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EP-4738621-A1 - SELF-ALIGNING ELECTRICAL CONNECTOR

EP4738621A1EP 4738621 A1EP4738621 A1EP 4738621A1EP-4738621-A1

Abstract

An electrical connector assembly (10) has a housing (16) with a mating connector receiving portion (32) and a panel mounting portion (44). The mating connector receiving portion (32) has side walls (34, 36) and end walls (38, 40). The mating connector receiving portion (32) extends from the panel mounting portion (44). The panel mounting portion (44) has an oversized flange (47) with a panel mounting surface (46). The panel mounting surface (46) has a width (W1) which is greater than a width (W2) of the mating connector receiving portion (32) and a length (L1) which is greater than the length (L2) of the mating connector receiving portion (32). First springs (64) and second springs (66) are provided about the periphery of the mating connector receiving portion (32). The first springs (64) and second springs (66) have panel engagement portions (68) and securing portions (70). The electrical connector assembly (10) is configured to float relative to a panel (12) and to compensate for misalignment of a mating electrical connector (14).

Inventors

  • WEAVER, BRIAN KEITH
  • MOSTOLLER, MATTHEW EDWARD

Assignees

  • TE Connectivity Solutions GmbH

Dates

Publication Date
20260506
Application Date
20251027

Claims (15)

  1. An electrical connector assembly (10) comprising: a housing (16) comprising: a mating connector receiving portion (32) having side walls (34, 36) and end walls (38, 40); a panel mounting portion (44), the mating connector receiving portion (32) extending from the panel mounting portion (32), the panel mounting portion (44) having a flange (47) or an oversized flange (47) with a panel mounting surface (46), the panel mounting surface (46) having a width (W1) which is greater than a width (W2) of the mating connector receiving portion (32) and a length (L1) which is greater than the length (L2) of the mating connector receiving portion (32); first springs (64) and second springs (66) being provided about the periphery of the mating connector receiving portion (32), the first springs (64) and second springs (66) having panel engagement portions (68) and securing portions (70); wherein upon the electrical connector assembly (10) being mounted in an opening (88) of a panel (12), the panel engagement portions (68) of the first springs (64) and the second springs (66) cooperate with projections (90) of the panel (12) which extend into the opening (88), such that the electrical connector assembly (10) floats relative to the panel (12) and compensates for misalignment of a mating electrical connector (14) in the X direction, misalignment of the mating electrical connector (14) in the Y direction and/or for torsional misalignment of the mating electrical connector (14).
  2. The electrical connector assembly as recited in claim 1, wherein the X direction is a first direction perpendicular or substantially perpendicular to a mating direction of the mating electrical connector (14) with the electrical connector assembly (10), and the Y direction is a second direction perpendicular or substantially perpendicular to the X direction and the mating direction.
  3. The electrical connector assembly as recited in claim 1 or 2, wherein the first springs (64) extend in a direction which is essentially or substantially parallel to the side walls (34, 36) of the mating connector receiving portion (32) and the second springs (66) extend in a direction which is essentially or substantially parallel to the end walls (38, 40) of the mating connector receiving portion (32), and optionally, each first spring (64) of the first springs has two panel engagement portions (68) and three securing portions (70) and each second spring (66) of the second springs has one panel engagement portions (68) and two securing portions (70).
  4. The electrical connector assembly as recited in claim 1, 2 or 3, wherein the securing portions (70) are positioned in recessed portions (54) of spring retention projections (52) which extend from the panel mounting surface (46) of the panel mounting portion (44), retaining shoulders (56) cooperate with the securing portions (70) to movably retain the first spring (64) and the second springs (66) in position proximate the panel mounting surface (46) of the panel mounting portion (44), and, optionally, overstress projections (60) are positioned proximate to, but spaced from the spring retention projections (52) to allow the first springs (64) and second springs (66) to be resiliently deformed while being maintained in position on the panel mounting surface (46) of the panel mounting portion (44) and to prevent the overstress of the first springs (64) and the second springs (66).
  5. The electrical connector assembly as recited in claim 1, 2 or 3, wherein overstress projections (60) extend outward from the panel mounting surface (46), the overstress projections (60) extend about the periphery of the mating connector receiving portion (32), and, optionally, the overstress projections (60) have spring engagement portions (62) which are positioned between respective spring retention projections (52, 58) of the overstress projections (60).
  6. The electrical connector assembly as recited in claim 1, 2 or 3, wherein mounting projections (48) extend outward from the panel mounting surface (46), the mounting projections (48) are provided proximate, but spaced from, corners (42) of the mating connector receiving portion (32), and mounting openings (50) extend through the mounting projections (48).
  7. The electrical connector assembly as recited in claim 6, wherein first spring retention projections (52) extend outward from the panel mounting surface (46) in the same direction as the mounting projections (48).
  8. The electrical connector assembly as recited in claim 7, wherein two first spring retention projections (52) are provided proximate each mounting projection (48), the two first spring retention projections (52) are positioned at essentially or substantially right angles to each other, each first spring retention projection (52) has a recessed portion (54) with a retaining shoulder (56) which is spaced from the panel mounting surface (46), and the retaining shoulders (56) extend in a direction which is essentially or substantially parallel to the panel mounting surface (46).
  9. The electrical connector assembly as recited in claim 8, wherein second spring retention projections (58) extend outward from the panel mounting surface (46) in the same direction as the mounting projections (48), and, optionally, at least one said second spring retention projection (58) is provided between respective first spring retention projections (52), each second spring retention projection (58) have recessed portions (54) each with a retaining shoulder (56) which is spaced from the panel mounting surface (46), the retaining shoulders (56) extend in a direction which is essentially or substantially parallel to the panel mounting surface (46).
  10. The electrical connector assembly as recited in any preceding claim, wherein the first springs (64) and the second springs (66) are leaf springs.
  11. The electrical connector assembly as recited in any preceding claim, wherein the housing (16) has a mating connector receiving surface (24) and an oppositely facing terminal receiving surface (26), terminal receiving cavities (28, 30) extend from the mating connector receiving surface (24) to the terminal receiving surface (26), terminals (18, 19) are positioned in the terminal receiving cavities (28, 30), and the panel mounting portion (44) is positioned between the mating connector receiving surface (24) and the terminal receiving surface (26).
  12. The electrical connector assembly as recited in claim 11, wherein a contact retention member (20) is secured to the housing (16) and extends from the terminal receiving surface (26) in a direction away from the mating connector receiving surface (24), the contact retention member (20) has contact receiving openings (72, 74) for receiving and maintaining respective terminals (18, 19) therein, resilient latch arms (76) are provided on the contact retention member (20), the resilient latch arms (76) cooperate with latching projections (78) on the housing (16) to retain the contact retention member (20) on the housing (16).
  13. The electrical connector assembly as recited in any preceding claim, wherein a respective side wall (34) of the side walls (34, 36) of the mating connector receiving portion (32) has an angled surface (43).
  14. The electrical connector assembly as recited in any preceding claim, wherein the electrical connector assembly (10) has a cover (22) with a housing receiving opening (80) which is dimensioned to receive the mating connector receiving portion (32) of the housing (16) therein, when assembled the panel (12) is positioned and retained between the panel mounting surface (46) of the panel mounting portion (44) of the housing (16) and the cover (22), the cover (22) retains the first springs (64) and the second springs (66) in position relative to the panel mounting surface (46) of the connector assembly (10) and relative to the panel (12).
  15. An electrical connector system comprising: an electrical connector assembly (10) as recited in any previous claim; and a panel (12) having a connector receiving opening (88) dimensioned to receive the mating connector receiving portion (32) therethrough, projections (90) extending into the connector receiving opening (88), the projections (90) align with the panel engagement portions (68) of the first springs (64) and second springs (66).

Description

BACKGROUND OF THE INVENTION The invention relates generally to a self-aligning electrical connector. In particular, the invention relates to self-aligning connector which can comply as needed in the X and Y directions and which can comply if a torsional mating misalignment occurs. Connectors of conventional electrical connector assemblies can often be difficult to properly mate without several attempts. That is particularly true as connectors are often situated or located such that one or more of the connectors is not easily visible or as connectors get smaller in size, thereby making them more difficult to see and manipulate. If the connectors are misaligned, the connectors may be prevented from being assembled, or if assembled, unwanted stresses may be applied to the housing and the contacts of the connectors, resulting in failure of the electrical connection and the system. In various known systems, one or both of the connectors may be configured to allow for the center axis of the connector to shift or move to correct for misalignment. However, the connectors allow for the movement in one or more of the X, Y or Z directions. There is no ability to compensate for torsional misalignment. Therefore, a need exists for an electrical connector assembly in which at least one electrical connector allows for movement to compensate for X, Y and torsional misalignment, to facilitate proper mating of the connectors, particularly when blind-mating the components or when the components are small and difficult to manipulate. SUMMARY OF THE INVENTION A connector housing has an oversized outer flange with integrated springs, such as leaf springs, a cover plate, and a specific panel cutout design. The panel is captured between the oversized flange of the connector housing and the cover plate. The leaf springs are preassembled and captured by features on the oversized flange of the connector housing. When fully assembled the leaf spring elements along the periphery of the flange put an outward force on the protruding features of the panel cutout (see attached presentation). The leaf spring elements allow the connector assembly to comply as needed in the X and Y directions. They will also allow the connector assembly to comply if a torsional mating mis-alignment occurs. The self-alignment feature as described herein allows for a reduced footprint and thickness of the connector assembly. In addition, the connector assembly can be used in various systems, including battery connection systems where there are applications with high mating cycle requirements and customers want the connection to be as simple and error proof as possible for the end user. An embodiment is directed to an electrical connector assembly having a housing with a mating connector receiving portion and a panel mounting portion. The mating connector receiving portion has side walls and end walls. The mating connector receiving portion extends from the panel mounting portion. The panel mounting portion has a flange with a panel mounting surface. The panel mounting surface has a width which is greater than a width of the mating connector receiving portion and a length which is greater than the length of the mating connector receiving portion. First springs and second springs are provided about the periphery of the mating connector receiving portion. The first springs and second springs have panel engagement portions and securing portions. With the electrical connector assembly mounted in an opening of a panel, the panel engagement portions of the first springs and the second springs cooperate with projections of the panel which extend into the opening to allow the electrical connector assembly to float relative to the panel and to compensate for misalignment of a mating electrical connector in the X direction, misalignment of the mating electrical connector in the Y direction and/or for torsional misalignment of the mating electrical connector. The flange may be an oversized flange. The X direction may be a first direction perpendicular or substantially perpendicular to a mating direction of the mating electrical connector with the electrical connector assembly, and the Y direction may be a second direction perpendicular or substantially perpendicular to the X direction and the mating direction. An embodiment is directed to an electrical connector system having an electrical connector assembly and a panel. The electrical connector assembly includes a housing with a mating connector receiving portion and a panel mounting portion. The mating connector receiving portion has side walls and end walls. The mating connector receiving portion extends from the panel mounting portion. The panel mounting portion has an oversized flange with a panel mounting surface. The panel mounting surface has a width which is greater than a width of the mating connector receiving portion and a length which is greater than the length of the mating connector receiving portion. First