Electrical contact element system, connector and data center

Abstract

An electrical contact element system 1 comprising a first contact element 10 and a second contact element 11 suitable for mutual electrical contacting in a pair of electrical connectors. The first con

Description

Description The present invention refers to an electrical contact element system. The present invention refers to a first contact element. The present invention refers to a data center or high-performance computing facility. The present invention refers to an electrical connector pair comprising a first electrical connector with a first electrical connector housing, which can be connected to a first electrical conductor, and a second electrical connector with a second, corresponding electrical connector housing, which can be connected to a second electrical conductor. The present invention refers to the use of either of an electrical contact element system, a first contact element, an electrical connector pair, a data center or a high-performance computing facility, alone or in any particular combination. Prior Art Data centers and high-performance computing facilities are known in the prior art. Nevertheless, energy consumption of data centers as well as high-performance computing facilities such as supercomputers is high and accounts for the majority of the respective total operating costs. A contributor to the energy consumption are the various electrical connections required to connect different devices within data centers and high-performance computing facilities. The resistance of any wiring increases at the points where a physical connection is made due to the electrical contact resistance of the two connectors used to establish the connection, especially in the high current range. Energy consumption due to electrical contact resistances is a particular concern, as this energy is not being used to fulfill the purpose of the data center or high-performance computing facility and therefore represents an energy loss. This increases the ecological footprint of the data center or high-performance facility without any economic benefit. To a certain extent, this contact resistance can be counteracted by adapting the geometric shape of the connectors and their contact elements used to establish the electric connection. However, the effect of such an adjustment is limited. Object of the invention It is an objective of the invention to reduce energy consumption and to provide a solution to reduce the ecological footprint of data centers as well as high-performance computing centers. This objective is achieved by an electrical contact element system comprising a first contact element and a second contact element for mutual electrical contacting in a pair of electrical connectors, wherein the first contact element comprises a first material and wherein the second contact element comprises a second material, wherein first material and second material are configured to be brought into electrical contact to conduct a current in a connected state, wherein the first material has a reduced electrical and / or thermal resistance - particularly with an increased electrical and / or thermal conductivity - compared to the second material. This electrical contact element system uses a first contact element and a second contact element, which in combination can be used to establish an electrical connection in a connected state of the electrical contact element system. The first material that the first contact element comprises and the second material that the second contact element comprises are configured such that the first contact element and the second contact element are brought into electrical contact with each other in the connected state of the electrical contact element system. This allows an electrical current to pass between the first contact element and the second contact element. In particular, the electrical contact between the first contact element and the second contact element can be achieved by an arrangement of the first material and the second material in the regions of the respective first contact element and second contact element that are in direct physical contact with each other in the connected state of the electrical contact element system. By using the first material, with a reduced resistance, in particular with an increased conductivity, compared to the second material, the electrical contact resistance between the first contact element and second contact element is reduced in the connected state. This reduction in contact resistance results in a reduced energy loss while conduction current through the connection and a more energy-efficient connection, which especially cannot be achieved by a mere change in geometry of the contact elements. The electrical contact element system can thus be used to reduce the ecological footprint of data centers or high-performance facilities that use this electrical contact element system for its electrical connections, e.g. in electrical connectors used to establish these electrical connections. The reduction of the electrical contact resistance can be achieved without a significant change to mechanical properties of the electrical contacts, e.g. the maximal insertion force required to insert the first contact element into the second contact element, compared to a connection of a second contact element and first contact element both comprising the second material by using the first material with reduced resistance for the first contact element, although a material with a reduced resistance usually has poorer mechanical properties. The first contact element and / or the second contact element can be configured in such a way that the first material of the first contact element can be at least partially inserted into the second contact element, in particular in regions comprising the second material. In this context, it is particularly advantageous if the first contact element is designed as a male contact element and the second contact element is designed as a female contact element, which can accommodate the male contact element for electrical contacting. In particular, the first contact element and / or the second contact element can be configured in such a way that they can be arranged, in particular inserted, in an electrical connector housing of an electrical connector. The first contact element and / or the second contact element can be handled in an easy and safe way by a user, if arranged in an electrical connector, i.e. in the form of a plug. The electrical connector housing can electrically isolate most of the first contact element and / or the second contact element from the environment thus reducing the risk of an electrical shock during handling, in particular when establishing the electric connection. Preferably, the first contact element and / or the second contact element can be arranged in the electrical connector housing together with other first contact elements or second contact elements of the same type thus enabling the establishment of multiple electrical connection simultaneously. The second contact element can be configured as a receptacle for the first contact element, in particular a pin-like first contact element. The mechanical properties of the electrical contact element system can therefore be mainly determined by the mechanical properties of the second contact element, i.e. the second material. The first contact element can be configured as an contact element without moving parts for establishing the connection with the second contact element, in particular as a pin-like contact element. As the pin has no moving parts for establishing the connection with the second contact element, the mechanical properties of the first material have no relevant effect on the properties of the entire electrical contact element system. Thus, a first material having different mechanical properties compared to the mechanical properties, e.g. spring properties, required for the second contact element can be used to achieve a reduced resistance without affecting the mechanical properties of the electrical contact element system. In order to hold the first contact element mechanically and to establish an electrical contact with the first contact element, the second contact element can have contacting arms that can spring radially outwards. The contacting arms can comprise the second material. The contacting arms can be formed as an integral part of a body of the second contact element. The second contact element can be made entirely from the second material to reduce the complexity of manufacture. Particularly, the second material comprises a brass alloy. The brass alloy can be used to achieve a second contact element with mechanical properties, e.g. the flexibility or spring properties of contacting arms or the maximal insertion force required for insertion of a first contact element, comparable with second contact elements currently used in the field. By largely retained mechanical properties a backwards compatibility of the electrical contact element system with other contactsystems can be ensured. In particular, it is preferred that the second material is the brass alloy. It can be advantageous if the first material comprises a high-Cu alloy. A high-Cu alloy is also called a high copper alloy. By using a high-Cu alloy a first material with reduced electrical resistance can be achieved. The use of a high-Cu alloy enables the use of other cost-saving manufacturing technologies that are not suitable for processing brass, especially not with comparable cost savings. Although high Cu-alloys are generally more expensive than brass, overall production costs can be reduced by using these cost-saving manufacturing technologies. In particular, it is preferred that the first material is the high-Cu alloy. Preferably, only one electrical contact element comprises a high-Cu alloy. The first contact element can consist partially, in particular completely, of the first material. Particularly, the first contact element can be made entirely from the high-Cu alloy to reduce the complexity of manufacture. In a further exemplary embodiment of the invention, the brass alloy of the second material, particularly comprised by a second contact element, comprises at least one of at least 50 % Cu, max. 44 % Zn or max. 4 % Pb. By limiting the lead (Pb) content, a more environmentally friendly electrical contact element system can be achieved. Furthermore, the increase of the electrical resistance of the second material compared to pure copper (Cu) due to the zinc (Zn) content can thus be limited. In particular, the brass alloy can be one of CuZn38Pb2, CuZn37, CuZn40 or CuZn42. Preferably, the second material, particularly comprised by a second contact element, has an electrical conductivity in the range of greater than 12 MS / m to 36 MS / m and / or in the range of 20 % IACS to 75 % IACS. A second material with a conductivity in the range of greater than 12 MS / m to 36 MS / m and / or in the range of 20 % IACS to 75 % IACS, wherein IACS is the International Annealed Copper Standard as it applies on the date of filing and / or on the priority date, can ensure that the second contact element itself does not increase the energy loss of the electrical contact element system while conducting current in the connected state. The high-Cu alloy of the first material preferably comprises at least 95 % Cu. By using a high-Cu alloy comprises at least 95 % Cu the electrical resistance of the first material can be further reduced and the conductivity further increased. In this way, a first contact element comprising of a highly conductive base material can be provided. Thus, the electrical contact resistance of the connection can be drastically reduced without reducing the mechanical properties of the electrical contact element system. Preferably, the high-Cu alloy of the first material has an electrical conductivity of greater than 36 MS / m, preferably greater than 48 MS / m, and / or of greater than 75 % IACS, preferably greater than 85 % IACS. A second material, particularly comprised by a second contact element, with a conductivity of greater than 36 MS / m, preferably greater than 48 MS / m, and / or of greater than 75 % IACS, preferably greater than 85 % IACS, wherein IACS is the International Annealed Copper Standard, as it applies on the date of filing and / or on the priority date, can ensure a significantly reduced resistance of the first material compared to the second material and thus a significantly reduced contact resistance in the connected state. The use of the claimed first contact element can allow a reduction of the contact resistance of a connection made with the first contact element by at least 30%, preferably by at least 50 %, compared to a conventional connection, e.g. of a CuZn40 first contact element with a CuZn40 second contact element. This can especially be achieved without a significant change to the maximal insertion force required to insert the first contact element into the second contact element. In a further embodiment of the invention, the second contact element comprises a region, in particular a crimping region, which comprises the first material. Thus, the second contact element comprises the first material - in one region - as well as the second material, in particular in a different region. The region comprising the first material is in particular a crimping region in which the second contact element can be crimped on an electrical conductor. Test results have shown that the crimping region of the electrical contact elements has an enormous influence on the electrical contact resistance. Therefore, the contact resistance can be further reduced by the crimping region, which comprises the first material. In order to maintain the mechanical properties of the electrical contact element system, a mating region of the second contact element can comprise the second material. The mating region can comprise components used to establish the connection between the second contact element and the first contact element, in particular movable parts, e.g. contacting arms. In order to further achieve the above objective with a first contact element of the type mentioned at the beginning, it is proposed that this first contact element is configured to form an electrical contact element system in a connected state, wherein the electrical contact element system is configured in the manner described above, which results in the advantages described in connection with the electrical contact element system. The features described in the context of the electrical contact element system according to the invention can also be used individually or in combination with the first contact element. This results in the same advantages that have already been discussed. In order to further achieve the above objective with an electrical connector pair of the type mentioned at the beginning, it is proposed that the electrical connector pair comprises least one electrical contact element system configured in the manner described above for mutual electrical contacting the electrical connectors, in particular the electrical conductors, wherein the first electrical connector housing has a first accommodating section in which the first electrical contact element is arranged connectable to the first electrical conductor, wherein the second electrical connector housing has a second accommodating section in which the second electrical contact element is arranged connectable to the second electrical conductor. In this way, the energy loss can be reduced, in particular for heavy or industrial electrical connectors, in which high currents are conducted in a relatively small space. The features described in the context of the electrical contact element system according to the invention can also be used individually or in combination with the electrical connector pair. This results in the same advantages that have already been discussed. The reduction of the energy consumption of a data center or a high-performance computing facility can be achieved, if the data center or high-performance computing facility comprises at least one of a electrical contact element system configured in the manner described above, at least a first contact element configured in the manner described above and / or at least an electrical connector pair configured in the manner described above. However, the application is not limited to use in data centers or other high-performance computing facilities. The invention can also be used in applications where high currents are conducted in a relatively small space, such as in heavy or industrial electrical connectors. The features described in the context of the electrical contact element system and the first contact element can also be used individually or in combination with the data center or high-performance computing facility. This results in the same advantages that have already been discussed. At least one of an electrical contact element system configured in the manner described above, a first contact element configured in the manner described above, an electrical connector pair configured in the manner described above, a data center configured in the manner described above or a high-performance computing facility configured in the manner described above can be used to achieve the objective. Embodiments An embodiment of the invention is shown in the drawing and is explained in more detail below. It is shown in: Fig. 1 an electrical contact element system according to the invention. Some of the figures contain simplified, schematic representations. In some cases, identical reference signs are used for the same, but possibly not identical, elements. Different views of the same elements might be scaled differently. Directions such as "left", "right", "up" and "down" are to be understood in relation to the respective figure and may vary in the individual representations compared to the object depicted. Fig. 1 shows an electrical contact element system 1 for establishing an electric connection. The electrical contact element system 1 comprises a first contact element 10 and a second contact element 11. The first contact element 10 and the second contact element 11 are shown in a disconnected state of the electrical contact element system 1 but can be used in combination to establish an electrical connection, as described below. The first contact element 10 is configured as a pin-like contact element without any moving parts for establishment of the electrical contact to the second contact element 11. The first contact element 10 has a mating region 2 for establishing an electrical contact with the second contact element 11. This mating region 2 extends like a pin towards the second contact element 11. The entire first contact element 10 is made of the same first material, in particular a highly conductive high-Cu alloy. This first material is characterized by its low electrical resistance, so that a low-resistance electrical connection can be established using the first contact element 10. Although the first material has poorer mechanical properties than the brass alloys typically used for contact elements, this does not have a negative effect on the mechanical properties of the entire electrical contact element system 1, since the first contact element 10 has no moving components for establishment of the connection to the second contact element 11. The second contact element 11 on the other hand has a corresponding hollow-cylindrical mating region 3 for receiving the mating region 2 of the first contact element 10. By introducing a plurality of axial slots 3.2, the mating region 3 is segmented, so that individual contacting arms 3.1 are formed. The ends of the contacting arms 3.1 surround a plug-in opening of the mating region 3, into which the mating region 2 of the first contact element 10 can be inserted to establish an electric contact. The ends of the contacting arms 3.1 are bent towards each other in the radial direction. The diameter of the plug-in opening of the mating region 3 is thus slightly smaller than the diameter of the mating region 2 to achieve a tight and secure fit. Alternatively, this profile can also be created by lathing. These contacting arms 3.1 are configured as spring arms that can spring radially outwards if the mating region 2 is inserted. The contacting arms 3.1 can therefore exert a radial force towards an inserted mating region 2 in order to ensure a physical contact between the mating regions 2, 3 and thus an electrical contact between the second contact element 11 and the inserted first contact element 10. Since the mating region 3 exerts a holding force on the mating region 2 of the first contact element 10 the mechanical properties of the mating region 3, especially its flexibility and the spring properties of the contacting arms 3.1, are decisive for the mechanical properties of the entire electrical contact element system 1. The material of the mating region 3 and in particular of the contacting arms 3.1 are the primary factors influencing the maximal insertion force required to insert the first contact element 10 into the second contact element 11. Since the mechanical properties are primarily relevant for the mating region 3, a brass alloy is used as a second material to form the mating region 3 of the second contact element 11. Although this second material has favorable mechanical properties, it cannot achieve as low an electrical resistance as the first material. Then again, this second material enables a backwards compatibility of the electrical contact element system 1 with conventional contact-systems. The first contact element 10 and the second contact element 11 are designed as crimp contacts. They have connection regions for connecting an electrical conductor, for example the stranded wire of an electrical cable, which are realized as crimping regions 5, 8. Alternatively, the connection to the electrical conductor can be made using other connection technologies, such as soldering or screws. Each of the crimping regions 5, 8 is realized in the form of a sleeve, namely hollow-cylindrically, and therefore features a cylindrical connection opening and a connection-side collar 6, 9 at its free end. In the perspective shown in Fig. 1, the connection openings are concealed by the respective connection-side collars 6, 9 of the first contact element 10 and second contact element 11. The crimping region 5 of the first contact element 10 is made of a high-Cu alloy, since the entire first contact element 10 is made of a high-Cu alloy as the first material. However, the mating region 3 of the second contact element 11 is made of the second material, which has a higher electrical resistance than the first material. In the simple implementation, the entire second contact element 11 is thus made of the second material. A electrical contact element system 1 with such a second contact element 11 would still reduce the electrical contact resistance, since the local contact resistance at the points where the second contact element 11 touches the first contact element 10 is still reduced due to the first material of the first contact element 10. However, the local contact resistance at the crimping region 8, where the second contact element 11 is in electrical connection with the electrical conductor, would not be reduce in comparison to conventional contact-systems, since this crimping region 8 would also be made of the second material. In order to reduce the local contact resistance at the crimping region 8 as well, this crimping region 8 is also made of the first material, as is the crimping region 5 of the first contact element 10. This results in a second contact element 11 that consist mainly of the second material, but also comprises a region made of the first material, i.e. the crimping region 8. A central collar 4, 7 is arranged between the respective mating region 2, 3 and the respective crimping region 5, 8. This central collar 4, 7 protrudes radially outwards, in particular with respect to the mating region 2, 3 and / or the crimping region 5, 8. On the one hand, the central collar 4, 7 has the function, together with the connection-side collar 6, 9, of ensuring the guidance of the first contact element 10 or the second contact element 11 within an electrical connector housing, in particular an accommodating section of the electrical connector housing, into which the first contact element 10 or second contact element 11 can be inserted for handling by a user, in particular together with other first contact elements 10 or second contact elements 11 of the same type. The central collar 4, 7 and the connection-side collar 6, 9 are thereby used for centering the first contact element 10 or the second contact element 11, for example in a hollow-cylindrical through-opening of the electrical connector’s accommodating section. On the other hand, the central collar 4, 7 can act as a stop to prevent the first contact element 10 or the second contact element 11 from penetrating too deeply into the respective electrical connector housing, for example during the insertion of the first contact element 10 or the second contact element 11 into the electrical connector housing, or from being pulled out of the electrical connector by frictional forces between the first contact element 10 an the second contact element 11 when the electrical connection between the pair of electrical connectors is disconnected. In the same way, the connection-side collar 6, 9 can act as a stop preventing the first contact element 10 or the second contact element 11 from being pushed into the respective electrical connector housing, for example during the insertion of the first contact element 10 into the second contact element 11 when the electrical connection between the pair of electrical connectors is established.. The definitions regarding features, structures, components and their respective functional links as well as regarding terms used to define and to describe one aspect or one embodiment may describe another aspect or embodiment as well. Therefore, respective links between features, structures, components may further specify alternative combinations of features, structures, components and their respective functional link described herein as long as the skilled person derives those combinations by applying technical sense and average skill. This applies to the respective advantages as they are described with respect to the aspects and / or the embodiments as well. Furthermore, features, structures, components and functional links of an aspect or an embodiment referring to one category - device, system, method, use - may describe and specify an aspect or embodiment of another category. Furthermore, any aspect, structure, component or tangible feature of a system and / or a device further discloses its use. Recasting of big portions of these descriptions and definitions is avoided for matters of readability and conciseness. It is referred to them as these descriptions apply with respect to the different aspects and embodiments, accordingly, particularly independent from the respective category. Electrical contact element system, connector and data center Reference signs 1 Electrical contact element system 2 Mating region 3 Mating region 3.1 Contacting arm 3.2 Slot 4 Central collar 5 Crimping region 6 Connection-side collar 7 Central collar 8 Crimping region 9 Connection-side collar 10 First contact element 11 Second contact element Electrical contact element system, connector and data center

Claims

1. Electrical contact element system (1) comprising a first contact element (10) and a second contact element (11) for mutual electrical contacting in a pair of electrical connectors, wherein the first contact element (10) comprises a first material and wherein the second contact element (11) comprises a second material, wherein first material and second material are configured to be brought into electrical contact to conduct a current in a connected state, wherein the first material has a reduced resistance -particularly with an increased conductivity - compared to the second material.

2. Electrical contact element system (1) according to claim 1, wherein the second material comprises a brass alloy.

3. Electrical contact element system (1) according to at least one of either claim 1 or 2, wherein the first material comprises a high-Cu alloy.

4. Electrical contact element system (1) according to at least one of the previous claims, wherein the brass alloy of the second material comprises at least one of at least 50 % Cu, max. 44% Zn or max. 4 % Pb.

5. Electrical contact element system (1) according to at least one of the previous claims, wherein the second material has an electrical conductivity in the range of greater than 12 MS / m to 36 MS / m and / or in the range of 20 % IACS to 75 % IACS.

6. Electrical contact element system (1) according to at least one of the previous claims, wherein the high-Cu alloy of the first material comprises at least 95 % Cu.

7. Electrical contact element system (1) according to at least one of the previous claims, wherein the high-Cu alloy of the first material has an electrical conductivity of greater than 36 MS / m, preferably greater than 48 MS / m, and / or of greater than 75 % IACS, preferably greater than 85 % IACS .

8. Electrical contact element system (1) according to at least one of the previous claims, wherein the second contact element (11) comprises a region (8), in particular a crimping region (8), which comprises the first material.

9. Electrical contact element (10) configured to form a system (1) in a connected state, wherein the system (1) is configured according to at least one of the previous claims.

10. Electrical connector pair comprising a first electrical connector with a first electrical connector housing, which can be connected to a first electrical conductor, and a second electrical connector with a second, corresponding electrical connector housing, which can be connected to a second electrical conductor, and at least one electrical contact element system (1) according to at least one of the claims 1 to 8 for mutual electrical contacting the electrical connectors, in particular the electrical conductors, wherein the first electrical connector housing has a first accommodating section in which the first electrical contact element (10) is arranged connectable to the first electrical conductor, wherein the second electrical connector housing has a second accommodating section in which the second electrical contact element (11) is arranged connectable to the second electrical conductor.

11. Data center or high-performance computing facility comprising at least one of an electrical contact element system (1) according to at least one of the claims 1 to 8, an electrical contact element (10) according to claim 9 and / or an electrical connector pair according to claim 10.

12. Use of at least one of an electrical contact element system (1) according to at least one of the claims 1 to 8, an electrical contact element (10) according to claim 9, an electrical connector pair according to claim 10, a data center according to claim 11 or a high-performance computing facility according to claim 11.

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