portion of the second housing with the fourth passage to couple the first and second cable contacts together;
• a first retaining device mounted in the first passage, the first retaining device engaging with at least a portion of the first retaining surface of the first cable contact to detachably retain the first cable contact in the first passage;
• a second retaining device mounted in the second passage, the second retaining device engaging with at least a portion of the second retaining surface of the second cable contact to detachably retain the second cable contact in the third passage;
• a first groove formed in the first retaining surface of the first cable contact, the first opening in the first housing is in communication with the first groove;
• a second groove formed in the second retaining surface of the second cable contact, the second opening in the second housing is in communication with the second groove;
• and
• a lever system pivotally connected to the first and second housings for connecting and disconnecting the first and second housings and the first and second cable contacts.

A method for making an electric connection, the method comprising:

• inserting a first cable contact with a mating surface and a retaining surface in a first passage in a first housing, the first housing has an opening which extends to one end of the first passage and has a third passage with a portion of the first cable contact for mating with a portion of a second cable contact;
• engaging the retaining surface of the first cable contact with a first retaining device mounted in the first passage to detachably retain the first cable contact in the first passage, wherein at least one first groove is formed in the retaining surface of the first cable contact and wherein the opening in the first housing is in communication with the first groove;
• inserting the second cable contact with a mating surface and a retaining surface in a second passage in a second housing, the second housing has an opening which extends to one end of the second passage and has a fourth passage with the portion of the second cable contact for mating with the portion of the first cable contact;
• engaging the retaining surface of the second cable contact with a second retaining device mounted in the second passage to detachably retain the second cable contact in the second passage, wherein at least one second groove is formed in the retaining surface of the second cable contact and wherein the opening in the second housing is in communication with the second groove;
• and
• detachably mating the third and fourth passages of the first and second housings together to couple the first and second cable contacts together.