Floating Mate Connector Series | Floating Blind Mate Connector

The Floating Mate Connector Series is a compact, high-current floating blind mate connector system that combines power and signal contacts in a single, hybrid interface. Engineered around proven RADSOK® technology, it delivers up to 120 A and 1,000–1,500 VDC capability in misalignment-tolerant, blind-mating drawer connections for modern battery-based systems.

Designed for energy storage systems (ESS), electric vehicles (EV), plug-in hybrid vehicles (PHEV), and other high-density power architectures, these floating blind mate connectors support tighter mechanical envelopes, faster module swaps, and more reliable harnessing at the rack or pack level.

Table of Contents

• • Floating Blind Mate Connector Series Overview
  • Performance and Electrical Ratings
  • Floating, Blind-Mate and Safety Features
  • Power and Signal Configurations
  • Applications in ESS and e-Mobility
  • Design-In and Integration Considerations

Floating Blind Mate Connector Series Overview

The Floating Mate Connector Series provides a robust, drawer-style interface that allows battery modules and power shelves to be inserted and removed without manually plugging individual cables. Each connector integrates high-voltage power contacts and low-voltage signal positions, enabling a single floating blind mate connector to carry both pack power and BMS communication signals.

Integral guide pins, floating hardware options, and finger-proof power contacts help simplify system assembly while improving safety and uptime in harsh industrial environments. When paired with properly keyed frames and mounting brackets, the series corrects typical rack and module tolerances during blind mating, reducing mechanical stress on both connectors and PCBs.

This family is ideal wherever compact, modular power shelves and battery drawers are used, including utility-scale and commercial ESS cabinets, EV and PHEV traction battery systems, and industrial power conversion equipment.

Performance and Electrical Ratings

Each floating blind mate connector in the series is built around high-performance RADSOK® power contacts for low resistance, low temperature rise, and long-term electrical stability. Key electrical characteristics include:

• High current capability: up to 120 A per power contact (5.7 mm RADSOK® interface, application dependent).
• High voltage ratings:
  • 2+12 and 4+12 variants: up to 1,000 VDC power contacts, 50 VDC signal contacts.
  • 4+12 Mini: up to 1,500 VDC power contacts, 200 VDC signal contacts.
• Dielectric and insulation: engineered for high-voltage battery modules and rack-level power distribution architectures.
• Mating durability: rated for 100+ mating/unmating cycles for serviceable drawers and modules.
• Operating temperature: –40 °C to +125 °C to match typical ESS and e-mobility environments.
• Flammability: insulators designed to meet 94 V-0 flammability requirements.

The combination of high current, elevated voltage capability, and controlled temperature rise enables compact, multi-kilowatt battery modules and power shelves without sacrificing safety or connector life.

Floating, Blind-Mate and Safety Features

The Floating Mate Connector Series is specifically designed to address the mechanical challenges of blind mating high-power modules in constrained spaces.

• Integral guide pins: help align the plug and receptacle during insertion, correcting typical X/Y tolerances in drawers and slide-in modules.
• Optional floating mount: allows the connector to “float” relative to the panel or frame, reducing fatiguing stress on contacts and housings during blind mating and unmating.
• Probe-proof power contacts: finger-proof interfaces on the power side help reduce the risk of accidental contact with live conductors.
• First-mate/last-break circuits: selected positions can be used for grounding or HVIL-style functions, so the system is grounded and monitored before power contacts fully engage.
• Rugged materials: high-strength thermoplastic housings and copper alloy contacts support demanding vibration and thermal cycling conditions in industrial and transportation applications.

Together, these features allow the floating blind mate connector to support repeatable, tool-less module servicing without compromising connector integrity or operator safety.

Power and Signal Configurations

The Floating Mate Connector Series is offered in three hybrid layouts so designers can right-size the interface for pack voltage, current, and signal count:

• 2+12 configuration
  • 2 high-current power contacts (up to 1,000 VDC).
  • 12 low-voltage signal contacts (up to 50 VDC).
  • Ideal for lower-current modules or systems where only a pair of main DC bus connections are required.
• 4+12 configuration
  • 4 high-current power contacts (up to 1,000 VDC).
  • 12 low-voltage signal contacts (up to 50 VDC).
  • Supports higher power levels, redundant feeds, or additional auxiliary power lines.
• 4+12 Mini configuration
  • 4 high-current power contacts (up to 1,500 VDC).
  • 12 signal contacts (up to 200 VDC).
  • Miniaturized envelope for high-voltage, high-density battery architectures with tighter mechanical spacing.

Across all variants, the floating blind mate connector supports common power cable sizes (for example, 10–25 mm² / 8–4 AWG, application dependent) and signal wiring down to small-gauge BMS conductors. Crimp contacts, removal tools, and panel mounting accessories are available to support efficient assembly and service.

Applications in ESS and e-Mobility

The Floating Mate Connector Series was developed for modular, high-density power systems where safe, repeatable blind mating is critical. Typical uses include:

• Battery energy storage systems (ESS): rack-mounted battery drawers, pack-level interconnects, and DC bus interfaces in utility, commercial, and industrial storage cabinets.
• EV and PHEV traction batteries: stackable battery modules, removable packs, and serviceable power shelves in electric vehicles and plug-in hybrids.
• Industrial and backup power: UPS cabinets, DC power distribution racks, and power conversion equipment leveraging drawer-style modules.
• Other modular power platforms: applications where high-current, high-voltage modules must slide in and out of a frame or rack without manual cable connections.

By consolidating power and signal into a single floating blind mate connector, designers can simplify harnessing, reduce connector count, and shorten service times while maintaining the electrical isolation and creepage/clearance needed for high-voltage systems.

Design-In and Integration Considerations

When designing the Floating Mate Connector Series into a new platform, consider the following guidelines:

• Mechanical envelope: verify available space for the connector pair, floating hardware, and guide features, including full insertion depth of the drawer or module.
• Float and tolerance stack-up: design the frame or panel to allow the connector’s floating features to correct expected X/Y/Z tolerances without excessive stress on the housing or contacts.
• Thermal performance: size conductor cross-sections, busbars, and PCB traces to complement the connector’s current capability and keep temperature rise within project limits.
• Grounding and HVIL: assign first-mate/last-break positions for grounding and any high-voltage interlock (HVIL) circuits required by system safety standards.
• Cable selection: match cable gauge and insulation to the rated current, voltage, and environmental conditions, using approved crimp tooling and terminations.
• Compliance and testing: review applicable standards (such as IEC 61984 and other regional requirements) and perform system-level validation for insulation coordination, creepage/clearance, and endurance.

For additional high-current connections within the same system, you can pair the Floating Mate Connector Series with other Amphenol Industrial solutions such as SurLok Plus™ compression power connectors or busbar interfaces built on RADSOK® high-current contact technology.

For background on battery energy storage systems and grid applications, refer to technical resources from organizations such as the U.S. Energy Information Administration on Energy Storage.

Contact Amphenol Industrial Operations for engineering support, custom configurations, or to discuss how the Floating Mate Connector Series can be tailored to your specific ESS, EV, or industrial power project.