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

Abstract: A connector system may include a connector having a connector housing. The connector system may include a cam member rotatably attached to the connector housing. The cam member may define an engaging lug offset from an axis of rotation of the cam member. A connector system may include user moveable member slidably attached to the connector housing. The user moveable member may define a first cam slot inboard having a strap across an entrance portion of the first cam slot in which the engaging lug is received. The engaging lug has a chamfered leading edge that is configured to lift the strap as the engaging lug is inserted into the first cam slot. The user moveable member is configured to rotate the cam member via movement of the engaging lug through the first cam slot. A method of assembling a connector system also presented.

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

Abstract: An electrical connection system is described that includes a module interface, a first terminal module, and a second terminal module. The first terminal module is configured to be retained in the module interface. The second terminal module is configured to be retained adjacent to the first terminal module in the module interface, secured in a predefined position staggered relative to the first terminal module. The module interface is configured to be seated on a header interface and moved relative to the header interface until the first terminal module is mated. The module interface is configured to be released once the first terminal module is mated and moved to a fully seated position on the header interface, which mates the second terminal module and locks the module interface to the header interface.

Abstract: A connector system may include a connector having a connector housing. A connector system may include a cam member rotatably attached to the connector housing, wherein the cam member defines an engaging lug extending along an axis substantially parallel to an axis of rotation of the cam member. A connector system may include a user moveable member slidably attached to the connector housing. The user moveable member defines a first cam slot in which the engaging lug is received. The first cam slot is shaped such that the cam member is rotated by movement of the engaging lug through the first cam slot as the user moveable member is moved longitudinally relative to the connector housing. Methods of operating and assembling a connector system are also provided.

Abstract: An electrical connection system is described which includes a common carrier. The common carrier includes a main channel configured to retain a cable bundle and a plurality of side channels that facilitate coupling of at least some cables of the cable bundle to an electronic control unit (ECU). The side channels are configured to retain a connector carrier configured to carry a pair of connectors slidable in each side channel between a pre-staged position in preparation for mating and a mated position which mates terminals carried by the pair of connectors and locks the pair of connectors to the ECU.

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

Abstract: Systems, methods, and devices providing for the robotic installation of vehicle electrical systems are described. A vehicle wiring harness includes first and second cables, a robotic gripping arm, and at least two pairs of stiffeners coupled to the cables to define folding points and corresponding segments that enable robotic folding and unfolding of the wiring harness. In other examples, a wiring harness is coupled to a plurality of electrical connectors carried by a carrier plate of an electrical control unit connection system (ECU), which is installed by robotically mating the plurality of electrical connectors carried by the carrier plate.

Abstract: A connector assembly includes a connector housing. The connector housing includes a first side having a first opening. The first opening includes a first planar surface within the connector housing. The connector housing includes a second side having a second opening. The connector assembly includes a terminal with an attachment portion and a conductive member. The conductive member includes a tanged portion. The attachment portion includes a socket opening accessible through the second opening of the connector housing. The connector assembly includes a stuffer insertable into the first opening of the connector housing. The tanged portion of the terminal is engageable with the stuffer to urge the conductive member toward the first planar surface.

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

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

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

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

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

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

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

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

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

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

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