Traxxas v. Sanders - Complaint

Case 2:20-cv-00331-JRG Document 1 Filed 10/13/20 Page 1 of 36 PageID #: 1
IN THE UNITED STATES DISTRICT COURT

FOR THE EASTERN DISTRICT OF TEXAS
MARSHALL DIVISION
TRAXXAS, L.P., §
§
Plaintiff, §
§ Civil Action No. 2:20-cv-331
v. §
§ JURY TRIAL DEMANDED
JEREMIAH FREDERICK WILLIAM §
SANDERS dba 365 HOBBIES, §
§
Defendant. §
COMPLAINT FOR TRADEMARK INFRINGEMENT, UNFAIR COMPETITION,

DILUTION, PATENT INFRINGEMENT, AND UNJUST ENRICHMENT
COMES NOW Plaintiff Traxxas, L.P. and files this Complaint for Trademark
Infringement, Unfair Competition, Dilution, Patent Infringement, and Unjust Enrichment against
Defendant Jeremiah Frederick William Sanders dba 365 Hobbies, alleging as follows:
I. NATURE OF THE SUIT
1. This is a claim in which Plaintiff seeks injunctive and monetary relief for trademark
infringement, unfair competition, and dilution arising under the Lanham Act, 15 U.S.C. § 1051 et
seq.; for patent infringement arising under the United States patent laws, 35 U.S.C. § 101 et seq.;
for trademark dilution arising under Texas Business and Commerce Code § 16.103; and for
trademark infringement, unfair competition, and unjust enrichment arising under Texas common
law.
II. THE PARTIES
2. Plaintiff Traxxas, L.P. (“Traxxas”) is a Texas limited partnership that maintains
its principal place of business in McKinney, Texas.

3. Defendant Jeremiah Frederick William Sanders is an individual residing in
Colorado Springs, Colorado and doing business as 365 Hobbies.
III. JURISDICTION AND VENUE
4. Pursuant to 15 U.S.C. § 1121(a) and 28 U.S.C. §§ 1331 and 1338, this Court has
subject matter jurisdiction over the federal trademark infringement, dilution, and related unfair
competition claims because those claims arise under the Lanham Act, 15 U.S.C. § 1051 et seq.,
and over the patent infringement and related unfair competition claims because those claims arise
under the United States patent laws, 35 U.S.C. § 101 et seq.
5. Pursuant to 28 U.S.C. § 1367(a), this Court has subject matter jurisdiction over the
state trademark dilution, trademark infringement, unfair competition, and unjust enrichment
claims because those claims arise from the same nucleus of operative facts as the federal trademark
infringement, dilution, patent infringement, and related unfair competition claims.
6. This Court has specific personal jurisdiction over Defendant as to these claims
pursuant to due process and the Texas Long Arm Statute because these claims arise from
Defendant’s acts or omissions (directly or through intermediaries) in this judicial District,
including but not limited to sales or offers to sell the Accused Products to persons in this District
and/or purposefully and voluntarily placing the Accused Products into the stream of commerce
with the expectation that those Accused Products will be purchased by consumers in Texas and in
this District.
7. Venue is proper in this Court under 28 U.S.C. §§ 1391(b)-(d) for the reasons set
forth above. Furthermore, venue is proper because Defendant, directly or through intermediaries,
sells and offers to sell its Accused Products to persons in this District, as discussed below. Each
of Defendant’s acts complained of herein occurring in this District gives rise to proper venue.
Original Complaint Page 2

IV. BACKGROUND
A. Traxxas and Its Intellectual Property
8. The business Traxxas operates was started in 1986. Since that time, Traxxas has
grown to become the number-one seller of Ready-to-Run nitro and electric model vehicles in the
United States.
1. The Asserted Trademarks
9. Since at least September 12, 1986, Traxxas has continuously used the standard
characters “TRAXXAS” (the “TRAXXAS Mark”) in interstate commerce to identify, advertise,
and promote its radio-controlled model vehicles and parts therefor to the consuming public.
10. On February 6, 2007, the United States Patent and Trademark Office (“USPTO”)
duly and legally issued to Traxxas United States Trademark Registration No. 3,205,399 (the
“TRAXXAS Class 028 Registration”), which comprises the standard characters “TRAXXAS” as
applied to radio-controlled model vehicles and parts therefor in International Class 028. A true
and correct copy of the TRAXXAS Class 028 Registration (as updated December 19, 2017) is
attached hereto as Exhibit 1.
11. Since at least May 26, 2004, Traxxas has continuously used the TRAXXAS Mark
in interstate commerce to identify, advertise, and promote its batteries and battery chargers to the
consuming public.
12. On July 11, 2017, the USPTO duly and legally issued to Traxxas United States
Trademark Registration No. 5,242,836 (the “TRAXXAS Class 009 Registration”), which
comprises the standard characters “TRAXXAS” as applied to batteries and battery chargers in
International Class 009. A true and correct copy of the TRAXXAS Class 009 Registration is
attached hereto as Exhibit 2.

13. Traxxas’ right to use its TRAXXAS Mark has become incontestable.
14. In addition to the TRAXXAS Class 028 Registration and the TRAXXAS Class 009
Registration, Traxxas owns three other USPTO trademark registrations comprising the word
“TRAXXAS”:
a. U.S. Trademark Registration No. 2,314,111, which comprises a design plus
the word “TRAXXAS” as applied to radio-controlled model vehicles and
parts therefor sold as a unit in International Class 028;
b. U.S. Trademark Registration No. 2,292,851, which comprises stylized
characters “TRAXXAS” as applied to radio-controlled model vehicles and
parts therefor, sold as a unit in International Class 028; and
c. U.S. Trademark Registration No. 5,257,656, which comprises stylized
characters “TRAXXAS” as applied to batteries and battery chargers in
International Class 009.
15. Traxxas has also filed with the USPTO three additional pending applications for
trademarks comprising the standard characters “TRAXXAS”:
a. U.S. Trademark Application No. 88/215,688, which comprises the standard
characters “TRAXXAS” as applied to hand tools adapted for use with
model vehicles in International Class 008;
b. U.S. Trademark Application No. 88/266,147, which comprises the standard
characters “TRAXXAS” as applied to decals; stickers; banners; posters;
pens; vehicle wraps in International Class 016, lanyards in International
Class 022, and apparel, namely, hats, shirts, sweaters, hoodies, jackets,
beanies, and scarfs in International Class 025; and

c. U.S. Trademark Application No. 88/266,155, which comprises the standard
characters “TRAXXAS” as applied to phone accessories, namely, pop
sockets in International Class 009, bags; duffel bags; backpacks in
International Class 018, and cups; tumblers; beverage sleeves; desk mats in
International Class 021.
16. Since at least October 31, 1988, Traxxas has continuously used the typeset letters
or standard characters “TRX” (the “TRX Mark”) in interstate commerce to identify, advertise, and
promote its radio-controlled model vehicles and parts therefor to the consuming public.
17. On January 7, 1992, the USPTO duly and legally issued United States Trademark
Registration No. 1,671,232 (the “TRX Class 028 Registration”), which comprises the typeset
letters “TRX” as applied to radio-controlled model vehicles and parts therefor in International
Class 028. A true and correct copy of the TRX Class 028 Registration (which was assigned to
Traxxas on July 25, 2003) is attached hereto as Exhibit 3.
18. Since at least June 7, 2017, Traxxas has continuously used the TRX Mark in
interstate commerce to identify, advertise, and promote its batteries and battery connectors to the
consuming public.
19. On April 7, 2020, the USPTO duly and legally issued United States Trademark
Registration No. 6,030,294 (the “TRX Class 009 Registration”), which comprises the standard
characters “TRX” as applied to batteries and battery connectors in International Class 009. A true
and correct copy of the TRX Class 009 is attached hereto as Exhibit 4.
20. Traxxas’ right to use its TRX Mark has become incontestable.
21. In addition to the above-referenced USPTO registrations, Traxxas has registered
each of the TRAXXAS Mark and the TRX Mark internationally.

22. Traxxas has made and continues to make a substantial investment of time, effort,
and expense in the design, manufacturing, and marketing of its radio-controlled model vehicles
and parts therefor bearing each of the TRAXXAS Mark and the TRX Mark.
23. As a result of Traxxas’ long use and substantial advertising and promotion of each
of the TRAXXAS Mark and the TRX Mark, each of the TRAXXAS Mark and the TRX Mark has
become distinctive and widely known to consumers to designate Traxxas as the source of products
bearing the TRAXXAS Mark or the TRX Mark, to distinguish Traxxas and its products from those
of others, and to distinguish the source or origin of Traxxas’ products. As a result of these efforts
by Traxxas, the consuming public in Texas and throughout the United States widely recognizes
and associates each of the TRAXXAS Mark and the TRX Mark with Traxxas and with Traxxas’
high-quality goods.
24. As a result of Traxxas’ long use and substantial advertising and promotion of each
of the TRAXXAS Mark and the TRX Mark in Texas and elsewhere, Traxxas has acquired valuable
common law rights in each of the TRAXXAS Mark and the TRX Mark, including but not limited
to the goodwill and reputation of Traxxas, Traxxas’ products, and each of the TRAXXAS Mark
and the TRX Mark.
25. Each of the TRAXXAS Mark and the TRX Mark is famous pursuant to 15 U.S.C.
§ 1125(c) and Texas Business and Commerce Code § 16.103.
2. The Asserted Patents
26. A true and correct copy of United States Patent No. 7,530,855 (the “’855 Patent”),
entitled “Electrical Connector Assembly,” is attached hereto as Exhibit 5.
27. Traxxas is the current owner by assignment of all rights, title, and interest in and
under the ’855 Patent, which duly and legally issued on May 12, 2009, with Seralaathan

Hariharesan, Brock Dennison, and Jon Kenneth Lampert as the named inventors. Traxxas has
standing to sue for infringement of the ’855 Patent.
28. Since at least July 1, 2011, each and every patentee of the ’855 Patent, and each
and every person making, offering for sale, or selling within the United States, or importing into
the United States, any patented article for or under the ’855 Patent, has complied with the marking
requirements set forth in 35 U.S.C. § 287.
under the ’038 Patent, which duly and legally issued on January 11, 2011, with Seralaathan
Hariharesan, Brock Dennison, and Jon Kenneth Lampert as the named inventors. Traxxas has
under the ’323 Patent, which duly and legally issued on October 20, 2015, with Jon Kenneth
Lampert, Seralaathan Hariharesan, and Brock Dennison as the named inventors. Traxxas has

34. Since at least August 17, 2017, each and every patentee of the ’323 Patent, and each
under the ’254 Patent, which duly and legally issued on July 11, 2017, with Jon Kenneth Lampert,
Seralaathan Hariharesan, and Brock Dennison as the named inventors. Traxxas has standing to
sue for infringement of the ’254 Patent.
under the ’500 Patent, which duly and legally issued on January 8, 2019, with Jon Kenneth
Lampert, Seralaathan Hariharesan, and Brock Dennison as the named inventors. Traxxas has
40. Since at least June 2, 2020, each and every patentee of the ’500 Patent, and each

41. A true and correct copy of United States Patent No. D573,536 (the “’536 Patent”),
entitled “Electrical Connector,” is attached hereto as Exhibit 10.
under the ’536 Patent, which duly and legally issued on July 22, 2008, with Seralaathan
Hariharesan, Brock Dennison, Jon Kenneth Lampert, Michael S. Jenkins, Kent Poteet, and Jaime
Felix Barajas as the named inventors. Traxxas has standing to sue for infringement of the ’536
Patent.
44. A true and correct copy of United States Patent No. D576,557 (the “’557 Patent”),
entitled “Electrical Connector,” is attached hereto as Exhibit 11.
under the ’557 Patent, which duly and legally issued on September 9, 2008, with Seralaathan
Hariharesan, Brock Dennison, Jon Kenneth Lampert, Michael S. Jenkins, Kent Poteet, and Jaime
Felix Barajas as the named inventors. Traxxas has standing to sue for infringement of the ’557
Patent.

47. The ’855 Patent, the ’038 Patent, the ’323 Patent, the ’254 Patent, the ’500 Patent,
the ’536 Patent, and the ’557 Patent are referred to collectively herein as the “Asserted Patents.”
B. Defendant and Its Products
48. Defendant, directly or through intermediaries, sells, offers for sale, distributes, or
advertises certain connectors for batteries and other remote-controlled vehicle components
(collectively the “Accused Products”) that comprise a male or female connector that is marketed
or intended to be compatible with Traxxas Gen 1 connectors. Exemplary Accused Products are
listed on Exhibit 12 attached hereto and are generally classified therein as “Gen 1 Male
Connectors” and “Gen 1 Female Connectors.”
49. Defendant, directly or through intermediaries, makes, uses, sells, or offers for sale
the Accused Products within the United States, or imports the Accused Products into the United
States.
50. Defendant, directly or through intermediaries, sells, offers for sale, distributes, and
advertises the Accused Products in direct competition with products of Traxxas and of Traxxas’
authorized retailers.
51. Defendant, directly or through intermediaries, purposefully and voluntarily places
the Accused Products into the stream of commerce with the expectation that they will be purchased
by consumers in Texas and in this judicial District.
52. The Accused Products are purchased by consumers in Texas and in this judicial
District.

53. At least some of Defendant’s Accused Products bear one or more spurious marks
that are identical to, or substantially distinguishable from, Traxxas’ federally registered TRX
Mark.
54. Defendant is not affiliated with or sponsored by Traxxas and has not been
authorized by Traxxas to make, sell, offer for sale, distribute, or advertise any Traxxas products or
any products bearing the TRAXXAS Mark, the TRX Mark, or any confusingly similar marks.
55. Defendant, directly or through intermediaries, began selling, offering for sale,
distributing, or advertising the Accused Products after Traxxas began using in commerce each of
the TRAXXAS Mark and the TRX Mark.
distributing, or advertising the Accused Products after Traxxas obtained federal trademark
registrations for each of the TRAXXAS Mark and the TRX Mark.
distributing, or advertising the Accused Products after it became aware of one or both of the
TRAXXAS Mark and the TRX Mark.
distributing, or advertising the Accused Products after it became aware of Traxxas’ rights in and
to one or both of the TRAXXAS Mark and the TRX Mark.
59. Alternatively, Defendant, directly or through intermediaries, began selling, offering
for sale, distributing, or advertising the Accused Products after it took deliberate actions to avoid
confirming Traxxas’ rights in and to one or both of the TRAXXAS Mark and the TRX Mark.
distributing, or advertising the Accused Products after it became aware of at least a high probability

that its use in commerce of a counterfeit TRAXXAS Mark or a counterfeit TRX Mark in
connection with the Accused Products would infringe Traxxas’ rights in and to one or both of the
TRAXXAS Mark and the TRX Mark.
61. Unless Defendant’s acts complained of herein are restrained by this Court, those
acts will continue and will continue to cause irreparable injury to Traxxas and to the public for
which there is no adequate remedy at law.
V. CLAIMS
A. Federal Trademark Infringement
62. Traxxas repeats and incorporates by reference the allegations of the foregoing
paragraphs as if fully set forth herein.
63. Defendant is, without Traxxas’ consent, applying spurious marks that are identical
to, or substantially distinguishable from, Traxxas’ federally registered TRAXXAS Mark to
advertisements (including at least Internet advertisements) intended to be used in commerce in
connection with the sale, offering for sale, distribution, or advertising of at least some of the
Accused Products.
64. For example, Defendant, directly or through intermediaries, offers its Accused
Product item number 131431095020 on ebay.com, which lists that product as “Traxxas 2-Male to
1-Female Series 2.5" TRX Connector Adapter E Revo LiPO Slash,” as shown on Exhibit 13
attached hereto.
65. Defendant is, without Traxxas’ consent, using in commerce spurious marks that are
identical to, or substantially distinguishable from, Traxxas’ federally registered TRX Mark in
Accused Products.

66. For example, the Accused Product depicted below bears a mark that is identical
with, or substantially indistinguishable from, the federally registered TRX Mark:
67. Defendant is, without Traxxas’ consent, applying spurious marks that are identical
to, or substantially distinguishable from, Traxxas’ federally registered TRX Mark to
advertisements (including at least Internet advertisements) intended to be used in commerce in
Accused Products.
68. For example, Defendant, directly or through intermediaries, offers its Accused
Product item number 131431095020 on ebay.com, which lists that product as “Traxxas 2-Male to
1-Female Series 2.5" TRX Connector Adapter E Revo LiPO Slash,” as shown on Exhibit 13
attached hereto.
69. Defendant’s unauthorized use of each of the TRAXXAS Mark and the TRX Mark
is likely to cause confusion, or to cause mistake, or to deceive customers and potential customers
of the parties, or associates of such customers and potential customers, at least as to some

affiliation, connection, or association of Defendant with Traxxas, or as to the origin, sponsorship,
or approval of the Accused Products by Traxxas.
70. Defendant, knowing each spurious mark described herein to be a counterfeit mark,
intentionally uses each such spurious mark in connection with the sale, offering for sale, or
distribution of the Accused Products.
71. Defendant’s acts complained of herein constitute infringement of each of Traxxas’
federally registered TRAXXAS Mark and TRX Mark in violation of 15 U.S.C. § 1114(1)(a) and
(b).
72. Defendant’s infringement of each of Traxxas’ federally registered TRAXXAS
Mark and TRX Mark in violation of 15 U.S.C. § 1114(1)(a) and (b) as complained of herein has
been, and continues to be, willful, rendering this case exceptional under 15 U.S.C. § 1117(a).
73. Defendant’s acts complained of herein have damaged Traxxas in an amount to be
proven at trial, but no less under 15 U.S.C. § 1117 than either: (a) three times either Defendant’s
profits or Traxxas’ actual damages from Defendant’s wrongful acts, whichever amount is greater,
together with Traxxas’ reasonable attorneys’ fees and costs, or (b) statutory damages of up to
$2,000,000 per counterfeit mark per type of Accused Product sold, offered for sale, or distributed,
together with Traxxas’ reasonable attorneys’ fees and costs.
74. Further, unless Defendant’s acts complained of herein are restrained by this Court,
those acts will continue and will continue to cause irreparable injury to Traxxas and to the public
for which there is no adequate remedy at law.
B. Federal Unfair Competition

76. Defendant’s unauthorized use in commerce of each of the TRAXXAS Mark and
the TRX Mark in connection with the Accused Products falsely designates the origin of the
Accused Products, or otherwise falsely or misleadingly describes or represents facts, which is
likely to cause confusion, or to cause mistake, or to deceive customers and potential customers of
the parties, or associates of such customers and potential customers, at least as to some affiliation,
connection, or association of Defendant with Traxxas, or as to the origin, sponsorship, or approval
of the Accused Products by Traxxas.
distributing, or advertising the Accused Products after it became aware of the goodwill and
reputation of Traxxas, Traxxas’ products, and one or both of the TRAXXAS Mark and the TRX
Mark.
78. At the time Defendant, directly or through intermediaries, began selling, offering
for sale, distributing, or advertising the Accused Products, Defendant intended to trade off of and
to take unfair advantage of the goodwill and reputation of Traxxas, Traxxas’ products, and one or
both of the TRAXXAS Mark and the TRX Mark.
the TRX Mark in connection with the Accused Products enables Defendant to trade on and receive
the benefit of the goodwill and reputation built up at great labor and expense by Traxxas over many
years, and to gain acceptance for the Accused Products not solely on their own merits, but on the
reputation and goodwill of Traxxas, Traxxas’ products, and each of the TRAXXAS Mark and the
TRX Mark.
80. Defendant’s acts complained of herein constitute unfair competition in violation of
15 U.S.C. § 1125(a).

81. Defendant’s unfair competition in violation of 15 U.S.C. § 1125(a) as complained
of herein has been, and continues to be, willful, rendering this case exceptional under 15 U.S.C.
§ 1117(a).
proven at trial, but no less under 15 U.S.C. § 1117 than up to three times either Defendant’s profits
or Traxxas’ actual damages from Defendant’s wrongful acts, whichever amount is greater, together
with Traxxas’ reasonable attorneys’ fees and costs.
C. Federal Trademark Dilution
distributing, or advertising the Accused Products after one or both of the TRAXXAS Mark and
the TRX Mark became famous and distinctive.
the TRX Mark in connection with the Accused Products removes from Traxxas the ability to
control the nature and quality of products provided under each of the TRAXXAS Mark and the
TRX Mark and places the valuable goodwill and reputation of Traxxas, Traxxas’ products, and
each of the TRAXXAS Mark and the TRX Mark in the hands of Defendant, over whom Traxxas
has no control.

the TRX Mark in connection with the Accused Products is likely to cause dilution by blurring or
dilution by tarnishment of one or both of the famous and distinctive TRAXXAS Mark and TRX
Mark.
88. Defendant’s acts complained of herein constitute dilution of one or both of Traxxas’
famous and distinctive TRAXXAS Mark and TRX Mark in violation of 15 U.S.C. § 1125(c).
89. Defendant’s dilution of one or both of Traxxas’ famous and distinctive TRAXXAS
Mark and TRX Mark in violation of 15 U.S.C. § 1125(c) as complained of herein has been, and
continues to be, willful, rendering this case exceptional under 15 U.S.C. § 1117(a).
proven at trial, but no less under 15 U.S.C. § 1117 than up to three times either Defendant’s profits
or Traxxas’ actual damages from Defendant’s wrongful acts, whichever amount is greater, together
with Traxxas’ reasonable attorneys’ fees and costs.
D. Patent Infringement
1. The ’855 Patent
93. At least Defendant’s Gen 1 Male Connectors are covered by at least claim 11 of the
’855 Patent.

94. Defendant has directly infringed and continues to infringe at least claim 11 of the
’855 Patent in violation of 35 U.S.C. § 271(a) by, directly or through intermediaries and without
Traxxas’ authority, making, using, selling, or offering to sell at least its Gen 1 Male Connectors in
the United States, or importing at least its Gen 1 Male Connectors into the United States.
95. Further and in the alternative, at least since the filing and service of this Complaint,
Defendant has been and now is actively inducing infringement of at least claim 11 of the ’855
Patent in violation of 35 U.S.C. § 271(b). Users of at least the Gen 1 Male Connectors directly
infringe at least claim 11 of the ’855 Patent when they use those connectors in the ordinary,
customary, and intended way. Defendant’s inducements include, without limitation and with
specific intent to encourage the infringement, knowingly inducing consumers to use the Gen 1
Male Connectors within the United States in the ordinary, customary, and intended way by,
directly or through intermediaries, supplying those connectors to consumers within the United
States and promoting (for example, in online marketing) the ordinary, customary, and intended use
of those connectors as substitutes for Traxxas’ genuine, patented connectors, which use Defendant
knows or should know infringes at least claim 11 of the ’855 Patent.
Defendant has been and now is actively contributing to infringement of at least claim 11 of the
’855 Patent in violation of 35 U.S.C. § 271(c). Defendant installs, configures, and sells at least its
Gen 1 Male Connectors with distinct components, including but not limited to male battery
connectors, that are especially made or especially adapted to practice the invention claimed in at
least claim 11 of the ’855 Patent. Each male battery connector within at least the Gen 1 Male
Connectors constitutes a material part of the claimed invention recited in at least claim 11 of the
’855 Patent and not a staple article or commodity of commerce because it is specifically configured

according to at least claim 11 of the ’855 Patent. Defendant’s contributions include, without
limitation, making, offering to sell, and/or selling within the United States, and/or importing into
the United States, its Gen 1 Male Connectors, which include a male battery connector, knowing
the male battery connector to be especially made or especially adapted for use in an infringement
of at least claim 11 of the ’855 Patent, and not a staple article or commodity of commerce suitable
for substantial noninfringing use.
97. At least Defendant’s Gen 1 Female Connectors are covered by at least claim 1 of
the ’855 Patent.
Traxxas’ authority, making, using, selling, or offering to sell at least its Gen 1 Female Connectors
in the United States, or importing at least its Gen 1 Female Connectors into the United States.
Defendant has been and now is actively inducing infringement of at least claim 1 of the ’855 Patent
in violation of 35 U.S.C. § 271(b). Users of at least the Gen 1 Female Connectors directly infringe
at least claim 1 of the ’855 Patent when they use those connectors in the ordinary, customary, and
intended way. Defendant’s inducements include, without limitation and with specific intent to
encourage the infringement, knowingly inducing consumers to use the Gen 1 Female Connectors
within the United States in the ordinary, customary, and intended way by, directly or through
intermediaries, supplying those connectors to consumers within the United States and promoting
(for example, in online marketing) the ordinary, customary, and intended use of those connectors
as substitutes for Traxxas’ genuine, patented connectors, which use Defendant knows or should
know infringes at least claim 1 of the ’855 Patent.

Defendant has been and now is actively contributing to infringement of at least claim 1 of the ’855
Patent in violation of 35 U.S.C. § 271(c). Defendant installs, configures, and sells at least its Gen
1 Female Connectors with distinct components, including but not limited to female battery
least claim 1 of the ’855 Patent. Each female battery connector within at least the Gen 1 Female
the United States, its Gen 1 Female Connectors, which include a female battery connector,
knowing the female battery connector to be especially made or especially adapted for use in an
infringement of at least claim 1 of the ’855 Patent, and not a staple article or commodity of
commerce suitable for substantial noninfringing use.
101. Defendant’s infringement of the ’855 Patent has been and continues to be willful
and deliberate.
proven at trial, but no less than up to three times the amount of a reasonable royalty under 35
U.S.C. § 284, together with Traxxas’ reasonable attorneys’ fees and costs under 35 U.S.C. § 285.

105. At least Defendant’s Gen 1 Male Connectors are covered by at least claim 1 of the
’038 Patent.
in violation of 35 U.S.C. § 271(b). Users of at least the Gen 1 Male Connectors directly infringe
encourage the infringement, knowingly inducing consumers to use the Gen 1 Male Connectors

1 Male Connectors with distinct components, including but not limited to male battery connectors,
that are especially made or especially adapted to practice the invention claimed in at least claim 1
of the ’038 Patent. Each male battery connector within at least the Gen 1 Male Connectors
constitutes a material part of the claimed invention recited in at least claim 1 of the ’038 Patent
and not a staple article or commodity of commerce because it is specifically configured according
to at least claim 1 of the ’038 Patent. Defendant’s contributions include, without limitation,
making, offering to sell, and/or selling within the United States, and/or importing into the United
States, its Gen 1 Male Connectors, which include a male battery connector, knowing the male
battery connector to be especially made or especially adapted for use in an infringement of at least
claim 1 of the ’038 Patent, and not a staple article or commodity of commerce suitable for
substantial noninfringing use.
the ’038 Patent.
Defendant has been and now is actively inducing infringement of at least claim 20 of the ’038
Patent in violation of 35 U.S.C. § 271(b). Users of at least the Gen 1 Female Connectors directly
infringe at least claim 20 of the ’038 Patent when they use those connectors in the ordinary,
customary, and intended way. Defendant’s inducements include, without limitation and with
specific intent to encourage the infringement, knowingly inducing consumers to use the Gen 1

Female Connectors within the United States in the ordinary, customary, and intended way by,
directly or through intermediaries, supplying those connectors to consumers within the United
States and promoting (for example, in online marketing) the ordinary, customary, and intended use
of those connectors as substitutes for Traxxas’ genuine, patented connectors, which use Defendant
knows or should know infringes at least claim 20 of the ’038 Patent.
Defendant has been and now is actively contributing to infringement of at least claim 20 of the
’038 Patent in violation of 35 U.S.C. § 271(c). Defendant installs, configures, and sells at least its
Gen 1 Female Connectors with distinct components, including but not limited to female battery
and deliberate.

the ’323 Patent.

and deliberate.

the ’254 Patent.

and deliberate.

the ’500 Patent.

and deliberate.
140. At least Defendant’s Gen 1 Male Connectors are covered by the claim of the ’536
Patent.

141. An ordinary observer comparing the design claimed by the ’536 Patent to the design
of at least Defendant’s Gen 1 Male Connector component depicted below in the context of the
prior art would think that the two designs are substantially the same:
’536 Patent Gen 1 Male Connector
142. Defendant has directly infringed and continues to infringe at least the claim of the
and deliberate.
proven at trial, but no less than Defendant’s profits under 35 U.S.C. § 289, together with Traxxas’
reasonable attorneys’ fees and costs under 35 U.S.C. § 285.

147. At least Defendant’s Gen 1 Female Connectors are covered by the claim of the ’557
Patent.
148. An ordinary observer comparing the design claimed by the ’557 Patent to the design
of at least Defendant’s Gen 1 Female Connector component depicted below in the context of the
prior art would think that the two designs are substantially the same:
’557 Patent Gen 1 Female Connector
149. Defendant has directly infringed and continues to infringe at least the claim of the
and deliberate.
proven at trial, but no less than Defendant’s profits under 35 U.S.C. § 289, together with Traxxas’
reasonable attorneys’ fees and costs under 35 U.S.C. § 285.

E. Texas Trademark Dilution
154. Defendant’s acts complained of herein constitute dilution of one or both of Traxxas’
famous and distinctive TRAXXAS Mark and TRX Mark in violation of Texas Business and
Commerce Code § 16.103.
F. Texas Trademark Infringement
156. Defendant’s acts complained of herein constitute trademark infringement in
violation of Texas state common law.
G. Texas Unfair Competition
158. Defendant’s acts complained of herein constitute unfair competition in violation of
Texas state common law.
H. Texas Unjust Enrichment
160. Defendant’s acts complained of herein unjustly enrich Defendant at Traxxas’
expense because Defendant, through its acts complained of herein, has obtained and continues to
obtain a benefit from Traxxas by taking unfair advantage of the goodwill and reputation of
Traxxas, Traxxas’ products, and each of the TRAXXAS Mark and the TRX Mark.

161. Specifically, Defendant has taken unfair advantage of Traxxas by trading on and
profiting from the goodwill and reputation of Traxxas, Traxxas’ products, and each of the
TRAXXAS Mark and the TRX Mark, all of which were developed and are owned by Traxxas,
resulting in Defendant wrongfully obtaining a monetary and reputational benefit for its own
business and products.
162. Defendant’s acts complained of herein constitute unjust enrichment of Defendant
at Traxxas’ expense in violation of Texas state common law.
VI. DAMAGES
proven at trial.
165. Defendant’s acts complained of herein have been deliberate, willful, intentional, or
in bad faith, with intent to trade on or harm Traxxas’ goodwill and reputation. In view of the
egregious nature of Defendant’s acts, this is an exceptional case within the meaning of 15 U.S.C.
§ 1117(a) and 35 U.S.C. § 285.
VII. PRAYER FOR RELIEF
Traxxas respectfully requests the following relief:
a. A judgment and order in favor of Traxxas that Defendant has infringed each of the
TRAXXAS Mark and the TRX Mark under federal and Texas state law, as described herein;
b. A judgment and order in favor of Traxxas that Defendant has unfairly competed
with Traxxas under federal and Texas state law, as described herein;

c. A judgment and order in favor of Traxxas that Defendant has diluted one or both
of Traxxas’ famous TRAXXAS Mark and TRX Mark under federal and Texas state law, as
described herein;
d. A judgment and order in favor of Traxxas that Defendant has been unjustly enriched
at Traxxas’ expense under Texas state law, as described herein;
e. A judgment and order in favor of Traxxas that Defendant has infringed each of the
Asserted Patents, whether literally or under the doctrine of equivalents, as described herein;
f. A judgment and order in favor of Traxxas that Defendant’s infringement and
conduct have been willful and deliberate;
g. A judgment and order in favor of Traxxas that this case is exceptional under 15
U.S.C. § 1117(a) and 35 U.S.C. § 285;
h. A permanent injunction:
(1) enjoining Defendant, its officers, directors, agents, subsidiaries, employees,
successors, and assigns, and all persons acting in privity, concert, or
participation with it, from using the TRAXXAS Mark, the TRX Mark, or
any other mark or design that is confusingly similar to or likely to cause
dilution of the TRAXXAS Mark or the TRX Mark, and from any attempt
to retain any part of the goodwill and reputation misappropriated from
Traxxas;
(2) enjoining Defendant, its officers, directors, agents, subsidiaries, employees,
participation with it, from making, using, selling, or offering for sale in the
United States, or importing into the United States, any products that directly

infringe, induce infringement of, or contribute to infringement of the
inventions claimed in the Asserted Patents;
(3) requiring Defendant, its officers, directors, agents, subsidiaries, employees,
participation with it, to deliver up and destroy all Accused Products, as well
as all signage, advertisements, commercials, Internet postings and
advertisements, and any other material bearing or using the TRAXXAS
Mark, the TRX Mark, or any other mark or design that is confusingly similar
to or likely to cause dilution of the TRAXXAS Mark or the TRX Mark; and
(4) requiring Defendant to file with this Court and to serve upon Traxxas,
within thirty days after the entry and service on Defendant of the injunction,
a report in writing and under oath setting forth in detail the manner and form
in which Defendant has complied with the injunction;
i. A judgment and order directing an accounting to determine Defendant’s profits
resulting from the activities complained of herein, including Defendant’s profits from any
continuing post-verdict or post-judgment activities, and that such profits, or, alternatively,
Traxxas’ actual damages, be paid over to Traxxas, increased as the Court finds to be just under the
circumstances of this case;
j. A judgment and order requiring Defendant to pay Traxxas its damages sustained as
a result of Defendant’s activities described herein, including supplemental damages for any
continuing post-verdict or post-judgment activities with an accounting as needed, and that such
damages be trebled;

k. A judgment and order requiring Defendant to pay Traxxas its costs, expenses, and
pre-judgment and post-judgment interest;
l. A judgment and order requiring Defendant to pay Traxxas its reasonable attorneys’
fees; and
m. Such other and further relief as the Court deems just and proper.
VIII. JURY DEMAND
Pursuant to Federal Rule of Civil Procedure 38(b), Traxxas requests a jury trial of all issues
triable of right by a jury.
Dated: October 13, 2020 Respectfully submitted,
By: /s/ William E. Davis, III

William E. Davis, III
Texas State Bar No. 24047416
bdavis@bdavisfirm.com
Debra Coleman (Of Counsel)
Texas State Bar No. 24059595
dcoleman@bdavisfirm.com
The Davis Firm, PC
213 N. Fredonia Street, Suite 230
Longview, Texas 75601
Telephone: (903) 230-9090
Facsimile: (903) 230-9661
Counsel for Plaintiff Traxxas, L.P.

Case 2:20-cv-00331-JRG Document 1-1 Filed 10/13/20 Page 1 of 3 PageID #: 37
EXHIBIT 1
TRAXXAS
Reg. No. 3,205,399 Traxxas, L.P. (TEXAS LIMITED PARTNERSHIP)
6250 Traxxas Way
Registered Feb. 06, 2007 Mckinney, TEXAS 75070
CLASS 28: Radio-controlled model vehicles and parts therefor

Corrected Dec. 19, 2017
FIRST USE 7-10-1986; IN COMMERCE 9-12-1986
Int. Cl.: 28
THE MARK CONSISTS OF STANDARD CHARACTERS WITHOUT CLAIM TO ANY
Trademark PARTICULAR FONT STYLE, SIZE OR COLOR
Principal Register SER. NO. 78-746,636, FILED 11-03-2005
?IP s"f h. 'h," ,ft, I

Perform ng t~ F"unct ons nd Outl s of the
Und r Secrc:1a,y of Commerce for
lntellc:ctu,11 Property and O."ctor of the
United States Patent ,id Tr demar Office
REQUIREMENTS TO MAINTAIN YOUR FEDERAL TRADEMARK REGISTRATION
WARNING: YOUR REGISTRATION WILL BE CANCELLED IF YOU DO NOT FILE THE

DOCUMENTS BELOW DURING THE SPECIFIED TIME PERIODS.
Requirements in the First Ten Years*

What and When to File:
• First Filing Deadline: You must file a Declaration of Use (or Excusable Nonuse) between the 5th and 6th
years after the registration date. See 15 U.S.C. §§1058, 1141k. If the declaration is accepted, the
registration will continue in force for the remainder of the ten-year period, calculated from the registration
date, unless cancelled by an order of the Commissioner for Trademarks or a federal court.
• Second Filing Deadline: You must file a Declaration of Use (or Excusable Nonuse) and an Application
for Renewal between the 9th and 10th years after the registration date.* See 15 U.S.C. §1059.
Requirements in Successive Ten-Year Periods*

• You must file a Declaration of Use (or Excusable Nonuse) and an Application for Renewal
between every 9th and 10th-year period, calculated from the registration date.*
Grace Period Filings*
The above documents will be accepted as timely if filed within six months after the deadlines listed above with
the payment of an additional fee.
*ATTENTION MADRID PROTOCOL REGISTRANTS: The holder of an international registration with an

extension of protection to the United States under the Madrid Protocol must timely file the Declarations of Use
(or Excusable Nonuse) referenced above directly with the United States Patent and Trademark Office (USPTO).
The time periods for filing are based on the U.S. registration date (not the international registration date). The
deadlines and grace periods for the Declarations of Use (or Excusable Nonuse) are identical to those for
nationally issued registrations. See 15 U.S.C. §§1058, 1141k. However, owners of international registrations
do not file renewal applications at the USPTO. Instead, the holder must file a renewal of the underlying
international registration at the International Bureau of the World Intellectual Property Organization, under
Article 7 of the Madrid Protocol, before the expiration of each ten-year term of protection, calculated from the
date of the international registration. See 15 U.S.C. §1141j. For more information and renewal forms for the
international registration, see http://www.wipo.int/madrid/en/.
NOTE: Fees and requirements for maintaining registrations are subject to change. Please check the
USPTO website for further information. With the exception of renewal applications for registered
extensions of protection, you can file the registration maintenance documents referenced above online at h
ttp://www.uspto.gov.
NOTE: A courtesy e-mail reminder of USPTO maintenance filing deadlines will be sent to trademark
owners/holders who authorize e-mail communication and maintain a current e-mail address with the
USPTO. To ensure that e-mail is authorized and your address is current, please use the Trademark
Electronic Application System (TEAS) Correspondence Address and Change of Owner Address Forms
available at http://www.uspto.gov.
Page: 2 of 2 / RN # 3205399
EXHIBIT 2
TRAXXAS
6250 Traxxas Way
Registered Jul. 11, 2017 McKinney, TX 75070
CLASS 9: Batteries and battery chargers

Int. Cl.: 9
Trademark
Principal Register PARTICULAR FONT STYLE, SIZE OR COLOR
SER. NO. 87-096,279, FILED 07-07-2016

ELLEN AWRICH, EXAMINING ATTORNEY
?IP s"f h. 'h," ,ft, I

Perform ng t~ F"unct ons nd Outl s of the
Und r Secrc:1a,y of Commerce for
lntellc:ctu,11 Property and O."ctor of the
United States Patent ,id Tr demar Office




Page: 2 of 2 / RN # 5242836
EXHIBIT 3
Int. Cl.: 28
Prior U.S. Cl.: 22
. , Reg. No. 1,671,232
_United States Patent and Trademark Office Registered Jan. 7, 1992
TRADE MARK
PRINCIP AL REGISTER
TRX
FIRST USE 8-23-1988; IN COMMERC E

TRAXXAS CORPORATJOJ',; (TEXAS CORPORA-
TION) 10-31-1988.
12150 SHILON ROAD
DALLAS, TX 75228
SER. NO. 74-039,613, FILED 3-19-1990.
FOR: RADJO-CO NTROLLED MODEL VEHI-

CLES AND PARTS THEREFOR , IN CLASS 28 ELIZABET H A. DUNN, EXAMININ G ATTOR-
(U.S. CL. 22). NEY
EXHIBIT 4
TRX
6250 Traxxas Way
Registered Apr. 07, 2020 Mckinney, TEXAS 75070
CLASS 9: Batteries and battery connectors

Int. Cl.: 9
Trademark
Principal Register PARTICULAR FONT STYLE, SIZE OR COLOR
SER. NO. 88-262,483, FILED 01-15-2019
Director of the United States

Patent and Trademark Office




Page: 2 of 2 / RN # 6030294
EXHIBIT 5
I 1111111111111111 11111 1111111111 1111111111 111111111111111 lll111111111111111
US007530855B2
c12) United States Patent (10) Patent No.: US 7,530,855 B2

Hariharesan et al. (45) Date of Patent: *May 12, 2009
(54) ELECTRICAL CONNECTOR ASSEMBLY 3,091,746 A 5/1963 Winkler

3,145,067 A 8/1964 Mishelevich et al.
(75) Inventors: Seralaathan Hariharesan, Flower 3,218,599 A 11/1965 Winkler
Mound, TX (US); Brock Dennison, 3,233,211 A 2/1966 Smith
3,259,870 A 7/1966 Winkler
Lewisville, TX (US); Jon Kenneth
3,273,105 A 9/1966 Klassen
Lampert, Garland, TX (US)
4,018,497 A 4/1977 Bulanchuk
(73) Assignee: Traxxas LP, Plano, TX (US) (Continued)
( *) Notice: Subject to any disclaimer, the term ofthis FOREIGN PATENT DOCUMENTS
patent is extended or adjusted under 35 DE 704 450 3/1941
U.S.C. 154(b) by O days.
(Continued)
This patent is subject to a terminal dis-
OTHER PUBLICATIONS
claimer.
Clarke, Brooke; "Power Pole" web page article; Brooke Clarke,
(21) Appl. No.: 11/951,754 Ukiah CA, U.S.A., 2003-2006.
(Continued)
(22) Filed: Dec. 6, 2007
Primary Examiner-Neil Abrams
(65) Prior Publication Data Assistant Examiner-Phuong Nguyen
US 2008/0261460Al Oct. 23, 2008 (74) Attorney, Agent, or Firm-Carr LLP
Related U.S. Application Data (57) ABSTRACT
(63) Continuation of application No. 11/736,460, filed on An electrical connector is provided comprising a female
Apr. 17, 2007. member and a male member configured such that the female
member is inhibited from being electrically coupled to the
(51) Int. Cl. male member if the electrical coupling would reverse the
HOJR 13/64 (2006.01) polarity of the electrical connector. The female member may
(52) U.S. Cl. ....................................... 439/679; 439/823 comprise a first and second chamber. The male member may
(58) Field of Classification Search ................. 439/680, comprise a first and second extension. The first and second
439/282,296,284,679,691, 693,823 chambers may be configured to insertably accommodate the
See application file for complete search history. first and second extensions. The female member may com-
prise one or more resilient members providing a pressing
(56) References Cited force to bias at least a portion of a male electrode against at
U.S. PATENT DOCUMENTS least a portion of a corresponding female electrode. Alterna-
tively, the cover of the male electrode in the first and second
2,121,338 A 6/1938 Chirelstein extensions may comprise a resilient member.
2,203,122 A 6/ 1940 Anderson
2,838,739 A 6/1958 Winkler 12 Claims, 11 Drawing Sheets
1000
~
US 7,530,855 B2
Page 2
U.S. PATENT DOCUMENTS Anderson Power Products; "SBS 50 Connector" data sheet; Ander-
son Power Products, Sterling, MA. U.S.A. (admitted prior art).
4,083,617 A * 4/ 1978 Wyatt ......................... 439/295 Horizon Hobby; "E-flite EC3 Device & Battery Connector, Male-
4,342,498 A 8/ 1982 Patton et al. Female" web page; Horizon Hobby, Inc., Champaign, IL, U.S.A.
4,630,876 A * 12/1986 Grunberg et al ............. 439/293 2006.
4,846,729 A * 7/1989 Hikami et al ............... 439/161
Tyco Electronics, "Hot Plug, High Current Dual Crown Clip Socket
4,990,099 A * 2/ 1991 Marin et al. ................ 439/284
Connector" ELCON Products International Co., Fremont, CA U.S.
5,533,915 A 7/1996 Deans
A. 2000-2001.
5,575,674 A 11/1996 Davis et al.
6,268,564 Bl 7/2001 Miyakoshi McMaster-Carr; "Quick-Disconnect Terminals" catalog p. 724;
6,488,546 B2 12/2002 Sakurai et al. McMaster-Carr Supply Co. (admitted prior art).
6,619,995 Bl 9/2003 Hayashi et al. Molex; "Standard .093" web pages; Molex, Lisle IL U.S.A. (admit-
6,619,996 B2 9/2003 Hara et al. ted prior art).
6,623,309 B2 9/2003 Sakurai et al. Hyperphysics, "Household Wiring-Polarized Receptacles" web
6,645,003 B2 11/2003 Yoshida et al. page article; http://hyperphysics.phy-astr.gsu.edu/hbase/electric/
7,004,795 B2 2/2006 Mancini et al. hsehld.htrnl (admitted prior art).
Traxxas; "REVO transmission" illustration (1 page); Traxxas LP,
FOREIGN PATENT DOCUMENTS
Plano TX U.S.A. (admitted prior art).
EP 0 318 831 A2 6/1989 Deans; "Ultra Plug" photographs (3 pages); Wm. F. Deans, Para-
FR 1036107 9/1953 mount CA U.S.A. (admitted prior art).
Molex; "Standard .093" connector photographs (7 pages); Molex,
OTHER PUBLICATIONS Lisle IL U.S.A. (admitted prior art).
Anderson Power Products; "PP15 Powerpole Connector" data sheet; "Standard ll 0V electrical plugs and receptacles" photographs ( 5
Anderson Power Products, Sterling, MA U.S.A. (admitted prior art). pages) (admitted prior art).
Anderson Power Products, "SB Connector Family" data sheet; Barajas, Jaime; "Styling Input from Jaime", Traxxas LP, Plano TX
Anderson Power Products, Sterling, MA, U.S.A. (admitted prior art). U.S.A. (confidential internal document, Jan. 23, 2007).
Anderson Power Products; "SB 50 Connector" data sheet; Anderson
Power Products, Sterling, MA, U.S.A. (admitted prior art). * cited by examiner
U.S. Patent May 12, 2009 Sheet 1 of 11 US 7,530,855 B2
1000
FIG.1
1000
500 FIG. 2
100 111
~ 121
FIG. 3A
100
102
,I
200
FIG.3B
100
,I
112C
200
FIG.3C
208 214
200~
□ 210
206
204
FIG. 4A
212A")___ ,r-214 /"210

200~ -11---K-~--'---------.10
) 212sf
"-208
FIG.4B
608 612
600~
610
604
FIG. 7A
612A")_
600
~ 1.1. . ._ _____._I.._I---.-,,,.------.-----LI
612BJ'"" \...514 "-610
FIG. 7B
300
324
FIG. SA
300
~
R
312A
324
FIG. SB
500 516
FIG. 6A
500
~ 502
FIG. 6B
111
1000
511
FIG. 8A
111
1000
FIG.BB
1000
~ W1 W2
516 526
214
600 600
FIG. 9A
1000
~ W2-W1 - -
FIG. 9B
ten t 55 B 2
D.S. Pa Sheet 9
Of JJ
U s 7,5
30,8
FIG. I O
2000
2310
2324
2322
2320
3000
,J
FIG.12
1500
~ W2
1520~
1650
D
138 138
L 1600
_J
1510.....,.
W1
FIG.13A
1500
1650
FIG.13B
US 7,530,855 B2
1 2
ELECTRICAL CONNECTOR ASSEMBLY FIG. 6A illustrates an orthogonal top view of a male mem-
ber;
CROSS-REFERENCE TO RELATED FIG. 6B illustrates a cross-sectional side view of the male
APPLICATIONS member of FIG. 6A;
FIG. 7A illustrates a top view of a male terminal;
This application is a continuation of, and claims the benefit FIG. 7B illustrates a side view of the male terminal of FIG.
of the filing date of, co-pending U.S. patent application Ser. 7A;
No. 11/736,460 entitled ELECTRICAL CONNECTOR FIG. SA illustrates an orthogonal top view of the electrical
ASSEMBLY, filedApr. 17, 2007. connector of FIG. 1 correctly assembled;
10 FIG. SB illustrates an orthogonal top view of the electrical
BACKGROUND OF THE INVENTION connector of FIG. 1 incorrectly assembled;
FIG. 9A illustrates a cross-sectional view of the correctly
1. Field of the Invention
assembled electrical connector of FIG. SA as viewed along
The present invention generally relates to electrical con- line 9A-9A;
nectors and, more particularly, to high current electrical con- 15
FIG. 9B illustrates a cross-sectional view of the incorrectly
nectars with protection against reverse polarity connections.
assembled electrical connector of FIG. SB as viewed along
2. Description of the Related Art
line 9B-9B;
A wide variety of electronic devices are powered through
FIG. 10 illustrates an orthogonal cross-sectional view of
the use of battery packs. For example, remotely controlled
the assembled electrical connector of FIG. 1;
vehicles of all types may have an on-board rechargeable
battery pack supplying stored electricity to an electric motor.
2
° FIG. 11 illustrates an orthogonal cross-sectional top view
of another embodiment of an electrical connector configured
In some of these lightweight vehicles, racing creates a
according to aspects of the present invention;
demand for more powerful motors along with increasing
levels of current capacity to energize the motors. As a battery FIG. 12 illustrates an orthogonal cross-sectional top view
pack is drained of the stored energy contained therein, a user of another embodiment of an electrical connector configured
25
must be able to easily exchange a depleted battery pack for a according to aspects of the present invention;
fully charged one. The depleted battery pack is then con- FIG. 13A illustrates a top view of another embodiment of
nected to a battery charger in order to be ready for the next a component of an electrical connector configured according
exchange. Consequently, there exists a need for a high current to aspects of the present invention; and
electrical connector with a lightweight and compact design. 30 FIG. 13B illustrates an orthogonal cross-sectional top view
of the component of FIG. 13A as viewed along line 13B-13B.
SUMMARY OF THE INVENTION
DETAILED DESCRIPTION
An embodiment of the present invention provides an elec-
trical connector comprising a housing forming a female 35 In the following discussion, numerous specific details are
receptacle for a male connector electrode. In addition, the set forth to provide a thorough understanding of the present
electrical connector may comprise a female electrode that invention. However, those skilled in the art will appreciate
may be at least partially secured against movement within the that the present invention may be practiced without such
female receptacle. A resilient member secured to the housing specific details. In other instances, well-known elements have
may be provided for urging a male connector electrode 40 been illustrated in schematic or block diagram form in order
toward the female electrode. not to obscure the present invention in unnecessary detail.
Additionally, for the most part, details concerning well
BRIEF DESCRIPTION OF THE DRAWINGS known features and elements have been omitted inasmuch as
such details are not considered necessary to obtain a complete
For a more complete understanding of the present inven- 45 understanding of the present invention, and are considered to
tion and the advantages thereof, reference is now made to the be within the understanding of persons of ordinary skill in the
following Detailed Description taken in conjunction with the relevant art.
accompanying drawings, in which: Turning now to the drawings, FIG. 1 shows a top orthogo-
FIG. 1 illustrates a general orthogonal top view of an nal view of an assembled electrical connector with attached
embodiment of an electrical connector configured according 50 wire conductors. In this drawing, reference numeral 1000
to the present invention and showing attached wire conduc- generally indicates an illustrative embodiment of an electrical
tors; connector 1000 at least partially configured according to the
FIG. 2 illustrates an exploded assembly view of the elec- present invention. The electrical connector 1000 may com-
trical connector of FIG. 1; prise a female member 100 and a male member 500. Attached
FIG. 3A illustrates an orthogonal top view of a female 55 to the electrical connector 1000 are wire conductors l0A,
member of the electrical connector of FIG. 1; 1 OB, 20A, and 20B. The wire conductors 1 0A, 1 OB, 20A, and
FIG. 3B illustrates a cross-sectional view of the female 20B, may not considered as components of the electrical
member of FIG. 3A as viewed along line 3B-3B; connector 1000 and are shown for the purposes of illustration.
FIG. 3C illustrates a cross-sectional view of the female Wire conductors l0A and l0B may carry a positive current
member of FIG. 3A as viewed along line 3C-3C; 60 flow and wire conductors 20A and 20B may carry a negative
FIG. 4A illustrates a top view of a female terminal; current flow. The various components of the electrical con-
FIG. 4B illustrates a side view of the female terminal of nector 1000 will be described in more detail in the following
FIG. 4A; illustrative embodiment.
FIG. SA illustrates an orthogonal top view of a resilient Referring to FIG. 2, the components of an embodiment of
member; 65 the electrical connector 1000 are shown in an exploded
FIG. SB illustrates a side view of the resilient member of assembly view. The female member 100 may comprise a
FIG. SA; female housing 102, a first and second female terminal 200,
US 7,530,855 B2
3 4
and a first and second resilient member 300. The male mem- An end of the female conductor housing 104 opposing the
ber 500 may comprise a male housing 502, and a first and female internal wall 105 may be open to provide access for a
second male terminal 600. conductor (not shown) to contact an exposed end of a female
terminal 200. In other embodiments, an end or side of the
Female Member
5 female conductor housing 104 adjacent to the female internal
Turning now to FIGS. 3A, 3B, and 3C, the female member
wall 105 may be open to provide conductor access. In the
100 may comprise a female housing 102, a first female ter-
embodiment shown, the female conductor housing 104 sub-
minal chamber 110, a second female terminal chamber 120,
stantially shrouds and insulates the ends of the female termi-
female terminals 200, and resilient members 300 (more
nals 200 from each other. In certain other embodiments the
clearly shown in FIG. 2). A first female polarity indicator 111
1o female conductor housing 104 may only partially surround an
and a second female polarity indicator 121 may indicate the
end of a female terminal 200 in each of the first and second
respective polarities of the first female terminal chamber 110
female terminal chambers 110 and 120.
and the second female terminal chamber 120. A first orifice
The female terminal housing 106 portions of each of the
116 and a second orifice 126 may be located at an end of the
first and second female terminal chambers 110 and 120 may
female member 100 opposite to the first and second female
15 comprise a female terminal support 107 and a resilient mem-
polarity indicators 111 and 121. An example of a resilient
ber support 109 (FIG. 3C). Each of the female terminal sup-
member 300 is shown in FIGS. 3B and 3C. A resilient mem-
ports 107 may help to retain a corresponding female terminal
ber 300 may be located in each of the first and second female
200 in the respective first and second female terminal cham-
terminal chambers 110 and 120 (however, only one is shown
bers 110 and 120. The female terminal support 107 may
in the FIGS. 3B and 3C for the purposes of illustration). The
20 comprise one or more retention members 112 (for example as
various components of the female member 100 will be
represented by 112A) configured to retain a female terminal
described in more detail in the following illustrative embodi-
200 after assembly into a female member 100. Although a
ment.
slanted ramp type of retention member 112 is shown in FIG.
Female Housing 3B to facilitate an insertion type of assembly (e.g., inserting a
Referring to FIG. 3B, the female housing 102 may be 25 female terminal 200 from left to right in the female housing
substantially rectangular in shape and comprise a female 102 with respect to FIG. 3B), a person ofordinary skill in the
conductor housing 104, a female internal wall 105, and a art would not be limited to just this type of retention member
female terminal housing 106, for each of the first and second 112. Pins, rivets, fasteners, other mechanical attachments,
female terminal chambers 110 and 120. Due to symmetry, welding, and chemical adhesives, among other various meth-
only the first female terminal chamber 110 will be described 30 ods may be used to secure a female terminal 200 in the female
from this point forward, reference numerals enclosed by housing 102. Further, similar additional retention members
parenthesis refer to the second female terminal chamber 120. 112B may be used to provide additional force to oppose the
Although a substantially rectangular shape is shown for the friction force generated during the assembly and disassembly
female housing 102, embodiments of the present invention of the electrical connector 1000 (FIG. 1) that may otherwise
may not be limited to this one configuration. Any configura- 35 move or dislocate one or both of the female terminals 200.
tion capable of accommodating one or more female terminals Other embodiments of the female member 100 may not com-
200 may be used. The female housing 102 may be manufac- prise retention members 112. In some cases the female ter-
tured from a dielectric material able to withstand the operat- minals 200 and resilient members 300 may be core molded
ing conditions of an intended application and provide suffi- into the female member 100 at the time of manufacture.
cient electrical insulation between the current carrying 40 The resilient member support 109 (FIG. 3C) may secure a
female terminals 200 (i.e., inhibiting the occurrence of elec- resilient member 300 in each of the first and second female
trical shorts between the female terminals 200). For example, terminal chambers 110 and 120. The resilient member sup-
the material of the female housing 102 may be a glass rein- port 109 is shown as proximate to the female internal wall
forced nylon such as Zytel® 70G33L, made by DuPont®. In 105. However, an embodiment of the resilient member sup-
some applications the reinforced nylon material may com- 45 port 109 may be located proximate to an end of the female
prise approximately 33% glass. The material may be used in terminal housing 106 opposite to the female internal wall 105
a remotely controlled vehicle operating in a natural environ- (i.e., the insertion end of the female terminal housing 106, for
ment for example and may experience a temperature range example, essentially configured 180 ° in a horizontal plane
from below -20° F. (-29° C.) to over 250° F. (121 ° C.) (e.g., relative to the embodiment shown in FIG. 3B) in addition to
when operated in desert conditions over solar heated road- 50 other locations. As with the female terminal support 107, the
ways, or due to battery heat, current flow, and electrical resis- resilient member support 109 may comprise one or more
tance). retention features 112, for example, as represented by 112C in
The female conductor housing 104 may be separated from FIG. 3C. The retention features 112 of the resilient member
the female terminal housing 106 by the female internal wall support 109 may comprise slanted ramp protrusions as with
105. The female internal wall 105 may comprise an opening 55 an embodiment of the female terminal support 107, or the
114 (124) to accommodate a female terminal 200. On the retention features 112 may comprise any of the mechanical,
female conductor housing 104 side of the female internal wall chemical, or welding methods of fastening previously
105, the female internal wall 105 may comprise an indicator recited. The previously recited methods of retaining and/or
113 identifying the connection side of the electrical connector fastening female terminals 200 and resilient members 3 00 are
1000 (FIG. 1) for example (e.g., "A" for the female member 60 not intended to form an exhaustive list, but are merely a
and "B" for the male member). In other embodiments, the sampling from amongst a broad variety of retaining and fas-
indicator 113 may comprise a polarity sign to be used in place tening methods known to those of ordinary skill in the art. As
of, or in addition to, the first and second female polarity with the female terminals 200, the resilient members 300 may
indicators 111 and 121 (FIG. 3A). be core molded into the female housing 102 during the pro-
The female conductor housing 104 may circumferentially 65 duction of the female housing 102.
surround an end of a female terminal 200 inserted into each of The ends of the first and second female terminal chambers
the first and second female terminal chambers 110 and 120. 110 and 120 located in the female terminal housing 106,
US 7,530,855 B2
5 6
opposite to the female internal wall 105, are referred to as the ment in a direction opposite to the assembly direction. At this
first and second orifices 116 and 126. Each of the first and point, the female terminal 200 may be substantially securely
second orifices 116 and 126 may be configured substantially coupled with the female housing 102.
in a rectangular shape as shown in FIG. 3A. However, in the
illustrative embodiment shown in these figures, an aspect of 5
Resilient Member
the first orifice 116, such as a width, may be configured Referring now to FIGS. SA and 5B, these figures respec-
differently than the same aspect of the second orifice 126. The tively show an orthogonal top view of a resilient member 300
difference in widths may inhibit an incorrectly polarized and a side view of the resilient member 300 of FIG. SA. The
assembly of a male member 500 (FIG. 1) with the female resilient member 300 may comprise a resilient base member
member 100. Although a difference in dimensional aspects 10 310 and a resilient contact member 3 20. The resilient member
such as widths may be used to inhibit reversing the polarities 300 may be punch formed from a sheet of stainless steel (e.g.,
during connection ofan electrical connector 1000 (FIG. 1) the SS 301 with no plating), spring steel (e.g., spring steel with
present invention may not be limited to this method. Different nickel plating) or other resilient material configured to work
configurations, devices, and dimensions may be used to within the anticipated environmental conditions of the elec-
facilitate the proper polar connection orientation during 15 trical connector 1000 (FIG. 1). In some embodiments, the
assembly of a male member 500 with a female member 100. resilient member 300 may be plated or otherwise coated to
inhibit rust or to provide an appropriate level of resistance
Female Terminals (e.g., friction force) necessary to maintain the connection
Turning now to FIGS. 4A and 4B, FIG. 4A shows a top between an assembled male member 500 and female member
view ofanembodiment ofa female terminal 200, and FIG. 4B 20 100.
shows a side view of the female terminal 200 of FIG. 4A. As The resilient base member 310 may be located at one end of
an example of an illustrative embodiment of a female termi- the resilient member 300 and comprise one or more resilient
nal 200, the female terminal 200 may comprise a terminal retention members 312A and 312B (FIG. 5B). The resilient
connector portion 204 and a terminal contact portion 206. The retention members 312A and 312B may engage correspond-
female terminal 200 may comprise an electrically conductive 25 ing retention members 112 within the resilient member sup-
material, such as brass, copper, or bronze. The female termi- port 109 (as seen in FIG. 3C, but only one retention member
nal 200 may be plated with gold (such as a gold-cobalt or 112C can be seen in this view), located in each of the first and
gold-nickel alloy) or silver, among other materials, preferably second terminal chambers 110 and 120. The resilient reten-
copper plated with nickel and then plated with gold (for tion members 312A and 312B may securely retain the resil-
example), in order to increase the electrical conductivity 30 ient members 300 within the female housing 102 during
between contacting portions of the male and female terminals assembly and disassembly of the electrical connector 1000
600 and 200. The female terminal 200 shown may be made (FIG. 1). The resilient base member 310 is shown as a sub-
from a standard plate of material and punched formed to the stantially flat quadrilateral but embodiments of the present
correct size and configuration, among other methods of form- invention may not be limited to this illustrative form. The
ing. 35 resilient base member 310 may be retained separate from the
The terminal connector portion 204 may be located on one corresponding female terminal 200 and separate from a fully
end of the female terminal 200 and configured to electrically inserted male terminal 500 (FIG. 2). In other words, the
couple with a copper wire conductor (for example) such as resilient base member 310 may not overlay a corresponding
wire conductors 10B and 20B (FIG.1). The terminal connec- male terminal 500 when an electrical connector 1000 (FIG. 1)
tor portion 204 may be electrically coupled to a wire conduc- 40 is electrically coupled.
tor through the use of soldering, mechanical fastening (e.g., As more easily seen in FIG. 5B, the resilient contact mem-
through the use of a screw clamp), standard insulated and ber 320 may comprise an arcuate portion defined by a radius
non-insulated connector fittings, crimping, and other meth- R. The arcuate portion may be resiliently deformed toward
ods of electrically coupling a wire conductor to a portion of a the radial center point in response to pressure or interference
terminal. Embodiments of the terminal connector portion 204 45 from portions of an installed male member 500 (FIG. 1). The
may comprise a variety of configurations in order to accom- arcuate portion may also be configured to interface with a
modate a particular electrical coupling method. depression or other engaging feature, detailed later, in an
The terminal contact portion 206 may be located at an opposing surface or portion of the male member 500 in order
opposite end of the female terminal 200 relative to the termi- to provide a disassembly retention force after coupling the
nal connector portion 204, and may comprise an angled end 50 male member 500 with the female member 100 (see FIG. 1).
210, one or more terminal retention features 212 (two are In the illustrative embodiment shown, only a single arcuate
shown in FIG. 4B, 212A and 212B), and a contact surface portion is illustrated in FIGS. SA and 5B. However, embodi-
214. The angled end 210 may help facilitate the coupling or ments of the present invention are not to be limited to this one
assembly of a corresponding male terminal 600 (FIG. 2) exemplary configuration. For example, larger and smaller
during the connection of an electrical connector 1000 (FIG. 55 radii either alone or in combination with one or more rela-
1). The contact surface 214 may directly contact an opposing tively straight portions may be used, an arcuate portion curv-
surface of a male terminal 600 in order to allow an electrical ing back upon the resilient contact member 320, a single
current to flow from one end of the electrical connector 1000 angular bend joining two straight portions together, or a plu-
to the other. rality of angular or arcuate portions such as in a zig-zag or
Terminal step 208 may separate the terminal connector 60 wave type of configuration may be used in order to more
portion 204 from the terminal contact portion 206. In some evenly apply a force from the female member 100 to the male
embodiments, during assembly of the female terminal 200 member 500. The listing is intended to provide a small rep-
into female housing 102 (FIG. 3 B ), the terminal step 208 may resentative sample of the various potential configurations
oppose a portion of the female housing 102 and prevent consistent with the present invention and is not intended to be
further movement in the assembly direction. The terminal 65 exhaustive.
retention features 212 may contact corresponding retention One end of the resilient contact member 320 may comprise
features 112 of the female housing 102 and prevent move- a housing interface 324. An example of the housing interface
US 7,530,855 B2
7 8
324 may be illustrated by a small radius curve rotating in an F. (121 ° C.) (e.g., when operated in desert conditions over
opposite direction relative to the arcuate portion defined by solar heated roadways, or due to battery heat, current flow,
the radius R. The housing interface 324 may facilitate a slid- and electrical resistance).
ing movement along a contacting portion of an inner wall of The male conductor housing 504 may be separated from
the female housing 102 (FIG. 3B) in response to assembly 5 the male terminal housing 506 by the male internal wall 505.
and disassembly of a male member 500 and a female member The male internal wall 505 may comprise an opening 514
100 (see FIG. 2). The sliding contact may prevent or inhibit (524) to accommodate a male terminal 600. On the male
the abrading or prematurely wearing down of the inner sur- conductor housing 504 side of the male internal wall 505, the
face of the female housing 102 over a multiple number of male internal wall 505 may comprise an indicator 513 iden-
connections and disconnections of the electrical connector 10 tifying the connection side of the electrical connector 1000
1000 (FIG. 1). In this example, the contacting portion of the (FIG. 1), for example (e.g., "A" for the female member and
housing interface 324 curves away from the inner surface of "B" for the male member). In other embodiments, the indi-
the female housing 102 in directions tangent to the small cator 513 may comprise a polarity sign to be used in place of,
radius curve. Further, the resilient contact member 320 may or in addition to, the first and second male polarity indicators
extend at an angle from the resilient base member 310 such 15 511 and 521 (FIG. 6A).
that the housing interface 324 may be located above (with The male conductor housing 504 may circumferentially
respect to FIG. 5B) a plane containing the resilient base surround an end of a male terminal 600 inserted into each of
member 310. This configuration may apply a pre-load to an the first and second male terminal extensions 510 and 520. An
assembled resilient member 300 via the housing interface end of the male conductor housing 504 opposing the internal
324. By adjusting the angle for the resilient contact member 20 wall 505 may be open to provide access for a conductor (not
320 relative to the resilient base member 310, and/or adjust- shown) to contact an exposed end of a male terminal 600. In
ing the radius R, the force applied to the male member 500 other embodiments, an end or side of the male conductor
through the resilient contact member 320 may be adjusted. housing 504 adjacent to the male internal wall 505 may be
Adjusting the force of the resilient contact member 320 may open to provide conductor access. In the embodiment shown,
adjust the amount of insertion and withdrawal force for the 25 the male conductor housing 504 substantially shrouds and
connecting and disconnecting of the electrical connector insulates the ends of the male terminals 600 from each other.
1000. Consequently, a desired amount of insertion and with- In certain other embodiments the male conductor housing
drawal force may be established for the connecting and dis- 504 may only partially surround an end of a male terminal 600
connecting of the electrical connector 1000. in each of the first and second male terminal extensions 510
30 and 520.
Male Member
The male internal wall 505 of each of the first and second
Turning now to FIGS. 6A, and 6B, the male member 500
male terminal extensions 510 and 520 may function as a male
may comprise a male housing 502, a first male terminal
terminal support (FIG. 6B). Each of the male terminal sup-
extension 510, a second male terminal extension 520, and
ports (i.e., male internal walls 505) may help to retain a
male terminals 600 (more clearly shown in FIG. 6B). A first
35 corresponding male terminal 600 in the respective first and
male polarity indicator 511 and a second male polarity indi-
second male terminal extensions 510 and 520. The male
cator 521 may indicate the respective polarities of the first
terminal support may comprise one or more retention mem-
male terminal extension 510 and the second male terminal
bers 512 (for example as represented by 512A), configured to
extension 520. An example of a male terminal 600 is shown in
retain a male terminal 600 after assembly into a male member
FIGS. 7A and 7B and is detailed later. The various compo-
40 500. Although a slanted ramp type ofretention member 512 is
nents of the male member 500 will be described in more detail
shown in FIG. 6B to facilitate an insertion type of assembly
in the following illustrative embodiment.
(e.g., inserting a male terminal 600 from the left to the right in
Male Housing the male housing 502 with respect to FIG. 6B), a person of
Referring to FIG. 6B, the male housing 502 may be sub- ordinary skill in the art would not be limited to just this type
stantially rectangular in shape and comprise a male conductor 45 of retention member 512. Pins, rivets, fasteners, other
housing 504, a male internal wall 505, and a male terminal tip mechanical attachments, welding, and chemical adhesives,
506 for each of the first and second male terminal extensions among other various methods may be used to secure a male
510 and 520. Due to their similarities, only the first male terminal 600 within the male housing 502. Further, similar
terminal extension 510 will be described from this point additional retention members 512B may be used to provide
forward, reference numerals enclosed by parenthesis refer to 50 additional force to oppose the friction force generated during
second male terminal extension 520. Although a substantially the connection and disconnection of the electrical connector
rectangular shape is shown for the male housing 502, embodi- 1000 (FIG. 1) that may otherwise move or dislocate one or
ments of the present invention may not be limited to this one both of the male terminals 600. Other embodiments of the
configuration. Any configuration capable of accommodating male member 500 may not comprise retention members 512.
one or more male terminals 600 may be used. The male 55 In some cases the male terminals 600 may be core molded
housing 502 may be manufactured from a dielectric material into the male housing 502 at the time of manufacture.
able to withstand the operating conditions of an intended The ends of the first and second male terminal extensions
application and provide sufficient electrical insulation 510 and 520 in the male terminal tips 506, opposite to the
between the current carrying male terminals 600 (i.e., inhib- internal wall 505, are referred to as the first and second male
iting the occurrence of an electrical short between the male 60 terminal covers 516 and 526. Each of the first and second
terminals 600). For example, the material of the male housing male terminal covers 516 and 526 may be configured sub-
502 may be a glass reinforced nylon such as Zytel® 70G33L, stantially in a rectangular shape as shown in FIG. 6A. How-
made by DuPont®. In some applications the reinforced nylon ever, in the illustrative embodiment shown in these figures, an
material may comprise approximately 33% glass. The mate- aspect of the first male terminal cover 516, for example width,
rial may be used in a remotely controlled vehicle operating in 65 may be configured differently than the same aspect of the
a natural environment for example and may experience a second male terminal cover 526. The difference in widths
temperature range from below -20° F. (-29° C.) to over 250° may inhibit an incorrectly polarized assembly of a male mem-
US 7,530,855 B2
9 10
ber 500 (FIG. 1) with the female member 100. Although a ing portions of the male and female terminals 600 and 200.
difference in dimensional aspects such as widths may be used The male terminal 600 shown may be made from a standard
to inhibit reversing the polarities during connection of an plate of material and punched formed to the correct size and
electrical connector 1000 (FIG. 1), the present invention may configuration, among other methods of forming.
not be limited to this method. Different configurations, 5 The terminal connector portion 604 may be located on one
devices, and dimensions may be used to facilitate the proper end of the male terminal 600 and configured to electrically
polar connection orientation during assembly of a male mem- couple with a copper wire conductor (for example) such as
ber 500 with a female member 100. wire conductors l0A and 20A (FIG. 1). The terminal connec-
The first and second male terminal covers 516 and 526 may tor portion 604 may be electrically coupled to a wire conduc-
each comprise a connector retention feature 507. In some 10 tor through the use of soldering, mechanical fastening (e.g.,
embodiments, the connector retention feature 507 may be through the use of a screw clamp), standard insulated and
configured as an arcuate cavity or depression corresponding non-insulated connector fittings, crimping, and other meth-
to an arcuate portion of the resilient contact member 320 of a ods of electrically coupling a wire conductor to a terminal.
resilient member 300 (see FIG. 5B). As the male member 500 Embodiments of the terminal connector portion 604 may
is connected to the female member 100 (see FIG. 1), the 15 comprise a variety of configurations in order to accommodate
resilient member 300 moves relative to a surface of the cor- a particular electrical coupling method.
responding first and second male terminal covers 516 and 526 The terminal contact portion 606 may be located at an
until a portion of the resilient contact member 320 engages a opposite end of the male terminal 600 relative to the terminal
corresponding portion of the connector retention feature 507. connector portion 604, and may comprise an angled end 610,
The engagement between the resilient contact member 320 20 one or more terminal retention features 612 (two are shown in
and the connector retention feature 507 may provide a sen- FIG. 7B, 612A and 612B), and a contact surface 614. The
sory indication that the male member 500 is fully connected angled end 610 may help facilitate the coupling or assembly
to the female member 100. In addition, the engagement of a corresponding female terminal 200 (FIG. 2) during the
between the resilient contact member 320 and the connector connection of an electrical connector 1000 (FIG. 1). The
retention feature 507 may help to prevent inadvertent discon- 25 contact surface 614 may directly contact an opposing surface
nection between the male member 500 and the female mem- of a female terminal 200 in order to allow an electrical current
ber 100 during the operation of the electrical connector 1000 to flow from one end of the electrical connector 1000 to the
in an applied device. other.
The first and second male terminal covers 516 and 526 may Terminal step 608 may separate the terminal connector
further comprise an angled or slanted portion 570, which may 30 portion 604 from the terminal contact portion 606. In some
be located at an end opposite to the male internal wall 505. embodiments, during assembly of the male terminal 600 into
The slanted portion 570 of each of the first and second male male housing 502 (FIG. 6B), the terminal step 608 may
terminal covers 516 and 526 may facilitate the insertion and/ oppose a portion of the male housing 502 and prevent further
or assembly of the male member 500 with the female member movement in the assembly direction. The terminal retention
100 (see FIG. 1). In some embodiments, rounded, arcuate, or 35 features 612 may contact corresponding retention features
other insertion facilitating features may be used in place of, or 512 of the male housing 502 and prevent movement in a
in addition to, the slanted portion 570 of each of the first and direction opposite to the assembly direction. At this point, the
second male terminal covers 516 and 526. At least part of the male terminal 600 may be substantially securely coupled with
remaining portions of the first and second male terminal the male housing 502.
covers 516 and 526 may provide a contact surface for the 40
resilient member 300, as previously explained, and may pro- Assembly
vide a degree ofinsulation between the resilient members 300 Turning now to FIGS. SA and 8B, FIG. SA illustrates a
and the male terminals 600. The material of the first and correctly assembled electrical connector 1000, while FIG. 8B
second male terminal covers 516 and 526 may be the same as illustrates an incorrectly assembled electrical connector
the material used for the rest of the male housing 502. In some 45 1000. As seen in FIG. SA, when the male member 500 is
embodiments, the first and second male terminal covers 516 correctly coupled to a female member 100, the first and sec-
and 526 may comprise a coating applied to a surface of the ond male polarity indicators 511 and 521 correspond to the
male terminals 600. Alternatively, a coating or texture may be first and second female polarity indicators 111 and 121, indi-
applied to a surface of the first and second male terminal cating the maintenance of proper polarity across the electrical
covers 516 and 526 to vary the level of frictional resistance 50 connector 1000. The correspondence between the sets of
between the surface and the contacting portion of the resilient polarity indicators 111, 121, 511, and 521, may provide a
contact member 320 of each of the respective resilient mem- visual indication of the correct coupling of the male and
bers 300. female members 500 and 100. As seen in FIG. 8B, the first and
second male polarity indicators 511 and 521 may not be
Male Terminals 55 visible from a top oriented viewing plane when the male
Turning now to FIGS. 7A and 7B, FIG. 7A shows a top member 500 is incorrectly assembled to the female member
view of an embodiment of a male terminal 600, and FIG. 7B 100. In addition, as indicated by the arrows for the first and
shows a side view of the male terminal 600 of FIG. 7A. As an second male polarity indicators 511 and 521 (the polarity
example of an illustrative embodiment of a male terminal indicators themselves are not visible in this view), the polari-
600, the male terminal 600 may comprise a terminal connec- 60 ties on each side of the incorrectly assembled electrical con-
tor portion 604 and a terminal contact portion 606. The male nector 1000 have been reversed.
terminal 600 may comprise an electrically conductive mate- Referring to FIGS. 9A and 9B, FIG. 9A illustrates a cross-
rial, such as brass, copper, or bronze. The male terminal 600 sectional view of the correctly assembled electrical connector
may be plated with gold (such as gold-cobalt or gold-nickel 1000 of FIG. SA as viewed along line 9A-9A, while FIG. 9B
alloy) or silver, among other materials, preferably copper 65 illustrates a cross-sectional view of the incorrectly assembled
plated with nickel and then plated with gold (for example), in electrical connector 1000 of FIG. 8B as viewed along line
order to increase the electrical conductivity between contact- 9B-9B. FIG. 9A shows an electrical connector 1000 in which
US 7,530,855 B2
11 12
a first male terminal cover 516 is inserted into a first orifice 100. Although only one side portion of the electrical connec-
116 and a contact surface 614 of the male terminal 600 is tor 1000 is described in detail, the other side portion may be
abutting a contact surface 214 of the female terminal 200. The similar due to the symmetry of the connector. However, com-
first male terminal cover 516 and the first orifice 116 may each plete symmetry is not a limitation required of an embodiment
have an approximate width ofWl with the first male terminal 5 of the present invention and differences beyond the widths of
cover 516 configured to fit within the first orifice 116. The the first and second male terminal covers 516 and 526 and
second male terminal cover 526 is inserted into a second corresponding first and second orifices 116 and 126 may
orifice 126 such that a contact surface 614 of the correspond- exist.
ing male terminal 600 is abutting a contact surface 214 of the
corresponding female terminal 200. The second male termi- 10
Another Embodiment
nal cover 526 and the second orifice 126 may each have an Referring now to FIG. 11, this figure shows an orthogonal
approximate width of W2 with the second male terminal top view with a cross-section taken through the side of an
cover 526 configured to fit within the second orifice 126. The embodiment of an electrical connector. In this figure, refer-
width Wl may be smaller than the width W2. This difference ence number 2000 generally refers to another illustrative
in widths may provide another method of inhibiting or pre- 15 embodiment of an electrical connector 2000 constructed
venting cross-polarization during connection of the male according to aspects of the present invention. One difference
member 500 to the female member 100 (FIG. SA), since the between the electrical connector 2000 and the previously
male member 500 may be connected to the female member described electrical connector 1000 (FIG. 1) may be the
100 when the male member 500 is properly oriented with replacement of one or more resilient members 300 (FIG. 2) of
respect to the female member 100. The proper orientation of 20 the previous illustrative embodiment with one or more resil-
the male and female members 500 and 100 may provide for ient members 23 00. Otherwise, the function and materials for
the correct polarity of the connection. the two electrical connectors 1000 and 2000 may be consid-
FIG. 9B shows an electrical connector 1000 in which a ered to be the same. Similar components may be identified
male member 500 is incorrectly connected to a female mem- with similar reference numerals used in the previous descrip-
ber 100. This type of connection may be substantially pre- 25 tion, and a detailed explanation of these components may not
vented by the interference between the width of the second be repeated.
male terminal cover 526 (W2) and the width of the first orifice Electrical connector 2000 may comprise a female member
116 (Wl) (e.g., W2-Wl ). However, if the male member 500 2100 and a male member 500, shown here in a connected
is somehow coupled to the female member 100 in spite of this state. The female member 2100 may comprise one or more
interference, cross-polarization of the electrical connector 30 female terminals 200 (only one is visible in this view) and the
1000 may still be prevented by the first and second male male member 500 may comprise a corresponding number of
terminal covers 516 and 526 separating the male and female male terminals 600. When the female member 2100 and the
terminals 600 and 200. The first and second male terminal male member 500 are coupled together, electricity may be
covers 516 and 526 may prevent contact between correspond- able to flow between wire conductors (not shown) through the
ing male and female terminals 600 and 200 when the male 35 electrical connector 2000 via the areas of contact between the
member 500 is in a second orientation with respect to the female and male terminals 200 and 600.
female member 100. Therefore, as seen in this illustrative The female member 2100 may comprise one or more resil-
embodiment, cross-polarization of the electrical connector ient members 2300. The resilient members 2300 may provide
1000 may be prevented and/or inhibited by at least two sepa- a pressing force to facilitate electrical conduction through the
rate and independent methods, in addition to the visual indi- 40 contact areas between the corresponding female and male
cation given by the first and second male and female polarity terminals 200 and 600. In addition, the resilient members
indicators, 111, 121, 511, and 521. 2300 may provide a securing force to inhibit or prevent the
Referring now to FIG. 10, this figure illustrates an orthogo- inadvertent disconnection of the male member 500 from the
nal cross-sectional view of a correctly assembled male mem- female member 2100 during the use of the electrical connec-
ber 500 and female member 100. In this figure, the first and 45 tor 2300 in a desired application (e.g., such as in a vibratory
second male terminal extensions 510 and 520 (FIG. 6A) have and dynamic environment of a remotely controlled vehicle).
been inserted into the first and second female terminal cham- In some exemplary embodiments, the number of resilient
bers 110 and 120 (FIG. 3A), or more specifically, the male members 2300 corresponds to the number of electrical con-
terminal housing 506 portions of the first and second male nections formed or broken during the connection and discon-
terminal extensions 510 and 520 have been inserted into the 50 nection of the electrical connector 2000 (e.g., two are shown
first and second orifices 116 and 126 of the first and second in FIG. 11). However, the number ofresilient members 2300
female terminal chambers 110 and 120. As the male member may not be required to equal the number of electrical connec-
500 is connected to the female member 100, the resilient tions formed or broken.
members 300 may initially contact the slanted portion 570 of Each resilient member 2300 may comprise a resilient hous-
the corresponding first and second male terminal covers 516 55 ing 2310 integrated with the housing of the female member
and 526. The resilient contact portions 320 may respectively 2100. As shown in FIG. 11, the resilient housing 2310 may be
slidingly engage a top surface of each of the first and second substantially cylindrical for example, but embodiments of the
male terminal covers 516 and 526. The resilient contact por- present invention may not be limited to this geometric con-
tions 320 may be compressed, causing the housing interface figuration. Each resilient member 23 00 may further comprise
324 portion of the resilient member 300 to slidingly engage an 60 a retention device 2324, a resilient device 2322, and a contact
interior surface of the respective first and second female ter- device 2320. The retention device 2324 may comprise an
minal chambers 110 and 120. The male member 500 may Allen set screw as shown for example, or may comprise any of
continue to be inserted into the female member 100 until the a number of devices able to retain the resilient device 2322
resilient contact portion 320 engages a corresponding con- and the contact device 2320 within the resilient housing 2310,
nector retention feature 507 of the respective first and second 65 while in some embodiments further providing a measure of
male terminal covers 516 and 526. At this point, the male adjustability. For example, a mechanical threaded fastener,
member 500 may be securely coupled to the female member angled key, or cam device, among others, may be used. In this
US 7,530,855 B2
13 14
example, the retention device 2324 may be threadably electrical connector 3000 via the contact areas between the
engaged with a top portion of the resilient housing 2310. female and male terminals 200 and 600.
The resilient device 2322 may be located between the The female member 3100 may comprise one or more resil-
retention device 2324 and the contact device 2320. The resilient members 3300. The resilient members 3300 may provide
ient device 2322 may be a spring, such as a coil spring, or 5
a pressing force to facilitate electrical conduction through the
resilient material, such as foam, among other devices. The contact area between the female terminals 200 and the male
resilient device 2322 may press against the contact device terminals 600. In addition, the resilient members 3300 may
2320, facilitating movement of the contact device 2320 as the
provide a securing force to inhibit or prevent the inadvertent
male member 500 and the female member 2100 are coupled
disconnection of the male member500 from the female mem-
together. The force applied to the contact device 2320 and 10
ber 3100 during the use of the electrical connector 3300 in a
consequently to the male and female terminals 200 and 600,
may be adjusted by tightening or loosening the retention desired application (e.g., such as in a vibratory and dynamic
device 2324, in addition to altering the spring stiffness or remotely controlled vehicle). In some exemplary embodi-
material, among other methods. In some embodiments, the ments, the number of resilient members 3300 corresponds to
male member 500 may be securely coupled to the female 15 the number of electrical connections formed or broken during
member 2100 by tightening the retention device 2324 so as to the connection and disconnection of the electrical connector
eliminate or reduce the ability of the contact device 2320 to 3000, two electrical connections are shown in this embodi-
move within the resilient housing 2310, thereby forcefully ment. However, the number of resilient members 3300 may
engaging the contact device 2320 with a connector retention not be required to equal the number of electrical connections
feature 507. 20 formed or broken.
The contact device 2320 may be spherical ball for example, Each resilient member 3300 may be configured to interfere
such as in a ball and spring type of mechanism. However, in with a opposing surface of a first and second male terminal
other embodiments the contact device 2320 may be any mem- cover 516 and 526 (only 516 is visible in this view) when a
ber capable of moving across the surface of the first and male member 500 is coupled to a female member 3100. As
second male terminal covers 516 and 526 (only the first male 25
shown in FIG. 12, the area indicated by cross-hatching may
terminal cover 516 is visible in this view), such as a rounded be the area ofinterference between the resilient member 3300
pin, angled member, cylinder, among others. The contact
and the top surface of the first male terminal cover 516,
device 2320 may be retained within theresilienthousing 2310
although only a portion of the abutting surfaces may be con-
between a protruding edge 2312 at one end and the retention
30 figured to be interfering. The resilient member 3300 may
device 2324 at the other end. During connection of the male
member500 and the female member 2100, the contact device comprise a rib interfacing with a portion of the respective top
2320 may engage the connector retention feature 507 as the surface of the first and second male terminal covers 516 and
male member 500 is fully coupled with the female member 526, or the resilient member 3300 may comprise the wall of
2100. The contact device 2320 and the connector retention the female member housing 3102, among numerous other
feature 507 may be configured to have corresponding or inter- 35 configurations such as those previously described for the
facing features, such that when the male member 500 is fully resilient contact portion 320. Essentially, in some embodi-
coupled with the female member 2100, a sensory indication ments the housing 3102 of the female member 3100 may
of the application device 2320 engaging the connector reten- function as a resilient member, allowing at least some degree
tion feature 507 may be provided. The sensory indication may of resilient deformation or movement designed to apply a
be visual, audible, tactile, or a combination of one or more of 40 force to at least a portion of an installed male member 500
these sensory indications, in addition to other methods. (e.g., such as the first and second male terminal covers 516
and 526, or in some embodiments, the male terminals them-
Another Embodiment selves, among other configurations). Alternatively, the first
Referring now to FIG. 12, this figure shows an orthogonal and second male terminal covers 516 and 526 may function as
top view with a cross-section taken through the side of an 45 a resilient member, allowing at least some degree of resilient
embodiment of an electrical connector. In this figure, refer- deformation or movement designed to urge the male termi-
ence number 3000 generally refers to another illustrative nals 600 together with the corresponding female terminals
embodiment of an electrical connector 3000 constructed 200. Further, in some embodiments, both the female housing
according to aspects of the present invention. One difference 3102 and the first and second male terminal covers 516 and
between the electrical connector 3000 and the previously 50 526 may experience some degree of resilient deformation,
described electrical connectors may be the replacement of combining together to provide a force urging the male termi-
one or more resilient members 300 (FIG. 2) or2300 (FIG.11) nals 600 together with the corresponding female terminals
of the previous illustrative embodiments, with one or more 200.
resilient members 3300. Otherwise, the function and materi- The resilient member 3300 may further comprise protru-
als for the electrical connectors 1000, 2000, and 3000 may be 55 sions or features configured to engage with corresponding
considered to be the same. Similar components may be iden- depressions or features located on the top surfaces of the first
tified with similar reference numerals used in the previous and second male terminal covers 516 and 526, such that the
description, and a detailed explanation of these components male member 500 may be securely coupled to the female
may not be repeated. member 3000 upon fully connecting the male member 500 to
Electrical connector 3000 may comprise a female member 60 the female member 3100. An example of a protrusion for the
3100 and a male member 500, shown here in a connected resilient member 3300 may be an arcuate ridge corresponding
state. The female member 3100 may comprise one or more to the connector retention feature 507 shown in FIG. 6B. The
female terminals 200 (only one is visible in this view) and the resilient member 3300 may at least partially resiliently
male member 500 may comprise a corresponding number of deform with respect to the area of interference. Alternatively,
male terminals 600. When the female member 3100 and the 65 the resilient member 3300 may take advantage of at least
male member 500 are coupled together, electricity may be some degree of resilient deformation in the configuration of
able to flow between wire conductors (not shown) through the the female member housing 3102.
US 7,530,855 B2
15 16
Another Embodiment a male member 1500. Although a slanted ramp type of reten-
Turning now to FIGS. 13A and 13B, the first figure shows tion member 512 is shown in FIG. 13B to facilitate an inser-
a top view of an illustrative embodiment of a male member tion type of assembly (e.g., inserting a male terminal 1600
1500 configured according to aspects of the present invention, from the right to the left in the male housing 1502 with respect
while the second figure shows an orthogonal cross-sectional 5 to FIG. 13B), a personofordinary skill in the art would not be
limited to just this type of retention member 512. Pins, rivets,
top view of the male member 1500 of FIG. 13A as viewed
fasteners, other mechanical attachments, welding, and
along line 13B-13B. One difference between the male mem-
chemical adhesives, among other various methods may be
ber 1500 and the previously described male member 500
used to secure the first and second male terminals 1600 and
(FIG. 1) may be the lack of first and second male terminal 10 1650 within the male housing 1502. Additionally, the first and
covers 516 and 526 (see FIGS. 6A and 6B) in the male second male terminals 1600 and 1650 may be core molded
member 1500. Another difference may be the use of first and along with the male housing 1502 at the time of manufacture.
second male terminals 1600 and 1650 in male member 1500 The first and second male terminals 1600 and 1650 may
in place of the male terminals 600 shown in male member 500 comprise retention members 612 (for example as represented
(see FIG. 2). Otherwise, the function and materials for the 15 by 612A and 612B, however, only the retention members 612
male members 500 and 1500 may be considered to be sub- of the first male terminal 1600 may be seen in FIG. 13B, the
stantially the same. Similar components may be identified second male terminal 1650 may be similarly configured)
with similar reference numerals used in previous descrip- corresponding to the retention members 512. As with the
tions, and a detailed explanation of these components may not retention member 512, a slanted ramp type of retention mem-
be repeated. 20 ber 612 is shown in FIG. 13B to facilitate an insertion type of
Male member 1500 may comprise a male housing 1502 assembly, however, a person of ordinary skill in the art would
and first and second male terminal extensions 1510 and 1520. not be limited to just this type of retention member 612. Pins,
rivets, fasteners, other mechanical attachments, welding, and
The first male terminal extension 1510 may comprise the first
chemical adhesives, among other various methods may be
male terminal 1600, while the second male terminal exten-
25 used to secure the first and second male terminals 1600 and
sion 1520 may comprise the second male terminal 1650. First
1650 within the male housing 1502.
and second male terminals 1600 and 1650 may be configured Having thus described embodiments of the present inven-
to be insertably engaged with the first and second orifices 116 tion by reference to certain exemplary embodiments, it is
and 126 of the first and second female terminal chambers 110 noted that the embodiments disclosed are illustrative rather
and 120 of a female member 100 (see FIG. 3A). In some 30 than limiting in nature. A wide range of variations, modifica-
embodiments, some aspects of the first male terminal 1600 tions, changes, and substitutions are contemplated in the fore-
may be different than similar aspects of the second male going disclosure. In some instances, some features of an
terminal 1650 in order to inhibit the cross-polarizing connec- embodiment of the present invention may be employed with-
tion of a male member 1500 and a female member 100. In the out a corresponding use of the other features. Many such
embodiment shown, the width Wl of the first male terminal 35 variations and modifications may be considered desirable by
1600 may be smaller that the width W2 of the second male those skilled in the art based upon a review of the foregoing
terminal 1650. Interference between the larger width W2 and description of the illustrative embodiments. Accordingly, it is
the first orifice 116 may inhibit the connection between a appropriate that the appended claims be construed broadly
female member 100 and an improperly oriented male mem- and in a manner consistent with the scope of the invention.
ber 1500 (i.e., the male member 1500 may be improperly 40 We claim:
oriented with respect to the female member 100). 1. An electrical connector comprising:
a housing comprising an insulating material at least par-
The male housing 1502 may be substantially rectangular in
tially forming a female receptacle having a receptacle
shape and comprise a male conductor housing 504 and a male opening for at least partially receiving a male connector
internal wall 1505 for each of the first and second male 45 electrode;
terminal extensions 1510 and 1520. Although a substantially a female electrode disposed at least partially within the
rectangular shape is shown for the male housing 1502, female receptacle;
embodiments of the present invention may not be limited to a resilient member retained by the female receptacle for
this one configuration. Any configuration capable of accom- urging together the female electrode and a male connec-
modating one or more first and second male terminals 1600 50 tor electrode, when a male electrode is at least partially
and 1650 may be used. The male housing 1502 may be inserted into the female receptacle, the resilient member
manufactured from a dielectric material able to withstand the farther comprising an anchor portion extending away
operating conditions of an intended application and provide from the receptacle opening; and
sufficient electrical insulation between the current carrying a channel formed by the housing and extending from the
first male terminal 1600 and second male terminal 1650 (i.e., 55 female receptacle;
inhibiting the occurrence of an electrical short between the wherein at least a portion of the anchor portion of the
first male terminal 1600 and the second male terminal 1650). resilient member is secured within at least a portion of
The male internal wall 1505 of each of the first and second the channel such that the housing electrically insulates
male terminal extensions 1510 and 1520 may function as a the anchor portion within the channel from the female
male terminal support. Each of the male terminal supports 60 electrode.
(i.e., male internal walls 1505) may respectively secure and 2. The electrical connector of claim 1, further comprising:
support the first and second male terminals 1600 and 1650 in a male connector electrode for at least partial insertion into
the corresponding first and second male terminal extensions the female receptacle; and
1510 and 1520. The male terminal support may comprise one an insulating member at least partially interposed between
or more retention members 512 (for example as represented 65 the resilient member and a surface of the male connector
by 512A and 512B) configured to retain the respective first electrode when the male connector electrode is at least
and second male terminals 1600 and 1650 after assembly into partially inserted into the female receptacle.
US 7,530,855 B2
17 18
3. The electrical connector of claim 1, wherein the resilient ing along a coupling length of the terminal outside of the
member further comprises: body portion for electrically coupling with a second
an arcuate portion for urging together the female electrode terminal disposed within a female connector receptacle;
and a male connector electrode at least partially inserted an insulating cover disposed along at least a portion of the
into the female receptacle; and coupling length of the first terminal for electrically insu-
a base portion for securing the resilient member to the lating one or more surfaces of the first terminal other
female housing. than the coupling surface;
4. The electrical connector of claim 1, wherein the resilient wherein at least a portion of the coupling length of the first
member further comprises a leaf spring. terminal, the insulating cover and the coupling surface
5. The electrical connector of claim 1, wherein the resilient 10 are configured for insertion through the opening of a
member further comprises a ball and spring assembly. female connector receptacle; and
6. The electrical connector assembly according to claim 1, wherein the insulating cover extends along and in contact
wherein the resilient member further comprises at least a with at least a portion of a surface of the first terminal
portion of the female receptacle. facing away from the coupling surface of the first termi-
7. The connector of claim 1, wherein the resilient member 15 nal.
is electrically insulated from the female electrode. 12. An electrical connector comprising:
8. The connector of claim 1, wherein the slot formed by the a housing forming at least a portion of a first chamber;
housing electrically insulates the resilient member from the a first terminal at least partially disposed within at least a
female connector. portion of the first chamber;
9. The connector of claim 1, further comprising:
20 a resilient member mounted to the housing, wherein the
resilient member is not operatively coupled to the first
one or more retention members extending from the anchor
terminal and at least a portion of the resilient member
portion of the resilient member and engaging one or
comprises an anchor;
more surfaces of the slot to resist withdrawal of the
wherein the resilient member directly contacts and applies
resilient member from the receptacle.
25 a bias directly to a second terminal at least partially
10. The connector of claim 1, wherein the contact surface
inserted within the first chamber, facilitating contact
of the female electrode is substantially planar when the elec-
between the corresponding first terminal and the second
trode is in an uncompressed state.
terminal; and
11. An electrical connector assembly having a first connec-
wherein at least a portion of the housing surrounds at least
tor, the first connector comprising:
30 a portion of the anchor of the resilient member to secure
an electrically insulating body portion; the anchor portion to the housing and to insulate at least
an electrically conductive first terminal retained by the a portion of the anchor from the first terminal.
body portion, wherein the first terminal extends from the
body portion and comprises a coupling surface extend- * * * * *
UNITED STATES PATENT AND TRADEMARK OFFICE

CERTIFICATE OF CORRECTION
PATENT NO. : 7,530,855 B2 Page 1 of 1
APPLICATION NO. :11/951754
DATED : May 12, 2009
INVENTOR(S) : Hariharesan et al.
It is certified that error appears in the above-identified patent and that said Letters Patent is hereby corrected as shown below:
In the Claims
Column 16, Claim 1, Line 12, delete the word "farther" and insert the word --further--.
Signed and Sealed this

Sixth Day of February, 2018
Joseph Mata!
Peiforming the Functions and Duties of the
Under Secretary of Commerce for Intellectual Property and
Director of the United States Patent and Trademark Office
EXHIBIT 6
I 1111111111111111 11111 1111111111 11111 1111111111 1111111111111111 IIII IIII IIII
US007867038B2
c12) United States Patent (10) Patent No.: US 7,867,038 B2

Hariharesan et al. (45) Date of Patent: *Jan. 11, 2011
(54) ELECTRICAL CONNECTOR ASSEMBLY 3,218,599 A 11/1965 Winkler

3,233,211 A 2/1966 Smith
(75) Inventors: Seralaathan Hariharesan, Flower
Mound, TX (US); Brock Dennison,
Lampert, Garland, TX (US) (Continued)
(73) Assignee: Traxxas LP, Plano, TX (US) FOREIGN PATENT DOCUMENTS
( *) Notice: Subject to any disclaimer, the term ofthis DE 704 450 3/1941
patent is extended or adjusted under 35
U.S.C. 154(b) by 9 days.
This patent is subject to a terminal dis- (Continued)

claimer.
OTHER PUBLICATIONS
(21) Appl. No.: 12/417, 792
Ukiah CA, U.S.A., 2003-2006.
(22) Filed: Apr. 3, 2009
(Continued)
(65) Prior Publication Data
US 2009/0186530Al Jul. 23, 2009 Primary Examiner-T C Patel
Assistant Examiner-Phuongchi T Nguyen
Related U.S. Application Data (74) Attorney, Agent, or Firm-Carr LLP
(63) Continuation of application No. 11/951,754, filed on (57) ABSTRACT
Dec. 6, 2007, now Pat. No. 7,530,855, which is a
continuation of application No. 11/736,460, filed on
Apr. 17, 2007, now Pat. No. 7,374,460. An electrical connector is provided comprising a female
member and a male member configured such that the female
(51) Int. Cl.
HOJR 13/64 (2006.01) member is inhibited from being electrically coupled to the
male member if the electrical coupling would reverse the
(52) U.S. Cl. ....................................... 439/679; 439/823
polarity of the electrical connector. The female member may
(58) Field of Classification Search ................. 439/679,
comprise a first and second chamber. The male member may
439/691, 693,282,296,284,680
comprise a first and second extension. The first and second
See application file for complete search history.
chambers may be configured to insertably accommodate the
(56) References Cited first and second extensions. The female member may com-
prise one or more resilient members providing a pressing
U.S. PATENT DOCUMENTS force to bias at least a portion of a male electrode against at
2,121,338 A 6/1938 Chirelstein least a portion of a corresponding female electrode. Alterna-
2,203,122 A 6/1940 Anderson tively, the cover of the male electrode in the first and second
2,838,739 A 6/1958 Winkler extensions may comprise a resilient member.
3,091,746 A 5/1963 Winkler
3,145,067 A 8/1964 Mishelevich et al. 27 Claims, 11 Drawing Sheets
500 516
~
US 7,867,038 B2
Page 2
U.S. PATENT DOCUMENTS Anderson Power Products, "SB Connector Family" data sheet;
Anderson Power Products, Sterling, MA, U.S.A. (admitted prior art).
3,259,870 A 7/1966 Winkler Anderson Power Products; "SB 50 Connector" data sheet; Anderson
3,273,105 A 9/1966 Klassen Power Products, Sterling, MA, U.S.A. (admitted prior art).
3,909,099 A 9/1975 Winkler
Anderson Power Products; "SBS 50 Connector" data sheet; Ander-
4,018,497 A 4/1977 Bulanchuk
son Power Products, Sterling, MA. U.S.A. (admitted prior art).
4,083,617 A 4/1978 Wyatt
4,342,498 A 8/1982 Patton et al. Horizon Hobby; "E-flite EC3 Device & Battery Connector, Male-
4,630,876 A 12/1986 Grunberg et al. Female" web page; Horizon Hobby, Inc., Champaign, IL, U.S.A.
4,639,061 A * 1/1987 Muzslay ..................... 439/587 2006.
4,737,118 A 4/1988 Lockard Tyco Electronics, "Hot Plug, High Current Dual Crown Clip Socket
4,846,729 A 7/1989 Hikami et al. Connector" ELCON Products International Co., Fremont, CA U.S.
4,990,099 A 2/1991 Marin et al. A. 2000-2001.
5,533,915 A 7/1996 Deans McMaster-Carr; "Quick-Disconnect Terminals" catalog p. 724;
5,575,674 A * 11/1996 Davis et al . ................. 439/284 McMaster-Carr Supply Co. (admitted prior art).
5,921,809 A * 7/1999 Fink ........................... 439/504 Molex; "Standard .093" web pages; Molex, Lisle IL U.S.A. (admit-
6,268,564 Bl 7/2001 Miyakoshi ted prior art).
6,488,546 B2 12/2002 Sakurai et al.
Hyperphysics, "Household Wiring-Polarized Receptacles" web
6,619,995 Bl 9/2003 Hayashi et al.
page article; http://hyperphysics.phy-astr.gsu.edu/hbase/electric/
6,619,996 B2 9/2003 Hara et al.
hsehld.htrnl (admitted prior art).
6,623,309 B2 9/2003 Sakurai et al.
6,645,003 B2 11/2003 Yoshida et al. Traxxas; "REVO transmission" illustration (1 page); Traxxas LP,
7,004,795 B2 2/2006 Mancini et al. Plano TX U.S.A. (admitted prior art).
7,374,460 Bl* 5/2008 Hariharesan et al. ........ 439/679 Deans; "Ultra Plug" photographs (3 pages); Wm. F. Deans, Para-
7,530,855 B2 * 5/2009 Hariharesan et al. ........ 439/679 mount CA U.S.A. (admitted prior art).
2004/0127104 Al 7/2004 Stefaniu et al. Molex; "Standard .093" connector photographs (7 pages); Molex,
Lisle IL U.S.A .. (admitted prior art).
"Standard ll 0V electrical plugs and receptacles" photographs ( 5
EP 0 318 831 A2 6/1989 pages) (admitted prior art).
FR 1036107 9/1953 Barajas, Jaime; "Styling Input from Jaime", Traxxas LP, Plano TX
GB 2076599 * 12/1981 U.S.A. (confidential internal document, Jan. 23, 2007).
OTHER PUBLICATIONS EP Patent Application No. 07254357.2; European Search Report,
Nov. 24, 2009.
Anderson Power Products; "PP15 Powerpole Connector" data sheet;
Anderson Power Products, Sterling, MA U.S.A. (admitted prior art). * cited by examiner
U.S. Patent Jan. 11, 2011 Sheet 1 of 11 US 7,867,038 B2
1000
FIG.1
1000
FIG. 2
100 111
~ 121
FIG. 3A
100
102
~
200
FIG.3B
100
~
112C
200
FIG.3C
208 214
200~
□ 210
206
204
FIG. 4A
212A""\.., r214 /'210

200~ . -II-----rK-~-~---n
, 212sf"
\._208
FIG.4B
608 612
600~
610
604
FIG. 7A
600~ . _I _ 6122:
____._I...__I-----.-,,.-------,-----□
61287 614 '-610
FIG. 7B
300
324
FIG. SA
300
,J
R
324
FIG. SB
500 516
FIG. 6A
500
~ 502
514
600
FIG. 6B
111
1000
511
FIG. BA
111
1000
FIG. 8B
1000
~ W1 W2
516 526
600 600
FIG. 9A
1000
~ W2-W1 - -
FIG. 9B
.s. P a tent Jan. 11

, 201 1 9 o f 11 67,0 38 B 2
U Sheet V s 7,8
FIG. I O
2000
,J
2310
2324
2322
2320
FIG. I I
3000
,J
FIG.12
1500
~ W2
1520~
1650
D
13B 13B
L ~....._______... _J
1600
1510~
W1
FIG.13A
1500
1650
FIG.13B
US 7,867,038 B2
1 2
ELECTRICAL CONNECTOR ASSEMBLY FIG. SB illustrates a side view of the resilient member of
FIG. SA;
CROSS-REFERENCE TO RELATED FIG. 6A illustrates an orthogonal top view of a male mem-
APPLICATIONS ber;
FIG. 6B illustrates a cross-sectional side view of the male
This application is a continuation of, and claims the benefit member of FIG. 6A;
of the filing date of, U.S. patent application Ser. No. 11/951, FIG. 7A illustrates a top view of a male terminal;
754 entitled ELECTRICAL CONNECTOR ASSEMBLY, FIG. 7B illustrates a side view of the male terminal of FIG.
filed Dec. 6, 2007 now U.S. Pat. No. 7,530,855, which is a 7A;
continuation of U.S. patent application Ser. No. 11/736,460 10 FIG. SA illustrates an orthogonal top view of the electrical
filed Apr. 17, 2007, now U.S. Pat. No. 7,374,460. connector of FIG. 1 correctly assembled;
FIG. SB illustrates an orthogonal top view of the electrical
BACKGROUND OF THE INVENTION connector of FIG. 1 incorrectly assembled;
1. Field of the Invention 15 assembled electrical connector of FIG. SA as viewed along
The present invention generally relates to electrical con- line 9A-9A;
nectors and, more particularly, to high current electrical con- FIG. 9B illustrates a cross-sectional view of the incorrectly
nectors with protection against reverse polarity connections. assembled electrical connector of FIG. SB as viewed along
2. Description of the Related Art line 9B-9B;
A wide variety of electronic devices are powered through 20 FIG. 10 illustrates an orthogonal cross-sectional view of
the use of battery packs. For example, remotely controlled the assembled electrical connector of FIG. 1;
vehicles of all types may have an on-board rechargeable FIG. 11 illustrates an orthogonal cross-sectional top view
battery pack supplying stored electricity to an electric motor. of another embodiment of an electrical connector configured
In some of these lightweight vehicles, racing creates a according to aspects of the present invention;
demand for more powerful motors along with increasing 25 FIG. 12 illustrates an orthogonal cross-sectional top view
levels of current capacity to energize the motors. As a battery of another embodiment of an electrical connector configured
pack is drained of the stored energy contained therein, a user according to aspects of the present invention;
must be able to easily exchange a depleted battery pack for a FIG. 13A illustrates a top view of another embodiment of
fully charged one. The depleted battery pack is then con- a component of an electrical connector configured according
nected to a battery charger in order to be ready for the next 30 to aspects of the present invention; and
exchange. Consequently, there exists a need for a high current FIG. 13B illustrates an orthogonal cross-sectional top view
electrical connector with a lightweight and compact design. of the component of FIG. 13A as viewed along line 13B-13B.
SUMMARY OF THE INVENTION DETAILED DESCRIPTION

35
An embodiment of the present invention provides an elec- In the following discussion, numerous specific details are
trical connector comprising a housing forming a female set forth to provide a thorough understanding of the present
receptacle for a male connector electrode. In addition, the invention. However, those skilled in the art will appreciate
electrical connector may comprise a female electrode that that the present invention may be practiced without such
may be at least partially secured against movement within the 40 specific details. In other instances, well-known elements have
female receptacle. A resilient member secured to the housing been illustrated in schematic or block diagram form in order
may be provided for urging a male connector electrode not to obscure the present invention in unnecessary detail.
toward the female electrode. Additionally, for the most part, details concerning well
known features and elements have been omitted inasmuch as
BRIEF DESCRIPTION OF THE DRAWINGS 45 such details are not considered necessary to obtain a complete
understanding of the present invention, and are considered to
For a more complete understanding of the present inven- be within the understanding of persons of ordinary skill in the
tion and the advantages thereof, reference is now made to the relevant art.
following Detailed Description taken in conjunction with the Turning now to the drawings, FIG. 1 shows a top orthogo-
accompanying drawings, in which: 50 nal view of an assembled electrical connector with attached
FIG. 1 illustrates a general orthogonal top view of an wire conductors. In this drawing, reference numeral 1000
embodiment of an electrical connector configured according generally indicates an illustrative embodiment of an electrical
to the present invention and showing attached wire conduc- connector 1000 at least partially configured according to the
tors; present invention. The electrical connector 1000 may com-
FIG. 2 illustrates an exploded assembly view of the elec- 55 prise a female member 100 and a male member 500. Attached
trical connector of FIG. 1; to the electrical connector 1000 are wire conductors l0A,
FIG. 3A illustrates an orthogonal top view of a female 1 OB, 20A, and 20B. The wire conductors 1 0A, 1 OB, 20A, and
member of the electrical connector of FIG. 1; 20B, may not considered as components of the electrical
FIG. 3B illustrates a cross-sectional view of the female connector 1000 and are shown for the purposes of illustration.
member of FIG. 3A as viewed along line 3B-3B; 60 Wire conductors l0A and l0B may carry a positive current
FIG. 3C illustrates a cross-sectional view of the female flow and wire conductors 20A and 20B may carry a negative
member of FIG. 3A as viewed along line 3C-3C; current flow. The various components of the electrical con-
FIG. 4A illustrates a top view of a female terminal; nector 1000 will be described in more detail in the following
FIG. 4B illustrates a side view of the female terminal of illustrative embodiment.
FIG. 4A; 65 Referring to FIG. 2, the components of an embodiment of
FIG. SA illustrates an orthogonal top view of a resilient the electrical connector 1000 are shown in an exploded
member; assembly view. The female member 100 may comprise a
US 7,867,038 B2
3 4
female housing 102, a first and second female terminal 200, the first and second female terminal chambers 110 and 120.
and a first and second resilient member 300. The male mem- An end of the female conductor housing 104 opposing the
ber 500 may comprise a male housing 502, and a first and female internal wall 105 may be open to provide access for a
second male terminal 600. conductor (not shown) to contact an exposed end of a female
Female Member 5 terminal 200. In other embodiments, an end or side of the
Turning now to FIGS. 3A, 3B, and 3C, the female member female conductor housing 104 adjacent to the female internal
100 may comprise a female housing 102, a first female ter- wall 105 may be open to provide conductor access. In the
minal chamber 110, a second female terminal chamber 120, embodiment shown, the female conductor housing 104 sub-
female terminals 200, and resilient members 300 (more stantially shrouds and insulates the ends of the female termi-
clearly shown in FIG. 2). A first female polarity indicator 111 lO nals 200 from each other. In certain other embodiments the
and a second female polarity indicator 121 may indicate the female conductor housing 104 may only partially surround an
respective polarities of the first female terminal chamber 110 end of a female terminal 200 in each of the first and second
and the second female terminal chamber 120. A first orifice female terminal chambers 110 and 120.
116 and a second orifice 126 may be located at an end of the The female terminal housing 106 portions of each of the
15
female member 100 opposite to the first and second female first and second female terminal chambers 110 and 120 may
polarity indicators 111 and 121. An example of a resilient comprise a female terminal support 107 and a resilient mem-
member 300 is shown in FIGS. 3B and 3C. A resilient member support 109 (FIG. 3C). Each of the female terminal sup-
ber 300 may be located in each of the first and second female ports 107 may help to retain a corresponding female terminal
terminal chambers 110 and 120 (however, only one is shown 200 in the respective first and second female terminal cham-
20
in the FIGS. 3B and 3C for the purposes of illustration). The bers 110 and 120. The female terminal support 107 may
various components of the female member 100 will be comprise one or more retention members 112 (for example as
described in more detail in the following illustrative embodi- represented by 112A) configured to retain a female terminal
ment. 200 after assembly into a female member 100. Although a
Female Housing 25 slanted ramp type of retention member 112 is shown in FIG.
Referring to FIG. 3B, the female housing 102 may be 3B to facilitate an insertion type of assembly (e.g., inserting a
substantially rectangular in shape and comprise a female female terminal 200 from left to right in the female housing
conductor housing 104, a female internal wall 105, and a 102 with respect to FIG. 3B), a person ofordinary skill in the
female terminal housing 106, for each of the first and second art would not be limited to just this type of retention member
female terminal chambers 110 and 120. Due to symmetry, 30 112. Pins, rivets, fasteners, other mechanical attachments,
only the first female terminal chamber 110 will be described welding, and chemical adhesives, among other various meth-
from this point forward, reference numerals enclosed by ods may be used to secure a female terminal 200 in the female
parenthesis refer to the second female terminal chamber 120. housing 102. Further, similar additional retention members
Although a substantially rectangular shape is shown for the 112B may be used to provide additional force to oppose the
female housing 102, embodiments of the present invention 35 friction force generated during the assembly and disassembly
may not be limited to this one configuration. Any configura- of the electrical connector 1000 (FIG. 1) that may otherwise
tion capable of accommodating one or more female terminals move or dislocate one or both of the female terminals 200.
200 may be used. The female housing 102 may be manufac- Other embodiments of the female member 100 may not com-
tured from a dielectric material able to withstand the operat- prise retention members 112. In some cases the female ter-
ing conditions of an intended application and provide suffi- 40 minals 200 and resilient members 300 may be core molded
cient electrical insulation between the current carrying into the female member 100 at the time of manufacture.
female terminals 200 (i.e., inhibiting the occurrence of elec- The resilient member support 109 (FIG. 3C) may secure a
trical shorts between the female terminals 200). For example, resilient member 300 in each of the first and second female
the material of the female housing 102 may be a glass rein- terminal chambers 110 and 120. The resilient member sup-
forced nylon such as Zytel® 70G33L, made by DuPont®. In 45 port 109 is shown as proximate to the female internal wall
some applications the reinforced nylon material may com- 105. However, an embodiment of the resilient member sup-
prise approximately 33% glass. The material may be used in port 109 may be located proximate to an end of the female
a remotely controlled vehicle operating in a natural environ- terminal housing 106 opposite to the female internal wall 105
ment for example and may experience a temperature range (i.e., the insertion end of the female terminal housing 106, for
from below -20° F. (-29° C.) to over 250° F. (121 ° C.) (e.g., 50 example, essentially configured 1800 in a horizontal plane
when operated in desert conditions over solar heated road- relative to the embodiment shown in FIG. 3B) in addition to
ways, or due to battery heat, current flow, and electrical resis- other locations. As with the female terminal support 107, the
tance). resilient member support 109 may comprise one or more
The female conductor housing 104 may be separated from retention features 112, for example, as represented by 112C in
the female terminal housing 106 by the female internal wall 55 FIG. 3C. The retention features 112 of the resilient member
105. The female internal wall 105 may comprise an opening support 109 may comprise slanted ramp protrusions as with
114 (124) to accommodate a female terminal 200. On the an embodiment of the female terminal support 107, or the
female conductor housing 104 side of the female internal wall retention features 112 may comprise any of the mechanical,
105, the female internal wall 105 may comprise an indicator chemical, or welding methods of fastening previously
113 identifying the connection side of the electrical connector 60 recited. The previously recited methods of retaining and/or
1000 (FIG. 1) for example (e.g., "A" for the female member fastening female terminals 200 and resilient members 3 00 are
and "B" for the male member). In other embodiments, the not intended to form an exhaustive list, but are merely a
indicator 113 may comprise a polarity sign to be used in place sampling from amongst a broad variety of retaining and fas-
of, or in addition to, the first and second female polarity tening methods known to those of ordinary skill in the art. As
indicators 111 and 121 (FIG. 3A). 65 with the female terminals 200, the resilient members 300 may
The female conductor housing 104 may circumferentially be core molded into the female housing 102 during the pro-
surround an end of a female terminal 200 inserted into each of duction of the female housing 102.
US 7,867,038 B2
5 6
The ends of the first and second female terminal chambers retention features 212 may contact corresponding retention
110 and 120 located in the female terminal housing 106, features 112 of the female housing 102 and prevent move-
opposite to the female internal wall 105, are referred to as the ment in a direction opposite to the assembly direction. At this
first and second orifices 116 and 126. Each of the first and point, the female terminal 200 may be substantially securely
second orifices 116 and 126 may be configured substantially 5 coupled with the female housing 102.
in a rectangular shape as shown in FIG. 3A. However, in the
illustrative embodiment shown in these figures, an aspect of Resilient Member
the first orifice 116, such as a width, may be configured Referring now to FIGS. SA and 5B, these figures respec-
differently than the same aspect of the second orifice 126. The tively show an orthogonal top view of a resilient member 300
difference in widths may inhibit an incorrectly polarized 10 and a side view of the resilient member 300 of FIG. SA. The
assembly of a male member 500 (FIG. 1) with the female resilient member 300 may comprise a resilient base member
member 100. Although a difference in dimensional aspects 310 and a resilient contact member 3 20. The resilient member
such as widths may be used to inhibit reversing the polarities 300 may be punch formed from a sheet of stainless steel (e.g.,
during connection ofan electrical connector 1000 (FIG. 1) the SS 301 with no plating), spring steel (e.g., spring steel with
present invention may not be limited to this method. Different 15 nickel plating) or other resilient material configured to work
configurations, devices, and dimensions may be used to within the anticipated environmental conditions of the elec-
facilitate the proper polar connection orientation during trical connector 1000 (FIG. 1). In some embodiments, the
assembly of a male member 500 with a female member 100. resilient member 300 may be plated or otherwise coated to
inhibit rust or to provide an appropriate level of resistance
Female Terminals 20 ( e.g., friction force) necessary to maintain the connection
view ofanembodiment ofa female terminal 200, and FIG. 4B 100.
nal 200, the female terminal 200 may comprise a terminal 25 retention members 312A and 312B (FIG. 5B). The resilient
female terminal 200 may comprise an electrically conductive ing retention members 112 within the resilient member sup-
gold-nickel alloy) or silver, among other materials, preferably 30 second terminal chambers 110 and 120. The resilient reten-
example), in order to increase the electrical conductivity ient members 300 within the female housing 102 during
from a standard plate of material and punched formed to the 35 stantially flat quadrilateral but embodiments of the present
ing. resilient base member 310 may be retained separate from the
couple with a copper wire conductor (for example) such as 40 resilient base member 310 may not overlay a corresponding
tor portion 204 may be electrically coupled to a wire conduc- is electrically coupled.
non-insulated connector fittings, crimping, and other meth- 45 R. The arcuate portion may be resiliently deformed toward
terminal. Embodiments of the terminal connector portion 204 from portions of an installed male member 500 (FIG. 1). The
The terminal contact portion 206 may be located at an 50 opposing surface or portion of the male member 500 in order
nal connector portion 204, and may comprise an angled end male member 500 with the female member 100 (see FIG. 1).
shown in FIG. 4B, 212A and 212B), and a contact surface portion is illustrated in FIGS. SA and 5B. However, embodi-
214. The angled end 210 may help facilitate the coupling or 55 ments of the present invention are not to be limited to this one
during the connection of an electrical connector 1000 (FIG. radii either alone or in combination with one or more rela-
current to flow from one end of the electrical connector 1000 60 angular bend joining two straight portions together, or a plu-
Terminal step 208 may separate the terminal connector wave type of configuration may be used in order to more
into female housing 102 (FIG. 3 B ), the terminal step 208 may 65 resentative sample of the various potential configurations
oppose a portion of the female housing 102 and prevent consistent with the present invention and is not intended to be
further movement in the assembly direction. The terminal exhaustive.
US 7,867,038 B2
7 8
One end of the resilient contact member 320 may comprise a natural environment for example and may experience a
a housing interface 324. An example of the housing interface temperature range from below -20° F. (-29° C.) to over 250°
324 may be illustrated by a small radius curve rotating in an F. (121 ° C.) (e.g., when operated in desert conditions over
opposite direction relative to the arcuate portion defined by solar heated roadways, or due to battery heat, current flow,
the radius R. The housing interface 324 may facilitate a slid- 5 and electrical resistance).
ing movement along a contacting portion of an inner wall of The male conductor housing 504 may be separated from
the female housing 102 (FIG. 3B) in response to assembly the male terminal housing 506 by the male internal wall 505.
and disassembly of a male member 500 and a female member The male internal wall 505 may comprise an opening 514
100 (see FIG. 2). The sliding contact may prevent or inhibit (524) to accommodate a male terminal 600. On the male
the abrading or prematurely wearing down of the inner sur- 10 conductor housing 504 side of the male internal wall 505, the
face of the female housing 102 over a multiple number of male internal wall 505 may comprise an indicator 513 iden-
connections and disconnections of the electrical connector tifying the connection side of the electrical connector 1000
1000 (FIG. 1). In this example, the contacting portion of the (FIG. 1), for example (e.g., "A" for the female member and
housing interface 324 curves away from the inner surface of "B" for the male member). In other embodiments, the indi-
the female housing 102 in directions tangent to the small 15 cator 513 may comprise a polarity sign to be used in place of,
radius curve. Further, the resilient contact member 320 may or in addition to, the first and second male polarity indicators
extend at an angle from the resilient base member 310 such 511 and 521 (FIG. 6A).
that the housing interface 324 may be located above (with The male conductor housing 504 may circumferentially
respect to FIG. 5B) a plane containing the resilient base surround an end of a male terminal 600 inserted into each of
member 310. This configuration may apply a pre-load to an 20 the first and second male terminal extensions 510 and 520. An
assembled resilient member 300 via the housing interface end of the male conductor housing 504 opposing the internal
324. By adjusting the angle for the resilient contact member wall 505 may be open to provide access for a conductor (not
320 relative to the resilient base member 310, and/or adjust- shown) to contact an exposed end of a male terminal 600. In
ing the radius R, the force applied to the male member 500 other embodiments, an end or side of the male conductor
through the resilient contact member 320 may be adjusted. 25 housing 504 adjacent to the male internal wall 505 may be
Adjusting the force of the resilient contact member 320 may open to provide conductor access. In the embodiment shown,
adjust the amount of insertion and withdrawal force for the the male conductor housing 504 substantially shrouds and
connecting and disconnecting of the electrical connector insulates the ends of the male terminals 600 from each other.
1000. Consequently, a desired amount of insertion and with- In certain other embodiments the male conductor housing
drawal force may be established for the connecting and dis- 30 504 may only partially surround an end of a male terminal 600
connecting of the electrical connector 1000. in each of the first and second male terminal extensions 510
and 520.
Male Member
The male internal wall 505 of each of the first and second
Turning now to FIGS. 6A, and 6B, the male member 500
male terminal extensions 510 and 520 may function as a male
may comprise a male housing 502, a first male terminal
35 terminal support (FIG. 6B). Each of the male terminal sup-
extension 510, a second male terminal extension 520, and
ports (i.e., male internal walls 505) may help to retain a
male terminals 600 (more clearly shown in FIG. 6B). A first
corresponding male terminal 600 in the respective first and
male polarity indicator 511 and a second male polarity indi-
second male terminal extensions 510 and 520. The male
cator 521 may indicate the respective polarities of the first
terminal support may comprise one or more retention mem-
male terminal extension 510 and the second male terminal
40 bers 512 (for example as represented by 512A), configured to
extension 520. An example of a male terminal 600 is shown in
retain a male terminal 600 after assembly into a male member
FIGS. 7A and 7B and is detailed later. The various compo-
500. Although a slanted ramp type ofretention member 512 is
nents of the male member 500 will be described in more detail
shown in FIG. 6B to facilitate an insertion type of assembly
in the following illustrative embodiment.
(e.g., inserting a male terminal 600 from the left to the right in
Male Housing 45 the male housing 502 with respect to FIG. 6B), a person of
stantially rectangular in shape and comprise a male conductor of retention member 512. Pins, rivets, fasteners, other
housing 504, a male internal wall 505, and a male terminal tip mechanical attachments, welding, and chemical adhesives,
510 and 520. Due to their similarities, only the first male 50 terminal 600 within the male housing 502. Further, similar
forward, reference numerals enclosed by parenthesis refer to additional force to oppose the friction force generated during
second male terminal extension 520. Although a substantially the connection and disconnection of the electrical connector
ments of the present invention may not be limited to this one 55 both of the male terminals 600. Other embodiments of the
one or more male terminals 600 may be used. The male In some cases the male terminals 600 may be core molded
housing 502 may be manufactured from a dielectric material into the male housing 502 at the time of manufacture.
application and provide sufficient electrical insulation 60 510 and 520 in the male terminal tips 506, opposite to the
iting the occurrence of an electrical short between the male terminal covers 516 and 526. Each of the first and second
terminals 600). For example, the material of the male housing male terminal covers 516 and 526 may be configured sub-
made by DuPont®. In some applications the reinforced nylon 65 ever, in the illustrative embodiment shown in these figures, an
material may comprise approximately 33% glass. The mate- aspect of the first male terminal cover 516, for example width,
rial may be used in a remotely controlled vehicle operating in may be configured differently than the same aspect of the
US 7,867,038 B2
9 10
second male terminal cover 526. The difference in widths plated with nickel and then plated with gold (for example), in
may inhibit an incorrectly polarized assembly of a male mem- order to increase the electrical conductivity between contact-
ber 500 (FIG. 1) with the female member 100. Although a ing portions of the male and female terminals 600 and 200.
difference in dimensional aspects such as widths may be used The male terminal 600 shown may be made from a standard
to inhibit reversing the polarities during connection of an 5 plate of material and punched formed to the correct size and
electrical connector 1000 (FIG. 1), the present invention may configuration, among other methods of forming.
not be limited to this method. Different configurations, The terminal connector portion 604 may be located on one
devices, and dimensions may be used to facilitate the proper end of the male terminal 600 and configured to electrically
polar connection orientation during assembly of a male mem- couple with a copper wire conductor (for example) such as
ber 500 with a female member 100. 10 wire conductors l0A and 20A (FIG. 1). The terminal connec-
The first and second male terminal covers 516 and 526 may tor portion 604 may be electrically coupled to a wire conduc-
each comprise a connector retention feature 507. In some tor through the use of soldering, mechanical fastening (e.g.,
embodiments, the connector retention feature 507 may be through the use of a screw clamp), standard insulated and
configured as an arcuate cavity or depression corresponding non-insulated connector fittings, crimping, and other meth-
to an arcuate portion of the resilient contact member 320 of a 15 ods of electrically coupling a wire conductor to a terminal.
resilient member 300 (see FIG. 5B). As the male member 500 Embodiments of the terminal connector portion 604 may
is connected to the female member 100 (see FIG. 1), the comprise a variety of configurations in order to accommodate
resilient member 300 moves relative to a surface of the cor- a particular electrical coupling method.
responding first and second male terminal covers 516 and 526 The terminal contact portion 606 may be located at an
until a portion of the resilient contact member 320 engages a 20 opposite end of the male terminal 600 relative to the terminal
corresponding portion of the connector retention feature 507. connector portion 604, and may comprise an angled end 610,
The engagement between the resilient contact member 320 one or more terminal retention features 612 (two are shown in
and the connector retention feature 507 may provide a sen- FIG. 7B, 612A and 612B), and a contact surface 614. The
sory indication that the male member 500 is fully connected angled end 610 may help facilitate the coupling or assembly
to the female member 100. In addition, the engagement 25 of a corresponding female terminal 200 (FIG. 2) during the
between the resilient contact member 320 and the connector connection of an electrical connector 1000 (FIG. 1). The
retention feature 507 may help to prevent inadvertent discon- contact surface 614 may directly contact an opposing surface
nection between the male member 500 and the female mem- of a female terminal 200 in order to allow an electrical current
ber 100 during the operation of the electrical connector 1000 to flow from one end of the electrical connector 1000 to the
in an applied device. 30 other.
The first and second male terminal covers 516 and 526 may Terminal step 608 may separate the terminal connector
further comprise an angled or slanted portion 570, which may portion 604 from the terminal contact portion 606. In some
be located at an end opposite to the male internal wall 505. embodiments, during assembly of the male terminal 600 into
The slanted portion 570 of each of the first and second male male housing 502 (FIG. 6B), the terminal step 608 may
terminal covers 516 and 526 may facilitate the insertion and/ 35 oppose a portion of the male housing 502 and prevent further
or assembly of the male member 500 with the female member movement in the assembly direction. The terminal retention
100 (see FIG. 1). In some embodiments, rounded, arcuate, or features 612 may contact corresponding retention features
other insertion facilitating features may be used in place of, or 512 of the male housing 502 and prevent movement in a
in addition to, the slanted portion 570 of each of the first and direction opposite to the assembly direction. At this point, the
second male terminal covers 516 and 526. At least part of the 40 male terminal 600 may be substantially securely coupled with
remaining portions of the first and second male terminal the male housing 502.
covers 516 and 526 may provide a contact surface for the
resilient member 300, as previously explained, and may pro- Assembly
vide a degree ofinsulation between the resilient members 300 Turning now to FIGS. SA and 8B, FIG. SA illustrates a
and the male terminals 600. The material of the first and 45 correctly assembled electrical connector 1000, while FIG. 8B
second male terminal covers 516 and 526 may be the same as illustrates an incorrectly assembled electrical connector
the material used for the rest of the male housing 502. In some 1000. As seen in FIG. SA, when the male member 500 is
embodiments, the first and second male terminal covers 516 correctly coupled to a female member 100, the first and sec-
and 526 may comprise a coating applied to a surface of the ond male polarity indicators 511 and 521 correspond to the
male terminals 600. Alternatively, a coating or texture may be 50 first and second female polarity indicators 111 and 121, indi-
applied to a surface of the first and second male terminal cating the maintenance of proper polarity across the electrical
covers 516 and 526 to vary the level of frictional resistance connector 1000. The correspondence between the sets of
between the surface and the contacting portion of the resilient polarity indicators 111, 121, 511, and 521, may provide a
contact member 320 of each of the respective resilient mem- visual indication of the correct coupling of the male and
bers 300. 55 female members 500 and 100. As seen in FIG. 8B, the first and
second male polarity indicators 511 and 521 may not be
Male Terminals visible from a top oriented viewing plane when the male
Turning now to FIGS. 7A and 7B, FIG. 7A shows a top member 500 is incorrectly assembled to the female member
view of an embodiment of a male terminal 600, and FIG. 7B 100. In addition, as indicated by the arrows for the first and
shows a side view of the male terminal 600 of FIG. 7A. As an 60 second male polarity indicators 511 and 521 (the polarity
example of an illustrative embodiment of a male terminal indicators themselves are not visible in this view), the polari-
600, the male terminal 600 may comprise a terminal connec- ties on each side of the incorrectly assembled electrical con-
tor portion 604 and a terminal contact portion 606. The male nector 1000 have been reversed.
terminal 600 may comprise an electrically conductive mate- Referring to FIGS. 9A and 9B, FIG. 9A illustrates a cross-
rial, such as brass, copper, or bronze. The male terminal 600 65 sectional view of the correctly assembled electrical connector
may be plated with gold (such as gold-cobalt or gold-nickel 1000 of FIG. SA as viewed along line 9A-9A, while FIG. 9B
alloy) or silver, among other materials, preferably copper illustrates a cross-sectional view of the incorrectly assembled
US 7,867,038 B2
11 12
electrical connector 1000 of FIG. 8B as viewed along line male terminal covers 516 and 526. At this point, the male
9B-9B. FIG. 9A shows an electrical connector 1000 in which member 500 may be securely coupled to the female member
abutting a contact surface 214 of the female terminal 200. The 5 similar due to the symmetry of the connector. However, com-
have an approximate width ofWl with the first male terminal of the present invention and differences beyond the widths of
orifice 126 such that a contact surface 614 of the correspond- 10 exist.
corresponding female terminal 200. The second male termi- Another Embodiment
nal cover 526 and the second orifice 126 may each have an
approximate width of W2 with the second male terminal Referring now to FIG. 11, this figure shows an orthogonal
cover 526 configured to fit within the second orifice 126. The 15 top view with a cross-section taken through the side of an
width Wl may be smaller than the width W2. This difference embodiment of an electrical connector. In this figure, refer-
in widths may provide another method of inhibiting or pre- ence number 2000 generally refers to another illustrative
venting cross-polarization during connection of the male embodiment of an electrical connector 2000 constructed
member 500 to the female member 100 (FIG. SA), since the according to aspects of the present invention. One difference
male member 500 may be connected to the female member 20 between the electrical connector 2000 and the previously
100 when the male member 500 is properly oriented with described electrical connector 1000 (FIG. 1) may be the
respect to the female member 100. The proper orientation of replacement of one or more resilient members 300 (FIG. 2) of
the male and female members 500 and 100 may provide for the previous illustrative embodiment with one or more resil-
the correct polarity of the connection. ient members 23 00. Otherwise, the function and materials for
FIG. 9B shows an electrical connector 1000 in which a 25 the two electrical connectors 1000 and 2000 may be consid-
male member 500 is incorrectly connected to a female mem- ered to be the same. Similar components may be identified
ber 100. This type of connection may be substantially pre- with similar reference numerals used in the previous descrip-
vented by the interference between the width of the second tion, and a detailed explanation of these components may not
male terminal cover 526 (W2) and the width of the first orifice be repeated.
116 (Wl)(e.g., W2-Wl). However, if the male member 500 30 Electrical connector 2000 may comprise a female member
is somehow coupled to the female member 100 in spite of this 2100 and a male member 500, shown here in a connected
interference, cross-polarization of the electrical connector state. The female member 2100 may comprise one or more
1000 may still be prevented by the first and second male female terminals 200 (only one is visible in this view) and the
terminal covers 516 and 526 separating the male and female male member 500 may comprise a corresponding number of
terminals 600 and 200. The first and second male terminal 35 male terminals 600. When the female member 2100 and the
covers 516 and 526 may prevent contact between correspond- male member 500 are coupled together, electricity may be
ing male and female terminals 600 and 200 when the male able to flow between wire conductors (not shown) through the
member 500 is in a second orientation with respect to the electrical connector 2000 via the areas of contact between the
female member 100. Therefore, as seen in this illustrative female and male terminals 200 and 600.
embodiment, cross-polarization of the electrical connector 40 The female member 2100 may comprise one or more resil-
1000 may be prevented and/or inhibited by at least two sepa- ient members 2300. The resilient members 2300 may provide
rate and independent methods, in addition to the visual indi- a pressing force to facilitate electrical conduction through the
cation given by the first and second male and female polarity contact areas between the corresponding female and male
indicators, 111, 121, 511, and 521. terminals 200 and 600. In addition, the resilient members
Referring now to FIG. 10, this figure illustrates an orthogo- 45 2300 may provide a securing force to inhibit or prevent the
nal cross-sectional view of a correctly assembled male mem- inadvertent disconnection of the male member 500 from the
ber 500 and female member 100. In this figure, the first and female member 2100 during the use of the electrical connec-
second male terminal extensions 510 and 520 (FIG. 6A) have tor 2300 in a desired application (e.g., such as in a vibratory
been inserted into the first and second female terminal cham- and dynamic environment of a remotely controlled vehicle).
bers 110 and 120 (FIG. 3A), or more specifically, the male 50 In some exemplary embodiments, the number of resilient
terminal housing 506 portions of the first and second male members 2300 corresponds to the number of electrical con-
terminal extensions 510 and 520 have been inserted into the nections formed or broken during the connection and discon-
first and second orifices 116 and 126 of the first and second nection of the electrical connector 2000 (e.g., two are shown
female terminal chambers 110 and 120. As the male member in FIG. 11). However, the number ofresilient members 2300
500 is connected to the female member 100, the resilient 55 may not be required to equal the number of electrical connec-
members 300 may initially contact the slanted portion 570 of tions formed or broken.
the corresponding first and second male terminal covers 516 Each resilient member 2300 may comprise a resilient hous-
and 526. The resilient contact portions 320 may respectively ing 2310 integrated with the housing of the female member
slidingly engage a top surface of each of the first and second 2100. As shown in FIG. 11, the resilient housing 2310 may be
male terminal covers 516 and 526. The resilient contact por- 60 substantially cylindrical for example, but embodiments of the
tions 320 may be compressed, causing the housing interface present invention may not be limited to this geometric con-
324 portion of the resilient member 300 to slidingly engage an figuration. Each resilient member 23 00 may further comprise
interior surface of the respective first and second female ter- a retention device 2324, a resilient device 2322, and a contact
minal chambers 110 and 120. The male member 500 may device 2320. The retention device 2324 may comprise an
continue to be inserted into the female member 100 until the 65 Allen set screw as shown for example, or may comprise any of
resilient contact portion 320 engages a corresponding con- a number of devices able to retain the resilient device 2322
nector retention feature 507 of the respective first and second and the contact device 2320 within the resilient housing 2310,
US 7,867,038 B2
13 14
while in some embodiments further providing a measure of male member 500 may comprise a corresponding number of
adjustability. For example, a mechanical threaded fastener, male terminals 600. When the female member 3100 and the
angled key, or cam device, among others, may be used. In this male member 500 are coupled together, electricity may be
example, the retention device 2324 may be threadably able to flow between wire conductors (not shown) through the
engaged with a top portion of the resilient housing 2310. 5 electrical connector 3000 via the contact areas between the
The resilient device 2322 may be located between the female and male terminals 200 and 600.
retention device 2324 and the contact device 2320. The resil- The female member 3100 may comprise one or more resil-
ient device 2322 may be a spring, such as a coil spring, or ient members 3300. The resilient members 3300 may provide
resilient material, such as foam, among other devices. The a pressing force to facilitate electrical conduction through the
resilient device 2322 may press against the contact device 10 contact area between the female terminals 200 and the male
2320, facilitating movement of the contact device 2320 as the terminals 600. In addition, the resilient members 3300 may
male member 500 and the female member 2100 are coupled provide a securing force to inhibit or prevent the inadvertent
together. The force applied to the contact device 2320 and disconnection of the male member500 from the female mem-
consequently to the male and female terminals 200 and 600, ber 3100 during the use of the electrical connector 3300 in a
may be adjusted by tightening or loosening the retention 15 desired application (e.g., such as in a vibratory and dynamic
male member 500 may be securely coupled to the female the number of electrical connections formed or broken during
eliminate or reduce the ability of the contact device 2320 to 20 3000, two electrical connections are shown in this embodi-
feature 507. formed or broken.
such as in a ball and spring type of mechanism. However, in 25 with a opposing surface of a first and second male terminal
second male terminal covers 516 and 526 (only the first male shown in FIG. 12, the area indicated by cross-hatching may
pin, angled member, cylinder, among others. The contact 30 and the top surface of the first male terminal cover 516,
device 2320 may be retained within theresilienthousing 2310 although only a portion of the abutting surfaces may be con-
between a protruding edge 2312 at one end and the retention figured to be interfering. The resilient member 3300 may
device 2324 at the other end. During connection of the male comprise a rib interfacing with a portion of the respective top
member500 and the female member 2100, the contact device surface of the first and second male terminal covers 516 and
2320 may engage the connector retention feature 507 as the 35 526, or the resilient member 3300 may comprise the wall of
male member 500 is fully coupled with the female member the female member housing 3102, among numerous other
2100. The contact device 2320 and the connector retention configurations such as those previously described for the
feature 507 may be configured to have corresponding or inter- resilient contact portion 320. Essentially, in some embodi-
facing features, such that when the male member 500 is fully ments the housing 3102 of the female member 3100 may
coupled with the female member 2100, a sensory indication 40 function as a resilient member, allowing at least some degree
of the application device 2320 engaging the connector reten- of resilient deformation or movement designed to apply a
tion feature 507 may be provided. The sensory indication may force to at least a portion of an installed male member 500
be visual, audible, tactile, or a combination of one or more of (e.g., such as the first and second male terminal covers 516
these sensory indications, in addition to other methods. and 526, or in some embodiments, the male terminals them-
45 selves, among other configurations). Alternatively, the first
Another Embodiment and second male terminal covers 516 and 526 may function as
a resilient member, allowing at least some degree of resilient
Referring now to FIG. 12, this figure shows an orthogonal deformation or movement designed to urge the male termi-
top view with a cross-section taken through the side of an nals 600 together with the corresponding female terminals
embodiment of an electrical connector. In this figure, refer- 50 200. Further, in some embodiments, both the female housing
ence number 3000 generally refers to another illustrative 3102 and the first and second male terminal covers 516 and
embodiment of an electrical connector 3000 constructed 526 may experience some degree of resilient deformation,
according to aspects of the present invention. One difference combining together to provide a force urging the male termi-
between the electrical connector 3000 and the previously nals 600 together with the corresponding female terminals
described electrical connectors may be the replacement of 55 200.
one or more resilient members 300 (FIG. 2) or2300 (FIG.11) The resilient member 3300 may further comprise protru-
of the previous illustrative embodiments, with one or more sions or features configured to engage with corresponding
resilient members 3300. Otherwise, the function and materi- depressions or features located on the top surfaces of the first
als for the electrical connectors 1000, 2000, and 3000 may be and second male terminal covers 516 and 526, such that the
considered to be the same. Similar components may be iden- 60 male member 500 may be securely coupled to the female
tified with similar reference numerals used in the previous member 3000 upon fully connecting the male member 500 to
description, and a detailed explanation of these components the female member 3100. An example of a protrusion for the
may not be repeated. resilient member 3300 may be an arcuate ridge corresponding
Electrical connector 3000 may comprise a female member to the connector retention feature 507 shown in FIG. 6B. The
3100 and a male member 500, shown here in a connected 65 resilient member 3300 may at least partially resiliently
state. The female member 3100 may comprise one or more deform with respect to the area of interference. Alternatively,
female terminals 200 (only one is visible in this view) and the the resilient member 3300 may take advantage of at least
US 7,867,038 B2
15 16
some degree of resilient deformation in the configuration of and second male terminals 1600 and 1650 after assembly into
the female member housing 3102. a male member 1500. Although a slanted ramp type of reten-
tion member 512 is shown in FIG. 13B to facilitate an inser-
Another Embodiment tion type of assembly (e.g., inserting a male terminal 1600
5 from the right to the left in the male housing 1502 with respect
Turning now to FIGS. 13A and 13B, the first figure shows to FIG. 13B), a person ofordinary skill in the art would not be
a top view of an illustrative embodiment of a male member limited to just this type of retention member 512. Pins, rivets,
1500 configured according to aspects of the present invention, fasteners, other mechanical attachments, welding, and
while the second figure shows an orthogonal cross-sectional chemical adhesives, among other various methods may be
top view of the male member 1500 of FIG. 13A as viewed 10 used to secure the first and second male terminals 1600 and
along line 13B-13B. One difference between the male mem- 1650 within the male housing 1502. Additionally, the first and
ber 1500 and the previously described male member 500 second male terminals 1600 and 1650 may be core molded
(FIG. 1) may be the lack of first and second male terminal along with the male housing 1502 at the time of manufacture.
covers 516 and 526 (see FIGS. 6A and 6B) in the male The first and second male terminals 1600 and 1650 may
member 1500. Another difference may be the use of first and 15 comprise retention members 612 (for example as represented
second male terminals 1600 and 1650 in male member 1500 by 612A and 612B, however, only the retention members 612
in place of the male terminals 600 shown in male member 500 of the first male terminal 1600 may be seen in FIG. 13B, the
(see FIG. 2). Otherwise, the function and materials for the second male terminal 1650 may be similarly configured)
male members 500 and 1500 may be considered to be sub- corresponding to the retention members 512. As with the
stantially the same. Similar components may be identified 20 retention member 512, a slanted ramp type of retention mem-
with similar reference numerals used in previous descrip- ber 612 is shown in FIG. 13B to facilitate an insertion type of
tions, and a detailed explanation of these components may not assembly, however, a person of ordinary skill in the art would
be repeated. not be limited to just this type of retention member 612. Pins,
Male member 1500 may comprise a male housing 1502 rivets, fasteners, other mechanical attachments, welding, and
and first and second male terminal extensions 1510 and 1520. 25 chemical adhesives, among other various methods may be
The first male terminal extension 1510 may comprise the first used to secure the first and second male terminals 1600 and
male terminal 1600, while the second male terminal exten- 1650 within the male housing 1502.
sion 1520 may comprise the second male terminal 1650. First Having thus described embodiments of the present inven-
and second male terminals 1600 and 1650 may be configured tion by reference to certain exemplary embodiments, it is
to be insertably engaged with the first and second orifices 116 30 noted that the embodiments disclosed are illustrative rather
and 126 of the first and second female terminal chambers 110 than limiting in nature. A wide range of variations, modifica-
and 120 of a female member 100 (see FIG. 3A). In some tions, changes, and substitutions are contemplated in the fore-
embodiments, some aspects of the first male terminal 1600 going disclosure. In some instances, some features of an
may be different than similar aspects of the second male embodiment of the present invention may be employed with-
terminal 1650 in order to inhibit the cross-polarizing connec- 35 out a corresponding use of the other features. Many such
tion of a male member 1500 and a female member 100. In the variations and modifications may be considered desirable by
embodiment shown, the width Wl of the first male terminal those skilled in the art based upon a review of the foregoing
1600 may be smaller that the width W2 of the second male description of the illustrative embodiments. Accordingly, it is
terminal 1650. Interference between the larger width W2 and appropriate that the appended claims be construed broadly
the first orifice 116 may inhibit the connection between a 40 and in a marmer consistent with the scope of the invention.
female member 100 and an improperly oriented male mem- We claim:
ber 1500 (i.e., the male member 1500 may be improperly 1. An electrical connector assembly having a first connec-
oriented with respect to the female member 100). tor, the first connector comprising:
The male housing 1502 may be substantially rectangular in an electrically insulating housing;
shape and comprise a male conductor housing 504 and a male 45 an electrically conductive first terminal retained by the
internal wall 1505 for each of the first and second male housing, wherein the first terminal extends from the
terminal extensions 1510 and 1520. Although a substantially housing and comprises a contact surface extending
rectangular shape is shown for the male housing 1502, along a coupling length of the first terminal outside of
embodiments of the present invention may not be limited to the housing for electrically coupling with a second ter-
this one configuration. Any configuration capable of accom- 50 minal disposed within a female connector receptacle;
modating one or more first and second male terminals 1600 an insulating cover disposed along at least a portion of the
and 1650 may be used. The male housing 1502 may be coupling length of the first terminal for electrically insu-
manufactured from a dielectric material able to withstand the lating one or more surfaces of the first terminal other
operating conditions of an intended application and provide than the contact surface; and
sufficient electrical insulation between the current carrying 55 wherein at least a portion of the coupling length of the first
first male terminal 1600 and second male terminal 1650 (i.e., terminal, the insulating cover and the contact surface are
inhibiting the occurrence of an electrical short between the configured for insertion through an opening of a female
first male terminal 1600 and the second male terminal 1650). connector receptacle.
The male internal wall 1505 of each of the first and second 2. The electrical connector assembly according to claim 1,
male terminal extensions 1510 and 1520 may function as a 60 wherein the insulating cover extends along substantially the
male terminal support. Each of the male terminal supports entire length of the coupling length of the first terminal.
(i.e., male internal walls 1505) may respectively secure and 3. The electrical connector assembly according to claim 1,
support the first and second male terminals 1600 and 1650 in wherein the insulating cover extends from the housing of the
the corresponding first and second male terminal extensions first connector.
1510 and 1520. The male terminal support may comprise one 65 4. The electrical connector assembly according to claim 1,
or more retention members 512 (for example as represented wherein the insulating cover comprises an extension of the
by 512A and 512B) configured to retain the respective first housing of the first connector.
US 7,867,038 B2
17 18
5. The electrical connector assembly according to claim 1, female terminals when electrically coupling the first
wherein at least a portion of the insulating cover is resiliently component with the second component would otherwise
deformable for urging contact between the contact surface of reverse polarity.
the first terminal and a second terminal when the first terminal 14. An electrical connector comprising a first component
is inserted at least partially into a female connector recep- 5 configured to electrically couple with a second component,
tacle. wherein the first component includes at least two male termi-
6. The electrical connector assembly according to claim 1, nals and the second component includes at least two cham-
wherein the first terminal is generally elongated, having a bers, each chamber containing at least a portion of at least one
rectangular longitudinal cross-section, the contact surface female terminal, the first component further comprising:
comprises a downwardly facing surface of the first terminal 10 an insulating housing wherein the male terminals extend at
and the insulating cover is disposed along an upwardly facing least partially from the insulating housing, and wherein
surface of the first terminal. each male terminal comprises a contact surface extend-
7. The electrical connector assembly according to claim 6, ing along a coupling length of the male terminal outside
wherein the insulating cover further comprises an engaging of the insulating housing for electrically coupling with at
recess configured to retain the first terminal within a female 15 least one female terminal disposed within each chamber;
connector. at least two terminal covers, each terminal cover covering
8. The electrical connector assembly according to claim 1, at least a portion of a leading edge surface of one of the
wherein the insulating cover extends beyond an end of the male terminals extending from the first component; and
first terminal. wherein each terminal cover insulates the leading edge
9. The electrical connector assembly according to claim 8, 20 surface of the male terminals from contacting a corre-
wherein the insulating cover extends at least partially across sponding edge surface of the female terminals during an
the end of the first terminal. initial engagement of the first component with the sec-
10. The electrical connector assembly according to claim ond component.
9, wherein the first terminal further comprises a retaining 15. An electrical connector comprising:
groove disposed a predetermined distance from the first con- 25 an insulating housing for supporting one or more male
nectar for retention of the first terminal within a female con- terminals;
nector receptacle. at least two male terminals wherein at least a first male
11. An electrical connector comprising a first component terminal comprises a first contact surface extending
configured to electrically couple with a second component, along a first coupling length of the first male terminal
wherein the first component includes at least two male termi- 30 outside of the insulating housing; and
nals and the second component includes at least two cham- a first terminal cover covering a portion of the first coupling
bers, each chamber containing at least a portion of at least one length of the first male terminal other than the first con-
female terminal, the first component further comprising: tact surface;
an insulating housing, wherein the male terminals extend at a depression in a first surface of the first terminal cover,
least partially from the insulating housing, and wherein 35 wherein the first surface covers a portion of the first
each male terminal comprises a contact surface extend- coupling length of the first male terminal on a side oppo-
ing along a coupling length of the male terminal outside site from the first contact surface to retain the at least two
of the insulating housing for electrically coupling with male terminals within a female connector.
the at least one female terminal disposed within each 16. The electrical connector according to claim 15,
chamber; 40 wherein the first terminal cover insulates at least a portion of
a surface of the first male terminal.
at least two terminal covers, wherein each terminal cover is
17. The electrical connector according to claim 16, further
disposed along at least a portion of the coupling length of
comprising:
each male terminal to cover one or more surfaces of each
a second male terminal comprising a second contact sur-
male terminal other than the contact surface; and
45 face extending along a second coupling length of the
wherein at least one dimension of one of the at least two second male terminal outside the insulating housing;
terminal covers is smaller than a corresponding dimen- a second terminal cover covering a portion of the second
sion of another of the at least two terminal covers. coupling length of the second male terminal other than
12. The electrical connector of claim 11, wherein at least the second contact surface; and
one of the terminal covers is comprised of electrically insu- 50 wherein the first terminal cover is configured with a differ-
lating material and is secured to at least a distal end of one of ent width than the second terminal cover.
the male terminals extending from the first component. 18. A female electrical connector configured to couple with
13. An electrical connector comprising a first component a male electrical connector to form an electrical connection,
configured to electrically couple with a second component, the female electrical connector comprising:
wherein the first component includes at least two male termi- 55 a female housing having a first chamber and a second
nals and the second component includes at least two cham- chamber wherein at least one dimensional aspect of the
bers, each chamber containing at least a portion of at least one first chamber is larger than a corresponding aspect of the
female terminal, the first component further comprising: second chamber;
an insulating housing, wherein the male terminals extend at a first terminal at least partially disposed within at least a
least partially from the insulating housing, and wherein 60 portion of the first chamber, the first terminal having a
each male terminal comprises a contact surface extend- coupling length and a first contact surface extending
ing along a coupling length of the male terminal outside along at least a portion of the coupling length for elec-
of the insulating housing for electrically coupling with at trically coupling the first terminal to a third terminal on
least one female terminal disposed within each chamber; the male electrical connector;
and 65 a second terminal at least partially disposed within at least
at least two terminal covers, wherein each terminal cover a portion of the second chamber, the second terminal
insulates the male terminals from the corresponding having a coupling length and a second contact surface
US 7,867,038 B2
19 20
extending along at least a portion of the coupling length a female terminal disposed at least partially within the
for electrically coupling the second terminal to a fourth female receptacle;
terminal on the male electrical connector; wherein at least one wall of the female receptacle is resil-
a first resilient member mounted within the first chamber iently deformable and disposed to urge the female ter-
wherein at least a portion of the first resilient member is 5 minal and a male connector terminal together when the
spaced from the first terminal; male connector terminal is at least partially inserted
a second resilient member mounted within the second within the female receptacle and into electrical contact
chamber, wherein at least a portion of the second resil- with at least a portion of a contact surface of the female
ient member is spaced from the second terminal; terminal; and
wherein the first resilient member and the second resilient 10 wherein the at least one wall of the female receptacle urges
members are each adapted to apply a biasing force to an the female terminal and male connector terminal
insulating cover on each of the third and fourth termi- together with an urging force, at least a portion of the
nals, respectively, which insulating covers are disposed urging force having at least a force component perpen-
along at least a portion of a coupling length of the third dicularto and at a location laterally adjacent to the length
and fourth terminal for electrically insulating one or 15 of the female terminal at which at least a portion of the
more surfaces of each of the third and fourth terminal; contact surface is disposed when the male connector
and terminal is at least partially inserted within the female
whereby the electrical connection is established when the receptacle and is in electrical contact with the at least a
male electrical connector is coupled to the female elec- portion of the contact surface of the female terminal.
trical connector and the resilient members cause the first 20 21. The electrical connector of claim 20, wherein the
and third terminals and second and fourth terminals to female housing comprises a uniform insulating material.
engage in electrical contact. 22. The electrical connector of claim 20, wherein the at
19. An electrical connector assembly having a first connec- least a portion of the female terminal contact surface is con-
tor, the first connector comprising: figured to establish electrical contact with the male connector
an electrically insulating housing; 25
terminal and is substantially planar.
an electrically conductive first terminal retained by the
23. The electrical connector of claim 20, wherein the
electrically insulating housing, wherein the first termi-
female terminal is generally elongated, having a rectangular
nal extends from the electrically insulating housing and
longitudinal cross-section, and wherein the contact surface of
comprises a contact surface extending along a coupling
the female terminal is substantially planar.
length of the terminal outside of the electrically insulat- 30
24. The electrical connector of claim 20, wherein the
ing housing for electrically coupling with a second ter-
minal disposed within a female connector receptacle; female receptacle comprises a tubular shape having a closed-
an insulating cover disposed along at least the portion of shaped cross-section.
the coupling length of the first terminal for electrically 25. The electrical connector of claim 24, wherein the tubu-
insulating one or more surfaces of the first terminal other 35 lar shape comprises a substantially rectangular cross-section.
than the contact surface; 26. The electrical connector of claim 20, wherein the
wherein at least a portion of the coupling length of the first female terminal is configured to be coupled with the male
terminal, the insulating cover and the contact surface are connector terminal substantially by an interference fit
configured for insertion through an opening of a female between the at least one wall of the female receptacle and at
connector receptacle; and 40 least one surface of the male connector terminal causing the at
wherein the insulating cover extends along and in contact least one wall of the female receptacle to resiliently deform.
with at least a portion of a surface of the first terminal 27. The electrical connector of claim 26, wherein any resil-
facing away from the contact surface of the first termi- ient deformation of the female housing caused by introduc-
nal. tion of the male connector terminal into the female receptacle
20. An electrical connector comprising: 45 is provided substantially by the at least one wall of the female
a female housing comprising an insulating material at least receptacle without substantial deformation of the at least one
partially forming a female receptacle, wherein the surface of the male connector terminal.
female receptacle comprises a receptacle opening for at
least partially receiving a male connector terminal; * * * * *
EXHIBIT 7
I 1111111111111111 11111 lllll lllll lllll lllll 111111111111111 111111111111111111
US009166323B2
c12) United States Patent (IO) Patent No.: US 9,166,323 B2

Lampert et al. (45) Date of Patent: Oct. 20, 2015
(54) ELECTRICAL CONNECTOR ASSEMBLY (2013.01); H0lR 13/64 (2013.01); H0lR

13/642 (2013.01); HOlR 13/41 (2013.01);
(71) Applicant: TRAXXAS LP, Plano, TX (US) HOlR 13/465 (2013.01)
(58) Field of Classification Search
(72) Inventors: Jon Kenneth Lampert, Allen, TX (US); USPC .......... 439/679, 691, 693, 680, 282, 296, 284
Seralaathan Hariharesan, Flower See application file for complete search history.
Lewisville, TX (US)
(56) References Cited
(73) Assignee: TRAXXAS LP, McKinney, TX (US) U.S. PATENT DOCUMENTS
( *) Notice: Subject to any disclaimer, the term ofthis 2,121,338 A 6/1938 Chirelstein
patent is extended or adjusted under 35 2,203,122 A 6/ 1940 Anderson
U.S.C. 154(b) by O days. 2,838,739 A 6/1958 Winkler
3,091,746 A 5/1963 Winkler
(21) Appl. No.: 14/171,568 (Continued)
(22) Filed: Feb.3,2014 FOREIGN PATENT DOCUMENTS
(65) Prior Publication Data DE 704 450 3/1941

EP 0 318 831 A2 6/1989
US 2014/0148064 Al May 29, 2014 (Continued)
Related U.S. Application Data OTHER PUBLICATIONS
(63) Continuation of application No. 12/959,872, filed on Clarke, Brooke; "Power Pole" web page article; Brooke Clarke,
Dec. 3, 2010, now Pat. No. 8,641,440, which is a Ukiah CA, U.S.A., 2003-2006.
(Continued)
Apr. 3, 2009, now Pat. No. 7,867,038, which is a
Dec. 6, 2007, now Pat. No. 7,530,855, which is a Primary Examiner - Phuongchi T Nguyen
continuation of application No. 11/736,460, filed on (74) Attorney, Agent, or Firm - CARR Law Firm PLLC
Apr. 17, 2007, now Pat. No. 7,374,460.
(57) ABSTRACT
(51) Int. Cl.
H0lR 25100 (2006.01) An electrical connector is provided comprising a female
H0lR 13/187 (2006.01) member configured to couple with male member. The female
H0lR 13/26 (2006.01) member includes a female receptacle having an opening, and
H0lR 13/64 (2006.01) a female electrode is at least partially disposed within the
H0lR 13/642 (2006.01) female receptacle. A resilient member is configured to
HOlR 13/41 (2006.01) enhance electrical connection between the female electrode
HOlR 13/46 (2006.01) and a male connector electrode.
(52) U.S. Cl.
CPC .............. H0lR 13/187 (2013.01); H0lR 13/26 59 Claims, 11 Drawing Sheets
1000
500
US 9,166,323 B2
Page 2
(56) References Cited JP H5-87837 U 11/1993

JP H06-013064 1/1994
U.S. PATENT DOCUMENTS JP H07-75237 A 3/1995
JP Hll-329630 11/1999
3,218,599 A 11/1965 Winkler
OTHER PUBLICATIONS
3,233,211 A 2/1966 Smith Anderson Power Products; "PP15 Powerpole Connector" data sheet;
3,259,870 A 7/1966 Winkler
3,273,105 A 9/1966 Klassen Anderson Power Products, Sterling, MA U.S.A. (admitted prior art).
3,810,070 A 5/1974 Ludwig Anderson Power Products, "SB Connector Family" data sheet;
3,909,099 A 9/1975 Winkler Anderson Power Products, Sterling, MA, U.S.A. (admitted prior art).
4,018,497 A 4/1977 Bulanchuk Anderson Power Products; "SB 50 Connector" data sheet; Anderson
4,083,617 A 4/1978 Wyatt Power Products, Sterling, MA, U.S.A. (admitted prior art).
4,342,498 A 8/1982 Patton et al. Anderson Power Products; "SBS 50 Connector" data sheet; Ander-
4,416,498 A 11/1983 Sado et al. son Power Products, Sterling, MA. U.S.A. (admitted prior art).
4,630,876 A 12/1986 Grunberg et al. Horizon Hobby; "E-flite EC3 Device & Battery Connector, Male-
4,639,061 A 1/1987 Muzslay Female" web page; Horizon Hobby, Inc., Champaign, IL, U.S.A.
4,737,118 A 4/1988 Lockard 2006.
4,846,729 A 7/1989 Hikami et al. Tyco Electronics, "Hot Plug, High Current Dual CROWN CLIP
4,990,099 A 2/1991 Marin et al. Socket Connector" ELCON Products International Co., Fremont,
5,533,915 A 7/1996 Deans
CA U.S.A. 2000-2001.
5,575,674 A 11/1996 Davis et al.
McMaster-Carr; "Quick-Disconnect Terminals" catalog p. 724;
5,882,212 A 3/1999 McHugh et al.
5,921,809 A 7/1999 Fink McMaster-Carr Supply Co. (admitted prior art).
6,268,564 Bl 7/2001 Miyakoshi Molex; "Standard .093" web pages; Molex, Lisle IL U.S.A. (admit-
6,488,546 B2 12/2002 Sakurai et al. ted prior art).
6,619,995 Bl 9/2003 Hayashi et al. Hyperphysics, "Household Wiring-Polarized Receptacles" web
6,619,996 B2 9/2003 Hara et al. page article; http://hyperphysics.phy-astr.gsu.edu/hbase/electric/
6,623,309 B2 9/2003 Sakurai et al. hsehld.htrnl (admitted prior art).
6,645,003 B2 11/2003 Yoshida et al. TRAXXAS; "REVO transmission" illustration ( 1 page); Traxxas LP,
6,790,067 B2 * 9/2004 Douty et al. .................. 439/284 Plano TX U.S.A. (admitted prior art).
6,994,596 B2 2/2006 Katsuma et al. Deans; "Ultra Plug" photographs (3 pages); Wm. F. Deans, Para-
7,004,795 B2 2/2006 Mancini et al. mount CA U.S.A. (admitted prior art).
7,374,460 Bl 5/2008 Hariharesan et al.
MOLEX; "Standard .093" connector photographs (7 pages); Molex,
7,530,855 B2 5/2009 Hariharesan et al.
Lisle IL U.S.A. (admitted prior art).
"Standard 11 0V electrical plugs and receptacles" photographs ( 5
2004/0127104 Al 7/2004 Stefaniu et al. pages) (admitted prior art).
2007/0010113 Al 1/2007 F ukatsu et al. Barajas, Jaime; "Styling Input from Jaime", Traxxas LP, Plano TX
2007/0059970 Al 3/2007 Ichio et al. U.S.A. (confidential internal document, Jan. 23, 2007).
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JP S62-25477 U 2/1987 * cited by examiner
U.S. Patent Oct. 20, 2015 Sheet 1 of 11 US 9,166,323 B2
1000
FIG.1
1000
FIG. 2
100 111
~ 121
FIG. 3A
100
102
,J
200
FIG.3B
100
,J
112C
200
FIG.3C
208 214
,----..-----,}
200----.
□ 210
206
204
FIG. 4A
212A~ ,214 /'210

200----. --~K-~-~---n
r
rr-11
212B_./""
\_208
FIG.4B
608 612
610
604
FIG. 7A
600----. ~
11 - ~1 ~1
6122:
----=--------.-------'lo
612B7 614 "-610
FIG. 7B
300
324
FIG. SA
300
,I
R
312A
312B
FIG. SB
500 516
FIG. 6A
500
~ 502
FIG. 6B
111
1000
511
FIG. 8A
111
1000
FIG. 8B
1000
~ W1 W2
516 526
600 600
FIG. 9A
1000
~ W2-W1 - -
FIG. 9B
a.s . P at ent Oct. 20

, 2015 Sheet 9
Of JJ U S 9 '1 66,323 B
2
FIG. I O
2000
2310
2324
2322
2320
I
FIG. I 600
3000
FIG.12
1500
~ W2
1520~
1650
D
13B 13B
L-..._____ _J
1600
1510__,.
W1
FIG.13A
1500
1650
FIG.13B
US 9,166,323 B2
1 2
ELECTRICAL CONNECTOR ASSEMBLY FIG. 4B illustrates a side view of the female terminal of
FIG. 4A;
CROSS-REFERENCE TO RELATED FIG. SA illustrates an orthogonal top view of a resilient
APPLICATIONS member;
FIG. SB illustrates a side view of the resilient member of
This application is a continuation of, and claims the benefit FIG. SA;
of the filing date of, co-pending U.S. patent application Ser. FIG. 6A illustrates an orthogonal top view of a male mem-
No. 12/959,872 entitled ELECTRICAL CONNECTOR ber;
ASSEMBLY, filed Dec. 10, 2010, which is a continuation of FIG. 6B illustrates a cross-sectional side view of the male
10
U.S. patent application Ser. No. 12/417,792 entitled ELEC- member of FIG. 6A;
TRICAL CONNECTOR ASSEMBLY, filed Apr. 3, 2009, FIG. 7A illustrates a top view of a male terminal;
now U.S. Pat. No. 7,867,038, which is a continuation of U.S. FIG. 7B illustrates a side view of the male terminal of FIG.
patent application Ser. No. 11/951,754 entitled ELECTRI- 7A;
CAL CONNECTOR ASSEMBLY, filed Dec. 6, 2007, now 15
FIG. SA illustrates an orthogonal top view of the electrical
U.S. Pat. No. 7,530,855, which is a continuation of U.S. connector of FIG. 1 correctly assembled;
patent application Ser. No. 11/736,460 filed Apr. 17, 2007, FIG. SB illustrates an orthogonal top view of the electrical
now U.S. Pat. No. 7,374,460. connector of FIG. 1 incorrectly assembled;
BACKGROUND OF THE INVENTION 20 assembled electrical connector of FIG. SA as viewed along
line 9A-9A;
1. Field of the Invention FIG. 9B illustrates a cross-sectional view of the incorrectly
The present invention generally relates to electrical con- assembled electrical connector of FIG. SB as viewed along
nectors and, more particularly, to high current electrical con- line 9B-9B;
nectors with protection against reverse polarity connections. 25 FIG. 10 illustrates an orthogonal cross-sectional view of
2. Description of the Related Art the assembled electrical connector of FIG. 1;
A wide variety of electronic devices are powered through FIG. 11 illustrates an orthogonal cross-sectional top view
the use of battery packs. For example, remotely controlled of another embodiment of an electrical connector configured
vehicles of all types may have an on-board rechargeable according to aspects of the present invention;
battery pack supplying stored electricity to an electric motor. 30
FIG. 12 illustrates an orthogonal cross-sectional top view
In some of these lightweight vehicles, racing creates a of another embodiment of an electrical connector configured
demand for more powerful motors along with increasing according to aspects of the present invention;
levels of current capacity to energize the motors. As a battery FIG. 13A illustrates a top view of another embodiment of
pack is drained of the stored energy contained therein, a user a component of an electrical connector configured according
must be able to easily exchange a depleted battery pack for a 35
to aspects of the present invention; and
fully charged one. The depleted battery pack is then con-
FIG. 13B illustrates an orthogonal cross-sectional top view
nected to a battery charger in order to be ready for the next
of the component of FIG. 13A as viewed along line 13B-13B.
exchange. Consequently, there exists a need for a high current
electrical connector with a lightweight and compact design.
40 DETAILED DESCRIPTION
SUMMARY OF THE INVENTION
In the following discussion, numerous specific details are
In accordance with an embodiment of the present inven- set forth to provide a thorough understanding of the present
tion, an electrical connector having a lightweight and com- invention. However, those skilled in the art will appreciate
pact design is provided wherein a resilient member is config- 45 that the present invention may be practiced without such
ured to enhance electrical connection between a female specific details. In other instances, well-known elements have
electrode and a male connector electrode. been illustrated in schematic or block diagram form in order
not to obscure the present invention in unnecessary detail.
BRIEF DESCRIPTION OF THE DRAWINGS Additionally, for the most part, details concerning well
50 known features and elements have been omitted inasmuch as
For a more complete understanding of the present inven- such details are not considered necessary to obtain a complete
tion and the advantages thereof, reference is now made to the understanding of the present invention, and are considered to
following Detailed Description taken in conjunction with the be within the understanding of persons of ordinary skill in the
accompanying drawings, in which: relevant art.
FIG. 1 illustrates a general orthogonal top view of an 55 Turning now to the drawings, FIG. 1 shows a top orthogo-
embodiment of an electrical connector configured according nal view of an assembled electrical connector with attached
to the present invention and showing attached wire conduc- wire conductors. In this drawing, reference numeral 1000
tors; generally indicates an illustrative embodiment of an electrical
FIG. 2 illustrates an exploded assembly view of the elec- connector 1000 at least partially configured according to the
trical connector of FIG. 1; 60 present invention. The electrical connector 1000 may com-
FIG. 3A illustrates an orthogonal top view of a female prise a female member 100 and a male member 500. Attached
member of the electrical connector of FIG. 1; to the electrical connector 1000 are wire conductors l0A,
FIG. 3B illustrates a cross-sectional view of the female 1 OB, 20A, and 20B. The wire conductors 1 0A, 1 OB, 20A, and
member of FIG. 3A as viewed along line 3B-3B; 20B, may not considered as components of the electrical
FIG. 3C illustrates a cross-sectional view of the female 65 connector 1000 and are shown for the purposes of illustration.
member of FIG. 3A as viewed along line 3C-3C; Wire conductors l0A and l0B may carry a positive current
FIG. 4A illustrates a top view of a female terminal; flow and wire conductors 20A and 20B may carry a negative
US 9,166,323 B2
3 4
current flow. The various components of the electrical con- indicator 113 may comprise a polarity sign to be used in place
nector 1000 will be described in more detail in the following of, or in addition to, the first and second female polarity
illustrative embodiment. indicators 111 and 121 (FIG. 3A).
Referring to FIG. 2, the components of an embodiment of The female conductor housing 104 may circumferentially
the electrical connector 1000 are shown in an exploded 5 surround an end of a female terminal 200 inserted into each of
assembly view. The female member 100 may comprise a the first and second female terminal chambers 110 and 120.
female housing 102, a first and second female terminal 200, An end of the female conductor housing 104 opposing the
and a first and second resilient member 300. The male mem- female internal wall 105 may be open to provide access for a
ber 500 may comprise a male housing 502, and a first and conductor (not shown) to contact an exposed end of a female
second male terminal 600. 10 terminal 200. In other embodiments, an end or side of the
Female Member female conductor housing 104 adjacent to the female internal
Turning now to FIGS. 3A, 3B, and 3C, the female member wall 105 may be open to provide conductor access. In the
100 may comprise a female housing 102, a first female ter- embodiment shown, the female conductor housing 104 sub-
minal chamber 110, a second female terminal chamber 120, stantially shrouds and insulates the ends of the female termi-
female terminals 200, and resilient members 300 (more 15 nals 200 from each other. In certain other embodiments the
clearly shown in FIG. 2). A first female polarity indicator 111 female conductor housing 104 may only partially surround an
and a second female polarity indicator 121 may indicate the end of a female terminal 200 in each of the first and second
respective polarities of the first female terminal chamber 110 female terminal chambers 110 and 120.
and the second female terminal chamber 120. A first orifice The female terminal housing 106 portions of each of the
116 and a second orifice 126 may be located at an end of the 20 first and second female terminal chambers 110 and 120 may
female member 100 opposite to the first and second female comprise a female terminal support 107 and a resilient mem-
polarity indicators 111 and 121. An example of a resilient ber support 109 (FIG. 3C). Each of the female terminal sup-
member 300 is shown in FIGS. 3B and 3C. A resilient mem- ports 107 may help to retain a corresponding female terminal
ber 300 may be located in each of the first and second female 200 in the respective first and second female terminal cham-
terminal chambers 110 and 120 (however, only one is shown 25 bers 110 and 120. The female terminal support 107 may
in the FIGS. 3B and 3C for the purposes of illustration). The comprise one or more retention members 112 (for example as
various components of the female member 100 will be represented by 112A) configured to retain a female terminal
described in more detail in the following illustrative embodi- 200 after assembly into a female member 100. Although a
ment. slanted ramp type of retention member 112 is shown in FIG.
Female Housing 30 3B to facilitate an insertion type of assembly (e.g., inserting a
Referring to FIG. 3B, the female housing 102 may be female terminal 200 from left to right in the female housing
substantially rectangular in shape and comprise a female 102 with respect to FIG. 3B), a person ofordinary skill in the
conductor housing 104, a female internal wall 105, and a art would not be limited to just this type of retention member
female terminal housing 106, for each of the first and second 112. Pins, rivets, fasteners, other mechanical attachments,
female terminal chambers 110 and 120. Due to symmetry, 35 welding, and chemical adhesives, among other various meth-
only the first female terminal chamber 110 will be described ods may be used to secure a female terminal 200 in the female
parenthesis refer to the second female terminal chamber 120. 112B may be used to provide additional force to oppose the
Although a substantially rectangular shape is shown for the friction force generated during the assembly and disassembly
female housing 102, embodiments of the present invention 40 of the electrical connector 1000 (FIG. 1) that may otherwise
may not be limited to this one configuration. Any configura- move or dislocate one or both of the female terminals 200.
tion capable of accommodating one or more female terminals Other embodiments of the female member 100 may not com-
200 may be used. The female housing 102 may be manufac- prise retention members 112. In some cases the female ter-
tured from a dielectric material able to withstand the operat- minals 200 and resilient members 300 may be core molded
ing conditions of an intended application and provide suffi- 45 into the female member 100 at the time of manufacture.
cient electrical insulation between the current carrying The resilient member support 109 (FIG. 3C) may secure a
female terminals 200 (i.e., inhibiting the occurrence of elec- resilient member 300 in each of the first and second female
trical shorts between the female terminals 200). For example, terminal chambers 110 and 120. The resilient member sup-
the material of the female housing 102 may be a glass rein- port 109 is shown as proximate to the female internal wall
forced nylon such as Zytel® 70G33L, made by DuPont®. In 50 105. However, an embodiment of the resilient member sup-
some applications the reinforced nylon material may com- port 109 may be located proximate to an end of the female
prise approximately 33% glass. The material may be used in terminal housing 106 opposite to the female internal wall 105
a remotely controlled vehicle operating in a natural environ- (i.e., the insertion end of the female terminal housing 106, for
ment for example and may experience a temperature range example, essentially configured 180° in a horizontal plane
from below -20° F. (-29° C.) to over 250° F. (121 ° C.) (e.g., 55 relative to the embodiment shown in FIG. 3B) in addition to
when operated in desert conditions over solar heated road- other locations. As with the female terminal support 107, the
ways, or due to battery heat, current flow, and electrical resis- resilient member support 109 may comprise one or more
tance). retention features 112, for example, as represented by 112C in
The female conductor housing 104 may be separated from FIG. 3C. The retention features 112 of the resilient member
the female terminal housing 106 by the female internal wall 60 support 109 may comprise slanted ramp protrusions as with
105. The female internal wall 105 may comprise an opening an embodiment of the female terminal support 107, or the
114 (124) to accommodate a female terminal 200. On the retention features 112 may comprise any of the mechanical,
female conductor housing 104 side of the female internal wall chemical, or welding methods of fastening previously
105, the female internal wall 105 may comprise an indicator recited. The previously recited methods of retaining and/or
113 identifying the connection side of the electrical connector 65 fastening female terminals 200 and resilient members 3 00 are
1000 (FIG. 1) for example (e.g., "A" for the female member not intended to form an exhaustive list, but are merely a
and "B" for the male member). In other embodiments, the sampling from amongst a broad variety of retaining and fas-
US 9,166,323 B2
5 6
tening methods known to those of ordinary skill in the art. As into female housing 102 (FIG. 3 B ), the terminal step 208 may
with the female terminals 200, the resilient members 300 may oppose a portion of the female housing 102 and prevent
be core molded into the female housing 102 during the pro- further movement in the assembly direction. The terminal
duction of the female housing 102. retention features 212 may contact corresponding retention
The ends of the first and second female terminal chambers 5 features 112 of the female housing 102 and prevent move-
110 and 120 located in the female terminal housing 106, ment in a direction opposite to the assembly direction. At this
opposite to the female internal wall 105, are referred to as the point, the female terminal 200 may be substantially securely
first and second orifices 116 and 126. Each of the first and coupled with the female housing 102.
second orifices 116 and 126 may be configured substantially Resilient Member
in a rectangular shape as shown in FIG. 3A. However, in the 10
Referring now to FIGS. SA and 5B, these figures respec-
illustrative embodiment shown in these figures, an aspect of
tively show an orthogonal top view of a resilient member 300
the first orifice 116, such as a width, may be configured
and a side view of the resilient member 300 of FIG. SA. The
differently than the same aspect of the second orifice 126. The
difference in widths may inhibit an incorrectly polarized resilient member 300 may comprise a resilient base member
assembly of a male member 500 (FIG. 1) with the female 15
310 and a resilient contact member 3 20. The resilient member
member 100. Although a difference in dimensional aspects 300 may be punch formed from a sheet of stainless steel (e.g.,
such as widths may be used to inhibit reversing the polarities SS 301 with no plating), spring steel (e.g., spring steel with
during connection ofan electrical connector 1000 (FIG. 1) the nickel plating) or other resilient material configured to work
present invention may not be limited to this method. Different within the anticipated environmental conditions of the elec-
configurations, devices, and dimensions may be used to 20 trical connector 1000 (FIG. 1). In some embodiments, the
facilitate the proper polar connection orientation during resilient member 300 may be plated or otherwise coated to
assembly of a male member 500 with a female member 100. inhibit rust or to provide an appropriate level of resistance
Female Terminals (e.g., friction force) necessary to maintain the connection
view ofanembodiment ofa female terminal 200, and FIG. 4B 25 100.
nal 200, the female terminal 200 may comprise a terminal retention members 312A and 312B (FIG. 5B). The resilient
female terminal 200 may comprise an electrically conductive 30 ing retention members 112 within the resilient member sup-
gold-nickel alloy) or silver, among other materials, preferably second terminal chambers 110 and 120. The resilient reten-
example), in order to increase the electrical conductivity 35 ient members 300 within the female housing 102 during
from a standard plate of material and punched formed to the stantially flat quadrilateral but embodiments of the present
ing. 40 resilient base member 310 may be retained separate from the
couple with a copper wire conductor (for example) such as resilient base member 310 may not overlay a corresponding
tor portion 204 may be electrically coupled to a wire conduc- 45 is electrically coupled.
non-insulated connector fittings, crimping, and other meth- R. The arcuate portion may be resiliently deformed toward
terminal. Embodiments of the terminal connector portion 204 50 from portions of an installed male member 500 (FIG. 1). The
The terminal contact portion 206 may be located at an opposing surface or portion of the male member 500 in order
nal connector portion 204, and may comprise an angled end 55 male member 500 with the female member 100 (see FIG. 1).
shown in FIGS. 4B, 212A and 212B), and a contact surface portion is illustrated in FIGS. SA and 5B. However, embodi-
214. The angled end 210 may help facilitate the coupling or ments of the present invention are not to be limited to this one
during the connection of an electrical connector 1000 (FIG. 60 radii either alone or in combination with one or more rela-
current to flow from one end of the electrical connector 1000 angular bend joining two straight portions together, or a plu-
Terminal step 208 may separate the terminal connector 65 wave type of configuration may be used in order to more
US 9,166,323 B2
7 8
resentative sample of the various potential configurations material may comprise approximately 33% glass. The mate-
consistent with the present invention and is not intended to be rial may be used in a remotely controlled vehicle operating in
exhaustive. a natural environment for example and may experience a
One end of the resilient contact member 320 may comprise temperature range from below -20° F. (-29° C.) to over 250°
a housing interface 324. An example of the housing interface 5 F. (121 ° C.) (e.g., when operated in desert conditions over
324 may be illustrated by a small radius curve rotating in an solar heated roadways, or due to battery heat, current flow,
opposite direction relative to the arcuate portion defined by and electrical resistance).
the radius R. The housing interface 324 may facilitate a slid- The male conductor housing 504 may be separated from
ing movement along a contacting portion of an inner wall of the male terminal housing 506 by the male internal wall 505.
the female housing 102 (FIG. 3B) in response to assembly 10 The male internal wall 505 may comprise an opening 514
and disassembly of a male member 500 and a female member (524) to accommodate a male terminal 600. On the male
100 (see FIG. 2). The sliding contact may prevent or inhibit conductor housing 504 side of the male internal wall 505, the
the abrading or prematurely wearing down of the inner sur- male internal wall 505 may comprise an indicator 513 iden-
face of the female housing 102 over a multiple number of tifying the connection side of the electrical connector 1000
connections and disconnections of the electrical connector 15 (FIG. 1), for example (e.g., "A" for the female member and
1000 (FIG. 1). In this example, the contacting portion of the "B" for the male member). In other embodiments, the indi-
housing interface 324 curves away from the inner surface of cator 513 may comprise a polarity sign to be used in place of,
the female housing 102 in directions tangent to the small or in addition to, the first and second male polarity indicators
radius curve. Further, the resilient contact member 320 may 511 and 521 (FIG. 6A).
extend at an angle from the resilient base member 310 such 20 The male conductor housing 504 may circumferentially
that the housing interface 324 may be located above (with surround an end of a male terminal 600 inserted into each of
respect to FIG. 5B) a plane containing the resilient base the first and second male terminal extensions 510 and 520. An
member 310. This configuration may apply a pre-load to an end of the male conductor housing 504 opposing the internal
assembled resilient member 300 via the housing interface wall 505 may be open to provide access for a conductor (not
324. By adjusting the angle for the resilient contact member 25 shown) to contact an exposed end of a male terminal 600. In
320 relative to the resilient base member 310, and/or adjust- other embodiments, an end or side of the male conductor
ing the radius R, the force applied to the male member 500 housing 504 adjacent to the male internal wall 505 may be
through the resilient contact member 320 may be adjusted. open to provide conductor access. In the embodiment shown,
Adjusting the force of the resilient contact member 320 may the male conductor housing 504 substantially shrouds and
adjust the amount of insertion and withdrawal force for the 30 insulates the ends of the male terminals 600 from each other.
connecting and disconnecting of the electrical connector In certain other embodiments the male conductor housing
1000. Consequently, a desired amount of insertion and with- 504 may only partially surround an end of a male terminal 600
drawal force may be established for the connecting and dis- in each of the first and second male terminal extensions 510
connecting of the electrical connector 1000. and 520.
Male Member 35 The male internal wall 505 of each of the first and second
Turning now to FIGS. 6A, and 6B, the male member 500 male terminal extensions 510 and 520 may function as a male
may comprise a male housing 502, a first male terminal terminal support (FIG. 6B). Each of the male terminal sup-
extension 510, a second male terminal extension 520, and ports (i.e., male internal walls 505) may help to retain a
male terminals 600 (more clearly shown in FIG. 6B). A first corresponding male terminal 600 in the respective first and
male polarity indicator 511 and a second male polarity indi- 40 second male terminal extensions 510 and 520. The male
cator 521 may indicate the respective polarities of the first terminal support may comprise one or more retention mem-
male terminal extension 510 and the second male terminal bers 512 (for example as represented by 512A), configured to
extension 520. An example of a male terminal 600 is shown in retain a male terminal 600 after assembly into a male member
FIGS. 7A and 7B and is detailed later. The various compo- 500. Although a slanted ramp type ofretention member 512 is
nents of the male member 500 will be described in more detail 45 shown in FIG. 6B to facilitate an insertion type of assembly
in the following illustrative embodiment. (e.g., inserting a male terminal 600 from the left to the right in
Male Housing the male housing 502 with respect to FIG. 6B), a person of
stantially rectangular in shape and comprise a male conductor of retention member 512. Pins, rivets, fasteners, other
housing 504, a male internal wall 505, and a male terminal tip 50 mechanical attachments, welding, and chemical adhesives,
510 and 520. Due to their similarities, only the first male terminal 600 within the male housing 502. Further, similar
forward, reference numerals enclosed by parenthesis refer to additional force to oppose the friction force generated during
second male terminal extension 520. Although a substantially 55 the connection and disconnection of the electrical connector
ments of the present invention may not be limited to this one both of the male terminals 600. Other embodiments of the
one or more male terminals 600 may be used. The male In some cases the male terminals 600 may be core molded
housing 502 may be manufactured from a dielectric material 60 into the male housing 502 at the time of manufacture.
application and provide sufficient electrical insulation 510 and 520 in the male terminal tips 506, opposite to the
iting the occurrence of an electrical short between the male terminal covers 516 and 526. Each of the first and second
terminals 600). For example, the material of the male housing 65 male terminal covers 516 and 526 may be configured sub-
made by DuPont®. In some applications the reinforced nylon ever, in the illustrative embodiment shown in these figures, an
US 9,166,323 B2
9 10
aspect of the first male terminal cover 516, for example width, alloy) or silver, among other materials, preferably copper
may be configured differently than the same aspect of the plated with nickel and then plated with gold (for example), in
second male terminal cover 526. The difference in widths order to increase the electrical conductivity between contact-
may inhibit an incorrectly polarized assembly of a male mem- ing portions of the male and female terminals 600 and 200.
ber 500 (FIG. 1) with the female member 100. Although a 5 The male terminal 600 shown may be made from a standard
difference in dimensional aspects such as widths may be used plate of material and punched formed to the correct size and
to inhibit reversing the polarities during connection of an configuration, among other methods of forming.
electrical connector 1000 (FIG. 1), the present invention may The terminal connector portion 604 may be located on one
not be limited to this method. Different configurations, end of the male terminal 600 and configured to electrically
devices, and dimensions may be used to facilitate the proper 10 couple with a copper wire conductor (for example) such as
polar connection orientation during assembly of a male mem- wire conductors l0A and 20A (FIG. 1). The terminal connec-
ber 500 with a female member 100. tor portion 604 may be electrically coupled to a wire conduc-
The first and second male terminal covers 516 and 526 may tor through the use of soldering, mechanical fastening (e.g.,
each comprise a connector retention feature 507. In some through the use of a screw clamp), standard insulated and
embodiments, the connector retention feature 507 may be 15 non-insulated connector fittings, crimping, and other meth-
configured as an arcuate cavity or depression corresponding ods of electrically coupling a wire conductor to a terminal.
to an arcuate portion of the resilient contact member 320 of a Embodiments of the terminal connector portion 604 may
resilient member 300 (see FIG. 5B). As the male member 500 comprise a variety of configurations in order to accommodate
is connected to the female member 100 (see FIG. 1), the a particular electrical coupling method.
resilient member 300 moves relative to a surface of the cor- 20 The terminal contact portion 606 may be located at an
responding first and second male terminal covers 516 and 526 opposite end of the male terminal 600 relative to the terminal
until a portion of the resilient contact member 320 engages a connector portion 604, and may comprise an angled end 610,
corresponding portion of the connector retention feature 507. one or more terminal retention features 612 (two are shown in
The engagement between the resilient contact member 320 FIGS. 7B, 612A and 612B), and a contact surface 614. The
and the connector retention feature 507 may provide a sen- 25 angled end 610 may help facilitate the coupling or assembly
sory indication that the male member 500 is fully connected of a corresponding female terminal 200 (FIG. 2) during the
to the female member 100. In addition, the engagement connection of an electrical connector 1000 (FIG. 1). The
between the resilient contact member 320 and the connector contact surface 614 may directly contact an opposing surface
retention feature 507 may help to prevent inadvertent discon- of a female terminal 200 in order to allow an electrical current
nection between the male member 500 and the female mem- 30 to flow from one end of the electrical connector 1000 to the
ber 100 during the operation of the electrical connector 1000 other.
in an applied device. Terminal step 608 may separate the terminal connector
The first and second male terminal covers 516 and 526 may portion 604 from the terminal contact portion 606. In some
further comprise an angled or slanted portion 570, which may embodiments, during assembly of the male terminal 600 into
be located at an end opposite to the male internal wall 505. 35 male housing 502 (FIG. 6B), the terminal step 608 may
The slanted portion 570 of each of the first and second male oppose a portion of the male housing 502 and prevent further
terminal covers 516 and 526 may facilitate the insertion and/ movement in the assembly direction. The terminal retention
or assembly of the male member 500 with the female member features 612 may contact corresponding retention features
100 (see FIG. 1). In some embodiments, rounded, arcuate, or 512 of the male housing 502 and prevent movement in a
other insertion facilitating features may be used in place of, or 40 direction opposite to the assembly direction. At this point, the
in addition to, the slanted portion 570 of each of the first and male terminal 600 may be substantially securely coupled with
second male terminal covers 516 and 526. At least part of the the male housing 502.
remaining portions of the first and second male terminal Assembly
covers 516 and 526 may provide a contact surface for the Turning now to FIGS. SA and 8B, FIG. SA illustrates a
resilient member 300, as previously explained, and may pro- 45 correctly assembled electrical connector 1000, while FIG. 8B
vide a degree ofinsulation between the resilient members 300 illustrates an incorrectly assembled electrical connector
and the male terminals 600. The material of the first and 1000. As seen in FIG. SA, when the male member 500 is
second male terminal covers 516 and 526 may be the same as correctly coupled to a female member 100, the first and sec-
the material used for the rest of the male housing 502. In some ond male polarity indicators 511 and 521 correspond to the
embodiments, the first and second male terminal covers 516 50 first and second female polarity indicators 111 and 121, indi-
and 526 may comprise a coating applied to a surface of the cating the maintenance of proper polarity across the electrical
male terminals 600. Alternatively, a coating or texture may be connector 1000. The correspondence between the sets of
applied to a surface of the first and second male terminal polarity indicators 111, 121, 511, and 521, may provide a
covers 516 and 526 to vary the level of frictional resistance visual indication of the correct coupling of the male and
between the surface and the contacting portion of the resilient 55 female members 500 and 100. As seen in FIG. 8B, the first and
contact member 320 of each of the respective resilient mem- second male polarity indicators 511 and 521 may not be
bers 300. visible from a top oriented viewing plane when the male
Male Terminals member 500 is incorrectly assembled to the female member
Turning now to FIGS. 7A and 7B, FIG. 7A shows a top 100. In addition, as indicated by the arrows for the first and
view of an embodiment of a male terminal 600, and FIG. 7B 60 second male polarity indicators 511 and 521 (the polarity
shows a side view of the male terminal 600 of FIG. 7A. As an indicators themselves are not visible in this view), the polari-
example of an illustrative embodiment of a male terminal ties on each side of the incorrectly assembled electrical con-
600, the male terminal 600 may comprise a terminal connec- nector 1000 have been reversed.
tor portion 604 and a terminal contact portion 606. The male Referring to FIGS. 9A and 9B, FIG. 9A illustrates a cross-
terminal 600 may comprise an electrically conductive mate- 65 sectional view of the correctly assembled electrical connector
rial, such as brass, copper, or bronze. The male terminal 600 1000 of FIG. SA as viewed along line 9A-9A, while FIG. 9B
may be plated with gold (such as gold-cobalt or gold-nickel illustrates a cross-sectional view of the incorrectly assembled
US 9,166,323 B2
11 12
electrical connector 1000 of FIG. 8B as viewed along line male terminal covers 516 and 526. At this point, the male
9B-9B. FIG. 9A shows an electrical connector 1000 in which member 500 may be securely coupled to the female member
abutting a contact surface 214 of the female terminal 200. The 5 similar due to the symmetry of the connector. However, com-
have an approximate width ofWl with the first male terminal of the present invention and differences beyond the widths of
orifice 126 such that a contact surface 614 of the correspond- 10 exist.
corresponding female terminal 200. The second male termi- Another Embodiment
nal cover 526 and the second orifice 126 may each have an
approximate width of W2 with the second male terminal Referring now to FIG. 11, this figure shows an orthogonal
cover 526 configured to fit within the second orifice 126. The 15 top view with a cross-section taken through the side of an
width Wl may be smaller than the width W2. This difference embodiment of an electrical connector. In this figure, refer-
in widths may provide another method of inhibiting or pre- ence number 2000 generally refers to another illustrative
venting cross-polarization during connection of the male embodiment of an electrical connector 2000 constructed
member 500 to the female member 100 (FIG. SA), since the according to aspects of the present invention. One difference
male member 500 may be connected to the female member 20 between the electrical connector 2000 and the previously
100 when the male member 500 is properly oriented with described electrical connector 1000 (FIG. 1) may be the
respect to the female member 100. The proper orientation of replacement of one or more resilient members 300 (FIG. 2) of
the male and female members 500 and 100 may provide for the previous illustrative embodiment with one or more resil-
the correct polarity of the connection. ient members 23 00. Otherwise, the function and materials for
FIG. 9B shows an electrical connector 1000 in which a 25 the two electrical connectors 1000 and 2000 may be consid-
male member 500 is incorrectly connected to a female mem- ered to be the same. Similar components may be identified
ber 100. This type of connection may be substantially pre- with similar reference numerals used in the previous descrip-
vented by the interference between the width of the second tion, and a detailed explanation of these components may not
male terminal cover 526 (W2) and the width of the first orifice be repeated.
116 (Wl)(e.g., W2-Wl). However, if the male member 500 30 Electrical connector 2000 may comprise a female member
is somehow coupled to the female member 100 in spite of this 2100 and a male member 500, shown here in a connected
interference, cross-polarization of the electrical connector state. The female member 2100 may comprise one or more
1000 may still be prevented by the first and second male female terminals 200 (only one is visible in this view) and the
terminal covers 516 and 526 separating the male and female male member 500 may comprise a corresponding number of
terminals 600 and 200. The first and second male terminal 35 male terminals 600. When the female member 2100 and the
covers 516 and 526 may prevent contact between correspond- male member 500 are coupled together, electricity may be
ing male and female terminals 600 and 200 when the male able to flow between wire conductors (not shown) through the
member 500 is in a second orientation with respect to the electrical connector 2000 via the areas of contact between the
female member 100. Therefore, as seen in this illustrative female and male terminals 200 and 600.
embodiment, cross-polarization of the electrical connector 40 The female member 2100 may comprise one or more resil-
1000 may be prevented and/or inhibited by at least two sepa- ient members 2300. The resilient members 2300 may provide
rate and independent methods, in addition to the visual indi- a pressing force to facilitate electrical conduction through the
cation given by the first and second male and female polarity contact areas between the corresponding female and male
indicators, 111, 121, 511, and 521. terminals 200 and 600. In addition, the resilient members
Referring now to FIG. 10, this figure illustrates an orthogo- 45 2300 may provide a securing force to inhibit or prevent the
nal cross-sectional view of a correctly assembled male mem- inadvertent disconnection of the male member 500 from the
ber 500 and female member 100. In this figure, the first and female member 2100 during the use of the electrical connec-
second male terminal extensions 510 and 520 (FIG. 6A) have tor 2300 in a desired application (e.g., such as in a vibratory
been inserted into the first and second female terminal cham- and dynamic environment of a remotely controlled vehicle).
bers 110 and 120 (FIG. 3A), or more specifically, the male 50 In some exemplary embodiments, the number of resilient
terminal housing 506 portions of the first and second male members 2300 corresponds to the number of electrical con-
terminal extensions 510 and 520 have been inserted into the nections formed or broken during the connection and discon-
first and second orifices 116 and 126 of the first and second nection of the electrical connector 2000 (e.g., two are shown
female terminal chambers 110 and 120. As the male member in FIG. 11). However, the number ofresilient members 2300
500 is connected to the female member 100, the resilient 55 may not be required to equal the number of electrical connec-
members 300 may initially contact the slanted portion 570 of tions formed or broken.
the corresponding first and second male terminal covers 516 Each resilient member 2300 may comprise a resilient hous-
and 526. The resilient contact portions 320 may respectively ing 2310 integrated with the housing of the female member
slidingly engage a top surface of each of the first and second 2100. As shown in FIG. 11, the resilient housing 2310 may be
male terminal covers 516 and 526. The resilient contact por- 60 substantially cylindrical for example, but embodiments of the
tions 320 may be compressed, causing the housing interface present invention may not be limited to this geometric con-
324 portion of the resilient member 300 to slidingly engage an figuration. Each resilient member 23 00 may further comprise
interior surface of the respective first and second female ter- a retention device 2324, a resilient device 2322, and a contact
minal chambers 110 and 120. The male member 500 may device 2320. The retention device 2324 may comprise an
continue to be inserted into the female member 100 until the 65 Allen set screw as shown for example, or may comprise any of
resilient contact portion 320 engages a corresponding con- a number of devices able to retain the resilient device 2322
nector retention feature 507 of the respective first and second and the contact device 2320 within the resilient housing 2310,
US 9,166,323 B2
13 14
while in some embodiments further providing a measure of male member 500 may comprise a corresponding number of
adjustability. For example, a mechanical threaded fastener, male terminals 600. When the female member 3100 and the
angled key, or cam device, among others, may be used. In this male member 500 are coupled together, electricity may be
example, the retention device 2324 may be threadably able to flow between wire conductors (not shown) through the
engaged with a top portion of the resilient housing 2310. 5 electrical connector 3000 via the contact areas between the
The resilient device 2322 may be located between the female and male terminals 200 and 600.
retention device 2324 and the contact device 2320. The resil- The female member 3100 may comprise one or more resil-
ient device 2322 may be a spring, such as a coil spring, or ient members 3300. The resilient members 3300 may provide
resilient material, such as foam, among other devices. The a pressing force to facilitate electrical conduction through the
resilient device 2322 may press against the contact device 10 contact area between the female terminals 200 and the male
2320, facilitating movement of the contact device 2320 as the terminals 600. In addition, the resilient members 3300 may
male member 500 and the female member 2100 are coupled provide a securing force to inhibit or prevent the inadvertent
together. The force applied to the contact device 2320 and disconnection of the male member500 from the female mem-
consequently to the male and female terminals 200 and 600, ber 3100 during the use of the electrical connector 3300 in a
may be adjusted by tightening or loosening the retention 15 desired application (e.g., such as in a vibratory and dynamic
male member 500 may be securely coupled to the female the number of electrical connections formed or broken during
eliminate or reduce the ability of the contact device 2320 to 20 3000, two electrical connections are shown in this embodi-
feature 507. formed or broken.
such as in a ball and spring type of mechanism. However, in 25 with a opposing surface of a first and second male terminal
second male terminal covers 516 and 526 (only the first male shown in FIG. 12, the area indicated by cross-hatching may
pin, angled member, cylinder, among others. The contact 30 and the top surface of the first male terminal cover 516,
device 2320 may be retained within theresilienthousing 2310 although only a portion of the abutting surfaces may be con-
between a protruding edge 2312 at one end and the retention figured to be interfering. The resilient member 3300 may
device 2324 at the other end. During connection of the male comprise a rib interfacing with a portion of the respective top
member500 and the female member 2100, the contact device surface of the first and second male terminal covers 516 and
2320 may engage the connector retention feature 507 as the 35 526, or the resilient member 3300 may comprise the wall of
male member 500 is fully coupled with the female member the female member housing 3102, among numerous other
2100. The contact device 2320 and the connector retention configurations such as those previously described for the
feature 507 may be configured to have corresponding or inter- resilient contact portion 320. Essentially, in some embodi-
facing features, such that when the male member 500 is fully ments the housing 3102 of the female member 3100 may
coupled with the female member 2100, a sensory indication 40 function as a resilient member, allowing at least some degree
of the application device 2320 engaging the connector reten- of resilient deformation or movement designed to apply a
tion feature 507 may be provided. The sensory indication may force to at least a portion of an installed male member 500
be visual, audible, tactile, or a combination of one or more of (e.g., such as the first and second male terminal covers 516
these sensory indications, in addition to other methods. and 526, or in some embodiments, the male terminals them-
45 selves, among other configurations). Alternatively, the first
Another Embodiment and second male terminal covers 516 and 526 may function as
a resilient member, allowing at least some degree of resilient
Referring now to FIG. 12, this figure shows an orthogonal deformation or movement designed to urge the male termi-
top view with a cross-section taken through the side of an nals 600 together with the corresponding female terminals
embodiment of an electrical connector. In this figure, refer- 50 200. Further, in some embodiments, both the female housing
ence number 3000 generally refers to another illustrative 3102 and the first and second male terminal covers 516 and
embodiment of an electrical connector 3000 constructed 526 may experience some degree of resilient deformation,
according to aspects of the present invention. One difference combining together to provide a force urging the male termi-
between the electrical connector 3000 and the previously nals 600 together with the corresponding female terminals
described electrical connectors may be the replacement of 55 200.
one or more resilient members 300 (FIG. 2) or2300 (FIG.11) The resilient member 3300 may further comprise protru-
of the previous illustrative embodiments, with one or more sions or features configured to engage with corresponding
resilient members 3300. Otherwise, the function and materi- depressions or features located on the top surfaces of the first
als for the electrical connectors 1000, 2000, and 3000 may be and second male terminal covers 516 and 526, such that the
considered to be the same. Similar components may be iden- 60 male member 500 may be securely coupled to the female
tified with similar reference numerals used in the previous member 3000 upon fully connecting the male member 500 to
description, and a detailed explanation of these components the female member 3100. An example of a protrusion for the
may not be repeated. resilient member 3300 may be an arcuate ridge corresponding
Electrical connector 3000 may comprise a female member to the connector retention feature 507 shown in FIG. 6B. The
3100 and a male member 500, shown here in a connected 65 resilient member 3300 may at least partially resiliently
state. The female member 3100 may comprise one or more deform with respect to the area of interference. Alternatively,
female terminals 200 (only one is visible in this view) and the the resilient member 3300 may take advantage of at least
US 9,166,323 B2
15 16
some degree of resilient deformation in the configuration of and second male terminals 1600 and 1650 after assembly into
the female member housing 3102. a male member 1500. Although a slanted ramp type of reten-
tion member 512 is shown in FIG. 13B to facilitate an inser-
Another Embodiment tion type of assembly (e.g., inserting a male terminal 1600
5 from the right to the left in the male housing 1502 with respect
Turning now to FIGS. 13A and 13B, the first figure shows to FIG. 13B), a person ofordinary skill in the art would not be
a top view of an illustrative embodiment of a male member limited to just this type of retention member 512. Pins, rivets,
1500 configured according to aspects of the present invention, fasteners, other mechanical attachments, welding, and
while the second figure shows an orthogonal cross-sectional chemical adhesives, among other various methods may be
top view of the male member 1500 of FIG. 13A as viewed 10
used to secure the first and second male terminals 1600 and
along line 13B-13B. One difference between the male mem-
1650 within the male housing 1502. Additionally, the first and
ber 1500 and the previously described male member 500
second male terminals 1600 and 1650 may be core molded
(FIG. 1) may be the lack of first and second male terminal
covers 516 and 526 (see FIGS. 6A and 6B) in the male along with the male housing 1502 at the time of manufacture.
member 1500. Another difference may be the use of first and 15
The first and second male terminals 1600 and 1650 may
second male terminals 1600 and 1650 in male member 1500 comprise retention members 612 (for example as represented
in place of the male terminals 600 shown in male member 500 by 612A and 612B, however, only the retention members 612
(see FIG. 2). Otherwise, the function and materials for the of the first male terminal 1600 may be seen in FIG. 13B, the
male members 500 and 1500 may be considered to be sub- second male terminal 1650 may be similarly configured)
stantially the same. Similar components may be identified 20 corresponding to the retention members 512. As with the
with similar reference numerals used in previous descrip- retention member 512, a slanted ramp type of retention mem-
tions, and a detailed explanation of these components may not ber 612 is shown in FIG. 13B to facilitate an insertion type of
be repeated. assembly, however, a person of ordinary skill in the art would
Male member 1500 may comprise a male housing 1502 not be limited to just this type of retention member 612. Pins,
and first and second male terminal extensions 1510 and 1520. 25 rivets, fasteners, other mechanical attachments, welding, and
The first male terminal extension 1510 may comprise the first chemical adhesives, among other various methods may be
male terminal 1600, while the second male terminal exten- used to secure the first and second male terminals 1600 and
sion 1520 may comprise the second male terminal 1650. First 1650 within the male housing 1502.
and second male terminals 1600 and 1650 may be configured Having thus described embodiments of the present inven-
to be insertably engaged with the first and second orifices 116 30 tion by reference to certain exemplary embodiments, it is
and 126 of the first and second female terminal chambers 110 noted that the embodiments disclosed are illustrative rather
and 120 of a female member 100 (see FIG. 3A). In some than limiting in nature. A wide range of variations, modifica-
embodiments, some aspects of the first male terminal 1600 tions, changes, and substitutions are contemplated in the fore-
may be different than similar aspects of the second male going disclosure. In some instances, some features of an
terminal 1650 in order to inhibit the cross-polarizing connec- 35 embodiment of the present invention may be employed with-
tion of a male member 1500 and a female member 100. In the out a corresponding use of the other features. Many such
embodiment shown, the width Wl of the first male terminal variations and modifications may be considered desirable by
1600 may be smaller that the width W2 of the second male those skilled in the art based upon a review of the foregoing
terminal 1650. Interference between the larger width W2 and description of the illustrative embodiments. Accordingly, it is
the first orifice 116 may inhibit the connection between a 40 appropriate that the appended claims be construed broadly
female member 100 and an improperly oriented male mem- and in a manner consistent with the scope of the invention.
ber 1500 (i.e., the male member 1500 may be improperly
oriented with respect to the female member 100). We claim:
The male housing 1502 may be substantially rectangular in 1. A female electrical connector comprising:
shape and comprise a male conductor housing 504 and a male 45 a female housing comprising an insulating material at least
internal wall 1505 for each of the first and second male partially forming a first female receptacle comprising a
terminal extensions 1510 and 1520. Although a substantially first receptacle opening for at least partially receiving a
rectangular shape is shown for the male housing 1502, first male connector electrode;
embodiments of the present invention may not be limited to a first female electrode disposed at least partially within the
this one configuration. Any configuration capable of accom- 50 first female receptacle, wherein the first female elec-
modating one or more first and second male terminals 1600 trode comprises a first surface for electrically coupling
and 1650 may be used. The male housing 1502 may be with a first male connector electrode;
manufactured from a dielectric material able to withstand the a first resilient member retained by the first female recep-
operating conditions of an intended application and provide tacle, wherein the first resilient member comprises a first
sufficient electrical insulation between the current carrying 55 resilient contact member configured to deform while a
first male terminal 1600 and second male terminal 1650 (i.e., first male connector electrode is at least partially
inhibiting the occurrence of an electrical short between the inserted into the first female receptacle;
first male terminal 1600 and the second male terminal 1650). wherein a first end of the first resilient member further
The male internal wall 1505 of each of the first and second comprises a first base member fixed relative to a first
male terminal extensions 1510 and 1520 may function as a 60 portion of the female housing when a first male connec-
male terminal support. Each of the male terminal supports tor electrode is at least partially inserted into the first
(i.e., male internal walls 1505) may respectively secure and female receptacle between a non-inserted and fully
support the first and second male terminals 1600 and 1650 in inserted configuration and a second end of the first resil-
the corresponding first and second male terminal extensions ient member is moveable within the first female recep-
1510 and 1520. The male terminal support may comprise one 65 tacle upon deformation while a first male connector
or more retention members 512 (for example as represented electrode is at least partially inserted into the first female
by 512A and 512B) configured to retain the respective first receptacle;
US 9,166,323 B2
17 18
wherein the first resilient member is configured to provide direction of insertion of a first male connector electrode to at
a biasing force to facilitate an electrical coupling of the least partially into the first female receptacle.
first female electrode with only a first male connector 14. The female electrical connector of claim 1, wherein the
electrode; first resilient member is not in contact with a male connector
wherein the first resilient contact member resiliently 5 electrode unless and until a male connector electrode is at
deforms in response to interference from one or more least partially inserted into within the first female receptacle.
portions of a first male connector electrode, when a first 15. The female electrical connector of claim 1, wherein the
male connector electrode is at least partially inserted first female electrode is configured to remain fixed relative to
into the first female receptacle; and the female housing to prevent movement away from a first
wherein the first resilient member is retained within the 10
male connector electrode when a first male connector elec-
female housing spaced from the first female electrode,
trode is at least partially inserted into the first female recep-
whereby the first resilient member and the first female
tacle between a non-inserted and fully inserted configuration.
electrode are not in contact with one another.
2. The female electrical connector of claim 1, wherein the
16. The female electrical connector of claim 15, wherein
first female electrode comprises a plate of conductive mate- 15
the first female electrode further comprises one or more
rial having a planar first surface. anchor portions extending from the first female electrode for
3. The female electrical connector of claim 1, wherein the securing the female electrode against longitudinal movement
first female electrode is configured to remain fixed relative to relative to the female housing in at least one direction.
the first base member. 17. The female electrical connector or claim 1, wherein the
4. The female electrical connector of claim 1, wherein the 20 second end of the first resilient member slides along at least a
first female electrode extends within a first plane configured portion of the wall of the first female receptacle upon defor-
to remain fixed relative to a second plane when a first male mation.
connector electrode is at least partially inserted into the first 18. The female electrical connector of claim 17, wherein
female receptacle between an unconnected configuration and the second end of the first resilient member comprises a bend
a connected configuration, wherein the first base member 25 away from the at least a portion of the wall of the first female
extends within the second plane. receptacle, with the bend facilitating sliding movement of the
5. The female electrical connector of claim 1, wherein the first resilient member along the at least a portion of the wall of
first resilient member is disposed within the first female the first female receptacle upon deformation.
receptacle on the same side of the first female electrode as the 19. The female electrical connector of claim 1, wherein the
first surface. 30 first surface is planar and substantially aligned with the direc-
6. The female electrical connector of claim 1, wherein the tion of insertion of a first male connector electrode to at least
first resilient member is retained within the female housing partially into the first female receptacle.
separately from the first female electrode, whereby a first 20. The female electrical connector of claim 19, wherein
male connector electrode is disposed between the first resil- the first surface extends to the end of the first female elec-
ient member and the first female electrode when a first male 35 trade.
connector electrode is inserted into the first female receptacle. 21. The female electrical connector of claim 19, wherein
7. The female electrical connector of claim 1, wherein at the first female electrode further comprises a first female
least a portion of the first base member is secured within the connector portion, and wherein the first surface is substan-
first female receptacle separately from the first female elec- tially co-planar with the first female connector portion.
trode such that the female housing electrically insulates the 40 22. The female electrical connector of claim 1, wherein a
first base member from the first female electrode. first male connector electrode is secured within the first
8. The female electrical connector of claim 1, wherein the female receptacle by an interference fit.
first base member extends from the first resilient contact 23. The female electrical connector of claim 22, wherein a
member along the direction of insertion of a first male con- first male connector electrode is secured within the first
nectar electrode to at least partially into the first female recep- 45 female receptacle by an interference fit without substantial
tacle. deformation of a surface of a first male connector electrode.
9. The female electrical connector of claim 1, wherein the 24. The female electrical connector of claim 22, wherein
first female electrode abuts an inner surface of the first female the first resilient contact member is configured to deform
receptacle along at least a portion of the surface of the first while a first male connector electrode is at least partially
female electrode, with the inner surface of the first female 50 inserted into the first female receptacle without any substan-
receptacle disposed on the directly opposite side of the first tial deformation of the female housing.
female electrode from the side of the first female electrode 25. The female electrical connector of claim 1, wherein the
comprising the first surface. first resilient contact member comprises an arcuate portion,
10. The female electrical connector of claim 1, wherein the and wherein the arcuate portion resiliently deforms in
female housing comprises a uniform insulating material. 55 response to interference from one or more portions of a first
11. The female electrical connector of claim 1, wherein the male connector electrode, when a first male connector elec-
female housing comprises a single piece of material. trode is at least partially inserted into the first female recep-
12. The female electrical connector of claim 1, wherein tacle.
deformation of the first resilient contact member in response 26. The female electrical connector of claim 25, wherein
to interference from one or more portions of a first male 60 the portions of the first surface extending substantially along
connector electrode, when a first male connector electrode is the length of the first female electrode are substantially
at least partially inserted into within the first female recep- aligned with a component of displacement of the first resilient
tacle, causes the first resilient member to extend in a direction member as the first resilient member deforms.
substantially parallel to the direction of insertion of a first 27. The female electrical connector of claim 25, wherein
male connector electrode. 65 the first surface is substantially normal to a component of the
13. The female electrical connector of claim 1, wherein the displacement of the first resilient member as the first resilient
first surface extends in a direction substantially parallel to the member deforms.
US 9,166,323 B2
19 20
28. The female electrical connector of claim 25, wherein 34. The female electrical connector of claim 33, wherein
the first resilient member further comprises a leaf spring. the first surface extends in a direction substantially parallel to
29. The female electrical connector of claim 1, further the direction of insertion of a first male connector electrode
comprising: along substantially the entire length of at least one side of the
the insulating material at least partially forming a second 5 first surface.
female receptacle comprising a second receptacle open- 35. The female electrical connector of claim 33, wherein
ing for at least partially receiving a second male connec- the first base member extends away from the first resilient
tor electrode; contact member substantially along the direction of insertion
a second female electrode disposed at least partially within of a first male connector electrode.
the second female receptacle, wherein the second 10 36. The female electrical connector of claim 33, wherein
female electrode comprises a second surface for electri- the first female electrode is configured to remain fixed relative
cally coupling with a second male connector electrode; to the first base member.
and 37. The female electrical connector of claim 33, wherein a
a second resilient member retained by the second female first male connector electrode is secured within the first
receptacle, wherein the second resilient member com- 15 female receptacle by an interference fit without substantial
prises a second resilient contact member configured deformation of a surface of a first male connector electrode.
deform while a second male connector electrode is at 38. The female electrical connector of claim 33, wherein at
least partially inserted into the second female receptacle. least a portion of the first base member is secured within the
30. The female electrical connector of claim 29, wherein at first female receptacle separately from the first female elec-
least one dimension of the first receptacle opening is larger 20 trade such that the female housing electrically insulates the
than a corresponding dimension of the second receptacle first base member from the first female electrode.
opening. 39. The female electrical connector of claim 33, wherein
31. The female electrical connector of claim 29, wherein the first resilient member is retained within the female hous-
the second resilient member further comprises a second base ing separately from the first female electrode, whereby a first
member fixed relative to a second portion of the female hous- 25 male connector electrode is disposed between the first resil-
ing when a second male connector electrode is at least par- ient member and the first female electrode when a first male
tially inserted into the second female receptacle between a connector electrode is inserted into the first female receptacle.
non-inserted and fully inserted configuration. 40. The female electrical connector of claim 33, further
32. The female electrical connector of claim 29, wherein comprising an insulating member at least partially interposed
the second resilient member is configured to provide a biasing 30 between the first resilient member and a surface of a first male
force to facilitate an electrical coupling of the second female connector electrode when a first male connector electrode is
electrode with only a second male connector electrode. at least partially inserted into the first female receptacle.
33. A female electrical connector comprising: 41. The female electrical connector of claim 33, wherein
a female housing comprising a single piece of insulating deformation of the first resilient contact member in response
material at least partially forming a first female recep- 35 to interference from one or more portions of a first male
tacle comprising a receptacle opening for at least par- connector electrode, when a first male connector electrode is
tially receiving a first male connector electrode; at least partially inserted into within the first female recep-
a first female electrode disposed at least partially within the tacle, causes the first resilient member to extend in a direction
first female receptacle; substantially parallel to the direction of insertion of a first
a first resilient member retained by the first female recep- 40 male connector electrode.
tacle, wherein the first resilient member comprises a first 42. The female electrical connector of claim 33, wherein
resilient contact member configured to provide an inter- the first surface extends in a direction substantially parallel to
ference fit between the first female electrode and a first the direction of insertion of a first male connector electrode to
male connector electrode to secure the first female elec- at least partially into the first female receptacle.
trode and a first male connector electrode, when a first 45 43. The female electrical connector of claim 33, wherein
male connector electrode is at least partially inserted the first surface is disposed along a portion of the length of the
into the first female receptacle; first female electrode facing towards the first resilient mem-
wherein a first end of the first resilient member further ber.
comprises a first base member fixed relative to a first 44. The female electrical connector of claim 33, wherein
portion of the female housing when a first male connec- 50 the first female electrode is configured to remain in a fixed
tor electrode is at least partially inserted into the first position relative to a portion of the female housing while a
female receptacle between a non-inserted and fully male electrode is inserted to within the first female receptacle
inserted configuration; and moving from between a non-inserted to a fully inserted
wherein the first resilient contact member is configured to configuration.
deform while a first male connector electrode is at least 55 45. The female electrical connector of claim 33, wherein
partially inserted into the first female receptacle without the first resilient member is retained within the female hous-
any substantial deformation of the female housing; ing spaced from the first female electrode, whereby the first
wherein the first resilient member is configured to provide resilient member and the first female electrode are not in
a biasing force to facilitate an electrical coupling of the contact with one another.
first female electrode with only a first male connector 60 46. The female electrical connector of claim 45, wherein
electrode; and the first resilient member is not in contact with a male con-
wherein the first female electrode comprises a first surface nector electrode unless and until a male connector electrode is
configured to make an electrical coupling with a male at least partially inserted into within the first female recep-
contact surface of a first male connector electrode; and tacle.
wherein the first female electrode abuts an inner surface of 65 47. The female electrical connector of claim 33, wherein
the first female receptacle along at least a portion of a the first female electrode further comprises one or more
surface of the first female electrode. anchor portions extending from the first female electrode for
US 9,166,323 B2
21 22
securing the first female electrode against longitudinal move- the second female receptacle is configured to receive a
ment relative to the female housing in at least one direction. second male connector electrode;
48. The female electrical connector of claim 47 wherein a second female electrode disposed at least partially within
the first female electrode is configured to remain fix~d relative the second female receptacle;
to the female housing to prevent movement away from a first 5 a second resilient member retained by the second female
receptacle, wherein the second resilient member com-
male connector electrode when a first male connector elec-
prises a second resilient contact member configured to
trode is at least partially inserted into the first female recep- provide an interference fit between the second female
tacle between an unconnected configuration and a connected electrode and a second male connector electrode to
configuration. secure the second female electrode and a second male
10
49. The female electrical connector or claim 33, wherein a connector electrode, when a second male connector
second end of the first resilient member is moveable within electrode is at least partially inserted into the second
the first female receptacle upon deformation while a first male female receptacle; and
connector electrode is at least partially inserted into the first wherein the second resilient member further comprises a
female receptacle. second base member fixed relative to a second portion of
15 the female housing when a second male connector elec-
50. The female electrical connector or claim 49 wherein
the second end of the first resilient member slide; along at trode is at least partially inserted into the second female
least a portion of the wall of the first female receptacle upon receptacle between a non-inserted and fully inserted
deformation. configuration; and
51. The female electrical connector of claim 50, wherein 20 wherein the second female electrode comprises a second
the second end of the first resilient member comprises a bend surface configured to make an electrical coupling with a
away from the at least a portion of the wall of the first female second male contact surface of a second male connector
receptacle, with the bend facilitating sliding movement of the electrode.
57. The female electrical connector of claim 56 wherein at
first resilient member along the at least a portion of the wall of
the first female receptacle upon deformation. least one dimension of the first receptacle openi~g is larger
25 than a corresponding dimension of the second receptacle
the first female electrode comprises a plate of conductive opening.
58. The female electrical connector of claim 56 wherein
material having a planar first surface.
the second resilient contact member is configured ;o deform
the first female electrode further comprises a planar first 30 while a second male connector electrode is at least partially
female connector portion, and wherein the first surface is inserted into the second female receptacle without any sub-
substantially co-planar with the first female connector por- stantial deformation of the female housing;
tion. wherein the second resilient member is configured to pro-
54. The female electrical connector of claim 52, wherein vide a biasing force to facilitate an electrical coupling of
the first surface is planar and aligned with the direction of 35 the second female electrode with only a second male
insertion of a first male connector electrode. connector electrode; and
wherein the second female electrode comprises a second
the planar first surface extends substantially to the end of the surface configured to make an electrical coupling with a
first female electrode. male contact surface of a second male connector elec-
56. The female electrical connector of claim 33 further 40
trode, with the second surface disposed along a portion
comprising: ' of the length of the second female electrode facing
the female housing comprising an insulating material at towards the second resilient member.
least partially forming a second female receptacle com- 59. The female electrical connector of claim 56 wherein
the female housing comprises a uniform insulating,material.
prising a second receptacle opening for at least partially
receiving a second male connector electrode, wherein * * * * *
EXHIBIT 8
I 1111111111111111 11111 1111111111 11111 111111111111111 111111111111111 IIII IIII
US009705254B2

Lampert et al. (45) Date of Patent: *Jul. 11, 2017
(54) ELECTRICAL CONNECTOR ASSEMBLY (58) Field of Classification Search

CPC ................................ H0lR 13/64; H0lR 13/18
(71) Applicant: TRAXXAS LP, McKinney, TX (US) USPC ........ 439/679, 691, 693, 680, 282, 296, 284
(72) Inventors: Jon Kenneth Lampert, Allen, TX
(US); Serlaathan Hariharesan, Flower (56) References Cited
Lewisville, TX (US) U.S. PATENT DOCUMENTS
2,121,338 A 6/1938 Chirelstein
(73) Assignee: TRAXXAS LP, McKinney, TX (US) 2,203,122 A 6/ 1940 Anderson
2,838,739 A 6/1958 Winkler
( *) Notice: Subject to any disclaimer, the term ofthis 3,091,746 A 5/1963 Winkler
patent is extended or adjusted under 35 3,145,067 A 8/ 1964 Mishelevich et al.
U.S.C. 154(b) by 0 days. 3,218,599 A 11/1965 Winkler
3,233,211 A 2/1966 Smith
This patent is subject to a terminal dis- (Continued)
claimer.
(21) Appl. No.: 14/887,128
DE 704 450 3/1941
(22) Filed: Oct. 19, 2015 EP 0 318 831 A2 6/1989
(Continued)
(65) Prior Publication Data
US 2016/0043506 Al Feb. 11, 2016 OTHER PUBLICATIONS
Related U.S. Application Data Ukiah CA, U.S.A., 2003-2006.
(63) Continuation of application No. 14/171,568, filed on (Continued)
Feb. 3, 2014, now Pat. No. 9,166,323.
Primary Examiner - Phuongchi T Nguyen
(51) Int. Cl. (74) Attorney, Agent, or Firm - Carr Law Firm PLLC
HOlR 13/64 (2006.01)
HOlR 13/642 (2006.01) (57) ABSTRACT
HOlR 13/187 (2006.01) An electrical connector is provided comprising a female
HOlR 13/26 (2006.01) member configured to couple with male member. The
HOlR 13/41 (2006.01) female member includes a female receptacle having an
HOlR 13/46 (2006.01) opening, and a female electrode is at least partially disposed
(52) U.S. Cl. within the female receptacle. A resilient member is config-
CPC ......... HOlR 13/642 (2013.01); HOlR 13/187 ured to enhance electrical connection between the female
(2013.01); HOlR 13/26 (2013.01); HOlR electrode and a male connector electrode.
13/64 (2013.01); HOlR 13/41 (2013.01); HOlR
13/465 (2013.01) 9 Claims, 11 Drawing Sheets
1000
~ W1 W2
516
214
600
US 9,705,254 B2
Page 2
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U.S. Patent Jul. 11, 2017 Sheet 1 of 11 US 9,705,254 B2
1000
FIG.1
1000
FIG. 2
100 111
~ 121
FIG. 3A
100
102
,J
200
FIG.3B
100
,J
112C
200
FIG.JC
208 214
,------,,------,J
200----.
□ 210
206
204
FIG. 4A
212A~ ,214 /'210

200----. ~II--~K-~-~---n
212B_./"" r
\_208
FIG.4B
608 612
610
604
FIG. 7A
600
----. 1~1_ _I ~I~-~----u
6122:
612B7 614 "-610
FIG. 7B
300
324
FIG. SA
300
,I
R
FIG. SB
500 516
FIG. 6A
500
~ 502
FIG. 6B
111
1000
511
FIG. 8A
111
1000
FIG.SB
1000
~ W1 W2
516 526
214
600 600
FIG. 9A
1000
~ W2-W1 - -
FIG. 9B
.S. P a tent Jul. 11

, 2017
Sheet
9 o f 11 05,25 4 B2
U V s 9, 7
FIG. I O
2000
2310
2324
2322
2320
507
2312
FIG. I I
3000
FIG.12
1500
~ W2
1520._.
1650
D
138 138
L 1600
_J
1510__...
W1
FIG.13A
1500
1650
FIG.13B
US 9,705,254 B2
1 2
ELECTRICAL CONNECTOR ASSEMBLY FIG. 3B illustrates a cross-sectional view of the female
member of FIG. 3A as viewed along line 3B-3B;
CROSS-REFERENCE TO RELATED FIG. 3C illustrates a cross-sectional view of the female
APPLICATIONS member of FIG. 3A as viewed along line 3C-3C;
FIG. 4A illustrates a top view of a female terminal;
This application is a continuation of, and claims the FIG. 4B illustrates a side view of the female terminal of
benefit of the filing date of, co-pending U.S. patent appli- FIG. 4A;
cation Ser. No. 14/171,568 entitled ELECTRICAL CON- FIG. SA illustrates an orthogonal top view of a resilient
NECTOR ASSEMBLY, filed Feb. 3, 2014, which is a member;
continuation of U.S. patent application Ser. No. 12/959,872
10 FIG. SB illustrates a side view of the resilient member of
entitled ELECTRICAL CONNECTOR ASSEMBLY, filed FIG. SA;
FIG. 6A illustrates an orthogonal top view of a male
Dec. 10, 2010, now U.S. Pat. No. 8,641,440, which is a
member;
FIG. 6B illustrates a cross-sectional side view of the male
entitled ELECTRICAL CONNECTOR ASSEMBLY, filed
15 member of FIG. 6A;
Apr. 3, 2009, now U.S. Pat. No. 7,867,038, which is a FIG. 7A illustrates a top view of a male terminal;
continuation of U.S. patent application Ser. No. 11/951,754 FIG. 7B illustrates a side view of the male terminal of
entitled ELECTRICAL CONNECTOR ASSEMBLY, filed FIG. 7A;
Dec. 6, 2007, now U.S. Pat. No. 7,530,855, which is a FIG. SA illustrates an orthogonal top view of the electrical
continuation of U.S. patent application Ser. No. 11/736,460 20 connector of FIG. 1 correctly assembled;
filed Apr. 17, 2007, now U.S. Pat. No. 7,374,460. FIG. SB illustrates an orthogonal top view of the electrical
connector of FIG. 1 incorrectly assembled;
BACKGROUND OF THE INVENTION FIG. 9A illustrates a cross-sectional view of the correctly
assembled electrical connector of FIG. SA as viewed along
Field of the Invention 25 line 9A-9A;
The present invention generally relates to electrical con- FIG. 9B illustrates a cross-sectional view of the incor-
nectors and, more particularly, to high current electrical rectly assembled electrical connector of FIG. SB as viewed
connectors with protection against reverse polarity connec- along line 9B-9B;
tions. FIG. 10 illustrates an orthogonal cross-sectional view of
Description of the Related Art 30 the assembled electrical connector of FIG. 1;
A wide variety of electronic devices are powered through FIG. 11 illustrates an orthogonal cross-sectional top view
battery pack supplying stored electricity to an electric motor. FIG. 12 illustrates an orthogonal cross-sectional top view
In some of these lightweight vehicles, racing creates a 35 of another embodiment of an electrical connector configured
demand for more powerful motors along with increasing according to aspects of the present invention;
must be able to easily exchange a depleted battery pack for to aspects of the present invention; and
a fully charged one. The depleted battery pack is then 40 FIG. 13B illustrates an orthogonal cross-sectional top
connected to a battery charger in order to be ready for the view of the component of FIG. 13A as viewed along line
next exchange. Consequently, there exists a need for a high 13B-13B.
current electrical connector with a lightweight and compact
design. DETAILED DESCRIPTION
45
SUMMARY OF THE INVENTION In the following discussion, numerous specific details are
set forth to provide a thorough understanding of the present
In accordance with an embodiment of the present inven- invention. However, those skilled in the art will appreciate
tion, an electrical connector having a lightweight and com- that the present invention may be practiced without such
pact design is provided wherein a resilient member is 50 specific details. In other instances, well-known elements
configured to enhance electrical connection between a have been illustrated in schematic or block diagram form in
female electrode and a male connector electrode. order not to obscure the present invention in unnecessary
detail. Additionally, for the most part, details concerning
BRIEF DESCRIPTION OF THE DRAWINGS well known features and elements have been omitted inas-
55 much as such details are not considered necessary to obtain
For a more complete understanding of the present inven- a complete understanding of the present invention, and are
tion and the advantages thereof, reference is now made to considered to be within the understanding of persons of
the following Detailed Description taken in conjunction with ordinary skill in the relevant art.
the accompanying drawings, in which: Turning now to the drawings, FIG. 1 shows a top orthogo-
FIG. 1 illustrates a general orthogonal top view of an 60 nal view of an assembled electrical connector with attached
embodiment of an electrical connector configured according wire conductors. In this drawing, reference numeral 1000
to the present invention and showing attached wire conduc- generally indicates an illustrative embodiment of an electri-
tors; cal connector 1000 at least partially configured according to
FIG. 2 illustrates an exploded assembly view of the the present invention. The electrical connector 1000 may
electrical connector of FIG. 1; 65 comprise a female member 100 and a male member 500.
FIG. 3A illustrates an orthogonal top view of a female Attached to the electrical connector 1000 are wire conduc-
member of the electrical connector of FIG. 1; tors l0A, l0B, 20A, and 20B. The wire conductors l0A,
US 9,705,254 B2
3 4
10B, 20A, and 20B, may not considered as components of wall 105, the female internal wall 105 may comprise an
the electrical connector 1000 and are shown for the purposes indicator 113 identifying the connection side of the electrical
of illustration. Wire conductors lOA and 10B may carry a connector 1000 (FIG. 1) for example (e.g., "A" for the
positive current flow and wire conductors 20A and 20B may female member and "B" for the male member). In other
carry a negative current flow. The various components of the 5 embodiments, the indicator 113 may comprise a polarity
electrical connector 1000 will be described in more detail in sign to be used in place of, or in addition to, the first and
the following illustrative embodiment. second female polarity indicators 111 and 121 (FIG. 3A).
Referring to FIG. 2, the components of an embodiment of The female conductor housing 104 may circumferentially
the electrical connector 1000 are shown in an exploded surround an end of a female terminal 200 inserted into each
assembly view. The female member 100 may comprise a 10 of the first and second female terminal chambers 110 and
female housing 102, a first and second female terminal 200, 120. An end of the female conductor housing 104 opposing
and a first and second resilient member 300. The male the female internal wall 105 may be open to provide access
member 500 may comprise a male housing 502, and a first for a conductor (not shown) to contact an exposed end of a
and second male terminal 600. female terminal 200. In other embodiments, an end or side
Female Member 15 of the female conductor housing 104 adjacent to the female
Turning now to FIGS. 3A, 3B, and 3C, the female internal wall 105 may be open to provide conductor access.
member 100 may comprise a female housing 102, a first In the embodiment shown, the female conductor housing
female terminal chamber 110, a second female terminal 104 substantially shrouds and insulates the ends of the
chamber 120, female terminals 200, and resilient members female terminals 200 from each other. In certain other
300 (more clearly shown in FIG. 2). A first female polarity 20 embodiments the female conductor housing 104 may only
indicator 111 and a second female polarity indicator 121 partially surround an end of a female terminal 200 in each
may indicate the respective polarities of the first female of the first and second female terminal chambers 110 and
terminal chamber 110 and the second female terminal cham- 120.
ber 120. A first orifice 116 and a second orifice 126 may be The female terminal housing 106 portions of each of the
located at an end of the female member 100 opposite to the 25 first and second female terminal chambers 110 and 120 may
first and second female polarity indicators 111 and 121. An comprise a female terminal support 107 and a resilient
example of a resilient member 300 is shown in FIGS. 3B and member support 109 (FIG. 3C). Each of the female terminal
3C. A resilient member 300 may be located in each of the supports 107 may help to retain a corresponding female
first and second female terminal chambers 110 and 120 terminal 200 in the respective first and second female
(however, only one is shown in the FIGS. 3B and 3C for the 30 terminal chambers 110 and 120. The female terminal support
purposes of illustration). The various components of the 107 may comprise one or more retention members 112 (for
female member 100 will be described in more detail in the example as represented by 112A) configured to retain a
following illustrative embodiment. female terminal 200 after assembly into a female member
Female Housing 100. Although a slanted ramp type ofretention member 112
Referring to FIG. 3B, the female housing 102 may be 35 is shown in FIG. 3B to facilitate an insertion type of
substantially rectangular in shape and comprise a female assembly (e.g., inserting a female terminal 200 from left to
conductor housing 104, a female internal wall 105, and a right in the female housing 102 with respect to FIG. 3B), a
female terminal housing 106, for each of the first and second person of ordinary skill in the art would not be limited to just
female terminal chambers 110 and 120. Due to symmetry, this type of retention member 112. Pins, rivets, fasteners,
only the first female terminal chamber 110 will be described 40 other mechanical attachments, welding, and chemical adhe-
from this point forward, reference numerals enclosed by sives, among other various methods may be used to secure
parenthesis refer to the second female terminal chamber 120. a female terminal 200 in the female housing 102. Further,
Although a substantially rectangular shape is shown for the similar additional retention members 112B may be used to
female housing 102, embodiments of the present invention provide additional force to oppose the friction force gener-
may not be limited to this one configuration. Any configu- 45 ated during the assembly and disassembly of the electrical
ration capable of accommodating one or more female ter- connector 1000 (FIG. 1) that may otherwise move or dis-
minals 200 may be used. The female housing 102 may be locate one or both of the female terminals 200. Other
manufactured from a dielectric material able to withstand embodiments of the female member 100 may not comprise
the operating conditions of an intended application and retention members 112. In some cases the female terminals
provide sufficient electrical insulation between the current 50 200 and resilient members 300 may be core molded into the
carrying female terminals 200 (i.e., inhibiting the occurrence female member 100 at the time of manufacture.
of electrical shorts between the female terminals 200). For The resilient member support 109 (FIG. 3C) may secure
example, the material of the female housing 102 may be a a resilient member 300 in each of the first and second female
glass reinforced nylon such as Zytel® 70G33L, made by terminal chambers 110 and 120. The resilient member
DuPont®. In some applications the reinforced nylon mate- 55 support 109 is shown as proximate to the female internal
rial may comprise approximately 33% glass. The material wall 105. However, an embodiment of the resilient member
may be used in a remotely controlled vehicle operating in a support 109 may be located proximate to an end of the
natural environment for example and may experience a female terminal housing 106 opposite to the female internal
temperature range from below -20° F. (-29° C.) to over wall 105 (i.e., the insertion end of the female terminal
250° F. (121° C.) (e.g., when operated in desert conditions 60 housing 106, for example, essentially configured 180° in a
over solar heated roadways, or due to battery heat, current horizontal plane relative to the embodiment shown in FIG.
flow, and electrical resistance). 3B) in addition to other locations. As with the female
The female conductor housing 104 may be separated from terminal support 107, the resilient member support 109 may
the female terminal housing 106 by the female internal wall comprise one or more retention features 112, for example, as
105. The female internal wall 105 may comprise an opening 65 represented by 112C in FIG. 3C. The retention features 112
114 (124) to accommodate a female terminal 200. On the of the resilient member support 109 may comprise slanted
female conductor housing 104 side of the female internal ramp protrusions as with an embodiment of the female
US 9,705,254 B2
5 6
terminal support 107, or the retention features 112 may coupling or assembly of a corresponding male terminal 600
comprise any of the mechanical, chemical, or welding (FIG. 2) during the connection of an electrical connector
methods of fastening previously recited. The previously 1000 (FIG. 1). The contact surface 214 may directly contact
recited methods of retaining and/or fastening female termi- an opposing surface of a male terminal 600 in order to allow
nals 200 and resilient members 300 are not intended to form 5 an electrical current to flow from one end of the electrical
an exhaustive list, but are merely a sampling from amongst connector 1000 to the other.
a broad variety of retaining and fastening methods known to Terminal step 208 may separate the terminal connector
those of ordinary skill in the art. As with the female portion 204 from the terminal contact portion 206. In some
terminals 200, the resilient members 300 may be core embodiments, during assembly of the female terminal 200
molded into the female housing 102 during the production of 10 into female housing 102 (FIG. 3B), the terminal step 208
the female housing 102. may oppose a portion of the female housing 102 and prevent
The ends of the first and second female terminal chambers further movement in the assembly direction. The terminal
110 and 120 located in the female terminal housing 106, retention features 212 may contact corresponding retention
opposite to the female internal wall 105, are referred to as features 112 of the female housing 102 and prevent move-
the first and second orifices 116 and 126. Each of the first 15 ment in a direction opposite to the assembly direction. At
and second orifices 116 and 126 may be configured sub- this point, the female terminal 200 may be substantially
stantially in a rectangular shape as shown in FIG. 3A. securely coupled with the female housing 102.
However, in the illustrative embodiment shown in these Resilient Member
figures, an aspect of the first orifice 116, such as a width, Referring now to FIGS. SA and 5B, these figures respec-
may be configured differently than the same aspect of the 20 tively show an orthogonal top view of a resilient member
second orifice 126. The difference in widths may inhibit an 300 and a side view of the resilient member 300 of FIG. SA.
incorrectly polarized assembly of a male member 500 (FIG. The resilient member 300 may comprise a resilient base
1) with the female member 100. Although a difference in member 310 and a resilient contact member 320. The
dimensional aspects such as widths may be used to inhibit resilient member 300 may be punch formed from a sheet of
reversing the polarities during connection of an electrical 25 stainless steel (e.g., SS 301 with no plating), spring steel
connector 1000 (FIG. 1) the present invention may not be (e.g., spring steel with nickel plating) or other resilient
limited to this method. Different configurations, devices, and material configured to work within the anticipated environ-
dimensions may be used to facilitate the proper polar mental conditions of the electrical connector 1000 (FIG. 1).
connection orientation during assembly of a male member In some embodiments, the resilient member 300 may be
500 with a female member 100. 30 plated or otherwise coated to inhibit rust or to provide an
Female Terminals appropriate level of resistance (e.g., friction force) necessary
Turning now to FIGS. 4A and 4B, FIG. 4A shows a top to maintain the connection between an assembled male
view of an embodiment of a female terminal 200, and FIG. member 500 and female member 100.
4B shows a side view of the female terminal 200 of FIG. 4A. The resilient base member 310 may be located at one end
As an example of an illustrative embodiment of a female 35 of the resilient member 300 and comprise one or more
terminal 200, the female terminal 200 may comprise a resilient retention members 312A and 312B (FIG. 5B). The
terminal connector portion 204 and a terminal contact por- resilient retention members 312A and 312B may engage
tion 206. The female terminal 200 may comprise an elec- corresponding retention members 112 within the resilient
trically conductive material, such as brass, copper, or member support 109 (as seen in FIG. 3C, but only one
bronze. The female terminal 200 may be plated with gold 40 retention member 112C can be seen in this view), located in
(such as a gold-cobalt or gold-nickel alloy) or silver, among each of the first and second terminal chambers 110 and 120.
other materials, preferably copper plated with nickel and The resilient retention members 312A and 312B may
then plated with gold (for example), in order to increase the securely retain the resilient members 300 within the female
electrical conductivity between contacting portions of the housing 102 during assembly and disassembly of the elec-
male and female terminals 600 and 200. The female terminal 45 trical connector 1000 (FIG. 1). The resilient base member
200 shown may be made from a standard plate of material 310 is shown as a substantially flat quadrilateral but embodi-
and punched formed to the correct size and configuration, ments of the present invention may not be limited to this
among other methods of forming. illustrative form. The resilient base member 310 may be
The terminal connector portion 204 may be located on retained separate from the corresponding female terminal
one end of the female terminal 200 and configured to 50 200 and separate from a fully inserted male terminal 500
electrically couple with a copper wire conductor (for (FIG. 2). In other words, the resilient base member 310 may
example) such as wire conductors 10B and 20B (FIG. 1). not overlay a corresponding male terminal 500 when an
The terminal connector portion 204 may be electrically electrical connector 1000 (FIG. 1) is electrically coupled.
coupled to a wire conductor through the use of soldering, As more easily seen in FIG. 5B, the resilient contact
mechanical fastening (e.g., through the use of a screw 55 member 320 may comprise an arcuate portion defined by a
clamp), standard insulated and non-insulated connector fit- radius R. The arcuate portion may be resiliently deformed
tings, crimping, and other methods of electrically coupling toward the radial center point in response to pressure or
a wire conductor to a portion of a terminal. Embodiments of interference from portions of an installed male member 500
the terminal connector portion 204 may comprise a variety (FIG. 1). The arcuate portion may also be configured to
of configurations in order to accommodate a particular 60 interface with a depression or other engaging feature,
electrical coupling method. detailed later, in an opposing surface or portion of the male
The terminal contact portion 206 may be located at an member 500 in order to provide a disassembly retention
opposite end of the female terminal 200 relative to the force after coupling the male member 500 with the female
terminal connector portion 204, and may comprise an angled member 100 (see FIG. 1). In the illustrative embodiment
end 210, one or more terminal retention features 212 (two 65 shown, only a single arcuate portion is illustrated in FIGS.
are shown in FIG. 4B, 212A and 212B), and a contact SA and 5B. However, embodiments of the present invention
surface 214. The angled end 210 may help facilitate the are not to be limited to this one exemplary configuration. For
US 9,705,254 B2
7 8
example, larger and smaller radii either alone or in combi- may not be limited to this one configuration. Any configu-
nation with one or more relatively straight portions may be ration capable of accommodating one or more male termi-
used, an arcuate portion curving back upon the resilient nals 600 may be used. The male housing 502 may be
contact member 320, a single angular bend joining two manufactured from a dielectric material able to withstand
straight portions together, or a plurality of angular or arcuate 5 the operating conditions of an intended application and
portions such as in a zig-zag or wave type of configuration provide sufficient electrical insulation between the current
may be used in order to more evenly apply a force from the carrying male terminals 600 (i.e., inhibiting the occurrence
female member 100 to the male member 500. The listing is of an electrical short between the male terminals 600). For
intended to provide a small representative sample of the example, the material of the male housing 502 may be a
various potential configurations consistent with the present 10 glass reinforced nylon such as Zytel® 70G33L, made by
invention and is not intended to be exhaustive. DuPont®. In some applications the reinforced nylon mate-
One end of the resilient contact member 320 may com- rial may comprise approximately 33% glass. The material
prise a housing interface 324. An example of the housing may be used in a remotely controlled vehicle operating in a
interface 324 may be illustrated by a small radius curve natural environment for example and may experience a
rotating in an opposite direction relative to the arcuate 15 temperature range from below -20° F. (-29° C.) to over
portion defined by the radius R. The housing interface 324 250° F. (121 ° C.) (e.g., when operated in desert conditions
may facilitate a sliding movement along a contacting portion over solar heated roadways, or due to battery heat, current
of an inner wall of the female housing 102 (FIG. 3B) in flow, and electrical resistance).
response to assembly and disassembly of a male member The male conductor housing 504 may be separated from
500 and a female member 100 (see FIG. 2). The sliding 20 the male terminal housing 506 by the male internal wall 505.
contact may prevent or inhibit the abrading or prematurely The male internal wall 505 may comprise an opening 514
wearing down of the inner surface of the female housing 102 (524) to accommodate a male terminal 600. On the male
over a multiple number of connections and disconnections conductor housing 504 side of the male internal wall 505,
of the electrical connector 1000 (FIG. 1). In this example, the male internal wall 505 may comprise an indicator 513
the contacting portion of the housing interface 324 curves 25 identifying the connection side of the electrical connector
away from the inner surface of the female housing 102 in 1000 (FIG.1), for example (e.g., "A" for the female member
directions tangent to the small radius curve. Further, the and "B" for the male member). In other embodiments, the
resilient contact member 320 may extend at an angle from indicator 513 may comprise a polarity sign to be used in
the resilient base member 310 such that the housing inter- place of, or in addition to, the first and second male polarity
face 324 may be located above (with respect to FIG. 5B) a 30 indicators 511 and 521 (FIG. 6A).
plane containing the resilient base member 310. This con- The male conductor housing 504 may circumferentially
figuration may apply a pre-load to an assembled resilient surround an end of a male terminal 600 inserted into each of
member 300 via the housing interface 324. By adjusting the the first and second male terminal extensions 510 and 520.
angle for the resilient contact member 320 relative to the An end of the male conductor housing 504 opposing the
resilient base member 310, and/or adjusting the radius R, the 35 internal wall 505 may be open to provide access for a
force applied to the male member 500 through the resilient conductor (not shown) to contact an exposed end of a male
contact member 320 may be adjusted. Adjusting the force of terminal 600. In other embodiments, an end or side of the
the resilient contact member 320 may adjust the amount of male conductor housing 504 adjacent to the male internal
insertion and withdrawal force for the connecting and dis- wall 505 may be open to provide conductor access. In the
connecting of the electrical connector 1000. Consequently, a 40 embodiment shown, the male conductor housing 504 sub-
desired amount of insertion and withdrawal force may be stantially shrouds and insulates the ends of the male termi-
established for the connecting and disconnecting of the nals 600 from each other. In certain other embodiments the
electrical connector 1000. male conductor housing 504 may only partially surround an
Male Member end of a male terminal 600 in each of the first and second
Turning now to FIGS. 6A, and 6B, the male member 500 45 male terminal extensions 510 and 520.
may comprise a male housing 502, a first male terminal The male internal wall 505 of each of the first and second
extension 510, a second male terminal extension 520, and male terminal extensions 510 and 520 may function as a
male terminals 600 (more clearly shown in FIG. 6B). A first male terminal support (FIG. 6B). Each of the male terminal
male polarity indicator 511 and a second male polarity supports (i.e., male internal walls 505) may help to retain a
indicator 521 may indicate the respective polarities of the 50 corresponding male terminal 600 in the respective first and
first male terminal extension 510 and the second male second male terminal extensions 510 and 520. The male
terminal extension 520. An example of a male terminal 600 terminal support may comprise one or more retention mem-
is shown in FIGS. 7A and 7B and is detailed later. The bers 512 (for example as represented by 512A), configured
various components of the male member 500 will be to retain a male terminal 600 after assembly into a male
described in more detail in the following illustrative embodi- 55 member 500. Although a slanted ramp type of retention
ment. member 512 is shown in FIG. 6B to facilitate an insertion
Male Housing type of assembly (e.g., inserting a male terminal 600 from
Referring to FIG. 6B, the male housing 502 may be the left to the right in the male housing 502 with respect to
substantially rectangular in shape and comprise a male FIG. 6B), a person of ordinary skill in the art would not be
conductor housing 504, a male internal wall 505, and a male 60 limited to just this type of retention member 512. Pins,
terminal tip 506 for each of the first and second male rivets, fasteners, other mechanical attachments, welding,
terminal extensions 510 and 520. Due to their similarities, and chemical adhesives, among other various methods may
only the first male terminal extension 510 will be described be used to secure a male terminal 600 within the male
parenthesis refer to second male terminal extension 520. 65 512B may be used to provide additional force to oppose the
Although a substantially rectangular shape is shown for the friction force generated during the connection and discon-
male housing 502, embodiments of the present invention nection of the electrical connector 1000 (FIG. 1) that may
US 9,705,254 B2
9 10
otherwise move or dislocate one or both of the male termi- surface and the contacting portion of the resilient contact
nals 600. Other embodiments of the male member 500 may member 320 of each of the respective resilient members 300.
not comprise retention members 512. In some cases the male Male Terminals
terminals 600 may be core molded into the male housing 502 Turning now to FIGS. 7A and 7B, FIG. 7A shows a top
at the time of manufacture. 5 view of an embodiment of a male terminal 600, and FIG. 7B
The ends of the first and second male terminal extensions shows a side view of the male terminal 600 of FIG. 7A. As
510 and 520 in the male terminal tips 506, opposite to the an example of an illustrative embodiment of a male terminal
internal wall 505, are referred to as the first and second male 600, the male terminal 600 may comprise a terminal con-
terminal covers 516 and 526. Each of the first and second nector portion 604 and a terminal contact portion 606. The
male terminal covers 516 and 526 may be configured 10 male terminal 600 may comprise an electrically conductive
substantially in a rectangular shape as shown in FIG. 6A. material, such as brass, copper, or bronze. The male terminal
However, in the illustrative embodiment shown in these 600 may be plated with gold (such as gold-cobalt or gold-
figures, an aspect of the first male terminal cover 516, for nickel alloy) or silver, among other materials, preferably
example width, may be configured differently than the same copper plated with nickel and then plated with gold (for
aspect of the second male terminal cover 526. The difference 15 example), in order to increase the electrical conductivity
in widths may inhibit an incorrectly polarized assembly of a between contacting portions of the male and female termi-
male member 500 (FIG. 1) with the female member 100. nals 600 and 200. The male terminal 600 shown may be
Although a difference in dimensional aspects such as widths made from a standard plate of material and punched formed
may be used to inhibit reversing the polarities during con- to the correct size and configuration, among other methods
nection of an electrical connector 1000 (FIG. 1), the present 20 of forming.
invention may not be limited to this method. Different The terminal connector portion 604 may be located on
configurations, devices, and dimensions may be used to one end of the male terminal 600 and configured to electri-
facilitate the proper polar connection orientation during cally couple with a copper wire conductor (for example)
assembly of a male member 500 with a female member 100. such as wire conductors l0A and 20A (FIG. 1). The terminal
The first and second male terminal covers 516 and 526 25 connector portion 604 may be electrically coupled to a wire
may each comprise a connector retention feature 507. In conductor through the use of soldering, mechanical fasten-
some embodiments, the connector retention feature 507 may ing (e.g., through the use of a screw clamp), standard
be configured as an arcuate cavity or depression correspond- insulated and non-insulated connector fittings, crimping, and
ing to an arcuate portion of the resilient contact member 320 other methods of electrically coupling a wire conductor to a
of a resilient member 300 (see FIG. 5B). As the male 30 terminal. Embodiments of the terminal connector portion
member 500 is connected to the female member 100 (see 604 may comprise a variety of configurations in order to
FIG. 1), the resilient member 300 moves relative to a surface accommodate a particular electrical coupling method.
of the corresponding first and second male terminal covers The terminal contact portion 606 may be located at an
516 and 526 until a portion of the resilient contact member opposite end of the male terminal 600 relative to the terminal
320 engages a corresponding portion of the connector reten- 35 connector portion 604, and may comprise an angled end
tion feature 507. The engagement between the resilient 610, one or more terminal retention features 612 (two are
contact member 320 and the connector retention feature 507 shown in FIG. 7B, 612A and 612B), and a contact surface
may provide a sensory indication that the male member 500 614. The angled end 610 may help facilitate the coupling or
is fully connected to the female member 100. In addition, the assembly of a corresponding female terminal 200 (FIG. 2)
engagement between the resilient contact member 320 and 40 during the connection of an electrical connector 1000 (FIG.
the connector retention feature 507 may help to prevent 1). The contact surface 614 may directly contact an opposing
inadvertent disconnection between the male member 500 surface of a female terminal 200 in order to allow an
and the female member 100 during the operation of the electrical current to flow from one end of the electrical
electrical connector 1000 in an applied device. connector 1000 to the other.
The first and second male terminal covers 516 and 526 45 Terminal step 608 may separate the terminal connector
may further comprise an angled or slanted portion 570, portion 604 from the terminal contact portion 606. In some
which may be located at an end opposite to the male internal embodiments, during assembly of the male terminal 600 into
wall 505. The slanted portion 570 of each of the first and male housing 502 (FIG. 6B), the terminal step 608 may
second male terminal covers 516 and 526 may facilitate the oppose a portion of the male housing 502 and prevent further
insertion and/or assembly of the male member 500 with the 50 movement in the assembly direction. The terminal retention
female member 100 (see FIG. 1). In some embodiments, features 612 may contact corresponding retention features
rounded, arcuate, or other insertion facilitating features may 512 of the male housing 502 and prevent movement in a
be used in place of, or in addition to, the slanted portion 570 direction opposite to the assembly direction. At this point,
of each of the first and second male terminal covers 516 and the male terminal 600 may be substantially securely coupled
526. At least part of the remaining portions of the first and 55 with the male housing 502.
second male terminal covers 516 and 526 may provide a Assembly
contact surface for the resilient member 300, as previously Turning now to FIGS. SA and 8B, FIG. SA illustrates a
explained, and may provide a degree of insulation between correctly assembled electrical connector 1000, while FIG.
the resilient members 300 and the male terminals 600. The 8B illustrates an incorrectly assembled electrical connector
material of the first and second male terminal covers 516 and 60 1000. As seen in FIG. SA, when the male member 500 is
526 may be the same as the material used for the rest of the correctly coupled to a female member 100, the first and
male housing 502. In some embodiments, the first and second male polarity indicators 511 and 521 correspond to
second male terminal covers 516 and 526 may comprise a the first and second female polarity indicators 111 and 121,
coating applied to a surface of the male terminals 600. indicating the maintenance of proper polarity across the
Alternatively, a coating or texture may be applied to a 65 electrical connector 1000. The correspondence between the
surface of the first and second male terminal covers 516 and sets of polarity indicators 111, 121, 511, and 521, may
526 to vary the level of frictional resistance between the provide a visual indication of the correct coupling of the
US 9,705,254 B2
11 12
male and female members 500 and 100. As seen in FIG. SB, first and second female terminal chambers 110 and 120. As
the first and second male polarity indicators 511 and 521 the male member 500 is connected to the female member
may not be visible from a top oriented viewing plane when 100, the resilient members 300 may initially contact the
the male member 500 is incorrectly assembled to the female slanted portion 570 of the corresponding first and second
member 100. In addition, as indicated by the arrows for the 5 male terminal covers 516 and 526. The resilient contact
first and second male polarity indicators 511 and 521 (the portions 320 may respectively slidingly engage a top surface
polarity indicators themselves are not visible in this view), of each of the first and second male terminal covers 516 and
the polarities on each side of the incorrectly assembled 526. The resilient contact portions 320 may be compressed,
electrical connector 1000 have been reversed. causing the housing interface 324 portion of the resilient
Referring to FIGS. 9A and 9B, FIG. 9A illustrates a 10 member 300 to slidingly engage an interior surface of the
cross-sectional view of the correctly assembled electrical respective first and second female terminal chambers 110
connector 1000 of FIG. SA as viewed along line 9A-9A, and 120. The male member 500 may continue to be inserted
while FIG. 9B illustrates a cross-sectional view of the into the female member 100 until the resilient contact
incorrectly assembled electrical connector 1000 of FIG. SB portion 320 engages a corresponding connector retention
as viewed along line 9B-9B. FIG. 9A shows an electrical 15 feature 507 of the respective first and second male terminal
connector 1000 in which a first male terminal cover 516 is covers 516 and 526. At this point, the male member 500 may
inserted into a first orifice 116 and a contact surface 614 of be securely coupled to the female member 100. Although
the male terminal 600 is abutting a contact surface 214 of the only one side portion of the electrical connector 1000 is
female terminal 200. The first male terminal cover 516 and described in detail, the other side portion may be similar due
the first orifice 116 may each have an approximate width of 20 to the symmetry of the connector. However, complete sym-
Wl with the first male terminal cover 516 configured to fit metry is not a limitation required of an embodiment of the
within the first orifice 116. The second male terminal cover present invention and differences beyond the widths of the
526 is inserted into a second orifice 126 such that a contact first and second male terminal covers 516 and 526 and
surface 614 of the corresponding male terminal 600 is corresponding first and second orifices 116 and 126 may
abutting a contact surface 214 of the corresponding female 25 exist.
terminal 200. The second male terminal cover 526 and the Another Embodiment
second orifice 126 may each have an approximate width of Referring now to FIG. 11, this figure shows an orthogonal
W2 with the second male terminal cover 526 configured to top view with a cross-section taken through the side of an
fit within the second orifice 126. The width Wl may be embodiment of an electrical connector. In this figure, refer-
smaller than the width W2. This difference in widths may 30 ence number 2000 generally refers to another illustrative
provide another method of inhibiting or preventing cross- embodiment of an electrical connector 2000 constructed
polarization during connection of the male member 500 to according to aspects of the present invention. One difference
the female member 100 (FIG. SA), since the male member between the electrical connector 2000 and the previously
500 may be connected to the female member 100 when the described electrical connector 1000 (FIG. 1) may be the
male member 500 is properly oriented with respect to the 35 replacement of one or more resilient members 300 (FIG. 2)
female member 100. The proper orientation of the male and of the previous illustrative embodiment with one or more
female members 500 and 100 may provide for the correct resilient members 2300. Otherwise, the function and mate-
polarity of the connection. rials for the two electrical connectors 1000 and 2000 may be
FIG. 9B shows an electrical connector 1000 in which a considered to be the same. Similar components may be
male member 500 is incorrectly connected to a female 40 identified with similar reference numerals used in the pre-
member 100. This type of connection may be substantially vious description, and a detailed explanation of these com-
prevented by the interference between the width of the ponents may not be repeated.
second male terminal cover 526 (W2) and the width of the Electrical connector 2000 may comprise a female member
first orifice 116 (Wl)(e.g., W2-Wl). However, if the male 2100 and a male member 500, shown here in a connected
member 500 is somehow coupled to the female member 100 45 state. The female member 2100 may comprise one or more
in spite of this interference, cross-polarization of the elec- female terminals 200 (only one is visible in this view) and
trical connector 1000 may still be prevented by the first and the male member 500 may comprise a corresponding num-
second male terminal covers 516 and 526 separating the ber of male terminals 600. When the female member 2100
male and female terminals 600 and 200. The first and second and the male member 500 are coupled together, electricity
male terminal covers 516 and 526 may prevent contact 50 may be able to flow between wire conductors (not shown)
between corresponding male and female terminals 600 and through the electrical connector 2000 via the areas of contact
200 when the male member 500 is in a second orientation between the female and male terminals 200 and 600.
with respect to the female member 100. Therefore, as seen The female member 2100 may comprise one or more
in this illustrative embodiment, cross-polarization of the resilient members 2300. The resilient members 2300 may
electrical connector 1000 may be prevented and/or inhibited 55 provide a pressing force to facilitate electrical conduction
by at least two separate and independent methods, in addi- through the contact areas between the corresponding female
tion to the visual indication given by the first and second and male terminals 200 and 600. In addition, the resilient
male and female polarity indicators, 111, 121, 511, and 521. members 2300 may provide a securing force to inhibit or
Referring now to FIG. 10, this figure illustrates an prevent the inadvertent disconnection of the male member
orthogonal cross-sectional view of a correctly assembled 60 500 from the female member 2100 during the use of the
malemember500 and female member 100. In this figure, the electrical connector 2300 in a desired application (e.g., such
first and second male terminal extensions 510 and 520 (FIG. as in a vibratory and dynamic environment of a remotely
6A) have been inserted into the first and second female controlled vehicle). In some exemplary embodiments, the
terminal chambers 110 and 120 (FIG. 3A), or more specifi- number of resilient members 2300 corresponds to the num-
cally, the male terminal housing 506 portions of the first and 65 ber of electrical connections formed or broken during the
second male terminal extensions 510 and 520 have been connection and disconnection of the electrical connector
inserted into the first and second orifices 116 and 126 of the 2000 (e.g., two are shown in FIG. 11). However, the number
US 9,705,254 B2
13 14
of resilient members 2300 may not be required to equal the described electrical connectors may be the replacement of
number of electrical connections formed or broken. one or more resilient members 300 (FIG. 2) or 2300 (FIG.
Each resilient member 2300 may comprise a resilient 11) of the previous illustrative embodiments, with one or
housing 2310 integrated with the housing of the female more resilient members 3300. Otherwise, the function and
member 2100. As shown in FIG. 11, the resilient housing 5 materials for the electrical connectors 1000, 2000, and 3000
2310 may be substantially cylindrical for example, but may be considered to be the same. Similar components may
embodiments of the present invention may not be limited to be identified with similar reference numerals used in the
this geometric configuration. Each resilient member 2300 previous description, and a detailed explanation of these
may further comprise a retention device 2324, a resilient components may not be repeated.
device 2322, and a contact device 2320. The retention device 10
Electrical connector 3000 may comprise a female member
2324 may comprise an Allen set screw as shown for
3100 and a male member 500, shown here in a connected
example, or may comprise any of a number of devices able
state. The female member 3100 may comprise one or more
to retain the resilient device 2322 and the contact device
2320 within the resilient housing 2310, while in some female terminals 200 (only one is visible in this view) and
embodiments further providing a measure of adjustability. 15
the male member 500 may comprise a corresponding num-
For example, a mechanical threaded fastener, angled key, or ber of male terminals 600. When the female member 3100
cam device, among others, may be used. In this example, the and the male member 500 are coupled together, electricity
retention device 2324 may be threadably engaged with a top may be able to flow between wire conductors (not shown)
portion of the resilient housing 2310. through the electrical connector 3000 via the contact areas
The resilient device 2322 may be located between the 20 between the female and male terminals 200 and 600.
retention device 2324 and the contact device 2320. The The female member 3100 may comprise one or more
resilient device 2322 may be a spring, such as a coil spring, resilient members 3300. The resilient members 3300 may
or resilient material, such as foam, among other devices. The provide a pressing force to facilitate electrical conduction
resilient device 2322 may press against the contact device through the contact area between the female terminals 200
2320, facilitating movement of the contact device 2320 as 25 and the male terminals 600. In addition, the resilient mem-
the male member 500 and the female member 2100 are bers 3300 may provide a securing force to inhibit or prevent
coupled together. The force applied to the contact device the inadvertent disconnection of the male member 500 from
2320 and consequently to the male and female terminals 200 the female member 3100 during the use of the electrical
and 600, may be adjusted by tightening or loosening the connector 3300 in a desired application (e.g., such as in a
retention device 2324, in addition to altering the spring 30 vibratory and dynamic remotely controlled vehicle). In some
stiffness or material, among other methods. In some embodi- exemplary embodiments, the number of resilient members
ments, the male member 500 may be securely coupled to the 3300 corresponds to the number of electrical connections
female member 2100 by tightening the retention device formed or broken during the connection and disconnection
2324 so as to eliminate or reduce the ability of the contact of the electrical connector 3000, two electrical connections
device 2320 to move within the resilient housing 2310, 35 are shown in this embodiment. However, the number of
thereby forcefully engaging the contact device 2320 with a resilient members 3300 may not be required to equal the
connector retention feature 507. number of electrical connections formed or broken.
The contact device 2320 may be spherical ball for Each resilient member 3300 may be configured to inter-
example, such as in a ball and spring type of mechanism. fere with a opposing surface of a first and second male
However, in other embodiments the contact device 2320 40 terminal cover 516 and 526 (only 516 is visible in this view)
may be any member capable of moving across the surface of when a male member 500 is coupled to a female member
the first and second male terminal covers 516 and 526 (only 3100. As shown in FIG. 12, the area indicated by cross-
the first male terminal cover 516 is visible in this view), such hatching may be the area of interference between the resil-
as a rounded pin, angled member, cylinder, among others. ient member 3300 and the top surface of the first male
The contact device 2320 may be retained within the resilient 45 terminal cover 516, although only a portion of the abutting
housing 2310 between a protruding edge 2312 at one end surfaces may be configured to be interfering. The resilient
and the retention device 2324 at the other end. During member 3300 may comprise a rib interfacing with a portion
connection of the male member 500 and the female member of the respective top surface of the first and second male
2100, the contact device 2320 may engage the connector terminal covers 516 and 526, or the resilient member 3300
retention feature 507 as the male member 500 is fully 50 may comprise the wall of the female member housing 3102,
coupled with the female member 2100. The contact device among numerous other configurations such as those previ-
2320 and the connector retention feature 507 may be con- ously described for the resilient contact portion 320. Essen-
figured to have corresponding or interfacing features, such tially, in some embodiments the housing 3102 of the female
that when the male member 500 is fully coupled with the member 3100 may function as a resilient member, allowing
female member 2100, a sensory indication of the application 55 at least some degree of resilient deformation or movement
device 2320 engaging the connector retention feature 507 designed to apply a force to at least a portion of an installed
may be provided. The sensory indication may be visual, male member 500 (e.g., such as the first and second male
audible, tactile, or a combination of one or more of these terminal covers 516 and 526, or in some embodiments, the
sensory indications, in addition to other methods. male terminals themselves, among other configurations).
Another Embodiment 60 Alternatively, the first and second male terminal covers 516
Referring now to FIG. 12, this figure shows an orthogonal and 526 may function as a resilient member, allowing at
top view with a cross-section taken through the side of an least some degree of resilient deformation or movement
embodiment of an electrical connector. In this figure, refer- designed to urge the male terminals 600 together with the
ence number 3000 generally refers to another illustrative corresponding female terminals 200. Further, in some
embodiment of an electrical connector 3000 constructed 65 embodiments, both the female housing 3102 and the first and
according to aspects of the present invention. One difference second male terminal covers 516 and 526 may experience
between the electrical connector 3000 and the previously some degree of resilient deformation, combining together to
US 9,705,254 B2
15 16
provide a force urging the male terminals 600 together with provide sufficient electrical insulation between the current
the corresponding female terminals 200. carrying first male terminal 1600 and second male terminal
The resilient member 3300 may further comprise protru- 1650 (i.e., inhibiting the occurrence of an electrical short
sions or features configured to engage with corresponding between the first male terminal 1600 and the second male
depressions or features located on the top surfaces of the first 5 terminal 1650).
and second male terminal covers 516 and 526, such that the The male internal wall 1505 of each of the first and second
male member 500 may be securely coupled to the female male terminal extensions 1510 and 1520 may function as a
member 3000 upon fully connecting the male member 500 male terminal support. Each of the male terminal supports
to the female member 3100. An example of a protrusion for (i.e., male internal walls 1505) may respectively secure and
the resilient member 3300 may be an arcuate ridge corre- 10 support the first and second male terminals 1600 and 1650
sponding to the connector retention feature 507 shown in in the corresponding first and second male terminal exten-
FIG. 6B. The resilient member 3300 may at least partially sions 1510 and 1520. The male terminal support may
resiliently deform with respect to the area of interference. comprise one or more retention members 512 (for example
Alternatively, the resilient member 3300 may take advan- as represented by 512A and 512B) configured to retain the
tage of at least some degree of resilient deformation in the 15 respective first and second male terminals 1600 and 1650
configuration of the female member housing 3102. after assembly into a male member 1500. Although a slanted
Another Embodiment ramp type of retention member 512 is shown in FIG. 13B to
Turning now to FIGS. 13A and 13B, the first figure shows facilitate an insertion type of assembly (e.g., inserting a male
a top view of an illustrative embodiment of a male member terminal 1600 from the right to the left in the male housing
1500 configured according to aspects of the present inven- 20 1502 with respect to FIG. 13B), a person of ordinary skill in
tion, while the second figure shows an orthogonal cross- the art would not be limited to just this type of retention
sectional top view of the male member 1500 ofFIG.13Aas member 512. Pins, rivets, fasteners, other mechanical attach-
viewed along line 13B-13B. One difference between the ments, welding, and chemical adhesives, among other vari-
male member 1500 and the previously described male ous methods may be used to secure the first and second male
member 500 (FIG. 1) may be the lack of first and second 25 terminals 1600 and 1650 within the male housing 1502.
male terminal covers 516 and 526 (see FIGS. 6A and 6B) in Additionally, the first and second male terminals 1600 and
the male member 1500. Another difference may be the use 1650 may be core molded along with the male housing 1502
of first and second male terminals 1600 and 1650 in male at the time of manufacture.
member 1500 in place of the male terminals 600 shown in The first and second male terminals 1600 and 1650 may
male member 500 (see FIG. 2). Otherwise, the function and 30 comprise retention members 612 (for example as repre-
materials for the male members 500 and 1500 may be sented by 612A and 612B, however, only the retention
considered to be substantially the same. Similar components members 612 of the first male terminal 1600 may be seen in
may be identified with similar reference numerals used in FIG. 13B, the second male terminal 1650 may be similarly
previous descriptions, and a detailed explanation of these configured) corresponding to the retention members 512. As
components may not be repeated. 35 with the retention member 512, a slanted ramp type of
Male member 1500 may comprise a male housing 1502 retention member 612 is shown in FIG. 13B to facilitate an
and first and second male terminal extensions 1510 and insertion type of assembly, however, a person of ordinary
1520. The first male terminal extension 1510 may comprise skill in the art would not be limited to just this type of
the first male terminal 1600, while the second male terminal retention member 612. Pins, rivets, fasteners, other mechani-
extension 1520 may comprise the second male terminal 40 cal attachments, welding, and chemical adhesives, among
1650. First and second male terminals 1600 and 1650 may other various methods may be used to secure the first and
be configured to be insertably engaged with the first and second male terminals 1600 and 1650 within the male
second orifices 116 and 126 of the first and second female housing 1502.
terminal chambers 110 and 120 of a female member 100 (see Having thus described embodiments of the present inven-
FIG. 3A). In some embodiments, some aspects of the first 45 tion by reference to certain exemplary embodiments, it is
male terminal 1600 may be different than similar aspects of noted that the embodiments disclosed are illustrative rather
the second male terminal 1650 in order to inhibit the than limiting in nature. A wide range of variations, modifi-
cross-polarizing connection of a male member 1500 and a cations, changes, and substitutions are contemplated in the
female member 100. In the embodiment shown, the width foregoing disclosure. In some instances, some features of an
Wl of the first male terminal 1600 may be smaller that the 50 embodiment of the present invention may be employed
width W2 of the second male terminal 1650. Interference without a corresponding use of the other features. Many
between the larger width W2 and the first orifice 116 may such variations and modifications may be considered desir-
inhibit the connection between a female member 100 and an able by those skilled in the art based upon a review of the
improperly oriented male member 1500 (i.e., the male foregoing description of the illustrative embodiments.
member 1500 may be improperly oriented with respect to 55 Accordingly, it is appropriate that the appended claims be
the female member 100). construed broadly and in a manner consistent with the scope
The male housing 1502 may be substantially rectangular of the invention.
in shape and comprise a male conductor housing 504 and a We claim:
male internal wall 1505 for each of the first and second male 1. A female electrical connector comprising:
terminal extensions 1510 and 1520. Although a substantially 60 a female housing comprising an insulating material at
rectangular shape is shown for the male housing 1502, least partially forming a first female receptacle com-
embodiments of the present invention may not be limited to prising a first receptacle opening for at least partially
this one configuration. Any configuration capable of accom- receiving a first male connector electrode;
modating one or more first and second male terminals 1600 a first female electrode disposed at least partially within
and 1650 may be used. The male housing 1502 may be 65 the first female receptacle, wherein the first female
manufactured from a dielectric material able to withstand electrode comprises a first surface for electrically cou-
the operating conditions of an intended application and pling with a first male connector electrode;
US 9,705,254 B2
17 18
a first resilient member retained by the first female wherein the first female electrode comprises a first surface
receptacle, wherein the first resilient member com- configured to make an electrical coupling with a male
prises a first resilient contact member configured to contact surface of a first male connector electrode; and
deform while a first male connector electrode is at least wherein the first female electrode abuts an inner surface
partially inserted into the first female receptacle; of the first female receptacle along at least a portion of
wherein the first resilient member is configured to provide a surface of the first female electrode.
a biasing force to facilitate an electrical coupling of the 5. The female electrical connector of claim 4, further
first female electrode with only a first male connector comprising:
electrode; the female housing comprising an insulating material at
10 least partially forming a second female receptacle com-
wherein the first resilient contact member resiliently
prising a second receptacle opening for at least partially
deforms in response to interference from one or more
receiving a second male connector electrode, wherein
portions of a first male connector electrode, when a first
the second female receptacle is configured to receive a
male connector electrode is at least partially inserted second male connector electrode;
into the first female receptacle; and 15 a second female electrode disposed at least partially
wherein the first resilient member is retained within the within the second female receptacle;
female housing spaced from the first female electrode, a second resilient member retained by the second female
whereby the first resilient member and the first female receptacle, wherein the second resilient member com-
electrode are not in contact with one another. prises a second resilient contact member configured to
2. The female electrical connector of claim 1, wherein the 20 provide an interference fit between the second female
first resilient contact member comprises an arcuate portion, electrode and a second male connector electrode to
and wherein the arcuate portion resiliently deforms in secure the second female electrode and a second male
response to interference from one or more portions of a first connector electrode, when a second male connector
male connector electrode, when a first male connector electrode is at least partially inserted into the second
electrode is at least partially inserted into the first female 25 female receptacle; and
receptacle. wherein the second female electrode comprises a second
3. The female electrical connector of claim 1, further surface configured to make an electrical coupling with
comprising: a second male contact surface of a second male con-
the insulating material at least partially forming a second nector electrode.
30 6. The female electrical connector of claim 5, wherein at
female receptacle comprising a second receptacle
least one dimension of the first receptacle opening is larger
opening for at least partially receiving a second male
than a corresponding dimension of the second receptacle
connector electrode;
opening.
a second female electrode disposed at least partially
7. The female electrical connector of claim 5, wherein the
within the second female receptacle, wherein the sec- 35 second resilient contact member is configured to deform
ond female electrode comprises a second surface for while a second male connector electrode is at least partially
electrically coupling with a second male connector inserted into the second female receptacle without any
electrode; and substantial deformation of the female housing;
a second resilient member retained by the second female wherein the second resilient member is configured to
receptacle, wherein the second resilient member com- 40 provide a biasing force to facilitate an electrical cou-
prises a second resilient contact member configured pling of the second female electrode with only a second
deform while a second male connector electrode is at male connector electrode; and
least partially inserted into the second female recep- wherein the second female electrode comprises a second
tacle. surface configured to make an electrical coupling with
4. A female electrical connector comprising: 45 a male contact surface of a second male connector
a female housing comprising a single piece of insulating electrode, with the second surface disposed along a
material at least partially forming a first female recep- portion of the length of the second female electrode
tacle comprising a receptacle opening for at least facing towards the second resilient member.
partially receiving a first male connector electrode; 8. The female electrical connector of claim 5, wherein the
a first female electrode disposed at least partially within 50 female housing comprises a uniform insulating material.
the first female receptacle; 9. An electrical connector comprising:
a first resilient member retained by the first female a female connector, comprising:
receptacle, wherein the first resilient member com- a female housing comprising an insulating material at
prises a first resilient contact member configured to least partially forming a female receptacle, wherein
provide an interference fit between-the first female 55 the female receptacle comprises a receptacle opening
electrode and a first male connector electrode to secure for at least partially receiving at least a portion of a
the first female electrode and a first male connector male connector;
electrode, when a first male connector electrode is at a female terminal disposed at least partially within the
least partially inserted into the first female receptacle; female receptacle; and
wherein the first resilient contact member is configured to 60 a first resilient member retained within the first female
deform while a first male connector electrode is at least receptacle;
partially inserted into the first female receptacle with- a male connector configured to be insertable to within the
out any substantial deformation of the female housing; female receptacle, the male connector comprising:
wherein the first resilient member is configured to provide an electrically insulating male housing;
a biasing force to facilitate an electrical coupling of the 65 an electrically conductive male terminal retained by the
first female electrode with only a first male connector male housing, the male terminal extending from the
electrode; and male housing and comprising a male contact surface,
US 9,705,254 B2
19 20
the male contact surface disposed along a coupling
length of the male terminal and outside of the male
housing; and
an insulating cover disposed along at least a portion of
the coupling length of the male connector terminal 5
for electrically insulating one or more surfaces of the
male connector terminal other than the contact sur-
face;
wherein the male connector terminal electrically couples
with the female terminal at the male contact surface 10
while at least a portion of the coupling length of the
male terminal is inserted to within the female recep-
tacle; and
wherein at least a portion of the first resilient member
deforms to facilitate an electrical coupling of the male 15
terminal with the female terminal while at least a
portion of the coupling length of the male terminal is
inserted to within the female receptacle.
* * * * *
EXHIBIT 9
I 1111111111111111 1111111111 lllll 111111111111111 11111 11111 111111111111111111
US010177500B2

Lampert et al. (45) Date of Patent: *Jan. 8, 2019
(54) ELECTRICAL CONNECTOR ASSEMBLY (52) U.S. Cl.

CPC .................................. HOJR 13/642 (2013.01)
(71) Applicant: TRAXXAS LP, McKinney, TX (US) (58) Field of Classification Search
CPC ................................ H0lR 13/64; H0lR 13/18
(72) Inventors: Jon Kenneth Lampert, Allen, TX
USPC ........ 439/679, 691, 693, 680, 282, 296, 284
(US); Seralaathan Hariharesan,
Flower Mound, TX (US); Brock
Dennison, Lewisville, TX (US)
(56) References Cited
(73) Assignee: TRAXXAS LP, McKinney, TX (US) U.S. PATENT DOCUMENTS
( *) Notice: Subject to any disclaimer, the term ofthis 2,121,338 A 2/1938 Chirelstein
patent is extended or adjusted under 35 2,203,122 A 6/ 1940 Anderson
U.S.C. 154(b) by 0 days. 2,838,739 A 6/1958 Winkler
(Continued)
This patent is subject to a terminal dis-
claimer. FOREIGN PATENT DOCUMENTS
(21) Appl. No.: 15/645,867 DE 704450 C 3/1941
EP 0318831 A2 6/1989
(22) Filed: Jul. 10, 2017 (Continued)
(65) Prior Publication Data OTHER PUBLICATIONS

US 2017/0310050 Al Oct. 26, 2017
Clarke, Brooke; "Power Pole"; web page article; Brooke, Clarke,
Related U.S. Application Data Ukiah CA, USA, 2003-2006.
(63) Continuation of application No. 14/887,128, filed on (Continued)

Oct. 19, 2015, now Pat. No. 9,705,254, which is a
Primary Examiner - Phuong Chi T Nguyen
Feb. 3, 2014, now Pat. No. 9,166,323, which is a (74) Attorney, Agent, or Firm - Daryl R. Wright; Greg
continuation of application No. 12/959,872, filed on Carr
Dec. 3, 2010, now Pat. No. 8,641,440, which is a
(57) ABSTRACT
Apr. 3, 2009, now Pat. No. 7,867,038, which is a An electrical connector is provided comprising a female
continuation of application No. 11/951,754, filed on member configured to couple with male member. The
Dec. 6, 2007, now Pat. No. 7,530,855, which is a female member includes a female receptacle having an
continuation of application No. 11/736,460, filed on opening, and a female electrode is at least partially disposed
Apr. 17, 2007, now Pat. No. 7,374,460. within the female receptacle. A resilient member is config-
ured to enhance electrical connection between the female
(51) Int. Cl. electrode and a male connector electrode.
HOJR 13/64 (2006.01)
HOJR 13/642 (2006.01) 14 Claims, 11 Drawing Sheets
1500
1650
US 10,177,500 B2
Page 2
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6,619,995 Bl 9/2003 Hayashi et al. Plano TX U.S.A.
6,619,996 B2 9/2003 Hara et al. Deans; "Ultra Plug" photographs (3 pages); Wim. F. Deans, Para-
6,623,309 B2 9/2003 Sakurai et al. mount CA U.S.A.
6,645,003 B2 11/2003 Yoshida et al. Molex; "Standard .093" connector photographs (7 pages); Molex,
6,790,067 B2 9/2004 Douty et al. Lisle IL U.S.A.
6,994,596 B2 2/2006 Katsuma "Standard ll0V electrical plugs and receptacles" photographs (5
7,004,795 B2 2/2006 Mancini et al. pages).
7,374,460 Bl 5/2008 Hariharesan et al.
Barajas, Jaime; "Styling Input from Jaime", Traxxas LP, Plano TX
U.S.A (confidial internal document, Jan. 23, 2007).
8,641,440 B2 2/2014 Hariharesan et al. Hyperphysics, "Household Wiring-Polarized Receptacles" web
9,166,323 B2 10/2015 Lampert page article; http://hyperphysics.phy-astr.gsu.edu/hbase/ electric/
9,705,254 B2 * 7/2017 Lampert H0lR 13/642 hsehold.html.
2004/0127104 Al 7/2004 Stefaniu et al. EP Patent Application No. 072543572; European Search Report,
2007/0010113 Al 1/2007 F ukatsu et al. dated Nov. 24, 2009.
2007/0059970 Al 3/2007 Ichio et al. EP Patent Application No. 131763104; European Search Report,
dated Sep. 2, 2013.
FOREIGN PATENT DOCUMENTS EP Patent Application No. 131763104; Extended European Search
Report, dated Dec. 4, 2013.
EP 0887896 A2 12/1998
FR 1036107 A 9/1953 * cited by examiner
U.S. Patent Jan.8,2019 Sheet 1 of 11 US 10,177,500 B2
1000
FIG.1
1000
FIG.2
100 111
~ 121
FIG. 3A
100
102
,J
200
FIG.3B
100
,J
12C
200
FIG.JC
208 214
,---------,,------, J
200----.
□ 210
206
204
FIG. 4A
212A~
,214 /'210
200----. . . --11- -....... K-~~----n
r 212sf
\.208
FIG.4B
608 612
600----.
610
604
FIG. 7A
600
612:;:
----. 1~1- ~ I~I ----=---------.-----□
612B7 614 "-610
FIG. 7B
300
324
FIG. 5A
300
,I
FIG. 5B
500 516
FIG. 6A
500
~ 502
FIG. 6B
111
1000
511
FIG. BA
111
1000
FIG. BB
1000
~ W1 W2
526
214
600
FIG. 9A
1000
600 600
FIG.9B
.s. a tent 2019 o f 11 1,soo n2

a P Ja11.s, Sheet 9 vs 10,11
FIG. I O
2000
2310
2324
2322
2320
FIG. I I
3000
,J
FIG.12
1500
~ W2
1520~
1650
D
138 138
L 1600
_J
1510_,,..
W1
FIG.13A
1500
1650
FIG.13B
US 10,177,500 B2
1 2
ELECTRICAL CONNECTOR ASSEMBLY FIG. 2 illustrates an exploded assembly view of the
electrical connector of FIG. 1;
CROSS-REFERENCE TO RELATED FIG. 3A illustrates an orthogonal top view of a female
APPLICATIONS member of the electrical connector of FIG. 1;
FIG. 3B illustrates a cross-sectional view of the female
This application is a continuation of, and claims the member of FIG. 3A as viewed along line 3B-3B;
benefit of the filing date of, co-pending U.S. patent appli- FIG. 3C illustrates a cross-sectional view of the female
cation Ser. No. 14/887,128 entitled ELECTRICAL CON-
member of FIG. 3A as viewed along line 3C-3C;
NECTOR ASSEMBLY, filed Oct. 19, 2015, which is a
FIG. 4A illustrates a top view of a female terminal;
entitled ELECTRICAL CONNECTOR ASSEMBLY, filed
10 FIG. 4B illustrates a side view of the female terminal of
Feb. 3, 2014, now U.S. Pat. No. 9,166,323, which is a FIG. 4A;
continuation of U.S. patent application Ser. No. 12/959,872 FIG. SA illustrates an orthogonal top view of a resilient
entitled ELECTRICAL CONNECTOR ASSEMBLY, filed member;
Dec. 3, 2010, now U.S. Pat. No. 8,641,440, which is a FIG. SB illustrates a side view of the resilient member of
continuation of U.S. patent application Ser. No. 12/417,792 15 FIG. SA;
entitled ELECTRICAL CONNECTOR ASSEMBLY, filed FIG. 6A illustrates an orthogonal top view of a male
Apr. 3, 2009, now U.S. Pat. No. 7,867,038, which is a member;
continuation of U.S. patent application Ser. No. 11/951,754 FIG. 6B illustrates a cross-sectional side view of the male
entitled ELECTRICAL CONNECTOR ASSEMBLY, filed member of FIG. 6A;
Dec. 6, 2007, now U.S. Pat. No. 7,530,855, which is a 20 FIG. 7A illustrates a top view of a male terminal;
continuation of U.S. patent application Ser. No. 11/736,460 FIG. 7B illustrates a side view of the male terminal of
filed Apr. 17, 2007, now U.S. Pat. No. 7,374,460. FIG. 7A;
FIG. SA illustrates an orthogonal top view of the electrical
BACKGROUND OF THE INVENTION connector of FIG. 1 correctly assembled;
25 FIG. SB illustrates an orthogonal top view of the electrical
Field of the Invention connector of FIG. 1 incorrectly assembled;
The present invention generally relates to electrical con- assembled electrical connector of FIG. SA as viewed along
nectors and, more particularly, to high current electrical line 9A-9A;
connectors with protection against reverse polarity connec- 30 FIG. 9B illustrates a cross-sectional view of the incor-
tions. rectly assembled electrical connector of FIG. SB as viewed
along line 9B-9B;
Description of the Related Art FIG. 10 illustrates an orthogonal cross-sectional view of
the assembled electrical connector of FIG. 1;
A wide variety of electronic devices are powered through 35 FIG. 11 illustrates an orthogonal cross-sectional top view
battery pack supplying stored electricity to an electric motor. FIG. 12 illustrates an orthogonal cross-sectional top view
In some of these lightweight vehicles, racing creates a of another embodiment of an electrical connector configured
demand for more powerful motors along with increasing 40 according to aspects of the present invention;
must be able to easily exchange a depleted battery pack for to aspects of the present invention; and
a fully charged one. The depleted battery pack is then FIG. 13B illustrates an orthogonal cross-sectional top
connected to a battery charger in order to be ready for the 45 view of the component of FIG. 13A as viewed along line
next exchange. Consequently, there exists a need for a high 13B-13B.
current electrical connector with a lightweight and compact
design. DETAILED DESCRIPTION
SUMMARY OF THE INVENTION 50 In the following discussion, numerous specific details are
set forth to provide a thorough understanding of the present
In accordance with an embodiment of the present inven- invention. However, those skilled in the art will appreciate
tion, an electrical connector having a lightweight and com- that the present invention may be practiced without such
pact design is provided wherein a resilient member is specific details. In other instances, well-known elements
configured to enhance electrical connection between a 55 have been illustrated in schematic or block diagram form in
female electrode and a male connector electrode. order not to obscure the present invention in unnecessary
detail. Additionally, for the most part, details concerning
BRIEF DESCRIPTION OF THE DRAWINGS well known features and elements have been omitted inas-
much as such details are not considered necessary to obtain
For a more complete understanding of the present inven- 60 a complete understanding of the present invention, and are
tion and the advantages thereof, reference is now made to considered to be within the understanding of persons of
the following Detailed Description taken in conjunction with ordinary skill in the relevant art.
the accompanying drawings, in which: Turning now to the drawings, FIG. 1 shows a top orthogo-
FIG. 1 illustrates a general orthogonal top view of an nal view of an assembled electrical connector with attached
embodiment of an electrical connector configured according 65 wire conductors. In this drawing, reference numeral 1000
to the present invention and showing attached wire conduc- generally indicates an illustrative embodiment of an electri-
tors; cal connector 1000 at least partially configured according to
US 10,177,500 B2
3 4
the present invention. The electrical connector 1000 may The female conductor housing 104 may be separated from
comprise a female member 100 and a male member 500. the female terminal housing 106 by the female internal wall
Attached to the electrical connector 1000 are wire conduc- 105. The female internal wall 105 may comprise an opening
tors lOA, 10B, 20A, and 20B. The wire conductors lOA, 114 (124) to accommodate a female terminal 200. On the
10B, 20A, and 20B, may not considered as components of 5 female conductor housing 104 side of the female internal
the electrical connector 1000 and are shown for the purposes wall 105, the female internal wall 105 may comprise an
of illustration. Wire conductors lOA and 10B may carry a indicator 113 identifying the connection side of the electrical
positive current flow and wire conductors 20A and 20B may connector 1000 (FIG. 1) for example (e.g., "A" for the
female member and "B" for the male member). In other
carry a negative current flow. The various components of the
10 embodiments, the indicator 113 may comprise a polarity
electrical connector 1000 will be described in more detail in
sign to be used in place of, or in addition to, the first and
the following illustrative embodiment.
second female polarity indicators 111 and 121 (FIG. 3A).
Referring to FIG. 2, the components of an embodiment of
The female conductor housing 104 may circumferentially
the electrical connector 1000 are shown in an exploded surround an end of a female terminal 200 inserted into each
assembly view. The female member 100 may comprise a 15 of the first and second female terminal chambers 110 and
female housing 102, a first and second female terminal 200, 120. An end of the female conductor housing 104 opposing
and a first and second resilient member 300. The male the female internal wall 105 may be open to provide access
member 500 may comprise a male housing 502, and a first for a conductor (not shown) to contact an exposed end of a
and second male terminal 600. female terminal 200. In other embodiments, an end or side
Female Member 20 of the female conductor housing 104 adjacent to the female
Turning now to FIGS. 3A, 3B, and 3C, the female internal wall 105 may be open to provide conductor access.
member 100 may comprise a female housing 102, a first In the embodiment shown, the female conductor housing
female terminal chamber 110, a second female terminal 104 substantially shrouds and insulates the ends of the
chamber 120, female terminals 200, and resilient members female terminals 200 from each other. In certain other
300 (more clearly shown in FIG. 2). A first female polarity 25 embodiments the female conductor housing 104 may only
indicator 111 and a second female polarity indicator 121 partially surround an end of a female terminal 200 in each
may indicate the respective polarities of the first female of the first and second female terminal chambers 110 and
terminal chamber 110 and the second female terminal cham- 120.
ber 120. A first orifice 116 and a second orifice 126 may be The female terminal housing 106 portions of each of the
located at an end of the female member 100 opposite to the 30 first and second female terminal chambers 110 and 120 may
first and second female polarity indicators 111 and 121. An comprise a female terminal support 107 and a resilient
example of a resilient member 300 is shown in FIGS. 3B and member support 109 (FIG. 3C). Each of the female terminal
3C. A resilient member 300 may be located in each of the supports 107 may help to retain a corresponding female
first and second female terminal chambers 110 and 120 terminal 200 in the respective first and second female
(however, only one is shown in the FIGS. 3B and 3C for the 35 terminal chambers 110 and 120. The female terminal support
purposes of illustration). The various components of the 107 may comprise one or more retention members 112 (for
female member 100 will be described in more detail in the example as represented by 112A) configured to retain a
following illustrative embodiment. female terminal 200 after assembly into a female member
Female Housing 100. Although a slanted ramp type ofretention member 112
Referring to FIG. 3B, the female housing 102 may be 40 is shown in FIG. 3B to facilitate an insertion type of
substantially rectangular in shape and comprise a female assembly (e.g., inserting a female terminal 200 from left to
conductor housing 104, a female internal wall 105, and a right in the female housing 102 with respect to FIG. 3B), a
female terminal housing 106, for each of the first and second person of ordinary skill in the art would not be limited to just
female terminal chambers 110 and 120. Due to symmetry, this type of retention member 112. Pins, rivets, fasteners,
only the first female terminal chamber 110 will be described 45 other mechanical attachments, welding, and chemical adhe-
from this point forward, reference numerals enclosed by sives, among other various methods may be used to secure
parenthesis refer to the second female terminal chamber 120. a female terminal 200 in the female housing 102. Further,
Although a substantially rectangular shape is shown for the similar additional retention members 112B may be used to
female housing 102, embodiments of the present invention provide additional force to oppose the friction force gener-
may not be limited to this one configuration. Any configu- 50 ated during the assembly and disassembly of the electrical
ration capable of accommodating one or more female ter- connector 1000 (FIG. 1) that may otherwise move or dis-
minals 200 may be used. The female housing 102 may be locate one or both of the female terminals 200. Other
manufactured from a dielectric material able to withstand embodiments of the female member 100 may not comprise
the operating conditions of an intended application and retention members 112. In some cases the female terminals
provide sufficient electrical insulation between the current 55 200 and resilient members 300 may be core molded into the
carrying female terminals 200 (i.e., inhibiting the occurrence female member 100 at the time of manufacture.
of electrical shorts between the female terminals 200). For The resilient member support 109 (FIG. 3C) may secure
example, the material of the female housing 102 may be a a resilient member 300 in each of the first and second female
glass reinforced nylon such as Zytel® 70G33L, made by terminal chambers 110 and 120. The resilient member
DuPont®. In some applications the reinforced nylon mate- 60 support 109 is shown as proximate to the female internal
rial may comprise approximately 33% glass. The material wall 105. However, an embodiment of the resilient member
may be used in a remotely controlled vehicle operating in a support 109 may be located proximate to an end of the
natural environment for example and may experience a female terminal housing 106 opposite to the female internal
temperature range from below -20° F. (-29° C.) to over wall 105 (i.e., the insertion end of the female terminal
250° F. (121° C.) (e.g., when operated in desert conditions 65 housing 106, for example, essentially configured 180° in a
over solar heated roadways, or due to battery heat, current horizontal plane relative to the embodiment shown in FIG.
flow, and electrical resistance). 3B) in addition to other locations. As with the female
US 10,177,500 B2
5 6
terminal support 107, the resilient member support 109 may The terminal contact portion 206 may be located at an
comprise one or more retention features 112, for example, as opposite end of the female terminal 200 relative to the
represented by 112C in FIG. 3C. The retention features 112 terminal connector portion 204, and may comprise an angled
of the resilient member support 109 may comprise slanted end 210, one or more terminal retention features 212 (two
ramp protrusions as with an embodiment of the female 5 are shown in FIG. 4B, 212A and 212B), and a contact
terminal support 107, or the retention features 112 may surface 214. The angled end 210 may help facilitate the
comprise any of the mechanical, chemical, or welding coupling or assembly of a corresponding male terminal 600
methods of fastening previously recited. The previously (FIG. 2) during the connection of an electrical connector
recited methods of retaining and/or fastening female termi- 1000 (FIG. 1). The contact surface 214 may directly contact
10 an opposing surface of a male terminal 600 in order to allow
nals 200 and resilient members 300 are not intended to form
an electrical current to flow from one end of the electrical
an exhaustive list, but are merely a sampling from amongst
connector 1000 to the other.
a broad variety of retaining and fastening methods known to
Terminal step 208 may separate the terminal connector
those of ordinary skill in the art. As with the female portion 204 from the terminal contact portion 206. In some
terminals 200, the resilient members 300 may be core 15 embodiments, during assembly of the female terminal 200
molded into the female housing 102 during the production of into female housing 102 (FIG. 3B), the terminal step 208
the female housing 102. may oppose a portion of the female housing 102 and prevent
The ends of the first and second female terminal chambers further movement in the assembly direction. The terminal
110 and 120 located in the female terminal housing 106, retention features 212 may contact corresponding retention
opposite to the female internal wall 105, are referred to as 20 features 112 of the female housing 102 and prevent move-
the first and second orifices 116 and 126. Each of the first ment in a direction opposite to the assembly direction. At
and second orifices 116 and 126 may be configured sub- this point, the female terminal 200 may be substantially
stantially in a rectangular shape as shown in FIG. 3A. securely coupled with the female housing 102.
However, in the illustrative embodiment shown in these Resilient Member
figures, an aspect of the first orifice 116, such as a width, 25 Referring now to FIGS. SA and 5B, these figures respec-
may be configured differently than the same aspect of the tively show an orthogonal top view of a resilient member
second orifice 126. The difference in widths may inhibit an 300 and a side view of the resilient member 300 of FIG. SA.
incorrectly polarized assembly of a male member 500 (FIG. The resilient member 300 may comprise a resilient base
1) with the female member 100. Although a difference in member 310 and a resilient contact member 320. The
dimensional aspects such as widths may be used to inhibit 30 resilient member 300 may be punch formed from a sheet of
reversing the polarities during connection of an electrical stainless steel (e.g., SS 301 with no plating), spring steel
connector 1000 (FIG. 1) the present invention may not be (e.g., spring steel with nickel plating) or other resilient
limited to this method. Different configurations, devices, and material configured to work within the anticipated environ-
dimensions may be used to facilitate the proper polar mental conditions of the electrical connector 1000 (FIG. 1).
connection orientation during assembly of a male member 35 In some embodiments, the resilient member 300 may be
500 with a female member 100. plated or otherwise coated to inhibit rust or to provide an
Female Terminals appropriate level of resistance (e.g., friction force) necessary
Turning now to FIGS. 4A and 4B, FIG. 4A shows a top to maintain the connection between an assembled male
view of an embodiment of a female terminal 200, and FIG. member 500 and female member 100.
4B shows a side view of the female terminal 200 of FIG. 4A. 40 The resilient base member 310 may be located at one end
As an example of an illustrative embodiment of a female of the resilient member 300 and comprise one or more
terminal 200, the female terminal 200 may comprise a resilient retention members 312A and 312B (FIG. 5B). The
terminal connector portion 204 and a terminal contact por- resilient retention members 312A and 312B may engage
tion 206. The female terminal 200 may comprise an elec- corresponding retention members 112 within the resilient
trically conductive material, such as brass, copper, or 45 member support 109 (as seen in FIG. 3C, but only one
bronze. The female terminal 200 may be plated with gold retention member 112C can be seen in this view), located in
(such as a gold-cobalt or gold-nickel alloy) or silver, among each of the first and second terminal chambers 110 and 120.
other materials, preferably copper plated with nickel and The resilient retention members 312A and 312B may
then plated with gold (for example), in order to increase the securely retain the resilient members 300 within the female
electrical conductivity between contacting portions of the 50 housing 102 during assembly and disassembly of the elec-
male and female terminals 600 and 200. The female terminal trical connector 1000 (FIG. 1). The resilient base member
200 shown may be made from a standard plate of material 310 is shown as a substantially flat quadrilateral but embodi-
and punched formed to the correct size and configuration, ments of the present invention may not be limited to this
among other methods of forming. illustrative form. The resilient base member 310 may be
The terminal connector portion 204 may be located on 55 retained separate from the corresponding female terminal
one end of the female terminal 200 and configured to 200 and separate from a fully inserted male terminal 500
electrically couple with a copper wire conductor (for (FIG. 2). In other words, the resilient base member 310 may
example) such as wire conductors 10B and 20B (FIG. 1). not overlay a corresponding male terminal 500 when an
The terminal connector portion 204 may be electrically electrical connector 1000 (FIG. 1) is electrically coupled.
coupled to a wire conductor through the use of soldering, 60 As more easily seen in FIG. 5B, the resilient contact
mechanical fastening (e.g., through the use of a screw member 320 may comprise an arcuate portion defined by a
clamp), standard insulated and non-insulated connector fit- radius R. The arcuate portion may be resiliently deformed
tings, crimping, and other methods of electrically coupling toward the radial center point in response to pressure or
a wire conductor to a portion of a terminal. Embodiments of interference from portions of an installed male member 500
the terminal connector portion 204 may comprise a variety 65 (FIG. 1). The arcuate portion may also be configured to
of configurations in order to accommodate a particular interface with a depression or other engaging feature,
electrical coupling method. detailed later, in an opposing surface or portion of the male
US 10,177,500 B2
7 8
member 500 in order to provide a disassembly retention terminal extensions 510 and 520. Due to their similarities,
force after coupling the male member 500 with the female only the first male terminal extension 510 will be described
member 100 (see FIG. 1). In the illustrative embodiment from this point forward, reference numerals enclosed by
shown, only a single arcuate portion is illustrated in FIGS. parenthesis refer to second male terminal extension 520.
SA and 5B. However, embodiments of the present invention 5 Although a substantially rectangular shape is shown for the
are not to be limited to this one exemplary configuration. For male housing 502, embodiments of the present invention
example, larger and smaller radii either alone or in combi- may not be limited to this one configuration. Any configu-
nation with one or more relatively straight portions may be ration capable of accommodating one or more male termi-
used, an arcuate portion curving back upon the resilient nals 600 may be used. The male housing 502 may be
contact member 320, a single angular bend joining two 10 manufactured from a dielectric material able to withstand
straight portions together, or a plurality of angular or arcuate the operating conditions of an intended application and
portions such as in a zig-zag or wave type of configuration provide sufficient electrical insulation between the current
may be used in order to more evenly apply a force from the carrying male terminals 600 (i.e., inhibiting the occurrence
female member 100 to the male member 500. The listing is of an electrical short between the male terminals 600). For
intended to provide a small representative sample of the 15 example, the material of the male housing 502 may be a
various potential configurations consistent with the present glass reinforced nylon such as Zytel® 70G33L, made by
invention and is not intended to be exhaustive. DuPont®. In some applications the reinforced nylon mate-
One end of the resilient contact member 320 may com- rial may comprise approximately 33% glass. The material
prise a housing interface 324. An example of the housing may be used in a remotely controlled vehicle operating in a
interface 324 may be illustrated by a small radius curve 20 natural environment for example and may experience a
rotating in an opposite direction relative to the arcuate temperature range from below -20° F. (-29° C.) to over
portion defined by the radius R. The housing interface 324 250° F. (121 ° C.) (e.g., when operated in desert conditions
may facilitate a sliding movement along a contacting portion over solar heated roadways, or due to battery heat, current
of an inner wall of the female housing 102 (FIG. 3B) in flow, and electrical resistance).
response to assembly and disassembly of a male member 25 The male conductor housing 504 may be separated from
500 and a female member 100 (see FIG. 2). The sliding the male terminal housing 506 by the male internal wall 505.
contact may prevent or inhibit the abrading or prematurely The male internal wall 505 may comprise an opening 514
wearing down of the inner surface of the female housing 102 (524) to accommodate a male terminal 600. On the male
over a multiple number of connections and disconnections conductor housing 504 side of the male internal wall 505,
of the electrical connector 1000 (FIG. 1). In this example, 30 the male internal wall 505 may comprise an indicator 513
the contacting portion of the housing interface 324 curves identifying the connection side of the electrical connector
away from the inner surface of the female housing 102 in 1000 (FIG.1), for example (e.g., "A" for the female member
directions tangent to the small radius curve. Further, the and "B" for the male member). In other embodiments, the
resilient contact member 320 may extend at an angle from indicator 513 may comprise a polarity sign to be used in
the resilient base member 310 such that the housing inter- 35 place of, or in addition to, the first and second male polarity
face 324 may be located above (with respect to FIG. 5B) a indicators 511 and 521 (FIG. 6A).
plane containing the resilient base member 310. This con- The male conductor housing 504 may circumferentially
figuration may apply a pre-load to an assembled resilient surround an end of a male terminal 600 inserted into each of
member 300 via the housing interface 324. By adjusting the the first and second male terminal extensions 510 and 520.
angle for the resilient contact member 320 relative to the 40 An end of the male conductor housing 504 opposing the
resilient base member 310, and/or adjusting the radius R, the internal wall 505 may be open to provide access for a
force applied to the male member 500 through the resilient conductor (not shown) to contact an exposed end of a male
contact member 320 may be adjusted. Adjusting the force of terminal 600. In other embodiments, an end or side of the
the resilient contact member 320 may adjust the amount of male conductor housing 504 adjacent to the male internal
insertion and withdrawal force for the connecting and dis- 45 wall 505 may be open to provide conductor access. In the
connecting of the electrical connector 1000. Consequently, a embodiment shown, the male conductor housing 504 sub-
desired amount of insertion and withdrawal force may be stantially shrouds and insulates the ends of the male termi-
established for the connecting and disconnecting of the nals 600 from each other. In certain other embodiments the
electrical connector 1000. male conductor housing 504 may only partially surround an
Male Member 50 end of a male terminal 600 in each of the first and second
Turning now to FIGS. 6A, and 6B, the male member 500 male terminal extensions 510 and 520.
may comprise a male housing 502, a first male terminal The male internal wall 505 of each of the first and second
extension 510, a second male terminal extension 520, and male terminal extensions 510 and 520 may function as a
male terminals 600 (more clearly shown in FIG. 6B). A first male terminal support (FIG. 6B). Each of the male terminal
male polarity indicator 511 and a second male polarity 55 supports (i.e., male internal walls 505) may help to retain a
indicator 521 may indicate the respective polarities of the corresponding male terminal 600 in the respective first and
first male terminal extension 510 and the second male second male terminal extensions 510 and 520. The male
terminal extension 520. An example of a male terminal 600 terminal support may comprise one or more retention mem-
is shown in FIGS. 7A and 7B and is detailed later. The bers 512 (for example as represented by 512A), configured
various components of the male member 500 will be 60 to retain a male terminal 600 after assembly into a male
described in more detail in the following illustrative embodi- member 500. Although a slanted ramp type of retention
ment. member 512 is shown in FIG. 6B to facilitate an insertion
Male Housing type of assembly (e.g., inserting a male terminal 600 from
Referring to FIG. 6B, the male housing 502 may be the left to the right in the male housing 502 with respect to
substantially rectangular in shape and comprise a male 65 FIG. 6B), a person of ordinary skill in the art would not be
conductor housing 504, a male internal wall 505, and a male limited to just this type of retention member 512. Pins,
terminal tip 506 for each of the first and second male rivets, fasteners, other mechanical attachments, welding,
US 10,177,500 B2
9 10
and chemical adhesives, among other various methods may male housing 502. In some embodiments, the first and
be used to secure a male terminal 600 within the male second male terminal covers 516 and 526 may comprise a
housing 502. Further, similar additional retention members coating applied to a surface of the male terminals 600.
512B may be used to provide additional force to oppose the Alternatively, a coating or texture may be applied to a
friction force generated during the connection and discon- 5 surface of the first and second male terminal covers 516 and
nection of the electrical connector 1000 (FIG. 1) that may 526 to vary the level of frictional resistance between the
otherwise move or dislocate one or both of the male termi- surface and the contacting portion of the resilient contact
nals 600. Other embodiments of the male member 500 may member 320 of each of the respective resilient members 300.
not comprise retention members 512. In some cases the male Male Terminals
terminals 600 may be core molded into the male housing 502 10 Turning now to FIGS. 7A and 7B, FIG. 7A shows a top
at the time of manufacture. view of an embodiment of a male terminal 600, and FIG. 7B
The ends of the first and second male terminal extensions shows a side view of the male terminal 600 of FIG. 7A. As
510 and 520 in the male terminal tips 506, opposite to the an example of an illustrative embodiment of a male terminal
internal wall 505, are referred to as the first and second male 600, the male terminal 600 may comprise a terminal con-
terminal covers 516 and 526. Each of the first and second 15 nector portion 604 and a terminal contact portion 606. The
male terminal covers 516 and 526 may be configured male terminal 600 may comprise an electrically conductive
substantially in a rectangular shape as shown in FIG. 6A. material, such as brass, copper, or bronze. The male terminal
However, in the illustrative embodiment shown in these 600 may be plated with gold (such as gold-cobalt or gold-
figures, an aspect of the first male terminal cover 516, for nickel alloy) or silver, among other materials, preferably
example width, may be configured differently than the same 20 copper plated with nickel and then plated with gold (for
aspect of the second male terminal cover 526. The difference example), in order to increase the electrical conductivity
in widths may inhibit an incorrectly polarized assembly of a between contacting portions of the male and female termi-
male member 500 (FIG. 1) with the female member 100. nals 600 and 200. The male terminal 600 shown may be
Although a difference in dimensional aspects such as widths made from a standard plate of material and punched formed
may be used to inhibit reversing the polarities during con- 25 to the correct size and configuration, among other methods
nection of an electrical connector 1000 (FIG. 1), the present of forming.
invention may not be limited to this method. Different The terminal connector portion 604 may be located on
configurations, devices, and dimensions may be used to one end of the male terminal 600 and configured to electri-
facilitate the proper polar connection orientation during cally couple with a copper wire conductor (for example)
assembly of a male member 500 with a female member 100. 30 such as wire conductors l0A and 20A (FIG. 1). The terminal
The first and second male terminal covers 516 and 526 connector portion 604 may be electrically coupled to a wire
may each comprise a connector retention feature 507. In conductor through the use of soldering, mechanical fasten-
some embodiments, the connector retention feature 507 may ing (e.g., through the use of a screw clamp), standard
be configured as an arcuate cavity or depression correspond- insulated and non-insulated connector fittings, crimping, and
ing to an arcuate portion of the resilient contact member 320 35 other methods of electrically coupling a wire conductor to a
of a resilient member 300 (see FIG. 5B). As the male terminal. Embodiments of the terminal connector portion
member 500 is connected to the female member 100 (see 604 may comprise a variety of configurations in order to
FIG. 1), the resilient member 300 moves relative to a surface accommodate a particular electrical coupling method.
of the corresponding first and second male terminal covers The terminal contact portion 606 may be located at an
516 and 526 until a portion of the resilient contact member 40 opposite end of the male terminal 600 relative to the terminal
320 engages a corresponding portion of the connector reten- connector portion 604, and may comprise an angled end
tion feature 507. The engagement between the resilient 610, one or more terminal retention features 612 (two are
contact member 320 and the connector retention feature 507 shown in FIG. 7B, 612A and 612B), and a contact surface
may provide a sensory indication that the male member 500 614. The angled end 610 may help facilitate the coupling or
is fully connected to the female member 100. In addition, the 45 assembly of a corresponding female terminal 200 (FIG. 2)
engagement between the resilient contact member 320 and during the connection of an electrical connector 1000 (FIG.
the connector retention feature 507 may help to prevent 1). The contact surface 614 may directly contact an opposing
inadvertent disconnection between the male member 500 surface of a female terminal 200 in order to allow an
and the female member 100 during the operation of the electrical current to flow from one end of the electrical
electrical connector 1000 in an applied device. 50 connector 1000 to the other.
The first and second male terminal covers 516 and 526 Terminal step 608 may separate the terminal connector
may further comprise an angled or slanted portion 570, portion 604 from the terminal contact portion 606. In some
which may be located at an end opposite to the male internal embodiments, during assembly of the male terminal 600 into
wall 505. The slanted portion 570 of each of the first and male housing 502 (FIG. 6B), the terminal step 608 may
second male terminal covers 516 and 526 may facilitate the 55 oppose a portion of the male housing 502 and prevent further
insertion and/or assembly of the male member 500 with the movement in the assembly direction. The terminal retention
female member 100 (see FIG. 1). In some embodiments, features 612 may contact corresponding retention features
rounded, arcuate, or other insertion facilitating features may 512 of the male housing 502 and prevent movement in a
be used in place of, or in addition to, the slanted portion 570 direction opposite to the assembly direction. At this point,
of each of the first and second male terminal covers 516 and 60 the male terminal 600 may be substantially securely coupled
526. At least part of the remaining portions of the first and with the male housing 502.
second male terminal covers 516 and 526 may provide a Assembly
contact surface for the resilient member 300, as previously Turning now to FIGS. SA and 8B, FIG. SA illustrates a
explained, and may provide a degree of insulation between correctly assembled electrical connector 1000, while FIG.
the resilient members 300 and the male terminals 600. The 65 8B illustrates an incorrectly assembled electrical connector
material of the first and second male terminal covers 516 and 1000. As seen in FIG. SA, when the male member 500 is
526 may be the same as the material used for the rest of the correctly coupled to a female member 100, the first and
US 10,177,500 B2
11 12
second male polarity indicators 511 and 521 correspond to first and second male terminal extensions 510 and 520 (FIG.
the first and second female polarity indicators 111 and 121, 6A) have been inserted into the first and second female
indicating the maintenance of proper polarity across the terminal chambers 110 and 120 (FIG. 3A), or more specifi-
electrical connector 1000. The correspondence between the cally, the male terminal housing 506 portions of the first and
sets of polarity indicators 111, 121, 511, and 521, may 5 second male terminal extensions 510 and 520 have been
provide a visual indication of the correct coupling of the inserted into the first and second orifices 116 and 126 of the
male and female members 500 and 100. As seen in FIG. SB, first and second female terminal chambers 110 and 120. As
the first and second male polarity indicators 511 and 521 the male member 500 is connected to the female member
may not be visible from a top oriented viewing plane when 100, the resilient members 300 may initially contact the
the male member 500 is incorrectly assembled to the female 10 slanted portion 570 of the corresponding first and second
member 100. In addition, as indicated by the arrows for the male terminal covers 516 and 526. The resilient contact
first and second male polarity indicators 511 and 521 (the portions 320 may respectively slidingly engage a top surface
polarity indicators themselves are not visible in this view), of each of the first and second male terminal covers 516 and
the polarities on each side of the incorrectly assembled 526. The resilient contact portions 320 may be compressed,
electrical connector 1000 have been reversed. 15 causing the housing interface 324 portion of the resilient
Referring to FIGS. 9A and 9B, FIG. 9A illustrates a member 300 to slidingly engage an interior surface of the
cross-sectional view of the correctly assembled electrical respective first and second female terminal chambers 110
connector 1000 of FIG. SA as viewed along line 9A-9A, and 120. The male member 500 may continue to be inserted
while FIG. 9B illustrates a cross-sectional view of the into the female member 100 until the resilient contact
incorrectly assembled electrical connector 1000 of FIG. SB 20 portion 320 engages a corresponding connector retention
as viewed along line 9B-9B. FIG. 9A shows an electrical feature 507 of the respective first and second male terminal
connector 1000 in which a first male terminal cover 516 is covers 516 and 526. At this point, the male member 500 may
inserted into a first orifice 116 and a contact surface 614 of be securely coupled to the female member 100. Although
the male terminal 600 is abutting a contact surface 214 of the only one side portion of the electrical connector 1000 is
female terminal 200. The first male terminal cover 516 and 25 described in detail, the other side portion may be similar due
the first orifice 116 may each have an approximate width of to the symmetry of the connector. However, complete sym-
Wl with the first male terminal cover 516 configured to fit metry is not a limitation required of an embodiment of the
within the first orifice 116. The second male terminal cover present invention and differences beyond the widths of the
526 is inserted into a second orifice 126 such that a contact first and second male terminal covers 516 and 526 and
surface 614 of the corresponding male terminal 600 is 30 corresponding first and second orifices 116 and 126 may
abutting a contact surface 214 of the corresponding female exist.
terminal 200. The second male terminal cover 526 and the
second orifice 126 may each have an approximate width of Another Embodiment
W2 with the second male terminal cover 526 configured to
fit within the second orifice 126. The width Wl may be 35 Referring now to FIG. 11, this figure shows an orthogonal
smaller than the width W2. This difference in widths may top view with a cross-section taken through the side of an
provide another method of inhibiting or preventing cross- embodiment of an electrical connector. In this figure, refer-
polarization during connection of the male member 500 to ence number 2000 generally refers to another illustrative
the female member 100 (FIG. SA), since the male member embodiment of an electrical connector 2000 constructed
500 may be connected to the female member 100 when the 40 according to aspects of the present invention. One difference
male member 500 is properly oriented with respect to the between the electrical connector 2000 and the previously
female member 100. The proper orientation of the male and described electrical connector 1000 (FIG. 1) may be the
female members 500 and 100 may provide for the correct replacement of one or more resilient members 300 (FIG. 2)
polarity of the connection. of the previous illustrative embodiment with one or more
FIG. 9B shows an electrical connector 1000 in which a 45 resilient members 2300. Otherwise, the function and mate-
male member 500 is incorrectly connected to a female rials for the two electrical connectors 1000 and 2000 may be
member 100. This type of connection may be substantially considered to be the same. Similar components may be
prevented by the interference between the width of the identified with similar reference numerals used in the pre-
second male terminal cover 526 (W2) and the width of the vious description, and a detailed explanation of these com-
first orifice 116 (Wl)(e.g., W2-Wl). However, if the male 50 ponents may not be repeated.
member 500 is somehow coupled to the female member 100 Electrical connector 2000 may comprise a female member
in spite of this interference, cross-polarization of the elec- 2100 and a male member 500, shown here in a connected
trical connector 1000 may still be prevented by the first and state. The female member 2100 may comprise one or more
second male terminal covers 516 and 526 separating the female terminals 200 (only one is visible in this view) and
male and female terminals 600 and 200. The first and second 55 the male member 500 may comprise a corresponding num-
male terminal covers 516 and 526 may prevent contact ber of male terminals 600. When the female member 2100
between corresponding male and female terminals 600 and and the male member 500 are coupled together, electricity
200 when the male member 500 is in a second orientation may be able to flow between wire conductors (not shown)
with respect to the female member 100. Therefore, as seen through the electrical connector 2000 via the areas of contact
in this illustrative embodiment, cross-polarization of the 60 between the female and male terminals 200 and 600.
electrical connector 1000 may be prevented and/or inhibited The female member 2100 may comprise one or more
by at least two separate and independent methods, in addi- resilient members 2300. The resilient members 2300 may
tion to the visual indication given by the first and second provide a pressing force to facilitate electrical conduction
male and female polarity indicators, 111, 121, 511, and 521. through the contact areas between the corresponding female
Referring now to FIG. 10, this figure illustrates an 65 and male terminals 200 and 600. In addition, the resilient
orthogonal cross-sectional view of a correctly assembled members 2300 may provide a securing force to inhibit or
malemember500 and female member 100. In this figure, the prevent the inadvertent disconnection of the male member
US 10,177,500 B2
13 14
500 from the female member 2100 during the use of the Another Embodiment
electrical connector 2300 in a desired application (e.g., such
as in a vibratory and dynamic environment of a remotely Referring now to FIG. 12, this figure shows an orthogonal
controlled vehicle). In some exemplary embodiments, the top view with a cross-section taken through the side of an
number of resilient members 2300 corresponds to the num- 5 embodiment of an electrical connector. In this figure, refer-
ber of electrical connections formed or broken during the ence number 3000 generally refers to another illustrative
connection and disconnection of the electrical connector embodiment of an electrical connector 3000 constructed
2000 (e.g., two are shown in FIG. 11). However, the number according to aspects of the present invention. One difference
of resilient members 2300 may not be required to equal the between the electrical connector 3000 and the previously
number of electrical connections formed or broken. 10 described electrical connectors may be the replacement of
Each resilient member 2300 may comprise a resilient one or more resilient members 300 (FIG. 2) or 2300 (FIG.
housing 2310 integrated with the housing of the female 11) of the previous illustrative embodiments, with one or
member 2100. As shown in FIG. 11, the resilient housing more resilient members 3300. Otherwise, the function and
2310 may be substantially cylindrical for example, but materials for the electrical connectors 1000, 2000, and 3000
embodiments of the present invention may not be limited to 15 may be considered to be the same. Similar components may
this geometric configuration. Each resilient member 2300 be identified with similar reference numerals used in the
may further comprise a retention device 2324, a resilient previous description, and a detailed explanation of these
device 2322, and a contact device 2320. The retention device components may not be repeated.
2324 may comprise an Allen set screw as shown for Electrical connector 3000 may comprise a female member
example, or may comprise any of a number of devices able 20 3100 and a male member 500, shown here in a connected
to retain the resilient device 2322 and the contact device state. The female member 3100 may comprise one or more
2320 within the resilient housing 2310, while in some female terminals 200 (only one is visible in this view) and
embodiments further providing a measure of adjustability. the male member 500 may comprise a corresponding num-
For example, a mechanical threaded fastener, angled key, or ber of male terminals 600. When the female member 3100
cam device, among others, may be used. In this example, the 25 and the male member 500 are coupled together, electricity
retention device 2324 may be threadably engaged with a top may be able to flow between wire conductors (not shown)
portion of the resilient housing 2310. through the electrical connector 3000 via the contact areas
The resilient device 2322 may be located between the between the female and male terminals 200 and 600.
retention device 2324 and the contact device 2320. The The female member 3100 may comprise one or more
resilient device 2322 may be a spring, such as a coil spring, 30 resilient members 3300. The resilient members 3300 may
or resilient material, such as foam, among other devices. The provide a pressing force to facilitate electrical conduction
resilient device 2322 may press against the contact device through the contact area between the female terminals 200
2320, facilitating movement of the contact device 2320 as and the male terminals 600. In addition, the resilient mem-
the male member 500 and the female member 2100 are bers 3300 may provide a securing force to inhibit or prevent
coupled together. The force applied to the contact device 35 the inadvertent disconnection of the male member 500 from
2320 and consequently to the male and female terminals 200 the female member 3100 during the use of the electrical
and 600, may be adjusted by tightening or loosening the connector 3300 in a desired application (e.g., such as in a
retention device 2324, in addition to altering the spring vibratory and dynamic remotely controlled vehicle). In some
stiffness or material, among other methods. In some embodi- exemplary embodiments, the number of resilient members
ments, the male member 500 may be securely coupled to the 40 3300 corresponds to the number of electrical connections
female member 2100 by tightening the retention device formed or broken during the connection and disconnection
2324 so as to eliminate or reduce the ability of the contact of the electrical connector 3000, two electrical connections
device 2320 to move within the resilient housing 2310, are shown in this embodiment. However, the number of
thereby forcefully engaging the contact device 2320 with a resilient members 3300 may not be required to equal the
connector retention feature 507. 45 number of electrical connections formed or broken.
The contact device 2320 may be spherical ball for Each resilient member 3300 may be configured to inter-
example, such as in a ball and spring type of mechanism. fere with a opposing surface of a first and second male
However, in other embodiments the contact device 2320 terminal cover 516 and 526 (only 516 is visible in this view)
may be any member capable of moving across the surface of when a male member 500 is coupled to a female member
the first and second male terminal covers 516 and 526 (only 50 3100. As shown in FIG. 12, the area indicated by cross-
the first male terminal cover 516 is visible in this view), such hatching may be the area of interference between the resil-
as a rounded pin, angled member, cylinder, among others. ient member 3300 and the top surface of the first male
The contact device 2320 may be retained within the resilient terminal cover 516, although only a portion of the abutting
housing 2310 between a protruding edge 2312 at one end surfaces may be configured to be interfering. The resilient
and the retention device 2324 at the other end. During 55 member 3300 may comprise a rib interfacing with a portion
connection of the male member 500 and the female member of the respective top surface of the first and second male
2100, the contact device 2320 may engage the connector terminal covers 516 and 526, or the resilient member 3300
retention feature 507 as the male member 500 is fully may comprise the wall of the female member housing 3102,
coupled with the female member 2100. The contact device among numerous other configurations such as those previ-
2320 and the connector retention feature 507 may be con- 60 ously described for the resilient contact portion 320. Essen-
figured to have corresponding or interfacing features, such tially, in some embodiments the housing 3102 of the female
that when the male member 500 is fully coupled with the member 3100 may function as a resilient member, allowing
female member 2100, a sensory indication of the application at least some degree of resilient deformation or movement
device 2320 engaging the connector retention feature 507 designed to apply a force to at least a portion of an installed
may be provided. The sensory indication may be visual, 65 male member 500 (e.g., such as the first and second male
audible, tactile, or a combination of one or more of these terminal covers 516 and 526, or in some embodiments, the
sensory indications, in addition to other methods. male terminals themselves, among other configurations).
US 10,177,500 B2
15 16
Alternatively, the first and second male terminal covers 516 The male housing 1502 may be substantially rectangular
and 526 may function as a resilient member, allowing at in shape and comprise a male conductor housing 504 and a
least some degree of resilient deformation or movement male internal wall 1505 for each of the first and second male
designed to urge the male terminals 600 together with the terminal extensions 1510 and 1520. Although a substantially
corresponding female terminals 200. Further, in some 5 rectangular shape is shown for the male housing 1502,
embodiments, both the female housing 3102 and the first and embodiments of the present invention may not be limited to
second male terminal covers 516 and 526 may experience this one configuration. Any configuration capable of accom-
some degree of resilient deformation, combining together to modating one or more first and second male terminals 1600
provide a force urging the male terminals 600 together with and 1650 may be used. The male housing 1502 may be
10
the corresponding female terminals 200. manufactured from a dielectric material able to withstand
The resilient member 3300 may further comprise protru- the operating conditions of an intended application and
sions or features configured to engage with corresponding provide sufficient electrical insulation between the current
depressions or features located on the top surfaces of the first carrying first male terminal 1600 and second male terminal
and second male terminal covers 516 and 526, such that the 15
1650 (i.e., inhibiting the occurrence of an electrical short
male member 500 may be securely coupled to the female between the first male terminal 1600 and the second male
member 3000 upon fully connecting the male member 500 terminal 1650).
to the female member 3100. An example of a protrusion for The male internal wall 1505 of each of the first and second
the resilient member 3300 may be an arcuate ridge corre- male terminal extensions 1510 and 1520 may function as a
sponding to the connector retention feature 507 shown in 20 male terminal support. Each of the male terminal supports
FIG. 6B. The resilient member 3300 may at least partially (i.e., male internal walls 1505) may respectively secure and
resiliently deform with respect to the area of interference. support the first and second male terminals 1600 and 1650
Alternatively, the resilient member 3300 may take advan- in the corresponding first and second male terminal exten-
tage of at least some degree of resilient deformation in the sions 1510 and 1520. The male terminal support may
configuration of the female member housing 3102. 25 comprise one or more retention members 512 (for example
as represented by 512A and 512B) configured to retain the
Another Embodiment respective first and second male terminals 1600 and 1650
after assembly into a male member 1500. Although a slanted
Turning now to FIGS. 13A and 13B, the first figure shows ramp type of retention member 512 is shown in FIG. 13B to
a top view of an illustrative embodiment of a male member 30
facilitate an insertion type of assembly (e.g., inserting a male
1500 configured according to aspects of the present inven-
terminal 1600 from the right to the left in the male housing
tion, while the second figure shows an orthogonal cross-
1502 with respect to FIG. 13B), a person of ordinary skill in
sectional top view of the male member 1500 ofFIG.13Aas
the art would not be limited to just this type of retention
viewed along line 13B-13B. One difference between the
male member 1500 and the previously described male 35
member 512. Pins, rivets, fasteners, other mechanical attach-
member 500 (FIG. 1) may be the lack of first and second ments, welding, and chemical adhesives, among other vari-
male terminal covers 516 and 526 (see FIGS. 6A and 6B) in ous methods may be used to secure the first and second male
the male member 1500. Another difference may be the use terminals 1600 and 1650 within the male housing 1502.
of first and second male terminals 1600 and 1650 in male Additionally, the first and second male terminals 1600 and
member 1500 in place of the male terminals 600 shown in 40 1650 may be core molded along with the male housing 1502
male member 500 (see FIG. 2). Otherwise, the function and at the time of manufacture.
materials for the male members 500 and 1500 may be The first and second male terminals 1600 and 1650 may
considered to be substantially the same. Similar components comprise retention members 612 (for example as repre-
may be identified with similar reference numerals used in sented by 612A and 612B, however, only the retention
previous descriptions, and a detailed explanation of these 45 members 612 of the first male terminal 1600 may be seen in
components may not be repeated. FIG. 13B, the second male terminal 1650 may be similarly
Male member 1500 may comprise a male housing 1502 configured) corresponding to the retention members 512. As
and first and second male terminal extensions 1510 and with the retention member 512, a slanted ramp type of
1520. The first male terminal extension 1510 may comprise retention member 612 is shown in FIG. 13B to facilitate an
the first male terminal 1600, while the second male terminal 50 insertion type of assembly, however, a person of ordinary
extension 1520 may comprise the second male terminal skill in the art would not be limited to just this type of
1650. First and second male terminals 1600 and 1650 may retention member 612. Pins, rivets, fasteners, other mechani-
be configured to be insertably engaged with the first and cal attachments, welding, and chemical adhesives, among
second orifices 116 and 126 of the first and second female other various methods may be used to secure the first and
terminal chambers 110 and 120 of a female member 100 (see 55 second male terminals 1600 and 1650 within the male
FIG. 3A). In some embodiments, some aspects of the first housing 1502.
male terminal 1600 may be different than similar aspects of Having thus described embodiments of the present inven-
the second male terminal 1650 in order to inhibit the tion by reference to certain exemplary embodiments, it is
cross-polarizing connection of a male member 1500 and a noted that the embodiments disclosed are illustrative rather
female member 100. In the embodiment shown, the width 60 than limiting in nature. A wide range of variations, modifi-
Wl of the first male terminal 1600 may be smaller that the cations, changes, and substitutions are contemplated in the
width W2 of the second male terminal 1650. Interference foregoing disclosure. In some instances, some features of an
between the larger width W2 and the first orifice 116 may embodiment of the present invention may be employed
inhibit the connection between a female member 100 and an without a corresponding use of the other features. Many
improperly oriented male member 1500 (i.e., the male 65 such variations and modifications may be considered desir-
member 1500 may be improperly oriented with respect to able by those skilled in the art based upon a review of the
the female member 100). foregoing description of the illustrative embodiments.
US 10,177,500 B2
17 18
Accordingly, it is appropriate that the appended claims be a resilient member placed apart from the electrical
construed broadly and in a manner consistent with the scope terminal along another receptacle surface opposite
of the invention. the receptacle surface abutting the electric termi-
We claim: nal;
1. A female electrical connector comprising: w~erein a dimension of one of the receptacle openings
two female terminal assemblies each comprising; 1s larger than a corresponding dimension of another
receptacle opening;
a receptacle and receptacle opening in an insulated
housing; a male electrical connector comprising:
two male terminal assemblies each comprising;
an female terminal along a receptacle surface; and
a resilient member placed apart from the electrical 10 a ~ale ter~inal extending from an insulated housing;
terminal along another receptacle surface opposite an msulatmg cover on a surface of the male terminal·
the receptacle surface abutting the electric terminal; wherein a dimension of one of the insulating covers i~
wherein a dimension of one of the receptacle openings is larger than a corresponding dimension of another of
the insulating covers; and
larger than a corresponding dimension of another
receptacle opening; 15 wherei1: the dimension of the one of the receptacle
wherein the two female terminal assemblies are config- opemngs and the corresponding dimension of the one
ured to insertably engage two correspondingly sized of the insulating covers facilitates insertable engage-
ment of the male electrical connector and the female
male terminal assemblies between the female terminal
and the resilient member, each of the male terminal electrical connector to provide a proper polarity con-
assemblies comprising: 20 nection.
8. The electrical connector assembly according to claim 7
a male terminal with an insulating cover.
2. The female electrical connector according to claim 1 wherein the insulating covers of the male terminal assem-
blies have arcuate retention features for engaging the resil-
wherein each of the resilient members further comprise a
arcuate portion configured to bias each of the male terminals ient members of the female terminal assemblies.
into electrical engagement with the corresponding female 25
9. The electrical connector assembly according to claim 7
terminals. ~herein the resilient members are metal and electrically
to claim msulated from a corresponding female terminal.
3. The female electrical connector according 1
10. The electrical connector assembly according to claim
wherein each of the resilient member comprises metal and is
insulated from a corresponding female terminal. 7 wherein each of the receptacle openings is rectangular.
4. The female electrical connector according to claim 1 30
wherein the dimension of the receptacle opening is parallel 7 wherein each of the resilient members are anchored in a
to a contact surface of the female terminal. channel at an end of resilient members corresponding recep-
to claim tacle oppose the receptacle opening.
5. The female electrical connector according 1
wherein each of the resilient members contacts a corre-
35 7 wherein the male terminals and the female terminals are
sponding insulated cover of the male terminal.
6. The female electrical connector according to claim 1 blade terminals.
into a 13. The electrical connector assembly according to claim
wherein each of the resilient members is anchored
channel located in the housing at an end of the receptacle 12 wherein each of the insulating covers for the male
opposite the receptacle opening. terminals extend over three surfaces of the blade terminal
40 male terminal.
7. An electrical connector assembly comprising:
a female electrical connector comprising: 14. The electrical connector assembly according to claim
12 wherein the dimension of the insulating cover is parallel
two female terminal assemblies each comprising;
a receptacle and receptacle opening in an insulated to a contact surface of the corresponding male and female
housing; blade terminals.
an electrical terminal along a receptacle surface; and * * * * *
EXHIBIT 10
I 1111111111111111 111111111111111 1111111111 111111111111111 IIIIIII II IIIII IIII
US00D573536S
c12) United States Design Patent (10) Patent No.: US D573,536 S

Hariharesan et al. (45) Date of Patent: ** Jul. 22, 2008
(54) ELECTRICAL CONNECTOR D326,642 S * 6/1992 Lowe ..................... D13/138.1

5,123,071 A * 6/1992 Mulholland et al. ........... 385/53
(75) Inventors: Seralaathan Hariharesan, Flower 5,293,581 A * 3/1994 DiMarco ..................... 385/76
Mound, TX (US); Brock Dennison, (Continued)
Lampert, Garland, TX (US); Michael S. FOREIGN PATENT DOCUMENTS
Jenkins, Fairview, TX (US); Kent
DE 704 450 3/1941
Poteet, Lucas, TX (US); Jaime Felix
EP 0 318 831 A2 6/1989
Barajas, McKinney, TX (US) FR 1036107 9/1953
(73) Assignee: Traxxas LP, Plano, TX (US) OTHER PUBLICATIONS

(**) Term: 14 Years
Ukiah CA, U.S.A., 2003-2006.
Anderson Power Products; "PP15 Powerpole Connector" data sheet;
(21) Appl. No.: 29/279,011
Anderson Power Products, Sterling, MA U.S.A.
(22) Filed: Apr. 17, 2007 (Continued)
(51) LOC (8) Cl. .................................................. 13-03 Primary Examiner-Daniel D Bui

(52) U.S. Cl. ..................................... D13/133; D13/154 Assistant Examiner-Thomas J Johannes
(58) Field of Classification Search ........ D13/131-133, (74) Attorney, Agent, or Firm-Carr LLP
D13/134, 137.1, 138.1, 139.1, 146-147, 149,
(57) CLAIM
D13/154, 184, 199; 439/63, 115, 161, 284,
439/293,295,342,352, 507,678,692,701, The ornamental design for an electrical connector, as shown
439/825, 839, 851, 854-857; 174/58; 428/35.7 and described.
(56) References Cited DESCRIPTION
FIG. 1 is a perspective view of an electrical connector taken
U.S. PATENT DOCUMENTS from the front, top and left;
2,121,338 A 6/1938 Chirelstein FIG. 2 is a perspective view thereof taken from the rear,
2,203,122 A 6/1940 Anderson bottom and right;
2,838,739 A 6/1958 Winkler
3,091,746 A 5/1963 Winkler FIG. 3 is a front elevation view thereof;
3,145,067 A 8/1964 Mishelevich et al. FIG. 4 is a rear elevation view thereof;
3,218,599 A 11/1965 Winkler
3,233,211 A 2/1966 Smith FIG. 5 is a top plan view thereof;
3,259,870 A 7/1966 Winkler FIG. 6 is a bottom plan view thereof;
3,794,957 A * 2/1974 Winkler ...................... 439/295
FIG. 7 is a left side elevation view thereof; and,
4,018,497 A 4/1977 Bulanchuk
4,083,617 A 4/1978 Wyatt FIG. 8 is a right side elevation view thereof.
0258,429 S * 3/1981 Buckler .................. D13/138.1
The broken lines in the drawings are for illustrative purposes
4,342,498 A 8/1982 Patton et al.
only and form no part of the claimed design.
4,630,876 A 12/1986 Grunberg et al.
4,846,729 A 7/1989 Hikami et al.
4,990,099 A 2/1991 Marin et al. 1 Claim, 4 Drawing Sheets
US D573,536 S
Page 2
U.S. PATENT DOCUMENTS Horizon Hobby; "E-flite EC3 Device & Battery Connector, Male-
Female" web page; Horizon Hobby, Inc., Champaign, IL, U.S.A.
5,533,915 A 7/1996 Deans 2006.
5,575,674 A 11/1996 Davis et al. Tyco Electronics, "Hot Plug, High Current Dual Crown Clip Socket
5,748,821 A * 5/1998 Schempp et al ............... 385/76 Connector" Elcon Products International Co., Fremont, CA U.S.A.
D430,542 S * 9/2000 Hoferitza et al. ........... D13/154 2000.
D467,553 S * 12/2002 Cheng ....................... D13/154 McMaster-Carr Supply Co.
6,488,546 B2 12/2002 Sakurai et al. Molex; "Standard .093" web pages; Molex, Lisle IL U.S.A.
6,619,995 Bl 9/2003 Hayashi et al.
Hyperphysics, "Household Wiring-Polarized Receptacles" web
6,619,996 B2 9/2003 Hara et al.
page article; http://hyperphysics.phyastr.gsu.edu/hbase/electrical/
6,623,309 B2 9/2003 Sakurai et al.
hsehld.htrnl.
6,645,003 B2 11/2003 Yoshida et al.
Traxxas; "Revo transmission" illustration ( 1 page); Traxxas LP,
7,004,795 B2 2/2006 Mancini et al.
Plano TX U.S.A.
OTHER PUBLICATIONS Deans; "Ultra Plug" photographs (3 pages); Wm. F. Deans, Para-
mount CA U.S.A.
Anderson Power Products, "SB Connector Family" data sheet; Molex; "Standard .093" connector photographs (7 pages); Molex,
Anderson Power Products, Sterling, MA, U.S.A. Lisle IL U.S.A.
Anderson Power Products; "SB 50 Connector" data sheet; Anderson "Standard ll 0V electrical plugs and receptacles" photographs ( 5
Power Products, Sterling, MA, U.S.A. pages).
Anderson Power Products; "SBS 50 Connector" data sheet; Ander-
son Power Products, Sterling, MA, U.S.A. * cited by examiner
U.S. Patent Jul. 22, 2008 Sheet 1 of 4 US D573,536 S
FIG.1
FIG. 2
(f - - - - - - - - - - - -~ rr- ---------~
v- - - - - - - - - - - - -~ 1,,- - - - - - - - - - ~
L _ -I!.:-
-c-J -___
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FIG. 4
FIG. 5
11
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EXHIBIT 11
I 1111111111111111 111111111111111 111111111111111 IIIII IIIII IIIIIII II IIIII IIII
US00D576557S
c12) United States Design Patent (10) Patent No.: US D576,557 S

Hariharesan et al. (45) Date of Patent: ** Sep. 9, 2008
(54) ELECTRICAL CONNECTOR 4,990,099 A 2/1991 Marin et al.

D326,642 S * 6/1992 Lowe ..................... D13/138.l
(75) Inventors: Seralaathan Hariharesan, Flower 5,123,071 A * 6/1992 Mulholland et al. ........... 385/53
Mound, TX (US); Brock Dennison, 5,293,581 A * 3/1994 DiMarco ..................... 385/76
5,533,915 A 7/1996 Deans
5,575,674 A 1111996 Davis et al.
Lampert, Garland, TX (US); Michael S.
Jenkins, Fairview, TX (US); Kent FOREIGN PATENT DOCUMENTS
Poteet, Lucas, TX (US); Jaime Felix
DE 704 450 3/1941
Barajas, McKinney, TX (US)
(Continued)
(73) Assignee: Traxxas LP, Plano, TX (US)
OTHER PUBLICATIONS
(**) Term: 14 Years
Ukiah CA, U.S.A., 2003-2006.
(21) Appl. No.: 29/279,013
(Continued)
(22) Filed: Apr. 17, 2007
Primary Examiner-Daniel D Bui
(51) LOC (8) Cl. .................................................. 13-03 Assistant Examiner-Thomas J Johannes
(52) U.S. Cl. ..................................... D13/154; D13/133 (74) Attorney, Agent, or Firm-Carr LLP
(58) Field of Classification Search ........ D13/131-133,
D13/134, 137.1, 138.1, 139.1, 146-147, 149, (57) CLAIM
D13/154, 184, 199; 439/63, 115, 161, 284,
The ornamental design for an electrical connector, as shown
439/293,295,342,352, 507,678,692,701,
and described.
439/825, 839, 851, 854-857; 174/58; 428/35.7
See application file for complete search history. DESCRIPTION
(56) References Cited FIG. 1 is a perspective view of an electrical connector taken
from the front, top and left showing our new design;
U.S. PATENT DOCUMENTS
FIG. 2 is a perspective view thereof taken from the rear,
2,121,338 A 6/1938 Chirelstein bottom and right;
2,203,122 A 6/1940 Anderson
2,838,739 A 6/1958 Winkler FIG. 3 is a front elevation view thereof;
3,091,746 A 5/1963 Winkler FIG. 4 is a rear elevation view thereof;
3,218,599 A 11/1965 Winkler FIG. 5 is a top plan view thereof;
3,233,211 A 2/1966 Smith FIG. 6 is a bottom plan view thereof;
3,259,870 A 7/1966 Winkler
FIG. 7 is a left side elevation view thereof; and,
3,794,957 A * 2/1974 Winkler ...................... 439/295
4,018,497 A 4/1977 Bulanchuk FIG. 8 is a right side elevation view thereof.
4,083,617 A 4/1978 Wyatt The broken lines in the drawings are for illustrative purposes
0258,429 S * 3/1981 Buckler .................. D13/138.l
only and form no part of the claimed design.
4,342,498 A 8/1982 Patton et al.
4,630,876 A 12/1986 Grunberg et al.
4,846,729 A 7/1989 Hikami et al. 1 Claim, 2 Drawing Sheets
US D576,557 S
Page 2
U.S. PATENT DOCUMENTS Anderson Power Products; "SB 50 Connector" data sheet; Anderson
Power Products, Sterling, MA, U.S.A.
5,748,821 A * 5/1998 Schempp et al ............... 385/76 Anderson Power Products; "SBS 50 Connector" data sheet; Ander-
D430,542 S * 9/2000 Hoferitza et al. ........... D13/154 son Power Products, Sterling, MA. U.S.A.
6,240,228 Bl * 5/2001 Chen et al. .................... 385/53
Horizon Hobby; "E-flite EC3 Device & Battery Connector, Male-
6,268,564 Bl 7/2001 Miyakoshi
Female" web page; Horizon Hobby, Inc., Champaign, IL, U.S.A.
6,318,904 Bl * 11/2001 Reichle ... ... .. ... ... ... ... .. . 385/78
2006.
D467,553 S * 12/2002 Cheng ....................... D13/154
Tyco Electronics, "Hot Plug, High Current Dual Crown Clip Socket
6,488,546 B2 12/2002 Sakurai et al.
Connector" Elcon Products International Co., Fremont, CA U.S.A.
6,619,995 Bl 9/2003 Hayashi et al.
2000.
6,619,996 B2 9/2003 Hara et al.
McMaster-Carr; "Quick-Disconnect Terminals" catalog p. 724;
6,623,309 B2 9/2003 Sakurai et al.
McMaster-Carr Supply Co.
6,645,003 B2 11/2003 Yoshida et al.
Molex; "Standard .093" web pages; Molex, Lisle IL U.S.A.
6,761,488 B2 * 7/2004 Weigel ........................ 385/58
7,004,795 B2 2/2006 Mancini et al. Hyperphysics, "Household Wiring-Polarized Receptacles" web
7,325,980 B2 * 2/2008 Pepe . ... ... ... .. ... ... ... ... .. . 385/86 page article; http://hyperphysics.phy-astr.gsu.edu/hbase/electric/
hsehld.htrnl.
FOREIGN PATENT DOCUMENTS Traxxas; "Revo transmission" illustration ( 1 page); Traxxas LP,
Plano TX U.S.A.
EP 0 319 831 A2 6/1989 Deans; "Ultra Plug" photographs (3 pages); Wm. F. Deans, Para-
FR 1036107 9/1953 mount CA U.S.A.
OTHER PUBLICATIONS Molex; "Standard .093" connector photographs (7 pages); Molex,
Lisle IL U.S.A.
Anderson Power Products; "PP15 Powerpole Connector" data sheet; "Standard ll 0V electrical plugs and receptacles" photographs ( 5
Anderson Power Products, Sterling, MA U.S.A. pages).
Anderson Power Products, "SB Connector Family" data sheet;
Anderson Power Products, Sterling, MA, U.S.A. * cited by examiner
U.S. Patent Sep.9,2008 Sheet 1 of 2 US D576,557 S
FIG.1
FIG. 2
U.S. Patent Sep.9,2008 Sheet 2 of 2 US D576,557 S
FIG. 3 FIG. 4
FIG. 5 FIG. 6
~------~;:------
--------c-::,------
[J
FIG. 7
FIG. 8
EXHIBIT 12
Exemplary Accused Products
Gen 1 Male Connectors

eBay Item No. Description
131431095020 Traxxas 2-Male to 1-Female Series 2.5" TRX Connector Adapter E Revo LiPO Slash
131491535906 Male TRX Traxxas to Female Deans Connector Adapter LiPo High Quality Revo Slash
131706719809 QTY-(3) 2-Male Traxxas to 1-Female Deans Parallel Adapter Connector Brushless
131706738995 QTY-(1) 2-Male Traxxas TRX to 1-Female Deans Series 2.5" Connector Adapter LiPO
131770996271 QTY-1 Traxxas 2-Male to 1-Female Series 4.13" TRX Connector Adapter Revo Slash
141459570199 QTY-(2) Male Traxxas TRX to Female Tamiya Adapter Connector Battery Charger
141459615774 Male Traxxas TRX to Female Tamiya Connector Adapter Brushless Revo LiPO Charger
141642946303 Qty-2 Male TRX Traxxas to Female Deans Connector Adapter LiPo High Quality Slash
141847488293 QTY-2 Traxxas 2-Male to 1-Female Series 2.5" TRX Connector Adapter E Revo Slash
Gen 1 Female Connectors

eBay Item No. Description
131426326428 Male Deans to Female TRX Traxxas Connector Adapter Revo Brushless Lipo Battery
131431095020 Traxxas 2-Male to 1-Female Series 2.5" TRX Connector Adapter E Revo LiPO Slash
131561066318 QTY-(1) Female Traxxas TRX 14AWG Jumper Shorting Adapter Battery Eliminator
131561067234 QTY-(2) Female Traxxas TRX 14Awg Jumper Shorting Adapter Battery Eliminator
131653208813 QTY-(2) Male Losi EC3 to Female Traxxas TRX Connector Adapter E-Flite Tenergy
131706719809 QTY-(3) 2-Male Traxxas to 1-Female Deans Parallel Adapter Connector Brushless
131771050376 QTY-(1) Female Traxxas TRX 12AWG Jumper Shorting Adapter Battery Eliminator
141847488293 QTY-2 Traxxas 2-Male to 1-Female Series 2.5" TRX Connector Adapter E Revo Slash
EXHIBIT 13
012324141 5678879ÿ47
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JS 44 (Rev. 10/20) CIVIL COVER
Case 2:20-cv-00331-JRG Document SHEET
1-14 Filed 10/13/20 Page 1 of 2 PageID #: 187
The JS 44 civil cover sheet and the information contained herein neither replace nor supplement the filing and service of pleadings or other papers as required by law, except as
provided by local rules of court. This form, approved by the Judicial Conference of the United States in September 1974, is required for the use of the Clerk of Court for the
purpose of initiating the civil docket sheet. (SEE INSTRUCTIONS ON NEXT PAGE OF THIS FORM.)
I. (a) PLAINTIFFS DEFENDANTS
Traxxas, L.P. Jeremiah Frederick William Sanders dba 365 Hobbies
(b) County of Residence of First Listed Plaintiff Collin, Texas County of Residence of First Listed Defendant
(EXCEPT IN U.S. PLAINTIFF CASES) (IN U.S. PLAINTIFF CASES ONLY)
NOTE: IN LAND CONDEMNATION CASES, USE THE LOCATION OF
THE TRACT OF LAND INVOLVED.
(c) Attorneys (Firm Name, Address, and Telephone Number) Attorneys (If Known)
The Davis Firm, PC, 213 N. Fredonia Street, Suite 230

Longview, Texas 75601, Telephone: (903) 230-9090
II. BASIS OF JURISDICTION (Place an “X” in One Box Only) III. CITIZENSHIP OF PRINCIPAL PARTIES (Place an “X” in One Box for Plaintiff
(For Diversity Cases Only) and One Box for Defendant)
1 U.S. Government ✖ 3 Federal Question PTF DEF PTF DEF
Plaintiff (U.S. Government Not a Party) Citizen of This State 1 1 Incorporated or Principal Place 4 4
of Business In This State
2 U.S. Government 4 Diversity Citizen of Another State 2 2 Incorporated and Principal Place 5 5
Defendant (Indicate Citizenship of Parties in Item III) of Business In Another State
Citizen or Subject of a 3 3 Foreign Nation 6 6

Foreign Country
IV. NATURE OF SUIT (Place an “X” in One Box Only) Click here for: Nature of Suit Code Descriptions.
CONTRACT TORTS FORFEITURE/PENALTY BANKRUPTCY OTHER STATUTES
110 Insurance PERSONAL INJURY PERSONAL INJURY 625 Drug Related Seizure 422 Appeal 28 USC 158 375 False Claims Act
120 Marine 310 Airplane 365 Personal Injury - of Property 21 USC 881 423 Withdrawal 376 Qui Tam (31 USC
130 Miller Act 315 Airplane Product Product Liability 690 Other 28 USC 157 3729(a))
140 Negotiable Instrument Liability 367 Health Care/ 400 State Reapportionment
150 Recovery of Overpayment 320 Assault, Libel & Pharmaceutical PROPERTY RIGHTS 410 Antitrust
& Enforcement of Judgment Slander Personal Injury 820 Copyrights 430 Banks and Banking
151 Medicare Act 330 Federal Employers’ Product Liability 830 Patent 450 Commerce
152 Recovery of Defaulted Liability 368 Asbestos Personal 835 Patent - Abbreviated 460 Deportation
Student Loans 340 Marine Injury Product New Drug Application 470 Racketeer Influenced and
(Excludes Veterans) 345 Marine Product Liability ✖ 840 Trademark Corrupt Organizations
153 Recovery of Overpayment Liability PERSONAL PROPERTY LABOR 880 Defend Trade Secrets 480 Consumer Credit
of Veteran’s Benefits 350 Motor Vehicle 370 Other Fraud 710 Fair Labor Standards Act of 2016 (15 USC 1681 or 1692)
160 Stockholders’ Suits 355 Motor Vehicle 371 Truth in Lending Act 485 Telephone Consumer
190 Other Contract Product Liability 380 Other Personal 720 Labor/Management SOCIAL SECURITY Protection Act
195 Contract Product Liability 360 Other Personal Property Damage Relations 861 HIA (1395ff) 490 Cable/Sat TV
196 Franchise Injury 385 Property Damage 740 Railway Labor Act 862 Black Lung (923) 850 Securities/Commodities/
362 Personal Injury - Product Liability 751 Family and Medical 863 DIWC/DIWW (405(g)) Exchange
Medical Malpractice Leave Act 864 SSID Title XVI 890 Other Statutory Actions
REAL PROPERTY CIVIL RIGHTS PRISONER PETITIONS 790 Other Labor Litigation 865 RSI (405(g)) 891 Agricultural Acts
210 Land Condemnation 440 Other Civil Rights Habeas Corpus: 791 Employee Retirement 893 Environmental Matters
220 Foreclosure 441 Voting 463 Alien Detainee Income Security Act FEDERAL TAX SUITS 895 Freedom of Information
230 Rent Lease & Ejectment 442 Employment 510 Motions to Vacate 870 Taxes (U.S. Plaintiff Act
240 Torts to Land 443 Housing/ Sentence or Defendant) 896 Arbitration
245 Tort Product Liability Accommodations 530 General 871 IRS—Third Party 899 Administrative Procedure
290 All Other Real Property 445 Amer. w/Disabilities - 535 Death Penalty IMMIGRATION 26 USC 7609 Act/Review or Appeal of
Employment Other: 462 Naturalization Application Agency Decision
446 Amer. w/Disabilities - 540 Mandamus & Other 465 Other Immigration 950 Constitutionality of
Other 550 Civil Rights Actions State Statutes
448 Education 555 Prison Condition
560 Civil Detainee -
Conditions of
Confinement
V. ORIGIN (Place an “X” in One Box Only)
✖ 1 Original 2 Removed from 3 Remanded from 4 Reinstated or 5 Transferred from 6 Multidistrict 8 Multidistrict
Proceeding State Court Appellate Court Reopened Another District Litigation - Litigation -
(specify) Transfer Direct File
Cite the U.S. Civil Statute under which you are filing (Do not cite jurisdictional statutes unless diversity):
15 U.S.C. § 1114
VI. CAUSE OF ACTION Brief description of cause:
Infringement of federally registered trademarks, patent infringement, and related claims.
VII. REQUESTED IN CHECK IF THIS IS A CLASS ACTION DEMAND $ CHECK YES only if demanded in complaint:
COMPLAINT: UNDER RULE 23, F.R.Cv.P. JURY DEMAND: ✖ Yes No
VIII. RELATED CASE(S)
(See instructions):
IF ANY JUDGE not assigned DOCKET NUMBER 2:20-cv-329, 330, 332
DATE SIGNATURE OF ATTORNEY OF RECORD
Oct 13, 2020 deb coleman Digitally signed by deb coleman
Date: 2020.10.13 14:07:18 -05'00'
FOR OFFICE USE ONLY
RECEIPT # AMOUNT APPLYING IFP JUDGE MAG. JUDGE

JS 44 Reverse (Rev. 10/20)
INSTRUCTIONS FOR ATTORNEYS COMPLETING CIVIL COVER SHEET FORM JS 44

Authority For Civil Cover Sheet
The JS 44 civil cover sheet and the information contained herein neither replaces nor supplements the filings and service of pleading or other papers as
required by law, except as provided by local rules of court. This form, approved by the Judicial Conference of the United States in September 1974, is
required for the use of the Clerk of Court for the purpose of initiating the civil docket sheet. Consequently, a civil cover sheet is submitted to the Clerk of
Court for each civil complaint filed. The attorney filing a case should complete the form as follows:
I.(a) Plaintiffs-Defendants. Enter names (last, first, middle initial) of plaintiff and defendant. If the plaintiff or defendant is a government agency, use
only the full name or standard abbreviations. If the plaintiff or defendant is an official within a government agency, identify first the agency and then
the official, giving both name and title.
(b) County of Residence. For each civil case filed, except U.S. plaintiff cases, enter the name of the county where the first listed plaintiff resides at the
time of filing. In U.S. plaintiff cases, enter the name of the county in which the first listed defendant resides at the time of filing. (NOTE: In land
condemnation cases, the county of residence of the "defendant" is the location of the tract of land involved.)
(c) Attorneys. Enter the firm name, address, telephone number, and attorney of record. If there are several attorneys, list them on an attachment, noting
in this section "(see attachment)".
II. Jurisdiction. The basis of jurisdiction is set forth under Rule 8(a), F.R.Cv.P., which requires that jurisdictions be shown in pleadings. Place an "X"
in one of the boxes. If there is more than one basis of jurisdiction, precedence is given in the order shown below.
United States plaintiff. (1) Jurisdiction based on 28 U.S.C. 1345 and 1348. Suits by agencies and officers of the United States are included here.
United States defendant. (2) When the plaintiff is suing the United States, its officers or agencies, place an "X" in this box.
Federal question. (3) This refers to suits under 28 U.S.C. 1331, where jurisdiction arises under the Constitution of the United States, an amendment
to the Constitution, an act of Congress or a treaty of the United States. In cases where the U.S. is a party, the U.S. plaintiff or defendant code takes
precedence, and box 1 or 2 should be marked.
Diversity of citizenship. (4) This refers to suits under 28 U.S.C. 1332, where parties are citizens of different states. When Box 4 is checked, the
citizenship of the different parties must be checked. (See Section III below; NOTE: federal question actions take precedence over diversity
cases.)
III. Residence (citizenship) of Principal Parties. This section of the JS 44 is to be completed if diversity of citizenship was indicated above. Mark this
section for each principal party.
IV. Nature of Suit. Place an "X" in the appropriate box. If there are multiple nature of suit codes associated with the case, pick the nature of suit code
that is most applicable. Click here for: Nature of Suit Code Descriptions.
V. Origin. Place an "X" in one of the seven boxes.

Original Proceedings. (1) Cases which originate in the United States district courts.
Removed from State Court. (2) Proceedings initiated in state courts may be removed to the district courts under Title 28 U.S.C., Section 1441.
Remanded from Appellate Court. (3) Check this box for cases remanded to the district court for further action. Use the date of remand as the filing
date.
Reinstated or Reopened. (4) Check this box for cases reinstated or reopened in the district court. Use the reopening date as the filing date.
Transferred from Another District. (5) For cases transferred under Title 28 U.S.C. Section 1404(a). Do not use this for within district transfers or
multidistrict litigation transfers.
Multidistrict Litigation – Transfer. (6) Check this box when a multidistrict case is transferred into the district under authority of Title 28 U.S.C.
Section 1407.
Multidistrict Litigation – Direct File. (8) Check this box when a multidistrict case is filed in the same district as the Master MDL docket.
PLEASE NOTE THAT THERE IS NOT AN ORIGIN CODE 7. Origin Code 7 was used for historical records and is no longer relevant due to
changes in statue.
VI. Cause of Action. Report the civil statute directly related to the cause of action and give a brief description of the cause. Do not cite jurisdictional
statutes unless diversity. Example: U.S. Civil Statute: 47 USC 553 Brief Description: Unauthorized reception of cable service.
VII. Requested in Complaint. Class Action. Place an "X" in this box if you are filing a class action under Rule 23, F.R.Cv.P.
Demand. In this space enter the actual dollar amount being demanded or indicate other demand, such as a preliminary injunction.
Jury Demand. Check the appropriate box to indicate whether or not a jury is being demanded.
VIII. Related Cases. This section of the JS 44 is used to reference related pending cases, if any. If there are related pending cases, insert the docket
numbers and the corresponding judge names for such cases.
Date and Attorney Signature. Date and sign the civil cover sheet.

Traxxas v. Sanders - Complaint

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Case 2:20-cv-00331-JRG Document 1 Filed 10/13/20 Page 1 of 36 PageID #: 1

IN THE UNITED STATES DISTRICT COURT

COMPLAINT FOR TRADEMARK INFRINGEMENT, UNFAIR COMPETITION,

I. NATURE OF THE SUIT

II. THE PARTIES

2. Plaintiff Traxxas, L.P. (“Traxxas”) is a Texas limited partnership that maintains

its principal place of business in McKinney, Texas.

3. Defendant Jeremiah Frederick William Sanders is an individual residing in

Colorado Springs, Colorado and doing business as 365 Hobbies.

III. JURISDICTION AND VENUE

under the United States patent laws, 35 U.S.C. § 101 et seq.

infringement, dilution, patent infringement, and related unfair competition claims.

Defendant’s acts or omissions (directly or through intermediaries) in this judicial District,

Original Complaint Page 2

A. Traxxas and Its Intellectual Property

1. The Asserted Trademarks

characters “TRAXXAS” (the “TRAXXAS Mark”) in interstate commerce to identify, advertise,

attached hereto as Exhibit 1.

attached hereto as Exhibit 2.

Original Complaint Page 3

a. U.S. Trademark Registration No. 2,314,111, which comprises a design plus

the word “TRAXXAS” as applied to radio-controlled model vehicles and

parts therefor sold as a unit in International Class 028;

b. U.S. Trademark Registration No. 2,292,851, which comprises stylized

characters “TRAXXAS” as applied to radio-controlled model vehicles and

parts therefor, sold as a unit in International Class 028; and

c. U.S. Trademark Registration No. 5,257,656, which comprises stylized

characters “TRAXXAS” as applied to batteries and battery chargers in

International Class 009.

trademarks comprising the standard characters “TRAXXAS”:

a. U.S. Trademark Application No. 88/215,688, which comprises the standard

characters “TRAXXAS” as applied to hand tools adapted for use with

model vehicles in International Class 008;

b. U.S. Trademark Application No. 88/266,147, which comprises the standard

characters “TRAXXAS” as applied to decals; stickers; banners; posters;

pens; vehicle wraps in International Class 016, lanyards in International

beanies, and scarfs in International Class 025; and

Original Complaint Page 4

c. U.S. Trademark Application No. 88/266,155, which comprises the standard

characters “TRAXXAS” as applied to phone accessories, namely, pop

sockets in International Class 009, bags; duffel bags; backpacks in

International Class 021.

Traxxas on July 25, 2003) is attached hereto as Exhibit 3.

21. In addition to the above-referenced USPTO registrations, Traxxas has registered

each of the TRAXXAS Mark and the TRX Mark internationally.

Original Complaint Page 5

and the TRX Mark.

§ 1125(c) and Texas Business and Commerce Code § 16.103.

2. The Asserted Patents

entitled “Electrical Connector Assembly,” is attached hereto as Exhibit 5.

Original Complaint Page 6

standing to sue for infringement of the ’855 Patent.

requirements set forth in 35 U.S.C. § 287.

entitled “Electrical Connector Assembly,” is attached hereto as Exhibit 6.

standing to sue for infringement of the ’038 Patent.

requirements set forth in 35 U.S.C. § 287.

entitled “Electrical Connector Assembly,” is attached hereto as Exhibit 7.

standing to sue for infringement of the ’323 Patent.

Original Complaint Page 7

requirements set forth in 35 U.S.C. § 287.

entitled “Electrical Connector Assembly,” is attached hereto as Exhibit 8.

sue for infringement of the ’254 Patent.

requirements set forth in 35 U.S.C. § 287.

entitled “Electrical Connector Assembly,” is attached hereto as Exhibit 9.