International Business Machines Corporation

Delphi Technologies, Inc.

Aptiv Technologies Limited

Fci Americas Technology Inc.

Molex Corporation

Aptiv Technologies Ag

Fci Automotive Holding

Delphi International Operations Luxembourg S.a.r.l.

Jeffrey Scott Campbell

Wesley W Weber, Jr

Franklin Anthony Holub

Louis M Carrer

James T Holton

David R Peterson

Adam Price Tyler

David F Koehler

Adam Wade Kennedy

Joel A Pittenger

Robert W Nesky

Richard J Kakkuri

Gregory D Leece

Ralf Pfeilsticker

Rangarajan Sundarakrishnamachari

Jared Bilas

Richard A Johannes

David B Howe

William T Wike

Christian Schaefer

Kurt P Seifert

David Brian Stone

Duane Lee Brantingham

Joon Lee

Thomas G Macek

Kurt Paul Seifert

James D Herard

Ronald P Nowak

John R Slack

Rathnakumar Ramaswamy

Wesley J Weber, Jr

Frederick W Doolittle

Christopher S Pendleton

Wesley W Weber

Wesley W Weber Jr

Jr Wesley W Weber

Richard Kakkurui

Adam Kennedy

Self-aligning mounting systems and methods for an electrical connectors and controllers of an electrified vehicle include a dock member configured to be fixedly attached to a frame of the electrified vehicle and to at least temporarily secure the electrical controller therein and at least one floating electrical connector floatably mateable with the dock member such that the floating electrical connector is movable by a tolerance distance amount along each of at least first and second perpendicular axes that are each parallel to the base portion of the dock member, and configured to, during securement of the electrical controller within the dock member along a third axis perpendicular to the first and second axes, electrically connect a first connection portion of the floating electrical connector to a corresponding other electrical connector, such as an inline electrical connector or an electrical connector in a bottom surface of the electrical controller housing.

Self-aligning mate assurance modular docking electrical connector system

Electrical connector systems and methods create an electrical connection between a flexible circuit (FC) and a metal terminal of another connector. A reliable electrical connection is achieved with a low-cost tin contact plating, by an automatic FC to metal terminal wiping action with contact force, during the connector to FC assembly process. The connector to FC assembly process is also well suited for automated robotic assembly, which can save costs compared to manual assembly/installation.

Flexible circuit to terminal connector with wiping electrical contacts

A self-aligning mechanical mount and electrical connection system for an electronic module comprises a mechanical mount assembly configured to be integrated into or attached to a base frame and defining a mount connection position assurance (CPA) feature for self-aligning and securing of the electronic module therein, and an electrical connection assembly configured to be integrated into or attached to the mechanical mount assembly and comprising a modular electrical connector (i) being electrically connected to an electrical backbone wire cable and (ii) defining a connector CPA feature for self-aligning the modular electrical connector with a corresponding electrical connector integrated into or attached to the electronic module when the electronic module is secured in the mechanical mount assembly.

Self-aligning mechanical mount and electrical connection system for electronic modules with features for robotic assembly

An electrical connector assembly includes a housing that is configured to receive a planar first substrate, The first substrate includes an electrically conductive first contact region. The electrical connector assembly is further configured to receive a planar second substrate that includes an electrically conductive second contact region defining a ridge protruding from a surface of the second substrate. The housing is configured to align the first contact region with the second contact region. The electrical connector assembly also includes a force application device applying a compressive contact force to the first and second substrates, thereby putting the first contact region in intimate compressive contact with the second contact region.

Electrical connector

A connector assembly includes a connector body, a corresponding mating connector body, and a connection position assurance (CPA) device. The connector body includes a deflectable latching member and at least one outer detent feature located on an outer surface of the connector body. The corresponding mating connector body is configured to be removably connected with the connector body, wherein the deflectable latching member is configured to secure the connector body to the corresponding mating connector body. The CPA device is slidably positioned adjacent the connector body and moveable from a pre-stage position to a full-stage position, wherein the CPA device interacts with the at least one outer detent feature located on the outer surface of the connector body to deflect the connector body towards the corresponding mating connector body.

Anti-vibration stabilized connected system with self-rejecting ergonomic feedback mechanism

A printed circuit board assembly includes a circuit board substrate and a circuit board trace having a circuit board contact region configured to be in intimate contact with a cable contact region of a cable circuit trace contained in flat cable. The circuit board contact region defines a plurality of ridges protruding from a circuit board substrate surface.

Printed circuit board assembly and electrical connector assembly

A connector assembly includes a conductor retainer that is configured to relieve retain a conductor within a connector body of the connector assembly. The conductor retainer causes the conductor to helically twist at least 90 degrees about a longitudinal axis. A helical channel may be defined in the conductor retainer to cause the conductor to helically twist. Multiple conductors may be terminated within the connector assembly and the conductor retainer may define multiple helical channels. Some of the helical channels may have a right hand helical twist while others have a left hand helical twist. A method of manufacturing a connector assembly with these features is also presented.

Connector assembly with retainer

An electrical connector includes a housing that is configured to receive a planar first substrate having an electrically conductive first circuit trace with a first contact region, such a flat cable. The housing is further configured to receive a planar second substrate having an electrically conductive second circuit trace with a second contact region, such as a printed circuit board or another flat cable. The housing is configured to align the first contact region with the second contact region. The connector also includes a force application device configured to apply a compressive contact force to the first and second substrates, thereby putting the first contact region in intimate compressive contact with the second contact region. The connector may also include an moveable actuating member that is configured to selectively increase the compressive contact force applied to the first and second substrates via interaction with the force application device.

A connector assembly includes an electrical-terminal, a housing, and a lock-reinforcement. The a housing defines a cavity configured to receive the electrical-terminal. The housing includes a locking-finger overlaying the electrical-terminal configured to lock the electrical-terminal within the cavity. The locking-finger has a rib protruding from the locking-finger having a first-surface and a second-surface. A tip of the locking-finger includes a locking-ramp projecting from the locking-finger configured to engage a perimeter-edge of a lock-slot defined by the electrical-terminal. The lock-reinforcement is disposed within the cavity and configured to slideably engage both the first-surface and the second-surface of the rib after the lock-reinforcement is moved from a pre-stage-position to a seated-position. The lock-reinforcement is configured to inhibit a buckling of the cantilevered locking-finger when a removal-force is applied to the electrical-terminal when the lock-reinforcement is in the seated-position, thereby inhibiting the locking-ramp from rotating within the lock-slot of the electrical-terminal.

Connector assembly with lock reinforcement feature

A connector includes a first-housing, a second-housing, a shroud, and a stacked-gear. The stacked-gear is moveably mounted to the first-housing. The stacked-gear engages a first-gear-rack on the second-housing and a second-gear-rack on the shroud. The second-housing is mated with the first-housing when the shroud is moved along a mating-axis of the connector. The stacked-gear engages at least two teeth on the first-gear-rack and on the second-gear-rack when the second-housing is mated with the first-housing. A rotation of the stacked-gear is greater than ninety degrees when the shroud is moved from an unmated-position to a mated-position. The stacked-gear initially engages a first-side of a first-tooth of the first-gear-rack when the first-housing receives the second-housing. A uniform mating-force is maintained as the shroud is moved from an unmated-position to a mated-position. A mechanical advantage to produce the mating-force is increased as the shroud is moved from an unmated-position to a mated-position.

Connector assembly with variable axial assist

A connector includes a first housing, a second housing, a mate assist slider, and a cam gear. The first-housing has a first outer surface. The second housing is configured to mate with the first housing, and the second housing includes a pin extending from a second outer surface. The connector also includes a mate assist slider moveable from an unmated position to a mated position. The connector also includes a cam gear mounted to the first outer surface. The cam gear moves in response to a movement of the mate-assist-slider from the unmated position to the mated position. The cam gear has a cam slot with an inertial detent. A vibratory feedback is provided to an assembler indicative of a properly positioned connector housing when the pin is moved past the inertial detent.

Electrical connector assembly with axial connection assist

A connector includes a first-housing and a second-housing. The first-housing includes a connector-lock. The second-housing is configured to receive the first-housing and includes a connector-latch configured to removably retain the connector-lock when the first-housing is mated with the second-housing. The second-housing includes a connector-position-assurance (CPA)-device slidably mounted to the second-housing and movable from a disengaged-position to an engaged-position. The CPA-device applies a retention-force to the connector-latch. The retention-force deflects the connector-latch thereby applying the retention-force to the first-housing when the first-housing is mated with the second-housing and the CPA-device is in the engaged-position.

High vibration connector with a connector-position-assurance device

A connector includes a first-housing, a second-housing, a shroud, and a stacked-gear. The first-housing defines a guide-slot. The second-housing mates with the first-housing. The second-housing includes a linear-gear-rack extending from a second-outer-surface and engages the guide-slot. The shroud is moveable from an unmated-position to a mated-position. The shroud is longitudinally slideably mounted to and surrounding at least a portion of the first-housing. The shroud also includes a curved-gear-rack having a variable-pitch-radius. The stacked-gear is moveably mounted to the first-housing. The stacked-gear has a round-gear and a cam-gear having the variable-pitch-radius in communication with the round-gear. The round-gear engages the linear-gear-rack within the guide-slot. The cam-gear engages the curved-gear-rack such that the cam-gear moves in response to a movement of the shroud from the unmated-position to the mated-position. Rotation of the round-gear engaged with the linear-gear-rack axially pulls the linear-gear-rack into the guide-slot, thereby pulling the second-housing into the first-housing.

An electrical connector including electrical terminals along with a connector housing defining a first and second cavity, the first and second cavities configured to receive the terminals. The connector housing further defines a third cavity extending along a lateral axis. The electrical connector includes a terminal position assurance (TPA) device received within the third cavity. The TPA device is moveable from an terminal insertion position to a terminal locking position. The TPA device has flexible first and second primary locking features and rigid first and second secondary locking features configured to engage locking features of the terminals. Only the first primary and first secondary locking features engage the locking surface of the first electrical terminal and only the second primary and second secondary locking features engage the locking surface of the second electrical terminal when the TPA device is in the terminal locking position.

Electrical connector with a terminal position assurance device having rigid and flexible locking features

Growing community of inventors

West Bloomfield, MI, United States of America

Jeffrey Scott Campbell