Electrical connector assembly with floating mating interface

Abstract

A connector assembly (200) is provided that includes an electrical connector (210) that includes a housing (230) having a contact channel (238) and a contact (222) retained in the contact channel. The contacts are terminated to an end (214) of the cable. A cable (214) extends from the housing. The electrical connector includes a terminal position assurance (TPA) device (250) coupled to the housing and operable to ensure proper positioning of the contacts in the contact channels (268). The electrical connector includes a mating end (212). The connector assembly includes a support bracket (300) configured to support the electrical connector. The support bracket includes an opening (344). An electrical connector overhangs from the support bracket and is received in the opening with a mating end forward of the support bracket for mating with a mating electrical connector. The electrical connector has six mechanical degrees of freedom relative to the support bracket.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 530,000, filed on July 31, 2023, and U.S. Provisional Application No. 63 / 582,000, filed on September 12, 2023, the subject matter of which is incorporated herein by reference in its entirety. Technical Field

[0003] The subject matter herein relates generally to electrical connector assemblies. Background Art

[0004] A connector system typically includes two connector halves, such as a male connector and a female connector, that mate together to create an electrical connection between the various components of the system. Proper mating of the connector halves is important for the proper operation of the system. If the connectors are not properly mated, a degraded signal is transmitted between the components, or in some cases, no signal is transmitted. For example, if the contacts are only partially mated, a low-quality signal may be transmitted. Proper mating may require that the mating connectors be fully aligned before mating. However, in some applications, it may be difficult to properly align the connectors. For example, when blind mating connectors, it may be impossible to align the connectors before mating.

[0005] There remains a need for an electrical connector system that allows for reliable mating of connector assemblies. Summary of the invention

[0006] In one embodiment, a connector assembly is provided, which includes an electrical connector, the electrical connector including a housing having a contact channel and a contact retained in the contact channel. The contact is terminated to an end of a cable. The cable extends from the housing. The electrical connector includes a terminal position assurance (TPA) device, which is connected to the housing and is operable to ensure proper positioning of the contact in the contact channel. The electrical connector includes a mating end. The connector assembly includes a support bracket configured to support the electrical connector. The support bracket includes an opening. The electrical connector is cantilevered from the support bracket and received in the opening, wherein the mating end is in front of the support bracket for mating with a mating electrical connector. The electrical connector has six mechanical degrees of freedom relative to the support bracket. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The present invention will now be described by way of example with reference to the accompanying drawings, in which:

[0008] Figure 1 is a front perspective view of an electrical connector system according to an exemplary embodiment.

[0009] Figure 2 is a rear perspective view of an electrical connector system according to an exemplary embodiment.

[0010] Figure 3 is an exploded view of a first connector assembly according to an exemplary embodiment.

[0011] Figure 4 is a front perspective view of a first connector assembly according to an exemplary embodiment.

[0012] Figure 5 is a cross-sectional view of a first connector assembly according to an exemplary embodiment.

[0013] Figure 6 is an exploded view of a second connector assembly according to an exemplary embodiment.

[0014] Figure 7 is a partially assembled view of a portion of a second connector assembly showing the electrical connector coupled to the connector mount and showing the pivot frame ready to be mounted to the connector mount according to an exemplary embodiment.

[0015] Figure 8 is a cross-sectional view of a second connector assembly according to an exemplary embodiment.

[0016] Fig. 9 is a cross-sectional view of a second connector assembly according to an exemplary embodiment.

[0017] Fig.10 A connector assembly is shown ready to mate according to an exemplary embodiment.

[0018] Fig.11 A partially mated connector assembly is shown according to an exemplary embodiment.

[0019] Fig.12 A further mated connector assembly according to an exemplary embodiment is shown.

[0020] Fig.13 A fully mated connector assembly is shown according to an exemplary embodiment.

[0021] Fig.14 is a device according to an exemplary embodiment corresponding to Fig.12 A cross-sectional view of a connector assembly in a partially mated state.

[0022] Fig.15 is a device according to an exemplary embodiment corresponding to Fig.13 A cross-sectional view of a connector assembly in a fully mated state.

[0023] Fig.16 is a device according to an exemplary embodiment corresponding to Fig.12 A cross-sectional view of a connector assembly in a partially mated state.

[0024] Fig.17 is a device according to an exemplary embodiment corresponding to Fig.13 A cross-sectional view of a connector assembly in a fully mated state.

[0025] Fig.18 Axial movement of the electrical connector relative to the support bracket in the X direction is shown according to an exemplary embodiment.

[0026] Fig.19 Axial movement of the electrical connector relative to the support bracket in the X direction is shown according to an exemplary embodiment.

[0027] Fig. 20 Axial movement of the electrical connector relative to the support bracket in the Y direction is shown according to an exemplary embodiment.

[0028] Fig.21 Axial movement of the electrical connector relative to the support bracket in the Y direction is shown according to an exemplary embodiment.

[0029] Fig. 22 Rotation of an electrical connector relative to a support bracket in a yaw direction is shown according to an exemplary embodiment.

[0030] Fig.23 Rotation of the electrical connector relative to the support bracket in a pitch direction is shown according to an exemplary embodiment.

[0031] Fig.24 Rotation of an electrical connector relative to a support bracket in a rolling direction is shown according to an exemplary embodiment.

[0032] Fig.25 is a front perspective view of an electrical connector system according to an exemplary embodiment.

[0033] Fig.26 is a rear perspective view of an electrical connector system according to an exemplary embodiment.

[0034] Fig. 27 is an exploded view of a first connector assembly according to an exemplary embodiment.

[0035] Fig.28 is a front perspective view of a first connector assembly according to an exemplary embodiment.

[0036] Fig.29 is a cross-sectional view of a first connector assembly according to an exemplary embodiment.

[0037] Fig.30 is an exploded view of a second connector assembly according to an exemplary embodiment.

[0038] Fig.31is a front perspective view of a housing according to an exemplary embodiment, showing the housing in an open position.

[0039] Fig.32 is a front perspective view of a housing according to an exemplary embodiment, showing the housing in a closed position.

[0040] Fig.33 is a rear perspective view of a housing according to an exemplary embodiment, showing the housing in a closed position.

[0041] Fig.34 is a cross-sectional view of a pair of housings ready to be mated together to form a modular housing stack according to an exemplary embodiment.

[0042] Fig.35 is a front perspective view of a pair of housings mated together showing a clamping door in an open position according to an exemplary embodiment.

[0043] Fig.36 is a front perspective view of a pair of housings mated together showing a clamping door in a closed position according to an exemplary embodiment.

[0044] Fig.37 is a cross-sectional view of a connector mount according to an exemplary embodiment.

[0045] Fig.38 is a cross-sectional view of a connector mount according to an exemplary embodiment showing a portion of a housing relative to the connector mount.

[0046] Fig.39 is a cross-sectional view of a connector mount according to an exemplary embodiment showing a portion of a TPA device relative to the connector mount.

[0047] Fig.40 is a partially assembled view of a portion of a second connector assembly showing the electrical connector coupled to the connector mount and showing the pivot frame ready to be mounted to the connector mount according to an exemplary embodiment.

[0048] Fig.41 is a cross-sectional view of a second connector assembly according to an exemplary embodiment.

[0049] Fig.42 is a cross-sectional view of a second connector assembly according to an exemplary embodiment.

[0050] Fig.43 A connector assembly is shown ready to mate according to an exemplary embodiment.

[0051] Fig.44 A partially mated connector assembly is shown according to an exemplary embodiment.

[0052] Fig.45 A further mated connector assembly according to an exemplary embodiment is shown.

[0053] Fig.46 A fully mated connector assembly is shown according to an exemplary embodiment.

[0054] Fig.47 is a device according to an exemplary embodiment corresponding to Fig.45 A cross-sectional view of a connector assembly in a partially mated state.

[0055] Fig.48 is a device according to an exemplary embodiment corresponding to Fig.46 A cross-sectional view of a connector assembly in a fully mated state.

[0056] Fig.49 is a device according to an exemplary embodiment corresponding to Fig.45 A cross-sectional view of a connector assembly in a partially mated state.

[0057] Fig.50 is a device according to an exemplary embodiment corresponding to Fig.46 A cross-sectional view of a connector assembly in a fully mated state.

[0058] Fig.51 Axial movement of the electrical connector relative to the support bracket in the X direction is shown according to an exemplary embodiment.

[0059] Fig.52 Axial movement of the electrical connector relative to the support bracket in the X direction is shown according to an exemplary embodiment.

[0060] Fig.53 Axial movement of the electrical connector relative to the support bracket in the Y direction is shown according to an exemplary embodiment.

[0061] Fig.54 Axial movement of the electrical connector relative to the support bracket in the Y direction is shown according to an exemplary embodiment.

[0062] Fig.55 Rotation of an electrical connector relative to a support bracket in a yaw direction is shown according to an exemplary embodiment.

[0063] Fig.56 Rotation of the electrical connector relative to the support bracket in a pitch direction is shown according to an exemplary embodiment.

[0064] Fig.57 Rotation of an electrical connector relative to a support bracket in a rolling direction is shown according to an exemplary embodiment. DETAILED DESCRIPTION

[0065] Figure 1 is a front perspective view of an electrical connector system 10 according to an exemplary embodiment. Figure 2 1 is a rear perspective view of an electrical connector system 10 according to an exemplary embodiment. The electrical connector system 10 includes a first connector assembly 100 and a second connector assembly 200, the second connector assembly 200 being configured to mate with the first connector assembly 100 along a mating axis 12. The electrical connector system 10 is configured to transmit data and / or power through the first connector assembly 100 and the second connector assembly 200.

[0066] In various embodiments, the electrical connector system 10 can be used in automotive applications. For example, the connector assembly 100, 200 can be coupled to a vehicle, a component, a device, or a system such as an electric vehicle. However, in alternative embodiments, the electrical connector system 10 can be used in other applications, such as industrial applications, robotic applications, appliances, building wiring, computer systems, or other applications.

[0067] In an exemplary embodiment, the connector assemblies 100, 200 are designed for blind mating. For example, the connector assemblies 100, 200 include self-aligning features having a tolerance range that allows the mating interfaces of the connector assemblies 100, 200 to self-align during mating. In various embodiments, the connector assemblies 100, 200 can be mated by an automated mating process using a robot or a machine to mate the connector assemblies 100, 200. In various embodiments, one or both of the connector assemblies 100, 200 can be fixed to a module or component, such as a module or component of a vehicle, and mated during an automated vehicle assembly process. For example, the first connector assembly 100 can be fixed to a component, and the second connector assembly 200 can be held by a robot arm that is configured to mate the second connector assembly 200 with the first connector assembly 100 during an automated assembly process, and vice versa. In various other embodiments, the two connector assemblies 100, 200 can be held by a robot arm for mating the connector assemblies 100, 200 together during an automated assembly process.

[0068] In an exemplary embodiment, the second connector assembly 200 is equipped with features that allow it to move or float during mating to align with the first connector assembly 100 during the mating process. For example, the second connector assembly 200 can float in one or more axial directions to align with the first connector assembly 100. The second connector assembly 200 can float in one or more angular directions to align with the first connector assembly 100. In an exemplary embodiment, the second connector assembly 200 is equipped with features that allow it to move with six mechanical degrees of freedom relative to the first connector assembly 100. For example, the second connector assembly 200 has axial floats in the X, Y, and Z directions and rotational floats around a central pivot point in the yaw, pitch, and roll directions. The connector assemblies 100, 200 are able to compensate for some misalignments in almost all orientations due to positional and physical variations (e.g., tolerances). For example, the connector assemblies 100, 200 accommodate X, Y, and Z tolerances and three angular tolerances in the XY, XZ, and YZ planes to accommodate blind mating. Successful mating of the connector assemblies 100, 200 is achieved when the axial and angular alignment between the two components is within a specified tolerance zone. The float of the connector in all axial and angular degrees of freedom ensures that the terminated cables of the connector assemblies 100, 200 can be successfully mated without sacrificing signal integrity. For example, the second connector assembly 200 is equipped with features that allow axial and rotational float so that misalignment of the modules does not adversely affect the ability of the connector halves to mate, and subsequently does not adversely affect the ability of the terminated cables to align and transmit high-quality RF signals. In an exemplary embodiment, all floating (e.g., self-aligning) features are integrated into the second connector assembly 200 to simplify the design and reduce manufacturing costs. For example, the first connector assembly 100 can be made with a simple, low-cost design, which reduces the cost of the entire system. However, in alternative embodiments, some or all of the floating features may be included in the first connector assembly 100.

[0069] In an exemplary embodiment, the first connector assembly 100 includes an electrical connector 110 having a mating end 112 configured to mate with the second connector assembly 200 and a cable end 114 opposite the mating end 112. One or more cables 120 extend from the cable end 114. In the illustrated embodiment, the electrical connector 110 includes four cables 120; however, in alternative embodiments, the electrical connector 110 may include more or fewer cables 120. The cables 120 are representative and may be rigid or flexible signal or power transmission cables in various embodiments.

[0070] The electrical connector 110 includes a housing 130 and a terminal position assurance (TPA) device 150 coupled to the housing 130. The housing 130 holds one or more contacts 122 (eg, Figure 3 ). In various embodiments, the contacts 122 may be standard contacts, such as MATE-Ax, FAKRA, mini-FAKRA, GEMnet, or other types of contacts. The housing 130 is designed to receive a specific type of contact, such as by retaining the contact through a contact channel or latching feature having a specific shape. In various embodiments, the housing 130 may be designed to receive different types of contacts in different contact channels to provide a mating interface with different types and / or styles of contacts.

[0071] The TPA device 150 is operated to ensure proper positioning of the contacts 122 in the housing 130. In an exemplary embodiment, the TPA device 150 is movable between a preset position and a set position relative to the housing 130. After the contacts 122 are loaded in the housing 130, the TPA device 150 may be moved from the preset position to the set position. In various embodiments, if the contacts 122 are not correctly loaded into the housing 130, the TPA device 150 may not be moved to the set position, thereby ensuring proper positioning of the contacts 122 in the housing 130. In an exemplary embodiment, the TPA device 150 is used to hold the contacts 122 in the housing 130. For example, the TPA device 150 is used as a secondary fixing device for the contacts 122 in the housing 130.

[0072] In an exemplary embodiment, the TPA device 150 includes a receptacle 152 at a front end that is configured to receive a second connector assembly 200. For example, a front end of the second connector assembly 200 may be inserted into the receptacle 152. In an exemplary embodiment, the TPA device 150 includes a funnel 154 at a front end of the receptacle 152 to guide the second connector assembly 200 into the receptacle 152. The funnel 154 has a large capture area to receive the second connector assembly 200 and accommodate misalignment of the second connector assembly 200 during mating.

[0073] In an exemplary embodiment, the second connector assembly 200 includes an electrical connector 210 and a support bracket 300 for supporting the electrical connector 210. In an exemplary embodiment, the electrical connector 210 can move relative to the support bracket 300 to compensate for misalignment of the electrical connector 210 relative to the electrical connector 110 during mating. For example, the electrical connector 210 has a limited amount of floating movement relative to the support bracket 300 to compensate for position and orientation offsets of the electrical connector 210 relative to the electrical connector 110. In an exemplary embodiment, the electrical connector 210 has six mechanical degrees of freedom relative to the support bracket 300. For example, the electrical connector 210 has axial float in the X, Y, and Z directions and rotational float in the yaw, pitch, and roll directions about a central pivot point relative to the support bracket 300. In an exemplary embodiment, the support bracket 300 allows a limited amount of floating axial movement of the electrical connector 210 in the X direction; the support bracket 300 allows a limited amount of floating axial movement of the electrical connector 210 in the Y direction; the support bracket 300 allows a limited amount of floating axial movement of the electrical connector 210 in the Z direction; the support bracket 300 allows a limited amount of floating rotational movement of the electrical connector 210 in the yaw direction; the support bracket 300 allows a limited amount of floating rotational movement of the electrical connector 210 in the pitch direction; and the support bracket 300 allows a limited amount of floating rotational movement of the electrical connector 210 in the roll direction.

[0074] The electrical connector 210 has a mating end 212 configured to mate with the second connector assembly 200 and a cable end 214 opposite the mating end 212. One or more cables 220 extend from the cable end 214. In the illustrated embodiment, the electrical connector 210 includes four cables 220; however, in alternative embodiments, the electrical connector 210 may include more or fewer cables 220. The cables 220 are representative and may be rigid or flexible signal or power transmission cables in various embodiments.

[0075] The electrical connector 210 includes a housing 230 and a terminal position assurance (TPA) device 250 coupled to the housing 230. The housing 230 holds one or more contacts 222 (eg, Figure 6). In various embodiments, the contacts 222 can be standard contacts, such as MATE-Ax, FAKRA, mini-FAKRA, GEMnet, or other types of contacts. The housing 230 is designed to receive a specific type of contact, such as by having a contact channel or latch feature with a specific shape to retain the contact. In various embodiments, the housing 230 can be designed to receive different types of contacts in different contact channels to provide a mating interface with different types and / or styles of contacts. The external features of the housing 230 can be the same for all contact types, however the geometry of the cavity can be changed to receive and retain the desired contact 222.

[0076] The TPA device 250 is operated to ensure proper positioning of the contact 222 in the housing 230. In an exemplary embodiment, the TPA device 250 is movable between a preset position and a set position relative to the housing 230. After the contact 222 is loaded in the housing 230, the TPA device 250 may be moved from the preset position to the set position. In various embodiments, if the contact 222 is not correctly loaded into the housing 230, the TPA device 250 cannot be moved to the set position, thereby ensuring proper positioning of the contact 222 in the housing 230. In an exemplary embodiment, the TPA device 250 is used to hold the contact 222 in the housing 230. For example, the TPA device 250 is used as an auxiliary fixing device for the contact 222 in the housing 230.

[0077] In an exemplary embodiment, the TPA device 250 includes a plug end 252 at the front that is configured to be inserted into the receptacle 152 of the first connector assembly 100. In an exemplary embodiment, the TPA device 250 includes a lead-in surface at the plug end 252 to guide the second connector assembly 200 into the receptacle 252. The lead-in surface tapers inwardly toward the tip or nose to provide a large capture area for insertion into the receptacle 152 and to accommodate misalignment of the second connector assembly 200 during mating.

[0078] Figure 3 1 is an exploded view of a first connector assembly 100 according to an exemplary embodiment. The first connector assembly 100 includes an electrical connector 110 having a plurality of cables 120; however, in an alternative embodiment, the electrical connector 110 may include a single cable 120. The first connector assembly 100 includes a housing 130 for holding contacts 122 and cables 120 and a TPA device 150 for ensuring that the contacts 122 are properly positioned in the housing 130.

[0079] The contact 122 is coupled to the end 124 of the cable 120. In various embodiments, the contact 122 can be crimped to the end 124 of the cable 120. However, in alternative embodiments, the contact 122 can be terminated to the cable 120 by other devices or processes. In the illustrated embodiment, the contact 122 is a slot contact having a slot 126 at the mating end of the contact 122. Other types of contacts can be used in alternative embodiments, such as pin contacts, blade contacts, tuning fork contacts, spring beam contacts, or other types of contacts. The contact 122 has a separable mating interface at the mating end of the contact 122. In an exemplary embodiment, the contact 122 includes a retaining feature 128 for retaining the contact 122 in the housing 130. In the illustrated embodiment, the retaining feature 128 includes a flange, groove, or recess along the contact 122. The retaining feature 128 can extend circumferentially around the contact 122. The retaining feature 128 can be defined at the rear end of the contact 122. The retention feature 128 has a stop surface or shoulder that is configured to be engaged by the housing 130 to retain the contact 122 in the housing 130 .

[0080] The housing 130 includes a body 132 extending between a front portion 134 and a rear portion 136. The housing 130 includes one or more contact channels 138 extending through the body 132. The contact channels 138 receive corresponding contacts 122. In the illustrated embodiment, the housing 130 includes four contact channels 138. However, in alternative embodiments, the housing 130 may include more or fewer contact channels 138 corresponding to the number of contacts 122 used in the electrical connector 110. In some alternative embodiments, the housing 130 may include a single contact channel 138.

[0081] In an exemplary embodiment, the housing 130 includes a retention latch 140 that serves as a primary securing device for securing the contact 122 in the housing 130. In the illustrated embodiment, the retention latch 140 is disposed at the front 134. However, in alternative embodiments, the retention latch 140 may be located at other locations, such as within the housing 130 along an inner portion of the contact channel 138. The retention latch 140 is a deflectable latch. Each retention latch 140 is configured to engage with a retention feature 128 of a corresponding contact 122 to retain the contact 122 in the housing 130. For example, when the contact 122 is fully loaded into the housing 130, the retention latch 140 may snap into a groove defining the retention feature 128. In various embodiments, the contact 122 may be loaded into the contact channel 138 from the rear and pushed forward to the front 134 of the housing 130. In various embodiments, the mating ends of the contacts 122 may be located forward of the front 134 of the housing 130 for mating with the second connector assembly 200 .

[0082] In an exemplary embodiment, the housing 130 includes a housing latch 142 on the exterior of the housing 130. The housing latch 142 is used to secure the housing 130 to the TPA device 150. The housing latch 142 can be disposed along one or more sides of the housing 130. In various embodiments, the housing latch 142 is deflectable. In an alternative embodiment, the housing latch 142 is a fixed latch.

[0083] The TPA device 150 extends between a front portion 156 and a rear portion 158. In an exemplary embodiment, the TPA device 150 includes a shroud 160 surrounding a cavity 162. The cavity 162 receives the housing 130. In an exemplary embodiment, the cavity 162 opens at the rear portion 158 to receive the housing 130. The shroud 160 includes one or more latch features 164 for latchably coupling the TPA device 150 to the housing 130. In the illustrated embodiment, the latch features 164 include openings 166 along the shroud 160. The openings 166 are longitudinally offset from each other. The openings 166 are configured to receive the housing latches 142 of the housing 130. A plurality of openings 166 are provided to allow the TPA device 150 to be decoupled from the housing 130 at different positions. For example, the housing latch 142 is initially received in the rearward opening 166 to position the TPA device 150 in an initial or preset position. The housing latch 142 is received in the front opening 166 to position the TPA device 150 in a normal or set position. After the contacts 122 are loaded into the housing 130, the TPA device 150 can be moved to the set position. In an exemplary embodiment, the TPA device 150 is used to block or hold the retention latch 140 in the set position to prevent the retention latch 140 from deflecting when the TPA device 150 is in the set position. In this way, the TPA device 150 operates as a secondary latch or securing feature for securing the contacts 122 in the housing 130. However, when the TPA device 150 is in the preset position, the retention latch 140 is free to deflect to allow the contacts 122 to be loaded into the housing 130.

[0084] In an exemplary embodiment, the TPA device 150 includes a flange 170 at the front 156. Optionally, the flange 170 can be mounted to a component of the vehicle. For example, the flange 170 can include mounting features, such as openings, latches, clips, or other types of mounting features for mounting the electrical connector 110 to a component of the vehicle. In an alternative embodiment, the flange 170 can be held by a robot or assembler during mating, rather than being mounted to a component fixed to the vehicle. The flange 170 provides a holding or pressing surface for mating the first connector assembly 100 with the second connector assembly 200. The flange 170 surrounds the funnel 154 of the receptacle 152. The funnel 154 opens at the front 156 to receive the second connector assembly 200.

[0085] Figure 4is a front perspective view of a first connector assembly 100 according to an exemplary embodiment. Figure 5 1 is a cross-sectional view of the first connector assembly 100 according to an exemplary embodiment. When assembled, the housing 130 is received in the cavity 162 of the TPA device 150. The shroud 160 surrounds the housing 130. The housing 130 positions the contacts 122 to mate with the second connector assembly 200. When assembled, the contacts 122 and the cables 120 are received in corresponding contact channels 138. The retention latch 140 secures the contacts 122 in the housing 130. In an exemplary embodiment, the mating ends of the contacts 122 extend forward of the housing 130. In an exemplary embodiment, the mating ends of the contacts 122 are located in the contact channels 168 of the TPA device 150. The slots 126 are configured to receive corresponding pins of the contacts 222 of the second connector assembly 200.

[0086] In an exemplary embodiment, the receptacle 152 opens at a front 156 of the TPA device 150 to receive the second connector assembly 200. The funnel 154 is used to guide the second connector assembly 200 into the receptacle 152. In an exemplary embodiment, the funnel 154 tapers inwardly. The funnel 154 includes a lead-in surface 172 that extends from the flange 170 to a base wall 174 at the bottom or rear of the receptacle 152. The contact channel 168 opens through the base wall 174. The slots 126 of the contacts 122 are positioned in the base wall 174. The base wall 174 defines a stop wall to stop loading the second connector assembly 200 into the receptacle 152. The base wall 174 is used to position the second connector assembly 200 to mate with the contacts 122. The lead-in surface 172 guides the second connector assembly 200 to the base wall 174. In an exemplary embodiment, lead-in surfaces 172 provide lead-ins on the top, bottom, and sides of the funnel 154 to accommodate misalignment of the second connector assembly 200 from any direction into the receptacle 152. In an exemplary embodiment, the second connector assembly 200 has a shape complementary to the funnel 154 to ultimately align the second connector assembly 200 with the first connector assembly 100 within the receptacle 152 (e.g., axially and angularly).

[0087] Figure 6 2 is an exploded view of a second connector assembly 200 according to an exemplary embodiment. The second connector assembly 200 includes an electrical connector 210 having a plurality of cables 220; however, in an alternative embodiment, the electrical connector 210 may include a single cable 220. The second connector assembly 200 includes a housing 230 for holding contacts 222 and the cables 220 and a TPA device 250 for ensuring that the contacts 222 are properly positioned in the housing 230.

[0088] The contact 222 is coupled to the end 224 of the cable 220. In various embodiments, the contact 222 can be crimped to the end 224 of the cable 220. However, in alternative embodiments, the contact 222 can be terminated to the cable 220 by other devices or processes. In the illustrated embodiment, the contact 222 is a pin contact having a pin 226 at the mating end of the contact 222. Other types of contacts can be used in alternative embodiments, such as slot contacts, blade contacts, tuning fork contacts, spring beam contacts, or other types of contacts. The contact 222 has a separable mating interface at the mating end of the contact 222. In an exemplary embodiment, the contact 222 includes a retaining feature 228 for retaining the contact 222 in the housing 230. In the illustrated embodiment, the retaining feature 228 includes a flange, groove, or recess along the contact 222. The retaining feature 228 can extend circumferentially around the contact 222. The retaining feature 228 can be defined at the rear end of the contact 222. The retention feature 228 has a stop surface or shoulder that is configured to be engaged by the housing 230 to retain the contact 222 in the housing 230 .

[0089] The housing 230 includes a body 232 extending between a front portion 234 and a rear portion 236. The housing 230 includes one or more contact channels 238 extending through the body 232. The contact channels 238 receive corresponding contacts 222. In the illustrated embodiment, the housing 230 includes four contact channels 238. However, in alternative embodiments, the housing 230 may include more or fewer contact channels 238 corresponding to the number of contacts 222 used in the electrical connector 210. In some alternative embodiments, the housing 230 may include a single contact channel 238. The housing 230 may include a separate tube that forms part of the contact channel 238, for example at the rear portion 236.

[0090] In an exemplary embodiment, the housing 230 includes a contact retention latch 240, which is used as a primary fixing device for fixing the contact 222 in the housing 230. In the illustrated embodiment, the contact retention latch 240 is disposed at the front 234. However, in alternative embodiments, the contact retention latch 240 may be located at other locations, such as along the inner portion of the contact channel 238, inside the housing 230. The contact retention latch 240 is a deflectable latch. Each contact retention latch 240 is configured to engage with the retention feature 228 of the corresponding contact 222 to retain the contact 222 in the housing 230. For example, when the contact 222 is fully loaded into the housing 230, the contact retention latch 240 may snap into a groove defining the retention feature 228. In various embodiments, the contact 222 may be loaded into the contact channel 238 from the rear and pushed forward to the front 234 of the housing 230. In various embodiments, the mating ends of the contacts 222 may be located forward of the front portion 234 of the housing 230 for mating with the first connector assembly 100 .

[0091] In an exemplary embodiment, the housing 230 includes a housing latch 242 on the exterior of the housing 230. The housing latch 242 is used to secure the housing 230 to the support bracket 300. In an alternative embodiment, the housing latch 242 can be used to secure the housing 230 to the TPA device 250. The housing latch 242 can be disposed along one or more sides of the housing 230. In various embodiments, the housing latch 242 is deflectable. In an alternative embodiment, the housing latch 242 is a fixed latch.

[0092] The TPA device 250 extends between a front portion 256 and a rear portion 258. In an exemplary embodiment, the TPA device 250 includes a shield 260 surrounding a cavity 262. The cavity 262 receives the housing 230. In an exemplary embodiment, the cavity 262 opens at the rear portion 258 to receive the housing 230. The shield 260 may include an opening 261, such as at a side, configured to receive a portion of the support bracket 300. The shield 260 includes one or more latch features 264 for latchably coupling the TPA device 250 to the support bracket 300. In an alternative embodiment, the latch feature 264 may be latchably coupled to the housing 230. In the illustrated embodiment, the latch feature 264 includes a deflectable latch disposed along an end of the TPA device 250. In alternative embodiments, other locations are also possible. Other types of latch features, such as openings to receive latches, may be used in alternative embodiments. In an exemplary embodiment, the latch feature 264 is configured to be coupled to the support bracket 300 at different positions to allow the TPA device 250 to be positioned in an initial or preset position and a normal or set position. The TPA device 250 can move axially between the preset position and the set position, for example parallel to the mating axis. In an exemplary embodiment, the TPA device 250 is used to block or retain the contact retention latch 240 in the set position to prevent the contact retention latch 240 from deflecting when the TPA device 250 is in the set position. In this way, the TPA device 250 operates as a secondary latch or fixing feature for fixing the contact 222 in the housing 230. However, when the TPA device 250 is in the preset position, the contact retention latch 240 is free to deflect to allow the contact 222 to be loaded into the housing 230.

[0093] In an exemplary embodiment, the TPA device 250 includes a nose cone 270 at the front 256. In an exemplary embodiment, the nose cone 270 tapers inwardly. The nose cone 270 includes a guide surface 272 extending from an end wall 274 at the front 256 of the TPA device 250 to the shroud 260. The contact channel 268 opens through the end wall 274. The end wall 274 defines a stop wall to stop the loading of the second connector assembly 200 into the receptacle 152 of the first connector assembly 100. The end wall 274 is used to position the second connector assembly 200 to mate with the contacts 222 in the receptacle 152. The guide surface 272 guides the second connector assembly 200 into the funnel 154. In an exemplary embodiment, the guide surface 272 provides a lead-in at the top, bottom, and sides of the nose cone 270 to accommodate misalignment of the second connector assembly 200 into the receptacle 152 from any direction. In an exemplary embodiment, the nose cone 270 of the second connector assembly 200 has a shape that is complementary to the funnel portion 154 to ultimately align (eg, axially and angularly align) the second connector assembly 200 with the first connector assembly 100 within the receptacle 152 .

[0094] The support bracket 300 is used to support the electrical connector 210. In an exemplary embodiment, the electrical connector 210 has six mechanical degrees of freedom relative to the support bracket 300. For example, the electrical connector 210 has axial float in the X, Y, and Z directions and rotational float in the yaw, pitch, and roll directions about the central pivot point relative to the support bracket 300. In an exemplary embodiment, the support bracket 300 allows a limited amount of floating axial movement of the electrical connector 210 in the X direction; the support bracket 300 allows a limited amount of floating axial movement of the electrical connector 210 in the Y direction; the support bracket 300 allows a limited amount of floating axial movement of the electrical connector 210 in the Z direction; the support bracket 300 allows a limited amount of floating rotational movement of the electrical connector 210 in the yaw direction; the support bracket 300 allows a limited amount of floating rotational movement of the electrical connector 210 in the pitch direction; and the support bracket 300 allows a limited amount of floating rotational movement of the electrical connector 210 in the roll direction.

[0095] In an exemplary embodiment, the support bracket 300 includes a connector mount 302, a pivot frame 304, an X bracket 306, and a Y bracket 308. The connector mount 302 holds the electrical connector 210, such as the housing 230 of the electrical connector 210. The pivot frame 304 holds the connector mount 302. The X bracket 306 holds the pivot frame 304. The Y bracket 308 holds the X bracket 306. In alternative embodiments, other arrangements are possible, such as the Y bracket 308 holding the pivot frame 304 and / or the X bracket 306 holding the Y bracket 308. In an exemplary embodiment, the housing 230 of the electrical connector 210 is axially movable relative to the connector mount 302 in the Z direction parallel to the mating axis. The pivot frame 304 is axially movable relative to the X bracket 306 in the X direction. The X bracket 306 is axially movable relative to the Y bracket in the Y direction. The interaction between the housing 230, the connector mount 302, the pivot frame 304, the X bracket 306, and the Y bracket 308 compensates for misalignment of the second connector assembly 200 with the first connector assembly 100 due to positional and physical variations to accommodate X, Y, and Z mating tolerances. In an exemplary embodiment, the connector mount 302 is rotatably movable in the yaw, pitch, and roll directions relative to the pivot frame 304 to compensate for angular tolerances in the XY, YZ, and YZ planes.

[0096] The connector mount 302 includes a shell 310 having a cavity 312 configured to receive the housing 230. The shell 310 extends between a front portion 314 and a rear portion 316. The cavity 312 can be open at the front portion 314 to receive the housing 230. In an exemplary embodiment, the shell 310 includes a retaining latch 318 located on the exterior of the shell 310. The retaining latch 318 is used to secure the TPA device 250 to the shell 310. Optionally, the shell 310 may include a plurality of retaining latches 318 axially offset from each other to allow the TPA device 250 to be positioned in different positions, such as a preset position and a set position. The shell 310 may include one or more retaining features (not shown) within the cavity 312, which are used to secure the housing 230 in the cavity 312. For example, the retaining feature may be a latch configured to be latchably coupled to the housing 230.

[0097] In an exemplary embodiment, the connector mount 302 includes a pivot element 320 that is configured to be pivotally coupled to the pivot frame 304. In the illustrated embodiment, the pivot element 320 includes a hemispherical protrusion 322 on the exterior of the shell 310. Alternatively, the connector mount 302 may include a pair of pivot elements 320 on opposite sides of the shell 310. The pivot elements 320 are sized and shaped to allow the connector mount 302 to rotate relative to the pivot frame 304. In an exemplary embodiment, the pivot element 320 includes a control slot 324 in the hemispherical protrusion 322. The control slot 324 is used to control the amount of angular rotation of the connector mount 302 relative to the pivot frame 304. For example, the control slot 324 may have an hourglass shape to allow the pivot element 320 to rotate within the pivot joint of the pivot frame 304. In alternative embodiments, the control slot 324 may have other shapes.

[0098] In an exemplary embodiment, the biasing element 330 is configured to be positioned between the connector mount 302 and the housing 230. The biasing element 330 can be received in the cavity 312. In an exemplary embodiment, the biasing element 330 is a coil spring. However, other types of biasing elements can be used in alternative embodiments. The biasing element 330 is compressible and is configured to apply a spring force on the connector mount 302 and / or the housing 230. For example, the biasing element 330 is configured to bias the housing 230 forward relative to the shell 310 of the connector mount 302. The biasing element 330 maintains the housing 230 in a forward biased position to mate with the first connector assembly 100. The biasing element 330 can be compressed by the housing 230 during mating with the first connector assembly 100. The biasing element 330 allows the housing 230 to move in the Z direction relative to the connector mount 302 of the support bracket 300, which is parallel to the mating axis.

[0099] In an exemplary embodiment, the pivot frame 304 is a multi-piece frame having a first frame member 340 and a second frame member 342 that are configured to fit together to form the pivot frame 304. The frame members 340, 342 extend along opposite sides of the connector mount 302. The pivot frame 304 includes an opening 344 between the frame members 340, 342. Alternatively, the frame members 340, 342 may be identical or mirrored halves of one another.

[0100] In the exemplary embodiment, the pivot frame 304 includes a slot 346 in the frame members 340, 342. The slot 346 is configured to receive a mounting portion of the X-bracket 306 for mounting the X-bracket 306 to the pivot frame 304. In alternative embodiments, other types of mounting features may be used. In the exemplary embodiment, the slot 346 is elongated to allow the X-bracket 306 to move axially relative to the pivot frame 304.

[0101] The pivot frame 304 includes a pivot element 350 that receives the pivot element 320 of the connector mount 302. The pivot elements 350 are disposed on opposite sides of the opening 344. For example, each of the frame members 340, 342 includes a corresponding pivot element 350. In an exemplary embodiment, each pivot element 350 is a hemispherical socket 352 that is configured to receive a corresponding hemispherical protrusion 322 of the connector mount 302. The hemispherical protrusion 322 can rotate within the hemispherical socket 352 to allow rotational movement of the connector mount 302 and, therefore, the electrical connector 210 relative to the pivot frame 304. In an exemplary embodiment, the pivot element 350 includes a control rib 354 that extends into the hemispherical socket 352. The control rib 354 is configured to be received in a corresponding control socket 324 of the hemispherical protrusion 322. As the connector mount 302 pivots or rotates relative to the pivot frame 304, the control rib 354 is able to move in the control slot 324. The interaction between the control rib 354 and the hemispherical protrusion 322 controls the amount of floating movement of the connector mount 302 relative to the pivot frame 304. For example, the control rib 354 is configured to bottom out or abut the hemispherical protrusion 322 to limit or control the amount of angular movement of the connector mount 302 relative to the pivot frame 304. In an exemplary embodiment, the pivot member 320 is able to rotate relative to the pivot member 350 in multiple directions, such as a yaw direction, a pitch direction, and a roll direction.

[0102] In an exemplary embodiment, the X-bracket 306 is configured to be coupled to the pivot frame 304. However, in an alternative embodiment, the Y-bracket 308 can be coupled to the pivot frame 304. The X-bracket 306 includes a panel 360 having an opening 362 configured to receive the electrical connector 210. The opening 362 can be centered in the panel 360. The opening 362 can be oversized relative to the electrical connector 210 to allow the electrical connector 210 to move relative to the X-bracket 306, for example, the electrical connector 210 can rotate and / or translate relative to the X-bracket 306 in the opening 362.

[0103] In an exemplary embodiment, the X bracket 306 includes a flange 364 extending from the panel 360, such as a rear portion of the panel 360. The flange 364 is configured to be coupled to the pivot frame 304. For example, the flange 364 is received in a slot 346 in the pivot frame 304. The flange 364 can be clamped or latched to the pivot frame 304 to retain the pivot frame 304 on the panel 360. In an exemplary embodiment, the slot 346 is oversized relative to the flange 364 to allow axial movement of the flange 364 in the slot 346, such as in the X direction. In this way, the pivot frame 304 is configured to move relative to the X bracket 306 in the X direction.

[0104] In the exemplary embodiment, the X-carriage 306 includes a slot 366 in the panel 360. The slot 366 is configured to receive a mounting portion of the Y-carriage 308 for mounting the Y-carriage 308 to the X-carriage 306. In alternative embodiments, other types of mounting features may be used. In the exemplary embodiment, the slot 366 is elongated to allow the Y-carriage 308 to move axially relative to the X-carriage 306. In the exemplary embodiment, the slot 366 is oriented in a direction perpendicular to the slot 346.

[0105] In an exemplary embodiment, the Y-bracket 308 is configured to be coupled to the X-bracket 306. However, in an alternative embodiment, the Y-bracket 308 can be coupled to the pivot frame 304. The Y-bracket 308 includes a panel 370 having an opening 372 configured to receive the electrical connector 210. The opening 372 can be centered in the panel 370. The opening 372 can be oversized relative to the electrical connector 210 to allow the electrical connector 210 to move relative to the Y-bracket 308, for example, the electrical connector 210 can rotate and / or translate in the opening 372 relative to the Y-bracket 308.

[0106] In an exemplary embodiment, the Y-bracket 308 includes a flange 374 extending from the panel 370 (such as a rear portion of the panel 370). The flange 374 is configured to be coupled to the X-bracket 306. For example, the flange 374 is received in the slot 366 in the X-bracket 306. The flange 374 can be clamped or latched to the X-bracket 306 to retain the X-bracket 306 on the panel 370. In an exemplary embodiment, the slot 366 is oversized relative to the flange 374 to allow axial movement of the flange 374 in the slot 366, such as in the Y direction. In this way, the Y-bracket 308 is configured to move relative to the X-bracket 306 in the Y direction.

[0107] Figure 7 A partially assembled view of a portion of the second connector assembly 200 showing the electrical connector 210 coupled to the connector mount 302 and showing the pivot frame 304 ready to be mounted to the connector mount 302. During assembly, the housing 230 of the electrical connector 210 is received in the cavity 312 of the shell 310 of the connector mount 302.

[0108] In an exemplary embodiment, the TPA device 250 is configured to be coupled to the shell 310. For example, the latch feature 264 is configured to be coupled to the retention latch 318 of the connector mount 302. The retention latch 318 holds the TPA device 250 at one or more predetermined positions. For example, a plurality of retention latches 318 may be provided at different axial positions to hold the TPA device 250 at different axial positions relative to the shell 310. The TPA device 250 may be initially held in a preset position, wherein the TPA device 250 is only partially or initially coupled to the housing 230. The contacts 222 and the cable 220 are configured to be loaded into the housing 230 when the TPA device 250 is in the preset position. For example, the TPA device 250 does not block the retention latch of the housing 230, which allows the contacts 222 to be loaded into the housing 230 and engage the retention latch. After loading the contacts 222 into the housing 230, the TPA device 250 may be moved to the set position by pressing the TPA device 250 rearwardly relative to the housing 230 and / or the connector mount 302. In the set position, the latch feature 264 engages the rearward retention latch 318 to retain the TPA device 250 in the set position.

[0109] During assembly, the pivot frame 304 is coupled to the connector mount 302. For example, the pivot element 350 is aligned with the pivot element 320. The frame members 340, 342 are coupled together around the connector mount 302. During assembly, the control rib 354 is received in the control slot 324. The hemispherical protrusion 322 is received in the hemispherical socket 352. When assembled, the connector mount 302, and therefore the electrical connector 210, can be rotated relative to the pivot frame 304 in one or more rotational directions, such as all three angular degrees of freedom.

[0110] Figure 8 is a cross-sectional view of a second connector assembly 200 according to an exemplary embodiment. Fig. 9 is a cross-sectional view of a second connector assembly 200 according to an exemplary embodiment. When assembled, the electrical connector 210 is coupled to the support bracket 300. The second connector assembly 200 is equipped with features that allow the electrical connector 210 to move with six mechanical degrees of freedom relative to the support bracket 300. For example, the electrical connector 210 has axial float in the X, Y, and Z directions and rotational float about a central pivot point in the yaw, pitch, and roll directions.

[0111] During assembly, the housing 230 of the electrical connector 210 is received in the cavity 312 of the shell 310 of the connector mount 302. The biasing element 330 is coupled between the housing 230 and the connector mount 302. For example, the front end of the biasing element 330 engages the rear portion 236 of the housing 230, and the rear end of the biasing element 330 engages the end wall 315 at the rear portion 316 of the shell 310. In an exemplary embodiment, the end wall 315 includes a cable channel 317 therethrough, which receives a corresponding cable 220. Optionally, a portion of the housing 230 can be received in the cable channel 317.

[0112] In an exemplary embodiment, a retaining latch 280 is disposed between the housing 230 and the shell member 310, and the retaining latch 280 retains the housing 230 in an extended position relative to the shell member 310. In the illustrated embodiment, the extended position is a forward position. When the retaining latch 280 is engaged, the housing 230 cannot move backward into the cavity 312. In the illustrated embodiment, the retaining latch 280 is a part of the housing 230 and is configured to engage or seat on a part of the shell member 310. However, in an alternative embodiment, the retaining latch 280 can be a part of the shell member 310 and is configured to dock with the housing 230 to retain the housing 230 in the extended position. The retaining latch 280 is releasable to allow the housing 230 to move into the cavity 312 in the Z direction, which is parallel to the mating direction. In an exemplary embodiment, the retaining latch 280 is movable between a latched position and an unlocked position. When in the latched position, the retaining latch 280 supports the housing 230 in the extended position. When the latch 280 is retained in the unlocked position, the housing 230 is movable from the extended position to the released position.

[0113] In an exemplary embodiment, the TPA device 250 includes a release element 282 configured to engage with the retention latch 280 to release the retention latch 280 and allow the housing 230 to move axially relative to the connector mount 302. For example, when the TPA device 250 moves backward, the release element 282 engages the retention latch 280 and presses the retention latch 280 inward to release the retention latch 280 from the support wall of the shell 310. When the TPA device 250 is in the rearward position, the release element 282 engages the retention latch 280 and holds it in the released position. In an exemplary embodiment, when the electrical connector 210 is mated with the first connector assembly 100, the electrical connector 210 can be pushed backward and the housing 230 can move backward in the cavity 312 against the spring bias of the biasing element 330. The biasing element 330 biases the housing 230 and the contact 222 forward to maintain a reliable electrical connection with the first connector assembly 100.

[0114] In an exemplary embodiment, the TPA device 250 is coupled to the housing 310. For example, the latch feature 264 is coupled to the retaining latch 318 of the connector mount 302. The TPA device 250 may initially be retained in a preset position ( Figure 8 and Fig. 9 ), wherein the TPA device 250 is only partially or initially coupled to the housing 230. The TPA device 250 can be moved rearwardly to a set position by pressing the TPA device 250 rearwardly relative to the housing 230 and / or the connector mount 302. In the set position, the mating ends of the contacts 222 can be located forward of the plug ends 252 of the TPA device 250 to mate with the contacts of the first connector assembly 100.

[0115] During assembly, the pivot frame 304 is coupled to the connector mount 302, the X bracket 306 is coupled to the pivot frame 304, and the Y bracket 308 is coupled to the X bracket 306. The pivot element 320 is coupled to the pivot element 350. The pivot element 320 can rotate within the pivot element 350. In an exemplary embodiment, the control rib 354 controls the amount of angular movement of the hemispherical protrusion 322 in the hemispherical socket 352. In addition, the edges or end portions of the pivot elements 320, 350 can bottom out against each other to limit the amount of rotational movement of the connector mount 302 relative to the pivot frame 304, thereby limiting the amount of rotational movement of the electrical connector 210 relative to the pivot frame 304. In various embodiments, the pivot frame 304 can allow ±5° of angular movement. However, in alternative embodiments, the pivot frame 304 can be designed to allow greater or lesser angular movement.

[0116] When assembled, flange 364 of X bracket 306 is coupled to pivot frame 304. Flange 364 is movable in slot 346 to allow pivot frame 304 (and thus connector mount 302 and electrical connector 210) to move in the X direction. Similarly, flange 374 of Y bracket 308 is coupled to X bracket 306. Flange 374 is movable in slot 366 to allow X bracket 306 (and thus pivot frame 304 and connector mount 302 and electrical connector 210) to move in the Y direction.

[0117] Figures 10 to 13 A mating sequence of the first connector assembly 100 and the second connector assembly 200 according to an exemplary embodiment is shown. Fig.10 The connector assemblies 100, 200 are shown ready to mate. Fig.11 The connector assemblies 100 , 200 are shown partially mated. Fig.12 The connector assemblies 100 , 200 are shown further mated. Fig.13 The fully mated connector assemblies 100 , 200 are shown.

[0118] In an exemplary embodiment, the connector assemblies 100, 200 are designed for blind mating. For example, the connector assemblies 100, 200 include self-aligning features having a tolerance range that allows the mating interfaces of the connector assemblies 100, 200 to self-align during mating. In various embodiments, the connector assemblies 100, 200 can be mated through an automated mating process using a robot or machine to mate the connector assemblies 100, 200.

[0119] In an exemplary embodiment, the second connector assembly 200 is equipped with features that allow it to move or float during mating to align with the first connector assembly 100 during the mating process. For example, the second connector assembly 200 can float in one or more axial directions to align with the first connector assembly 100. The second connector assembly 200 can float in one or more angular directions to align with the first connector assembly 100. In an exemplary embodiment, the second connector assembly 200 is equipped with features that allow it to move with six mechanical degrees of freedom relative to the first connector assembly 100. For example, the second connector assembly 200 has axial floats in the X, Y, and Z directions and rotational floats around a central pivot point in yaw, pitch, and roll directions. The connector assemblies 100, 200 are able to compensate for some misalignments in almost all orientations due to physical position changes (e.g., tolerances). For example, the connector assemblies 100, 200 accommodate X, Y, and Z tolerances and three angular tolerances in the XY, XZ, and YZ planes to accommodate blind mating. The float of the connector in all axial and angular degrees of freedom ensures that the terminated cables of the connector assemblies 100, 200 can be successfully mated without sacrificing signal integrity. For example, the second connector assembly 200 is equipped with features that allow axial and rotational float so that misalignment of the modules does not adversely affect the ability of the connector halves to mate and subsequently does not adversely affect the ability of the terminated cables to align and transmit high-quality RF signals. The second connector assembly 200 can be equipped with features that load or bias the contacts forward in the mating direction in order to remove interface gaps between the contacts and mating contacts that may degrade the RF performance of the system.

[0120] During mating, the mating end 212 of the electrical connector 210 is generally aligned with the mating end 112 of the electrical connector 110 ( Fig.10). The nose cone 270 is generally aligned with the funnel 154. The funnel 154 has an enlarged area to receive the nose cone 270. For example, the size of the opening to the funnel 154 is larger than the end of the nose cone 270 to gather the nose cone 270 and guide the nose cone 270 into the funnel 154. Any axial or angular misalignment can be accommodated by the support bracket 300. For example, the electrical connector 210 can move in any direction of the X direction, the Y direction, or the Z direction, and / or the electrical connector 210 can move in any direction of the yaw direction, the pitch direction, or the roll direction to properly align the electrical connectors 210, 110 during the mating sequence. For example, the pivot frame 304 can accommodate rotation of the electrical connector 210 in any rotational direction. The connector mount 302, the X bracket 306, and the Y bracket 308 can accommodate translation of the electrical connector 210 in any axial direction. The guide surface 272 of the nose cone 270 engages the lead-in surface 172 to guide the nose cone 270 into proper alignment within the receptacle 152. The connector assemblies 100, 200 mate along the mating axis until the end wall 274 abuts against the base wall 174 ( Fig.11 ) bottoming out. The guide surface 272 and the lead-in surface 172 serve to self-align the second connector assembly 200 in the proper axial or translational orientation (X / Y / Z) relative to the first connector assembly 100. After bottoming out, the second connector assembly 200 can self-align in the proper rotational orientation (yaw / pitch / roll) relative to the first connector assembly 100 by ensuring that the planar end wall 274 and the planar base wall 174 are parallel to and against each other.

[0121] During initial engagement, the TPA device 250 is in a preset or forward position ( Fig.11 ). The TPA device 250 covers the contact 222 to prevent damage to the contact 222 during mating. After the end wall 274 bottoms out against the base wall 174, further mating of the connector assemblies 100, 200 causes the TPA device 250 to move rearward to the second position ( Fig.12 ). The latch feature 264 of the TPA device 250 moves from the forward retention latch 318 to the rearward retention latch 318. The end wall 274 moves toward the housing 230. Optionally, in the set position, the end wall 274 abuts against the front 234 of the housing 230. When the TPA device 250 moves to the set position, the mating end of the contact 222 protrudes forward from the end wall 274 and is received in the electrical connector 110 and mates with the contact 122. For example, the contact 222 is a pin contact, and the contact 122 is a socket contact, wherein the pin contact is received in the socket contact to make an electrical connection between the first connector assembly 100 and the second connector assembly 200.

[0122] In an exemplary embodiment, the second connector assembly 200 can accommodate further mating (eg, over-mating) in the mating direction. For example, when the first connector assembly 100 and the second connector assembly 200 are initially mated ( Fig.12 ), a gap 284 may exist between the flange 170 and the support bracket 300. Further engagement may close the gap until the flange 170 abuts against the support bracket 300 ( Fig.13 ) bottoms out. The electrical connector 210 can move in the Z direction to accommodate the mating end closure of the gap 284. For example, the TPA device 250 can slide backward along the connector mount 302. The housing 230 can move backward in the cavity 312 and compress the biasing element 330. The biasing element 330 is compressed, and the biasing element 330 applies a large spring force against the housing 230 in the forward direction, which presses the contact 222 forward into the contact 122 to maintain a reliable electrical connection and RF signal between the contacts 222, 122.

[0123] Fig.14 is corresponding to Fig.12 sectional view of the connector assemblies 100, 200 in a partially mated state. Fig.15 is corresponding to Fig.13 2 is a cross-sectional view of the connector assembly 100, 200 in a fully mated state. When assembled, the contact 222 and the cable 220 are loaded into the contact channel 238 of the housing 230. The contact retention latch 240 engages the retention feature 228 of the contact 222 to retain the contact 222 in the housing 230. The contact retention latch 240 defines a primary retention feature for the contact 222. Fig.14 The TPA device 250 is shown in a preset position. Fig.15 250 is shown in a set position. Fig.14 ), the contact retention latch 240 can be deflected outwardly to load the contact 222 into the housing 230. For example, the contact retention latch 240 is located in a recess 276 in the TPA device 250, which provides a space that allows the contact retention latch 240 to move or deflect (e.g., deflect outwardly). However, when the TPA device 250 moves back to the set position ( Fig.15 ), the blocking piece 278 of the TPA device 250 is located outside the contact retention latch 240. The blocking piece 278 engages the contact retention latch 240 and prevents the contact retention latch 240 from deflecting outward. In this way, the contact retention latch 240 cannot release the contact 222. The blocking piece 278 serves as a secondary retention feature to prevent the removal of the contact 222 by blocking the contact retention latch 240.

[0124] Fig.16 is corresponding to Fig.12sectional view of the connector assemblies 100, 200 in a partially mated state. Fig.17 is corresponding to Fig.13 sectional view of the connector assemblies 100, 200 in a fully mated state. Fig.16 and 17 A retention latch 280 is shown between the housing 230 and the shell 310, which holds the housing 230 in an extended position relative to the shell 310. When the retention latch 280 is engaged, the housing 230 cannot move back into the cavity 312. In the illustrated embodiment, the retention latch 280 is part of the housing 230 and is configured to engage or seat on a portion of the shell 310.

[0125] The retention latch 280 is releasable to allow the housing 230 to move into the cavity 312 in a Z-direction, which is parallel to the mating direction. Fig.16 and Fig.17 The movement of the electrical connector 210 relative to the support bracket 300 in the Z direction is shown. For example, Fig.16 The electrical connector 210 is shown in a forward position relative to the support bracket 300, and Fig.17 The electrical connector 210 is shown in a rearward position relative to the support bracket 300. In an exemplary embodiment, the release element 282 of the TPA device 250 is configured to engage the retention latch 280 to release the retention latch 280 and allow the housing 230 to move axially relative to the connector mount 302. For example, when the TPA device 250 moves rearward to the set position, the release element 282 engages the retention latch 280 and presses the retention latch 280 inward to release the retention latch 280 from the support wall of the housing 310. When the TPA device 250 is in the rearward position, the release element 282 engages the retention latch 280 and holds the retention latch 280 in the released position. In an exemplary embodiment, when the retention latch 280 is released, the electrical connector 210 can be pushed rearward when the electrical connector 210 is mated with the first connector assembly 100, and the housing 230 can move rearward in the cavity 312 against the spring bias of the biasing element 330.

[0126] Fig.18 and Fig.19 The axial movement of the electrical connector 210 relative to the support bracket 300 in the X direction is shown. For example, Fig.18 The electrical connector 210 is shown displaced to the right relative to the support bracket 300, and Fig.19 The electrical connector 210 is shown displaced to the left relative to the support bracket 300. The X bracket 306 accommodates movement of the electrical connector 210 in the X direction. For example, the flange 364 is configured to move axially within the slot 346 of the pivot frame 304 to allow movement in the X direction.

[0127] Fig. 20 and Fig.21 The axial movement of the electrical connector 210 relative to the support bracket 300 in the Y direction is shown. For example, Fig. 20 The electrical connector 210 is shown displaced upward relative to the support bracket 300, and Fig.21 The electrical connector 210 is shown displaced downward relative to the support bracket 300. The Y bracket 308 accommodates movement of the electrical connector 210 in the Y direction. For example, the flange 374 is configured to move axially within the slot 366 of the X bracket 306 to allow movement in the Y direction.

[0128] Figure 22-24 Rotation of the electrical connector 210 relative to the support bracket 300 at the pivot point is shown. Fig. 22 Rotation of the electrical connector 210 relative to the support bracket 300 in the yaw direction is shown. Fig.23 The rotation of the electrical connector 210 relative to the support bracket 300 in the pitch direction is shown. Fig.24 Rotation of the electrical connector 210 in a rolling direction relative to the support bracket 300 is shown. The pivot frame 304 accommodates movement of the electrical connector 210 in an angular direction. For example, the hemispherical protrusion 322 can pivot or rotate in the hemispherical slot 352. The connector mount 302 can bottom out against the pivot frame 304 to limit the amount of rotation (e.g., angle) (e.g., nose up or down, nose side to side, or body rotation). For example, the control ribs 354 can limit the amount of rotation (see, e.g., Fig.23 When engaging the pivot frame 304, the sides or walls of the connector mount 302 may limit the amount of rotation (see e.g. Fig. 22 and Fig.24 ).

[0129] Fig.25 is a front perspective view of an electrical connector system 10 according to an exemplary embodiment. Fig.26 is a rear perspective view of the electrical connector system 10 according to an exemplary embodiment. Fig.25 and Fig.26 A single position (eg, single contact and single cable) version of the connector assembly 100, 200 is shown, rather than Figure 1 and Figure 2 The four-position version shown in .

[0130] In an exemplary embodiment, the connector assemblies 100, 200 are designed for blind mating. For example, the connector assemblies 100, 200 include self-aligning features having a tolerance range that allows the mating interfaces of the connector assemblies 100, 200 to self-align during mating. In various embodiments, the connector assemblies 100, 200 can be mated through an automated mating process using a robot or machine to mate the connector assemblies 100, 200.

[0131] In an exemplary embodiment, the second connector assembly 200 is equipped with features that allow it to move or float during mating to align with the first connector assembly 100 during the mating process. For example, the second connector assembly 200 can float in one or more axial directions to align with the first connector assembly 100. The second connector assembly 200 can float in one or more angular directions to align with the first connector assembly 100. In an exemplary embodiment, the second connector assembly 200 is equipped with features that allow it to move with six mechanical degrees of freedom relative to the first connector assembly 100. For example, the second connector assembly 200 has axial floats in the X, Y, and Z directions and rotational floats around a central pivot point in yaw, pitch, and roll directions. The connector assemblies 100, 200 are able to compensate for some misalignments in almost all orientations due to physical position changes (e.g., tolerances). For example, the connector assemblies 100, 200 accommodate X, Y, and Z tolerances and three angular tolerances in the XY, XZ, and YZ planes to accommodate blind mating. When the axial and angular alignments between the two components are within the specified tolerance area, the successful mating of the connector assemblies 100, 200 is achieved. The float of the connector in all axial and angular degrees of freedom ensures that the terminated cables of the connector assemblies 100, 200 can be successfully mated without sacrificing signal integrity. For example, the second connector assembly 200 is equipped with features that allow axial and rotational float so that misalignment of the modules does not adversely affect the ability of the connector halves to mate, and subsequently does not adversely affect the ability of the terminated cables to align and transmit high-quality RF signals. In an exemplary embodiment, all floating (e.g., self-aligning) features are integrated into the second connector assembly 200 to simplify the design and reduce manufacturing costs. For example, the first connector assembly 100 can be made with a simple, low-cost design, which reduces the cost of the entire system.

[0132] In an exemplary embodiment, the first connector assembly 100 includes an electrical connector 110 having a mating end 112 configured to mate with the second connector assembly 200 and a cable end 114 opposite the mating end 112. A cable 120 extends from the cable end 114.

[0133] The electrical connector 110 includes a housing 130 and a terminal position assurance (TPA) device 150 coupled to the housing 130. Compared with the four-position application ( Figure 1-2 ), the shapes of the TPA device 150 and the housing 130 are designed differently for one position application. In addition, the TPA device 150 and the housing 130 may have different shapes for other variations, such as two position applications, etc. The housing 130 holds the contacts 122 (such as Fig. 27 130). The TPA device 150 is operated to ensure proper positioning of the contact 122 in the housing 130. In an exemplary embodiment, the TPA device 150 is movable between a preset position and a set position relative to the housing 130. After the contact 122 is loaded in the housing 130, the TPA device 150 may be moved from the preset position to the set position. In various embodiments, if the contact 122 is not correctly loaded into the housing 130, the TPA device 150 cannot be moved to the set position, thereby ensuring proper positioning of the contact 122 in the housing 130. In an exemplary embodiment, the TPA device 150 is used to hold the contact 122 in the housing 130. For example, the TPA device 150 is used as a secondary fixing device for the contact 122 in the housing 130.

[0134] In an exemplary embodiment, the TPA device 150 includes a receptacle 152 at a front end that is configured to receive a second connector assembly 200. For example, a front end of the second connector assembly 200 may be inserted into the receptacle 152. In an exemplary embodiment, the TPA device 150 includes a funnel 154 at a front end of the receptacle 152 to guide the second connector assembly 200 into the receptacle 152. The funnel 154 has a large capture area to receive the second connector assembly 200 and accommodate misalignment of the second connector assembly 200 during mating.

[0135] In an exemplary embodiment, the second connector assembly 200 includes an electrical connector 210 and a support bracket 300 for supporting the electrical connector 210. In an exemplary embodiment, the electrical connector 210 can move relative to the support bracket 300 to compensate for misalignment of the electrical connector 210 relative to the electrical connector 110 during mating. For example, the electrical connector 210 has a limited amount of floating movement relative to the support bracket 300 to compensate for position and orientation offsets of the electrical connector 210 relative to the electrical connector 110. In an exemplary embodiment, the electrical connector 210 has six mechanical degrees of freedom relative to the support bracket 300. For example, the electrical connector 210 has axial float in the X, Y, and Z directions and rotational float in the yaw, pitch, and roll directions about a central pivot point relative to the support bracket 300. In an exemplary embodiment, the support bracket 300 allows a limited amount of floating axial movement of the electrical connector 210 in the X direction; the support bracket 300 allows a limited amount of floating axial movement of the electrical connector 210 in the Y direction; the support bracket 300 allows a limited amount of floating axial movement of the electrical connector 210 in the Z direction; the support bracket 300 allows a limited amount of floating rotational movement of the electrical connector 210 in the yaw direction; the support bracket 300 allows a limited amount of floating rotational movement of the electrical connector 210 in the pitch direction; and the support bracket 300 allows a limited amount of floating rotational movement of the electrical connector 210 in the roll direction.

[0136] The electrical connector 210 has a mating end 212 configured to mate with the second connector assembly 200 and a cable end 214 opposite to the mating end 212. A cable 220 extends from the cable end 214.

[0137] The electrical connector 210 includes a housing 230 and a terminal position assurance (TPA) device 250 coupled to the housing 230. The housing 230 holds a single contact 222 disposed at an end of the cable 220. The TPA device 250 is operated to ensure proper positioning of the contact 222 in the housing 230. In an exemplary embodiment, the TPA device 250 is movable between a preset position and a set position relative to the housing 230. After the contact 222 is loaded in the housing 230, the TPA device 250 is movable from the preset position to the set position. In various embodiments, if the contact 222 is not correctly loaded into the housing 230, the TPA device 250 cannot be moved to the set position, thereby ensuring proper positioning of the contact 222 in the housing 230. In an exemplary embodiment, the TPA device 250 is used to hold the contact 222 in the housing 230. For example, the TPA device 250 is used as a secondary fixing device for the contact 222 in the housing 230.

[0138] In an exemplary embodiment, the TPA device 250 includes a plug end 252 at the front that is configured to be inserted into the receptacle 152 of the first connector assembly 100. In an exemplary embodiment, the TPA device 250 includes a guide surface at the plug end 252 to guide the second connector assembly 200 into the receptacle 152. The guide surface tapers inwardly toward the tip or nose to provide a large capture area for insertion into the receptacle 152 and to accommodate misalignment of the second connector assembly 200 during mating.

[0139] Fig. 27 1 is an exploded view of a first connector assembly 100 according to an exemplary embodiment. The first connector assembly 100 includes an electrical connector 110 having a cable 120 and a contact 122. The first connector assembly 100 includes a housing 130 for holding the contact 122 and the cable 120 and a TPA device 150 for ensuring that the contact 122 is correctly positioned in the housing 130.

[0140] The housing 130 includes a body 132 extending between a front portion 134 and a rear portion 136. The housing 130 includes a contact channel 138 extending through the body 132. The contact channel 138 receives the contact 122. In an exemplary embodiment, the housing 130 includes a retention latch 140 that serves as a primary securing device for securing the contact 122 in the housing 130. Each retention latch 140 is configured to engage with a retention feature 128 of a corresponding contact 122 to retain the contact 122 in the housing 130. In an exemplary embodiment, the housing 130 includes a housing latch 142 on the exterior of the housing 130. The housing latch 142 is used to secure the housing 130 to the TPA device 150.

[0141] The TPA device 150 extends between a front portion 156 and a rear portion 158. In an exemplary embodiment, the TPA device 150 includes a shroud 160 surrounding a cavity 162. The cavity 162 receives the housing 130. In an exemplary embodiment, the cavity 162 opens at the rear portion 158 to receive the housing 130. The shroud 160 includes one or more latch features 164 for latchably coupling the TPA device 150 to the housing 130. In the illustrated embodiment, the latch features 164 include openings 166 that are longitudinally offset from one another along the shroud 160 to receive the housing latches 142 of the housing 130 at different positions. For example, the housing latches 142 are initially received in the rearward openings 166 to position the TPA device 150 in an initial or preset position. The housing latches 142 are received in the front openings 166 to position the TPA device 150 in a normal or set position. After the contacts 122 are loaded into the housing 130 , the TPA device 150 may be moved to the set position to block or hold the retention latch 140 in the set position.

[0142] In an exemplary embodiment, the TPA device 150 includes a flange 170 at the front 156. Optionally, the flange 170 can be mounted to a component of the vehicle. The flange 170 provides a retaining or pressing surface for mating the first connector assembly 100 with the second connector assembly 200. The flange 170 surrounds the funnel 154 of the receptacle 152. The funnel 154 is open at the front 156 to receive the second connector assembly 200.

[0143] In an exemplary embodiment, the first connector assembly 100 includes a cable seal 190 configured to seal between the housing 130 and the cable 120. The cable seal 190 can be received in the contact channel 138 to engage and seal against the housing 130. In an exemplary embodiment, the first connector assembly 100 includes a housing seal 192 configured to seal between the housing 130 and the TPA device 150. The housing seal 192 can be received in the cavity 162 to engage and seal against the TPA device 150. In an exemplary embodiment, the first connector assembly 100 includes an interface seal 194 configured to seal an interface between the first connector assembly 100 and the second connector assembly 200. The interface seal 194 can be received in the receptacle 152 to engage and seal against the second connector assembly 200 when the second connector assembly 200 is inserted into the receptacle 152.

[0144] Fig.28 is a front perspective view of a first connector assembly 100 according to an exemplary embodiment. Fig.29 1 is a cross-sectional view of the first connector assembly 100 according to an exemplary embodiment. When assembled, the housing 130 is received in the cavity 162 of the TPA device 150. The shroud 160 surrounds the housing 130. The housing 130 positions the contacts 122 to mate with the second connector assembly 200. When assembled, the contacts 122 and the cable 120 are received in the contact channels 138. The retention latch 140 secures the contacts 122 in the housing 130. In an exemplary embodiment, the mating ends of the contacts 122 extend into the contact channels 168 of the TPA device 150 in front of the housing 130.

[0145] In an exemplary embodiment, the receptacle 152 opens at the front 156 of the TPA device 150 to receive the second connector assembly 200. The funnel 154 is used to guide the second connector assembly 200 into the receptacle 152. In an exemplary embodiment, the funnel 154 tapers inwardly. The funnel 154 includes a lead-in surface 172 that extends from the flange 170 to a base wall 174 at the bottom or rear of the receptacle 152. The contact channel 168 opens through the base wall 174. The base wall 174 defines a stop wall to stop loading the second connector assembly 200 into the receptacle 152. The base wall 174 is used to position the second connector assembly 200 to mate with the contact 122. The lead-in surface 172 guides the second connector assembly 200 to the base wall 174. In an exemplary embodiment, the lead-in surface 172 provides lead-in at the top, bottom, and sides of the funnel 154 to accommodate misalignment of the second connector assembly 200 into the receptacle 152 from any direction. In an exemplary embodiment, the second connector assembly 200 has a shape that is complementary to the funnel portion 154 to ultimately align (eg, axially and angularly align) the second connector assembly 200 with the first connector assembly 100 within the receptacle 152 .

[0146] The cable seal 190 is shown in the contact channel 138 to engage and seal against the cable 120 and the housing 130. The housing seal 192 is shown in the cavity 162 to engage and seal against the housing 130 and the TPA device 150. The interface seal 194 is shown sealed to the TPA device 150 in the receptacle 152 and is configured to engage and seal against the second connector assembly 200 when the second connector assembly 200 is inserted into the receptacle 152.

[0147] Fig.30 2 is an exploded view of a second connector assembly 200 according to an exemplary embodiment. The second connector assembly 200 includes an electrical connector 210 having a cable 220 and a contact 222 terminated to an end of the cable 220. The second connector assembly 200 includes a housing 230 for holding the contact 222 and the cable 220 and a TPA device 250 for ensuring that the contact 222 is correctly positioned in the housing 230.

[0148] The housing 230 includes a body 232 extending between a front portion 234 and a rear portion 236. The housing 230 includes a contact channel 238 extending through the body 232 to receive the contact 222. In an exemplary embodiment, the housing 230 includes a contact retention latch 240, which is used as a primary fixing device for fixing the contact 222 in the housing 230. Each contact retention latch 240 is configured to engage with a retention feature 228 of the contact 222 to hold the contact 222 in the housing 230. In an exemplary embodiment, the housing 230 includes a housing latch 242 for fixing the housing 230 to the support bracket 300 and / or the TPA device 250.

[0149] The TPA device 250 extends between a front portion 256 and a rear portion 258. In an exemplary embodiment, the TPA device 250 includes a shield 260 surrounding a cavity 262 that receives the housing 230. In an exemplary embodiment, the cavity 262 opens at the rear portion 258 to receive the housing 230. The shield 260 includes one or more latch features 264 for latchably coupling the TPA device 250 to the support bracket 300. In an exemplary embodiment, the latch features 264 are configured to couple to the support bracket 300 at different positions to allow the TPA device 250 to be positioned in an initial or preset position and a normal or set position. The TPA device 250 can move axially between the preset position and the set position, for example, parallel to the mating axis. In an exemplary embodiment, the TPA device 250 is used to block or retain the contact retention latch 240 in the set position to prevent the contact retention latch 240 from deflecting when the TPA device 250 is in the set position.

[0150] In an exemplary embodiment, the TPA device 250 includes a nose cone 270 at the front 256. In an exemplary embodiment, the nose cone 270 tapers inwardly. The nose cone 270 includes a guide surface 272 extending from an end wall 274 at the front 256 of the TPA device 250 to the shroud 260. The contact channel 268 opens through the end wall 274. The end wall 274 defines a stop wall to stop the loading of the second connector assembly 200 into the receptacle 152 of the first connector assembly 100. In an exemplary embodiment, the guide surface 272 provides a lead-in at the top, bottom, and sides of the nose cone 270 to accommodate misalignment of the second connector assembly 200 into the first connector assembly 100 from any direction. In an exemplary embodiment, the nose cone 270 of the second connector assembly 200 has a shape complementary to the funnel portion 154 of the first connector assembly 100 to align the second connector assembly 200 with the first connector assembly 100 within the receptacle 152 (e.g., axial and angular alignment).

[0151] The support bracket 300 is used to support the electrical connector 210. In an exemplary embodiment, the electrical connector 210 has six mechanical degrees of freedom relative to the support bracket 300. For example, the electrical connector 210 has axial float in the X, Y, and Z directions and rotational float in the yaw, pitch, and roll directions about the central pivot point relative to the support bracket 300. In an exemplary embodiment, the support bracket 300 allows a limited amount of floating axial movement of the electrical connector 210 in the X direction; the support bracket 300 allows a limited amount of floating axial movement of the electrical connector 210 in the Y direction; the support bracket 300 allows a limited amount of floating axial movement of the electrical connector 210 in the Z direction; the support bracket 300 allows a limited amount of floating rotational movement of the electrical connector 210 in the yaw direction; the support bracket 300 allows a limited amount of floating rotational movement of the electrical connector 210 in the pitch direction; and the support bracket 300 allows a limited amount of floating rotational movement of the electrical connector 210 in the roll direction.

[0152] In an exemplary embodiment, the support bracket 300 includes a connector mount 302, a pivot frame 304, an X bracket 306, and a Y bracket 308. The connector mount 302 holds the electrical connector 210, such as the housing 230 of the electrical connector 210. The pivot frame 304 holds the connector mount 302. The X bracket 306 holds the pivot frame 304. The Y bracket 308 holds the X bracket 306. In alternative embodiments, other arrangements are possible, such as the Y bracket 308 holding the pivot frame 304 and / or the X bracket 306 holding the Y bracket 308. In an exemplary embodiment, the housing 230 of the electrical connector 210 is axially movable relative to the connector mount 302 in the Z direction parallel to the mating axis. The pivot frame 304 is axially movable relative to the X bracket 306 in the X direction. The X bracket 306 is axially movable relative to the Y bracket in the Y direction. The interaction between the housing 230, the connector mount 302, the pivot frame 304, the X bracket 306, and the Y bracket 308 compensates for misalignment of the second connector assembly 200 with the first connector assembly 100 due to positional and physical variations to accommodate X, Y, and Z mating tolerances. In an exemplary embodiment, the connector mount 302 is rotatably movable in the yaw, pitch, and roll directions relative to the pivot frame 304 to compensate for angular tolerances in the XY, YZ, and YZ planes.

[0153] The connector mount 302 includes a shell 310 having a cavity 312 configured to receive the housing 230. The shell 310 extends between a front portion 314 and a rear portion 316. The cavity 312 can be open at the front portion 314 to receive the housing 230. In an exemplary embodiment, the shell 310 includes a retention latch 318 for securing the TPA device 250 to the shell 310. Optionally, the shell 310 can include a plurality of retention latches 318 that are axially offset from each other to allow the TPA device 250 to be positioned in different positions, such as a preset position and a set position.

[0154] In an exemplary embodiment, the connector mount 302 includes a pivot element 320 that is configured to be pivotally coupled to the pivot frame 304. In the illustrated embodiment, the pivot element 320 includes a hemispherical protrusion 322 on the exterior of the shell 310. Alternatively, the connector mount 302 may include a pair of pivot elements 320 on opposite sides of the shell 310. The pivot elements 320 are sized and shaped to allow the connector mount 302 to rotate relative to the pivot frame 304. In an exemplary embodiment, the pivot element 320 includes a control slot 324 in the hemispherical protrusion 322. The control slot 324 is used to control the amount of angular rotation of the connector mount 302 relative to the pivot frame 304. For example, the control slot 324 may have an hourglass shape to allow the pivot element 320 to rotate within the pivot joint of the pivot frame 304. In alternative embodiments, the control slot 324 may have other shapes.

[0155] In an exemplary embodiment, one or more biasing elements 330 are configured to be positioned between the connector mount 302 and the housing 230. The biasing element 330 can be received in the cavity 312. The biasing element 330 is compressible to apply a spring force on the connector mount 302 and / or the housing 230. For example, the biasing element 330 is configured to bias the housing 230 forward relative to the shell 310 of the connector mount 302. The biasing element 330 maintains the housing 230 in a forward biased position for mating with the first connector assembly 100. The biasing element 330 can be compressed by the housing 230 during mating with the first connector assembly 100. The biasing element 330 allows the housing 230 to move in a Z direction relative to the connector mount 302 of the support bracket 300, which is parallel to the mating axis.

[0156] In an exemplary embodiment, the pivot frame 304 is a multi-piece frame having a first frame member 340 and a second frame member 342 that are configured to fit together to form the pivot frame 304. The frame members 340, 342 extend along opposite sides of the connector mount 302. The pivot frame 304 includes an opening 344 between the frame members 340, 342. Alternatively, the frame members 340, 342 may be identical or mirrored halves of one another.

[0157] In the exemplary embodiment, the pivot frame 304 includes a slot 346 in the frame members 340, 342. The slot 346 is configured to receive a mounting portion of the X-bracket 306 for mounting the X-bracket 306 to the pivot frame 304. In alternative embodiments, other types of mounting features may be used. In the exemplary embodiment, the slot 346 is elongated to allow the X-bracket 306 to move axially relative to the pivot frame 304.

[0158] The pivot frame 304 includes a pivot element 350 that receives the pivot element 320 of the connector mount 302. The pivot elements 350 are disposed on opposite sides of the opening 344. For example, each of the frame members 340, 342 includes a corresponding pivot element 350. In an exemplary embodiment, each pivot element 350 is a hemispherical socket 352 that is configured to receive a corresponding hemispherical protrusion 322 of the connector mount 302. The hemispherical protrusion 322 can rotate within the hemispherical socket 352 to allow rotational movement of the connector mount 302 and, therefore, the electrical connector 210 relative to the pivot frame 304. In an exemplary embodiment, the pivot element 350 includes a control rib 354 that extends into the hemispherical socket 352. The control rib 354 is configured to be received in a corresponding control socket 324 of the hemispherical protrusion 322. As the connector mount 302 pivots or rotates relative to the pivot frame 304, the control rib 354 is able to move in the control slot 324. The interaction between the control rib 354 and the hemispherical protrusion 322 controls the amount of floating movement of the connector mount 302 relative to the pivot frame 304. For example, the control rib 354 is configured to bottom out or abut the hemispherical protrusion 322 to limit or control the amount of angular movement of the connector mount 302 relative to the pivot frame 304. In an exemplary embodiment, the pivot member 320 is able to rotate relative to the pivot member 350 in multiple directions, such as a yaw direction, a pitch direction, and a roll direction.

[0159] In an exemplary embodiment, the X-bracket 306 is configured to be coupled to the pivot frame 304. However, in an alternative embodiment, the Y-bracket 308 can be coupled to the pivot frame 304. The X-bracket 306 includes a panel 360 having an opening 362 configured to receive the electrical connector 210. The opening 362 can be centered in the panel 360. The opening 362 can be oversized relative to the electrical connector 210 to allow the electrical connector 210 to move relative to the X-bracket 306, for example, the electrical connector 210 can rotate and / or translate relative to the X-bracket 306 in the opening 362.

[0160] In an exemplary embodiment, X bracket 306 includes a flange 364 extending from panel 360, such as a rear portion of panel 360. Flange 364 is configured to couple to pivot frame 304. For example, flange 364 is received in slot 346 in pivot frame 304. Flange 364 can be clamped or latched to pivot frame 304 to retain pivot frame 304 on panel 360. In an exemplary embodiment, slot 346 is oversized relative to flange 364 to allow axial movement of flange 364 in slot 346, such as in the X direction. In this way, pivot frame 304 is configured to move relative to X bracket 306 in the X direction.

[0161] In the exemplary embodiment, the X-carriage 306 includes a slot 366 in the panel 360. The slot 366 is configured to receive a mounting portion of the Y-carriage 308 for mounting the Y-carriage 308 to the X-carriage 306. In alternative embodiments, other types of mounting features may be used. In the exemplary embodiment, the slot 366 is elongated to allow the Y-carriage 308 to move axially relative to the X-carriage 306. In the exemplary embodiment, the slot 366 is oriented in a direction perpendicular to the slot 346.

[0162] In an exemplary embodiment, the Y-bracket 308 is configured to be coupled to the X-bracket 306. However, in an alternative embodiment, the Y-bracket 308 can be coupled to the pivot frame 304. The Y-bracket 308 includes a panel 370 having an opening 372 configured to receive the electrical connector 210. The opening 372 can be centered in the panel 370. The opening 372 can be oversized relative to the electrical connector 210 to allow the electrical connector 210 to move relative to the Y-bracket 308, for example, the electrical connector 210 can rotate and / or translate in the opening 372 relative to the Y-bracket 308.

[0163] In an exemplary embodiment, the Y-bracket 308 includes a flange 374 extending from the panel 370, such as a rear portion of the panel 370. The flange 374 is configured to couple to the X-bracket 306. For example, the flange 374 is received in a slot 366 in the X-bracket 306. The flange 374 can be clamped or latched to the X-bracket 306 to retain the X-bracket 306 on the panel 370. In an exemplary embodiment, the slot 366 is oversized relative to the flange 374 to allow axial movement of the flange 374 in the slot 366, such as in the Y direction. In this way, the Y-bracket 308 is configured to move relative to the X-bracket 306 in the Y direction.

[0164] In an exemplary embodiment, the second connector assembly 200 includes a cable seal 290 configured to seal between the housing 230 and the cable 220. The cable seal 290 can be received in the contact channel 238 to engage the housing 230 and seal against the housing 130. In an exemplary embodiment, the second connector assembly 200 includes a housing seal 292 configured to seal between the housing 230 and the TPA device 250. The housing seal 292 can be received in the cavity 262 to engage the TPA device 250 and seal against the TPA device 150.

[0165] Fig.31 is a front perspective view of housing 230 according to an exemplary embodiment, showing housing 230 in an open position to receive cable seal 290 . Fig.32 is a front perspective view of housing 230 showing housing 230 in a closed position according to an exemplary embodiment. Fig.33 is a rear perspective view of housing 230 according to an exemplary embodiment, showing housing 230 in a closed position.

[0166] In an exemplary embodiment, the housing 230 includes one or more clamping doors 244 at the rear 236. The clamping door(s) 244 are configured to open and close. The clamping door(s) 244 are movable between an open position and a closed position. The clamping door(s) 244 are opened to receive the cable seal 290, the contact 222, and the cable 220. The clamping door(s) 244 are closed to clamp onto the cable 220 and hold the cable 220 and the contact 222 in the housing 230. In various embodiments, when the clamping door 244 is fully opened, the cable seal can be loaded into the housing 230. When the clamping door 244 is fully opened or partially opened, the contact 222 and the cable 220 can be loaded into the housing 230. For example, before the clamping door 244 is fully closed, a gap is defined between the clamping doors 244 to receive the contact 222 and the cable 220. Once the contacts 22 and cable 220 are installed, the clamping door 244 can be fully closed to retain the cable 220 in the housing 230. In various embodiments, the housing 230 can include a single clamping door on one side and a fixed cable support on the opposite side, wherein the cable 220 is clamped between the fixed cable support and the clamping door 244. In an alternative embodiment, the housing 230 includes a pair of clamping doors 244 arranged on opposite sides of the housing 230, and the clamping doors 244 are closed together around the cable 220 to clamp the cable 220 in the housing 230. The clamping door 244 can be opened to facilitate assembly and then forced closed by a tapered wedge to "bite into" the cable 220, thereby providing additional retention and fixation for the cable 220.

[0167] In an exemplary embodiment, each of the clamping doors 244 includes a cable channel 245 that receives the cable 220. The cable channel 245 may have a radius of curvature that matches the curvature of the cable 220. In an exemplary embodiment, the clamping doors 244 are connected to the body 232 of the housing 230 by a living hinge 246 that is integrally formed with the body 232 and the clamping doors 244.

[0168] In an exemplary embodiment, the clamping door 244 is configured to be pressed or clamped closed around the cable 220 by the TPA device 250. For example, when the housing 230 is loaded into the TPA device 250, the clamping door 244 can automatically close when the clamping door 244 engages the rear of the TPA device 250. Alternatively, when the TPA device 250 moves, for example, rearwardly, the TPA device 250 can slide along the clamping door 244 to clamp or press the clamping door 244 inwardly to clamp the clamping door 244 to the cable 220.

[0169] In an exemplary embodiment, the housing 230 includes a connection element 248 at a side of the body 232 of the housing 230. The connection element 248 may include a flange, a protrusion, a tab, a groove, an opening, a slot, or other types of connection elements. In an exemplary embodiment, the connection element 248 is used to stack the housing 230 with another identical housing to form a module or electrical connector 210 having a plurality of contacts 222 and a cable 220. For example, a connection element 248 at the left side of the housing can be mated with a complementary connection element on the right side of an adjacent housing, and vice versa.

[0170] Fig.34 2 is a cross-sectional view of a pair of housings 230 that are ready to be mated together to form a modular housing stack. The connecting elements 248 of adjacent housings 230 are configured to butt to stack the housings 230 in a stack. Any number of housings 230 may be stacked together depending on the number of contacts 222 desired in the electrical connector. In various embodiments, the housings 230 may hold different types of contacts 222 to form a modular mating interface.

[0171] Fig.35 is a front perspective view of a pair of housings 230 mated together, showing the clamping door 244 in an open position. Fig.36 2 is a front perspective view of a pair of housings 230 mated together, showing the clamping door 244 in a closed position. In an exemplary embodiment, the clamping door 244 includes connecting features 247, such as tabs, flanges, slots, grooves, etc., which abut against each other to allow the clamping doors 244 to be opened and closed together as a set.

[0172] Fig.37 is a cross-sectional view of a connector mount 302 according to an exemplary embodiment. Fig.38 is a cross-sectional view of the connector mount 302 , illustrating a portion of the housing 230 relative to the connector mount 302 . Fig.39 is a cross-sectional view of the connector mount 302 , illustrating a portion of the TPA device 250 relative to the connector mount 302 .

[0173] The connector mount 302 includes a shell 310 that forms a cavity 312 that receives the housing 230 and the shroud 260 of the TPA device 250. A retention latch 318 is disposed along the sidewall and extends into the cavity 312 to interface with the TPA device 250. In an exemplary embodiment, the connector mount 302 includes a retention latch 280 that extends from the end wall 315 into the cavity 312. The retention latch 280 is used to position the housing 230 within the cavity 312. When the retention latch 280 engages the housing 230, the retention latch 280 holds the housing 230 in an extended or forward position. The retention latch 280 is configured to be released from the housing 230 to allow the housing 230 to move in the Z direction, such as further back into the cavity 312. In an exemplary embodiment, the retention latch 280 is movable between a latched position and an unlocked position. When in the latched position, the retention latch 280 supports the housing 230 in the extended position. When the retention latch 280 is in the unlocked position, the housing 230 is movable from the extended position to the released position. In an exemplary embodiment, the shield 260 of the TPA device 250 is used to release the retention latch 280. For example, when the TPA device 250 is pressed rearwardly into the cavity 312, the rear end of the shield 260 engages the retention latch 280 and presses the retention latch 280 inwardly to release the retention latch 280 from the housing 230.

[0174] Fig.40 A partially assembled view of a portion of the second connector assembly 200 showing the electrical connector 210 coupled to the connector mount 302 and showing the pivot frame 304 ready to be mounted to the connector mount 302. During assembly, the housing 230 of the electrical connector 210 is received in the cavity 312 of the shell 310 of the connector mount 302.

[0175] In an exemplary embodiment, the TPA device 250 is configured to be coupled to the shell 310. For example, the latch feature 264 is configured to be coupled to the retention latch 318 of the connector mount 302. The retention latch 318 holds the TPA device 250 at one or more predetermined positions. For example, a plurality of retention latches 318 may be provided at different axial positions to hold the TPA device 250 at different axial positions relative to the shell 310. The TPA device 250 may be initially held in a preset position, wherein the TPA device 250 is only partially or initially coupled to the housing 230. The contacts 222 and the cable 220 are configured to be loaded into the housing 230 when the TPA device 250 is in the preset position. For example, the TPA device 250 does not block the retention latch of the housing 230, which allows the contacts 222 to be loaded into the housing 230 and engage the retention latch. After the contacts 222 are loaded into the housing 230, the TPA device 250 may be moved to the set position by pressing the TPA device 250 rearwardly relative to the housing 230 and / or the connector mount 302. In the set position, the latch feature 264 engages the rearward retention latch 318 to retain the TPA device 250 in the set position.

[0176] During assembly, the pivot frame 304 is coupled to the connector mount 302. For example, the pivot element 350 is aligned with the pivot element 320. The frame members 340, 342 are coupled together around the connector mount 302. During assembly, the control rib 354 is received in the control slot 324. The hemispherical protrusion 322 is received in the hemispherical socket 352. When assembled, the connector mount 302, and therefore the electrical connector 210, can be rotated relative to the pivot frame 304 in one or more rotational directions, such as all three angular degrees of freedom.

[0177] Fig.41 is a cross-sectional view of a second connector assembly 200 according to an exemplary embodiment. Fig.42 is a cross-sectional view of a second connector assembly 200 according to an exemplary embodiment. When assembled, the electrical connector 210 is coupled to the support bracket 300. The second connector assembly 200 is equipped with features that allow the electrical connector 210 to move with six mechanical degrees of freedom relative to the support bracket 300. For example, the electrical connector 210 has axial float in the X, Y, and Z directions and rotational float about a central pivot point in the yaw, pitch, and roll directions.

[0178] During assembly, the housing 230 of the electrical connector 210 is received in the cavity 312 of the shell 310 of the connector mount 302. The biasing element 330 is coupled between the housing 230 and the connector mount 302. For example, the front end of the biasing element 330 engages the rear portion 236 of the housing 230, and the rear end of the biasing element 330 engages the end wall 315 at the rear portion 316 of the shell 310. In an exemplary embodiment, the end wall 315 includes a cable channel 317 therethrough to receive the cable 220. Optionally, a portion of the housing 230 can be received in the cable channel 317.

[0179] In an exemplary embodiment, a retention latch 280 is disposed between the housing 230 and the shell 310, the retention latch 280 retaining the housing 230 in an extended position relative to the shell 310. In the illustrated embodiment, the extended position is a forward position. When the retention latch 280 is engaged, the housing 230 cannot move backward into the cavity 312. In the illustrated embodiment, the retention latch 280 is part of the shell 310 and is configured to engage or seat on a rear portion of the housing 230. However, in an alternative embodiment, the retention latch 280 can be part of the housing 230. The retention latch 280 is releasable to allow the housing 230 to move into the cavity 312 in a Z direction, which is parallel to the mating direction. In an exemplary embodiment, the TPA device 250 includes a release element configured to engage with the retention latch 280 to release the retention latch 280 and allow the housing 230 to move axially relative to the connector mount 302. For example, when the TPA device 250 moves backward, the release element engages the retention latch 280 and presses the retention latch 280 inward to release the retention latch 280 from the support wall of the shell 310. When the TPA device 250 is in the rearward position, the release element engages the retention latch 280 and holds the retention latch 280 in the released position. In an exemplary embodiment, when the electrical connector 210 is mated with the first connector assembly 100, the electrical connector 210 can be pushed backward and the housing 230 can move backward in the cavity 312 against the spring bias of the biasing element 330. The biasing element 330 biases the housing 230 and the contact 222 forward to maintain a reliable electrical connection with the first connector assembly 100.

[0180] In an exemplary embodiment, the TPA device 250 is coupled to the housing 310. For example, the latch feature 264 is coupled to the retaining latch 318 of the connector mount 302. The TPA device 250 may initially be retained in a preset position ( Fig.41 and Fig.42), wherein the TPA device 250 is only partially or initially coupled to the housing 230. The TPA device 250 can be moved rearwardly to a set position by pressing the TPA device 250 rearwardly relative to the housing 230 and / or the connector mount 302. In the set position, the mating ends of the contacts 222 can be located forward of the plug ends 252 of the TPA device 250 to mate with the contacts of the first connector assembly 100.

[0181] During assembly, the pivot frame 304 is coupled to the connector mount 302, the X bracket 306 is coupled to the pivot frame 304, and the Y bracket 308 is coupled to the X bracket 306. The pivot element 320 is coupled to the pivot element 350. The pivot element 320 can rotate within the pivot element 350. In an exemplary embodiment, the control rib 354 controls the amount of angular movement of the hemispherical protrusion 322 in the hemispherical socket 352. In addition, the edges or end portions of the pivot elements 320, 350 can bottom out against each other to limit the amount of rotational movement of the connector mount 302 relative to the pivot frame 304, thereby limiting the amount of rotational movement of the electrical connector 210 relative to the pivot frame 304. In various embodiments, the pivot frame 304 can allow ±5° of angular movement. However, in alternative embodiments, the pivot frame 304 can be designed to allow greater or lesser angular movement.

[0182] When assembled, flange 364 of X bracket 306 is coupled to pivot frame 304. Flange 364 is movable in slot 346 to allow pivot frame 304 (and thus connector mount 302 and electrical connector 210) to move in the X direction. Similarly, flange 374 of Y bracket 308 is coupled to X bracket 306. Flange 374 is movable in slot 366 to allow X bracket 306 (and thus pivot frame 304 and connector mount 302 and electrical connector 210) to move in the Y direction.

[0183] Figure 43 to Figure 46 A mating sequence of the first connector assembly 100 and the second connector assembly 200 according to an exemplary embodiment is shown. Fig.43 The connector assemblies 100, 200 are shown ready to mate. Fig.44 The connector assemblies 100 , 200 are shown partially mated. Fig.45 The connector assemblies 100 , 200 are shown further mated. Fig.46 The fully mated connector assemblies 100 , 200 are shown.

[0184] In an exemplary embodiment, the connector assemblies 100, 200 are designed for blind mating. For example, the connector assemblies 100, 200 include self-aligning features having a tolerance range that allows the mating interfaces of the connector assemblies 100, 200 to self-align during mating. In various embodiments, the connector assemblies 100, 200 can be mated through an automated mating process using a robot or machine to mate the connector assemblies 100, 200.

[0185] In an exemplary embodiment, the second connector assembly 200 is equipped with features that allow it to move or float during mating to align with the first connector assembly 100 during the mating process. For example, the second connector assembly 200 can float in one or more axial directions to align with the first connector assembly 100. The second connector assembly 200 can float in one or more angular directions to align with the first connector assembly 100. In an exemplary embodiment, the second connector assembly 200 is equipped with features that allow it to move with six mechanical degrees of freedom relative to the first connector assembly 100. For example, the second connector assembly 200 has axial floats in the X, Y, and Z directions and rotational floats around a central pivot point in the yaw, pitch, and roll directions. The connector assemblies 100, 200 are able to compensate for some misalignments in almost all orientations due to physical position changes (e.g., tolerances). For example, the connector assemblies 100, 200 accommodate X, Y, and Z tolerances and three angular tolerances in the XY, XZ, and YZ planes to accommodate blind mating. Connector float in all axial and angular degrees of freedom ensures that the terminated cables of the connector assemblies 100, 200 can be successfully mated without sacrificing signal integrity. For example, the second connector assembly 200 is equipped with features that allow for axial and rotational float so that misalignment of the modules does not adversely affect the ability of the connector halves to mate and subsequently the ability of the terminated cables to align and transmit high quality RF signals.

[0186] During mating, the mating end 212 of the electrical connector 210 is generally aligned with the mating end 112 of the electrical connector 110 ( Fig.43). The nose cone 270 is generally aligned with the funnel 154. The funnel 154 has an enlarged area to receive the nose cone 270. For example, the size of the opening to the funnel 154 is larger than the end of the nose cone 270 to gather the nose cone 270 and guide the nose cone 270 into the funnel 154. Any axial or angular misalignment can be accommodated by the support bracket 300. For example, the electrical connector 210 can move in any direction of the X direction, the Y direction, or the Z direction, and / or the electrical connector 210 can move in any direction of the yaw direction, the pitch direction, or the roll direction to properly align the electrical connectors 210, 110 during the mating sequence. For example, the pivot frame 304 can accommodate rotation of the electrical connector 210 in any rotational direction. The connector mount 302, the X bracket 306, and the Y bracket 308 can accommodate translation of the electrical connector 210 in any axial direction. The guide surface 272 of the nose cone 270 engages the lead-in surface 172 to guide the nose cone 270 into proper alignment within the receptacle 152. The connector assemblies 100, 200 mate along the mating axis until the end wall 274 abuts against the base wall 174 ( Fig.44 ) and / or the interface seal 194 at the base wall 174 bottoms out.

[0187] During initial engagement, the TPA device 250 is in a preset or forward position ( Fig.44 ). The TPA device 250 covers the contact 222 to prevent damage to the contact 222 during mating. After the end wall 274 bottoms out against the base wall 174, further mating of the connector assemblies 100, 200 causes the TPA device 250 to move rearward to the second position ( Fig.45 ). The latch feature 264 of the TPA device 250 moves from the forward retention latch 318 to the rearward retention latch 318. The end wall 274 moves toward the housing 230. Optionally, in the set position, the end wall 274 abuts against the front 234 of the housing 230. When the TPA device 250 moves to the set position, the mating end of the contact 222 protrudes forward from the end wall 274 and is received in the electrical connector 110 and mates with the contact 122. For example, the contact 222 is a pin contact, and the contact 122 is a socket contact, wherein the pin contact is received in the socket contact to make an electrical connection between the first connector assembly 100 and the second connector assembly 200.

[0188] In an exemplary embodiment, the second connector assembly 200 can accommodate further mating (eg, over-mating) in the mating direction. For example, when the first connector assembly 100 and the second connector assembly 200 are initially mated ( Fig.45 ), a gap 284 may exist between the flange 170 and the support bracket 300. Further engagement may close the gap until the flange 170 abuts against the support bracket 300 ( Fig.46) bottoms out. The electrical connector 210 can move in the Z direction to accommodate the closing of the gap 284. For example, the TPA device 250 can slide backward along the connector mount 302. The housing 230 can move backward in the cavity 312 and compress the biasing element 330. The biasing element 330 is compressed, and the biasing element 330 applies a large spring force against the housing 230 in the forward direction, which presses the contact 222 forward into the contact 122 to maintain a reliable electrical connection and RF signal between the contacts 222, 122.

[0189] Fig.47 is corresponding to Fig.45 sectional view of the connector assemblies 100, 200 in a partially mated state. Fig.48 is corresponding to Fig.46 312. The connector assembly 302 includes a retaining latch 280 extending from the end wall 315 into the cavity 312. The retaining latch 280 is used to position the housing 230 within the cavity 312. When the retaining latch 280 engages the housing 230, the retaining latch 280 holds the housing 230 in an extended or forward position. The retaining latch 280 is configured to be released from the housing 230 to allow the housing 230 to move in the Z direction, such as further back into the cavity 312. In an exemplary embodiment, the retaining latch 280 is movable between a latched position and an unlocked position. When in the latched position, the retaining latch 280 supports the housing 230 in an extended position. When the retaining latch 280 is in the unlocked position, the housing 230 is able to move from the extended position to the released position. In an exemplary embodiment, the shield 260 of the TPA device 250 includes a release element 282 for releasing the retaining latch 280. For example, when the TPA device 250 is pressed rearwardly into the cavity 312 , the release element 282 at the rear end of the shroud 260 engages the retention latch 280 and presses the retention latch 280 inwardly to release the retention latch 280 from the housing 230 .

[0190] Fig.49 is corresponding to Fig.45 sectional view of the connector assemblies 100, 200 in a partially mated state. Fig.50 is corresponding to Fig.46 sectional view of the connector assemblies 100, 200 in a fully mated state. Fig.49 and 50 A retention latch 280 is shown between the housing 230 and the shell 310, which holds the housing 230 in an extended position relative to the shell 310. When the retention latch 280 is engaged, the housing 230 cannot move back into the cavity 312. In the illustrated embodiment, the retention latch 280 is part of the shell 310 and is configured to engage or seat on a portion of the housing 230.

[0191] The retention latch 280 is releasable to allow the housing 230 to move into the cavity 312 in a Z-direction, which is parallel to the mating direction. Fig.49 and Fig.50 The movement of the electrical connector 210 relative to the support bracket 300 in the Z direction is shown. For example, Fig.49 The electrical connector 210 is shown in a forward position relative to the support bracket 300, and Fig.50 The electrical connector 210 is shown in a rearward position relative to the support bracket 300. In an exemplary embodiment, with the retention latch 280 released, when the electrical connector 210 is mated with the first connector assembly 100, the electrical connector 210 can be pushed rearward and the housing 230 can move rearward in the cavity 312 against the spring bias of the biasing element 330.

[0192] Fig.51 and Fig.52 The axial movement of the electrical connector 210 relative to the support bracket 300 in the X direction is shown. For example, Fig.51 The electrical connector 210 is shown displaced to the right relative to the support bracket 300, and Fig.52 The electrical connector 210 is shown displaced to the left relative to the support bracket 300. The X bracket 306 accommodates movement of the electrical connector 210 in the X direction. For example, the flange 364 is configured to move axially within the slot 346 of the pivot frame 304 to allow movement in the X direction.

[0193] Fig.53 and 54 The axial movement of the electrical connector 210 relative to the support bracket 300 in the Y direction is shown. For example, Fig.53 The electrical connector 210 is shown displaced upward relative to the support bracket 300, and Fig.54 The electrical connector 210 is shown displaced downward relative to the support bracket 300. The Y bracket 308 accommodates movement of the electrical connector 210 in the Y direction. For example, the flange 374 is configured to move axially within the slot 366 of the X bracket 306 to allow movement in the Y direction.

[0194] Figure 55 to Figure 57 Rotation of the electrical connector 210 relative to the support bracket 300 at the pivot point is shown. Fig.55 Rotation of the electrical connector 210 relative to the support bracket 300 in the yaw direction is shown. Fig.56 The rotation of the electrical connector 210 relative to the support bracket 300 in the pitch direction is shown. Fig.57Rotation of the electrical connector 210 in a rolling direction relative to the support bracket 300 is shown. The pivot frame 304 accommodates movement of the electrical connector 210 in an angular direction. For example, the hemispherical protrusion 322 can pivot or rotate in the hemispherical slot 352. The connector mount 302 can bottom out against the pivot frame 304 to limit the amount of rotation (e.g., angle) (e.g., nose up or down, nose side to side, or body rotation). For example, the control ribs 354 can limit the amount of rotation (see, e.g., Fig.56 When engaging the pivot frame 304, the sides or walls of the connector mount 302 may limit the amount of rotation (see e.g. Fig.55 and Fig.57 ).

Claims

1. A connector assembly (200), comprising: An electrical connector (210) comprising a housing (230) having a contact channel (238) and a contact (222) held in the contact channel, the contact being terminated to an end (214) of a cable, the cable (220) extending from the housing, the electrical connector comprising a terminal position assurance (TPA) device (250) coupled to the housing and operable to ensure that the contact is properly positioned in the contact channel (268), the electrical connector comprising a mating end (212); as well as a support bracket (300) configured to support the electrical connector, the support bracket including an opening (344), wherein the electrical connector is cantilevered from the support bracket and received in the opening, wherein the mating end is forward of the support bracket for mating with a mating electrical connector (110); Wherein, the electrical connector has six mechanical degrees of freedom relative to the supporting bracket.

2. The connector assembly (200) according to claim 1, wherein: The support bracket (300) allows a limited amount of floating axial movement in the X direction, the support bracket allows a limited amount of floating axial movement in the Y direction, the support bracket allows a limited amount of floating axial movement in the Z direction, the support bracket allows a limited amount of floating rotational movement in the yaw direction, the support bracket allows a limited amount of floating rotational movement in the pitch direction, and the support bracket allows a limited amount of floating rotational movement in the roll direction.

3. The connector assembly (200) according to claim 1, wherein: The support bracket (300) includes at least one pivot joint to allow rotational movement of the electrical connector (210) in at least one angular direction.

4. The connector assembly (200) according to claim 1, wherein: The housing (230) includes a primary latch (240) configured to be latchably connected to the contact (222) to retain the contact in the contact channel (238), the TPA device (250) being movable between a preset position and a set position, the primary latch being deflectable when the TPA is in the preset position, and the TPA device blocking the primary latch in the set position to block deflection of the primary latch.

5. The connector assembly (200) according to claim 1, wherein: The support bracket (300) includes a connector mount (302), a pivot frame (304), an X bracket (306) and a Y bracket (308), the connector mount retaining the electrical connector (210), the pivot frame including an opening (344), the opening (344) receiving the connector mount and the electrical connector, wherein the mating end (212) is forward of the pivot frame to mate with the mating electrical connector, the pivot frame retaining the connector mount, the X bracket retaining the pivot frame, and the Y bracket retaining the X bracket; wherein the housing (230) is capable of axial movement in a Z direction relative to the connector mounting member, the Z direction being parallel to a mating axis with the mating electrical connector; wherein the connector mount is rotatably movable relative to the pivot frame in a yaw direction, a pitch direction, and a roll direction, the yaw direction, the pitch direction, and the roll direction being mutually exclusive; wherein the pivot frame is capable of axial movement relative to the pivot frame in an X direction perpendicular to the Z direction; and The X bracket can move axially relative to the Y bracket in a Y direction perpendicular to the X direction and perpendicular to the Z direction.

6. The connector assembly (200) according to claim 5, wherein: The connector mounting member (302) includes a shell member (310) having a cavity (312), wherein the housing (230) is received in the cavity and is movable in the cavity in a direction parallel to a mating axis, wherein a biasing element (320) is connected between the shell member and the housing, and the biasing element is compressible along the mating axis to bias the housing forward toward the mating electrical connector (110).

7. The connector assembly (200) according to claim 6 further includes a retaining latch (318) between the shell member (310) and the housing (230) to maintain the housing and the shell member in an extended position, and the TPA device (250) releases the retaining latch to allow the housing and the shell member to move to a compressed position.

8. The connector assembly (200) according to claim 5, wherein: The connector mounting member (302) includes a pivot element (320), and the pivot frame (304) includes a pivot element (350), and the pivot element (350) of the pivot frame (304) is docked with the pivot element of the connector mounting member to control the rotational position of the electrical connector (210) relative to the support bracket (300) in at least one rotational degree of freedom.

9. The connector assembly (200) according to claim 8, wherein: The pivoting element (320) controls the rotational position of the electrical connector relative to the support bracket (300) in all three rotational degrees of freedom.

10. The connector assembly (200) according to claim 8, wherein: The pivot element (320) of the connector mount (302) includes a hemispherical protrusion (322), and the pivot element of the pivot frame (304) includes a hemispherical socket (352) that receives the hemispherical protrusion.

11. The connector assembly (200) according to claim 10, wherein: The pivot element (320) of the pivot frame (304) includes a control rib (354) extending into the hemispherical socket (352), and the pivot element of the connector mount (302) includes a control groove (324) in the hemispherical protrusion (322) for receiving the control rib, and the control rib is capable of moving in the control groove to a limited amount to control the angular movement of the connector mount relative to the pivot frame.

12. The connector assembly (200) according to claim 5, wherein: The X-bracket (306) includes a panel (360) having an opening (362) that receives the electrical connector (210) and a flange (364) extending from the panel, the flange being coupled to the pivot frame (304) that is movable in an axial direction relative to the X-bracket.

13. The connector assembly (200) according to claim 12, wherein: The pivot frame (304) includes a slot (346) that receives the flange (364), the flange being movable in an axial direction within the slot.

14. The connector assembly (200) according to claim 5, wherein: The Y-bracket (308) includes a panel (370) having an opening (372) that receives the electrical connector (210) and a flange (374) extending from the panel, the opening being coupled to the X-bracket (306) being movable in an axial direction relative to the Y-bracket.

15. The connector assembly (200) according to claim 1, wherein: The contact (222) is one of a plurality of contacts held by the housing (230).

16. The connector assembly (200) according to claim 1, wherein: The TPA device (250) includes a mating interface, which is configured to dock with the mating electrical connector (110) at the mating end (212) of the electrical connector, and the mating interface includes an introduction surface (272) that defines an introduction mating window in at least two non-parallel directions.

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