Compact high current electrical plugs and connectors

Abstract

An electrical connector system that reduces the insertion and extraction forces of male into female electrical connectors and provide greater conductivity to minimize thermal energy generated from electrical contacts under load. Electrical connectors enable compact size and thermal management for 100 Amp current rating devices. Sleeve contacts are provided with varying number of spring members within the female contact for reduced contact resistance. High conductivity plating on male and / or female contacts is utilized to reduce contact resistance. Contact material selection is selected for thermal management and compact size. Novel contact shapes and configurations are provided to increase heat dissipation. Unique keying is employed to prevent intermateability with traditional 60 A devices.

Description

COMPACT HIGH CURRENT ELECTRICAL PLUGS AND CONNECTORSPRIORITY

[0001] This application claims priority to U.S. Provisional Patent Application Serial No. 63 / 654,526 filed May 31 , 2024, the contents of which are hereby incorporated by reference in its entirety.

[0002] This application also claims priority to U.S. Provisional Patent Application Serial No. 63 / 744,549 filed January 13, 2025, the contents of which are hereby incorporated by reference in its entirety.FIELD

[0003] The present disclosure relates to electrical connectors. More particularly, the present disclosure relates to manually mateable and unmateable electrical connectors requiring reduced effort and having reduced contact resistance and temperature rise.BACKGROUND

[0004] Electrical connectivity devices, such as electrical connectors, are prevalent anywhere power from a source must be carried through wires for power delivery to equipment and devices. Commonly encountered electrical connectors include so-called “pin-and-sleeve” connectors. As will be appreciated by one of ordinary skill in the art, pin- and-sleeve connectors typically comprise a male end having elongated “pins” that connects to a female “sleeve” comprising receptacles for the pins and having electrical contacts therein. With this configuration, the conductive portion of the pins can be fully encapsulated and insulated upon insertion to provide an internal electrical connection while protecting a user from inadvertent contact with the conductive pins. As will also be appreciated, these connections are typically friction fit connections that are intended to hold the connectors together to prevent accidental separation while also allowing a user to mate and unmate the connectors by hand.

[0005] In today’s environment, demand for higher amperage connectivity solutions is increasing. For example, data centers have a growing need for high amperage connectors. Artificial Intelligence (Al) and other technologies are driving servers and associated supporting equipment to consume more power. The conventional connectors available today to support these applications must be much larger than standard connectors and thus can be difficult for a user to mate and unmate. Specifically, while prior art pin-and-sleeve devices often utilize locking rings to maintain connection once they have been engaged, the engagement of male to female devices is typically done by hand. Typically, a considerable linear mating force is required to engage (and disengage) the conventional pin-and-sleeve connectivity devices. An increase for high amperage devices also results in a larger size of the electrical contacts, which forces these higher amperage devices to become larger and ultimately less ergonomically friendly to mate and unmate.

[0006] Currently, 60 Amp pin-and-sleeve wiring devices are used in data centers. When data centers need 100 Amp devices in the future, the existing 100 Amp pin-and- sleeve wiring devices may be too large. It would be advantageous to have 100 Amp devices in the size of 60 Amp devices.SUMMARY

[0007] The present disclosure describes devices suitable for 100 Amps but are sized the same or similar to traditional 60 Amp devices. The various disclosed embodiments enable compact size and thermal management for 100 Amp current rating devices. For example, sleeve contacts are provided with varying number of spring members within the female contact for reduced contact resistance. In one aspect, the shape of the male contact is configured to reduce mating force. In another aspect, high conductivity plating on male and / or female contacts is utilized to reduce contact resistance. In a further aspect, contact material selection is selected for thermal management and compact size. In certain embodiments, an increased number of wire terminal screws are provided for reduced contact resistance and for redundancy in mission-critical applications. In various embodiments, novel contact shapes are provided to increase heat dissipation. In further embodiments, vents are provided in the sleeve contacts and / or in the wiring devicehousings to dissipate heat. In other embodiments, liquid cooling is utilized to dissipate heat. In yet other embodiments, unique keying is employed to prevent intermateability with traditional 60 A devices.

[0008] Various examples of the present disclosure can overcome various of the aforementioned and other disadvantages associated with known connectors. For example, the present inventors recognized a need in the marketplace for connectivity devices that are easier to mate and unmate while maintaining the ability to hinder accidental decoupling. The present inventors also recognized a need for connected devices that run cooler than their predecessors. Cooler running connection solutions would aid in the cooling load that must be managed and mitigated with higher amperage operations.

[0009] Various embodiments of the present disclosure provide connectivity solutions that reduce insertion forces and / or extraction forces of male into female electrical connectors, thus minimizing the ergonomic burdens. The various embodiments provide other advantages and benefits. For example, another benefit of various embodiments is to produce male and female contacts with greater conductivity to minimize thermal energy generated from electrical contacts under load.

[0010] According to one aspect of various embodiments of the present disclosure there is provided various connectivity devices that make use of novel form factors, novel pin-and-sleeve configurations, and novel mechanical connection mechanisms that aid the ability to mate and unmate the devices with manageable effort.

[0011] According to one aspect of various examples of the present disclosure there is provided pin-and-sleeve connectors comprising a male connector and a female connector. The male connector includes at least one insertion pin of conductive material. The insertion pin has a full pin outside diameter and a tapered section positioned towards a distal end of the insertion pin. The female connector includes a sleeve having a sleeve inside diameter; wherein the sleeve inside diameter is larger than the full pin outside diameter; and wherein the sleeve is configured to receive the insertion pin to make an electrical connection.

[0012] In some embodiments, a spring element is configured as part of the female connector and has a spring inside diameter that varies as the spring element moves froma released position to an engaged position that creates electrical contact and provides a holding force for secure connection of the connector.

[0013] In some forms, the tapered section extends away from the distal end of the insertion pin a distance at least equal to one-half the full pin outside diameter. In other forms, the tapered section extends away from the distal end of the insertion pin a distance at least equal to the full pin outside diameter. In some forms, the tapered section has a taper angle of 1 .5° + / - 0.75°. In some embodiments, the pin includes a chamfered section positioned between the distal end and the tapered section.

[0014] In some forms, a silver plating or other plating is provided on parts or areas that contact each other to aid the electrical conductivity of the connector once engaged.

[0015] According to one aspect of the present disclosure , a pin-and-sleeve electrical connectivity apparatus is provided including a male connector; an insertion pin of conductive material with a distal end and a proximal end configured as part of the male connector, the insertion pin having a full pin outside diameter; a tapered section of the insertion pin positioned towards the distal end of the insertion pin; a female connector; a sleeve configured as part of the female connector, the sleeve having a sleeve inside diameter; wherein the sleeve inside diameter is larger than the full pin outside diameter of the insertion pin; and wherein the sleeve is configured to receive the insertion pin to make an electrical connection; a spring element configured as part of the female connector, the spring element having a spring inside diameter; wherein the spring inside diameter of the spring element in the released position is smaller than the full pin outside diameter of the insertion pin; and wherein the spring inside diameter of the spring element in the engaged position is at least as large as the full pin outside diameter of the insertion pin.

[0016] In another aspect, a pin-and-sleeve electrical connectivity apparatus further includes two or more springs elements configured as part of the female connector, said two or more spring elements providing holding force for said insertion pin and providing multiple areas of electrical contact.

[0017] In a further aspect, a pin-and-sleeve electrical connectivity apparatus further includes silver plating in at least said areas of said electrical contact.

[0018] In one aspect, a pin-and-sleeve electrical connectivity apparatus further includes a chamfered section positioned between the distal end and the tapered section.

[0019] In another aspect, the chamfered section has an angle of 45.0° + / - 15.0°.

[0020] In a further aspect, the tapered section has a taper angle of 2.5° + / - 2.0°.

[0021] In yet another aspect, the tapered section extends away from the distal end of the insertion pin a distance at least equal to one-half the full pin outside diameter.

[0022] In a further aspect, the tapered section has a taper angle of 1 .5° + / - 0.75°.

[0023] In one aspect, the tapered section extends away from the distal end of the insertion pin a distance at least equal to the full pin outside diameter.

[0024] In another aspect, a pin-and-sleeve electrical connectivity apparatus further includes two or more springs elements configured as a single spring, each of the two or more springs include a first end and a second end with a convolution portion disposed therebetween, wherein a first end of a first spring is coupled to a second end of a second spring, the single spring disposed in the sleeve.

[0025] In one aspect, the tapered section of the insertion pin is configured in a semi- spherical shape.

[0026] In yet a further aspect, the male connector and female connector include a termination portion for receiving a conductor, the termination portion including an internally threaded surface to reduce contact resistance with the conductor.

[0027] In still another aspect, the termination portion includes a cavity that receives the conductor and at least two apertures arranged circumferentially to the cavity, each aperture configured to receive a screw to secure the conductor in the cavity.

[0028] In one aspect, the screw includes a high strength copper alloy.

[0029] In a further aspect, the high strength copper alloy includes at least one of beryllium copper and copper titanium.

[0030] In another aspect, the male connector and female connector include a termination portion for receiving a conductor, further comprising a silver-plated ferrule disposed between the conductor and an internal surface of the termination portion.

[0031] In one aspect, the sleeve includes a termination portion for receiving an end of a conductor and sleeve portion, the sleeve portion includes a plurality of contact members arranged concentrically to form a channel to receive the insertion pin, each contactmember is individually coupled to the termination portion such that each contact member may individually flex upon receiving the insertion pin.

[0032] In another aspect, each contact member is configured to include a plurality of contact points on an inner surface of the formed channel.

[0033] In a further aspect, each contact member includes a slot disposed on an outer surface of the contact member, the respective slots on each contact member align to receive a generally circular ring spring to urge the contact points toward a center of the channel and maintain contact with the insertion pin.

[0034] In one aspect, the insertion pin and sleeve include a copper alloy.

[0035] In a further aspect, the copper alloy includes at least one of tellurium copper, chromium copper and zirconium copper.

[0036] In another aspect, the male connector and female connector include a termination portion for receiving a conductor, the termination portion including an internally threaded surface configured to receive a split bushing, the split bushing configured to be disposed over the conductor and includes a plurality of members that compress the conductor when the split bushing is advanced into the internally threaded surface of the termination portion.

[0037] In a further aspect, the male connector and female connector include a termination portion for receiving a conductor, the termination portion configured to be disposed over the conductor and includes a plurality of members having an externally threaded surface, the plurality of members compress the conductor when a capture nut is advanced onto the externally threaded surface of the termination portion.

[0038] In one aspect, the sleeve includes a termination portion for receiving an end of a conductor and a cylindrical sleeve portion, the cylindrical sleeve portion includes a plurality of fins that extend radially from a longitudinal axis of the cylindrical sleeve portion to draw heat generated inside the cylindrical sleeve portion away from the conductor.

[0039] In another aspect, the sleeve includes a termination portion for receiving an end of a conductor and a cylindrical sleeve portion, the cylindrical sleeve portion includes a plurality of fins that extend radially from a longitudinal axis of the cylindrical sleeve portion to draw heat generated inside the cylindrical sleeve portion away from the conductor.

[0040] In a further aspect, the sleeve includes a termination portion for receiving an end of a conductor and a cylindrical sleeve portion, the cylindrical sleeve portion includes a plurality of venting slots which enable heat dissipation from the conductor.

[0041] In still a further aspect, the sleeve includes a termination portion for receiving an end of a conductor and a cylindrical sleeve portion, the cylindrical sleeve portion includes a plurality of venting slots which enable heat dissipation at contact points between a spring element and conductor.

[0042] In one aspect, each venting slot is aligned with an internally disposed spring element such that the contact points that are created at concave portions of the spring element are exposed through the venting slots.

[0043] In another aspect, the plurality of contact members separated by a plurality of slits, portions of each contact member include at least one recess along a respective slit forming venting slots with adjacent contact members to facilitate heat dissipation from the conductor.

[0044] In a further aspect, the male connector includes a first housing and the female connector includes a second housing, each of the first and second housings include thermally conductive plastic to dissipate heat.

[0045] In yet another aspect, the male connector includes a first housing and the female connector includes a second housing, at least one of the first and second housings include venting elements to dissipate heat.

[0046] In one aspect, the female connector includes a housing with venting elements to dissipate heat, the venting elements being positioned on an outer surface of the housing to align with and to be parallel to the sleeves.

[0047] In another aspect, the male connector includes a first housing and the female connector includes a second housing, at least one of the first and second housings include a liquid circulation system that circulates a dielectric coolant through an interior of the housing.

[0048] In a further aspect, the male connector includes a first housing and the female connector includes a second housing, at least one of the first and second housings include a sealed liquid circulation module coupled to the housing.

[0049] In still another aspect, the male connector includes a plurality of insertion pins arranged in a circular manner, at least one of the plurality of insertions pins being an electrical ground pin, the ground pin located at a half-hour position.

[0050] In one aspect, the male connector includes a plurality of insertion pins arranged in a circular manner, at least one of the plurality of insertions pins being an electrical ground pin, the ground pin located at a 15 degree increment from a center position based on a rating of the male connector.

[0051] In a further aspect, the female connector includes a plurality of sleeves arranged in a circular manner, at least one of the plurality of sleeves designated as an electrical ground sleeve, the ground sleeve located at a half-hour position.

[0052] In another aspect, the female connector includes a plurality of sleeves arranged in a circular manner, at least one of the plurality of sleeves being an electrical ground sleeve, the ground sleeve located at a 15 degree increment from a center position based on a rating of the female connector.

[0053] According to one aspect of the present disclosure, a pin-and-receptacle electrical connectivity apparatus includes a male connector including a plurality of pins; an insertion pin of conductive material included among the plurality of pins, the insertion pin having a distal end and a proximal end configured as part of the male connector; a female connector including a plurality of receptacles; a sleeve receptacle included among the plurality of receptacles; a latch body hingedly affixed to one of the male connector or the female connector, the latch body including a clamping extension, an open boss receiving end, and a cradle section; a mating boss extending affix to the other of said male or said female connector; wherein in an engaged position the mating boss is in contact with the cradle section, and each one of the plurality of pins is fully inserted into a respective one of the plurality of receptacles.

[0054] In one aspect, the latch body defines a pivot pin opening to receive a pivot pin thereby allowing the latch body to hingedly rotate around the pivot pin.

[0055] In another aspect, a pin-and-receptacle electrical connectivity apparatus further includes a latch handle affixed to the latch body; said latch handle providing lever force to pull said male and female connectors into the engaged position.

[0056] In a further aspect, a pin-and-receptacle electrical connectivity apparatus further includes an arcuate latching groove section of the latch body positioned between the open pin receiving end and the cradle section and configured to receive said boss and draw said female and male connectors together as the boss travels the length of the arc during rotation of said latch body.

[0057] In one aspect, the boss is disposed on said female connector and is spaced a distance on said female connector to ensure complete insertion of said pins in said receptacles when said boss reaches the cradle section of said latch body hingedly disposed on said male connector to reach said engaged position.

[0058] In another aspect, a pin-and-receptacle electrical connectivity apparatus further includes a spring-loaded plunger disposed in said female connector configured to push said male connector out and away from said female connector when said latch is released from said engaged position.

[0059] In a further aspect, a pin-and-receptacle electrical connectivity apparatus further includes at least one spring loaded butt contact.BRIEF DESCRIPTION OF THE DRAWINGS

[0060] Various aspects and advantageous features of the present disclosure will become more apparent to those of ordinary skill when described in the detailed description of preferred embodiments and reference to the accompanying drawings, wherein:

[0061] FIG. 1 illustrates a plug and receptacle of a pin-and-sleeve type electrical connector in accordance with various embodiments disclosed herein.

[0062] FIG. 2 is an exploded view of the receptacle shown in FIG. 1 in accordance with various embodiments disclosed herein.

[0063] FIG. 3 is an exploded view of a contact carrier in accordance with various embodiments disclosed herein.

[0064] FIG. 4A is a cutaway view depicting a pin-and-sleeve connectivity device with a tapered diameter insertion pin, in accordance with various embodiments disclosed herein.

[0065] FIG. 4B is a cutaway view depicting a pin-and-sleeve connectivity device with a reduced spring element engagement, in accordance with various embodiments disclosed herein.

[0066] FIG. 4C is a cutaway view depicting a pin-and-sleeve connectivity device with multiple springs in the insertion sleeve, in accordance with various embodiments disclosed herein.

[0067] FIG. 4D illustrates various views of multiple springs integrated into a single device, in accordance with various embodiments disclosed herein.

[0068] FIG. 4E illustrates a pin tip with a blended radii, in accordance with various embodiments disclosed herein.

[0069] FIG. 4F a perspective view of a half-round spring element for use in the insertion sleeve, in accordance with various embodiments.

[0070] FIG. 4G is a cutaway of a pin-and-sleeve connectivity device with opposing half-round spring elements in the insertion sleeve, in accordance with various embodiments.

[0071] FIG. 5A is a perspective view of a split sleeve contact, in accordance with various embodiments disclosed herein.

[0072] FIG. 5B is another perspective view of the spilt sleeve contact as shown in FIG. 5A, in accordance with various embodiments disclosed herein.

[0073] FIG. 5C is a cross-sectional view of the split sleeve contact as shown in FIG. 5A, in accordance with various embodiments disclosed herein.

[0074] FIG. 6A is an oblique view depicting a pin-and-sleeve connectivity device with silver plating on key surface areas, in accordance with various embodiments disclosed herein.

[0075] FIGS. 6B-6C illustrate a pin-and-sleeve connectivity device with a silver-plated ferrule, in accordance with various embodiments disclosed herein.

[0076] FIG. 7A is a perspective view of a conventional contact.

[0077] FIG. 7B is a perspective view of a multi-termination contact, in accordance with various embodiments disclosed herein.

[0078] FIG. 70 is a cross-sectional view of the contact shown in FIG. 7B, in accordance with various embodiments disclosed herein.

[0079] FIG. 7D is a cross-sectional view of a contact with a threaded termination portion, in accordance with various embodiments disclosed herein.

[0080] FIG. 7E is an exemplary graph comparing temperature of a contact with no threads in a termination portion versus a contact with threads in a termination portion, in accordance with various embodiments disclosed herein.

[0081] FIG. 8A is a perspective view of a split bushing, in accordance with various embodiments disclosed herein.

[0082] FIG. 8B is a perspective view of sleeve contact, in accordance with various embodiments disclosed herein.

[0083] FIG. 8C illustrates a connector including the split bushing and sleeve contact, in accordance with various embodiments disclosed herein.

[0084] FIG. 8D is a cross-sectional view of the connector shown in FIG. 8C, in accordance with various embodiments disclosed herein.

[0085] FIGS. 9A-9G illustrates an alternate screw-less termination connector, in accordance with various embodiments disclosed herein.

[0086] FIG. 10A is a perspective view of a sleeve contact with heat sink, in accordance with various embodiments disclosed herein.

[0087] FIG. 10B is a front view of the sleeve contact with heat sink as shown in FIG. 10A, in accordance with various embodiments disclosed herein.

[0088] FIG. 11 A is a perspective view of a sleeve contact with venting elements, in accordance with various embodiments disclosed herein.

[0089] FIG. 11 B is a perspective view of another sleeve contact with venting elements, in accordance with various embodiments disclosed herein.

[0090] FIG. 12A illustrates a contact carrier with venting elements, in accordance with various embodiments disclosed herein.

[0091] FIG. 12B illustrates a contact carrier with a liquid cooling system, in accordance with various embodiments disclosed herein.

[0092] FIGS. 13A-13D illustrate various plugs and receptacles with different keying features, in accordance with various embodiments disclosed herein.

[0093] FIGS. 14A-14B are oblique views depicting a latching connectivity device with contacts arranged in a circular pattern, in accordance with various embodiments disclosed herein.

[0094] FIGS. 14C-14E are cutaway views depicting a connectivity device with spring loaded contacts, in accordance with various embodiments disclosed herein.

[0095] It should be understood that the drawings are for purposes of illustrating the concepts of the disclosure and are not necessarily the only possible configuration for illustrating the disclosure. It should be noted that the features illustrated in the drawings are not necessarily drawn to scale, and features of one embodiment may be employed with other embodiments as the skilled artisan would recognize, even if not explicitly stated herein. Descriptions of well-known components and processing techniques may be omitted so as to not unnecessarily obscure the embodiment.DETAILED DESCRIPTION

[0096] The various exemplary embodiments disclosed herein provide connectivity devices with reduced insertion and extraction forces that are easier to mate and unmate. Some of the various embodiments provide connectivity devices with greater conductivity characteristics.

[0097] As used in this application, terms such as “front,” “rear,” “side,” “top,” “bottom,” “above,” “below,” “upwardly” and “downwardly” are intended to facilitate the description of the electrical connector according to the present disclosure and are not to be construed as limiting the structure of the electrical connector to any particular position or orientation.

[0098] Referring to FIG. 1 , a male plug 1 for mating with a female receptacle 10 of a pin-and-sleeve type electrical connector is shown. As used in this application, the term plug relates to a male half of a pin-and-sleeve electrical connector, and the term “receptacle” relates to a female half of a pin-and-sleeve electrical connector regardless of how the receptacle is mounted, e.g., surface mounted, in-wall mounted or panel mounted, or how the receptacle is connected to a power source, e.g., connected to a power source via a cable. However, it should be readily appreciated that the plug may bea female half of the pin-and-sleeve electrical connector, and the receptacle may be a male half of the pin-and-sleeve electrical connector.

[0099] The plug 1 has a cylindrical front safety shroud 1 a surrounding a plurality of line contact pins 1 b and a rotatable locking ring 1d. In some embodiments, the shroud 1 a may also surround a ground contact pin 1 e. The line contact pins 1 b within the plug 1 are adapted to mate with contact sleeves 8 within sleeve carrier 30 in the receptacle 10. The ground contact pin 1 e is adapted to mate with a ground sleeve assembly. The shroud 1 a of the plug 1 has an integrally formed, radially projecting indexing rib 1 c at its front end. The indexing rib 1 c, which may be a tab, interacts with a keyway 20 of the receptacle 10. The rotatable locking ring 1d has two lugs (not shown) adapted to mate with two standard ramped locking flanges 2a at the front end of an upper housing 2 of the receptacle 10. A standard butted rubber gasket (not shown) seals the interface between the plug 1 and the receptacle 10 when they are fully mated.

[0100] The receptacle 10 has an upper housing 2 and a lower housing 36. The lower housing 36 is secured to the upper housing 2 using, for example, screws with an interposed sealing gasket between the two housings. In one exemplary embodiment, the lower housing 36 can be configured for connection to a cable. In another exemplary embodiment, the upper housing 2 can be mated instead to various adapters (not shown) using screws to enable mounting of the receptacle 10 on a surface, in a wall, in a panel, etc. A sleeve or contact carrier 30 according to the present disclosure is positioned within the receptacle 10.

[0101] FIG. 2 illustrates an exploded view of the receptacle 10 according to an embodiment of the present disclosure. As illustrated, the receptacle or connector 10 includes a contact carrier 30. The contact carrier 30 includes one or more power terminals 32 located on a first end 34 of the contact carrier 30. Although not illustrated, the contact carrier 30 may further include one or more second power terminals located on a second end 36 of the contact carrier 30. Although illustrated as having four power terminals 32, the connector 10 may include any number of power terminals and second power terminals, for example one power terminal and one second power terminal, two power terminals and two second power terminals, three power terminalsand three second power terminals, four power terminals and four second power terminals, five power terminals and five second power terminals, etc.

[0102] FIG. 3 illustrates an exploded view of the contact carrier 30 according to some embodiments of the present disclosure. As illustrated in the exploded view of FIG. 3, the contact carrier 30 includes a shell 38, a cover 40 and one or more connector contacts 42. The shell 38 is formed of a non-conductive material, such as but not limited to, a plastic material. The cover 40 is also formed of a nonconductive material, such as but not limited to, a plastic material. The shell 38, in conjunction with the cover 40, houses various components of the contact carrier 30. The one or more connector contacts 42 provide an electrical connection between the power terminals 32 and the second power terminals. In certain embodiments, the connector contacts 42 are contact sleeves configured to receive a contact pin of a male contact.

[0103] FIGS. 4A-D depict embodiments of pin-and-sleeve type connectors for use in achieving various of the advantageous features of the present disclosure. As shown in FIG. 4A, a pin-and-sleeve connectivity device 100 is provided with a male portion 101 having one or more pins 103 having a tapered diameter 105.The connectivity device 100 also includes a female portion or sleeve 102 having a metallic spring element 104 located within the chamber 106 of the sleeve 102 and positioned to exert mechanical force on a respective insertion pin 103. The pin insertion force is the force required to insert the insertion pin 103 into the sleeve 102. The pin retraction force is the force required to remove the insertion pin 103 from the fully inserted position out of the sleeve 102.

[0104] As will be appreciated by one of ordinary skill in the art, the mechanical force between the spring element 104 and the insertion pin 103 serves to create a low impedance electrical connection between the pin and sleeve. Temperature rise at the mating interface correlates to the impedance and a certain minimum amount of “normal force” is needed at the contact mating interface to achieve a “good” connection. The spring element 104 also contributes to the conductivity between the sleeve 102 and insertion pin 103.

[0105] The present inventors discovered that the pin insertion force can be significantly reduced by altering certain design characteristics of pin-and-sleeve connectivity devices 100 to allow for a gradual taper 105 of insertion pin 101. Theinsertion force is significantly lowered by adding the gradual taper 105 on distal ends 107 of insertion pins 103. In some forms, the tapered section 105 begins at the edge of the chamfered section 109 (or rounded edge) and extends in a proximal direction a length at least equal to one-half the full pin diameter 1 13 of insertion pin 103.

[0106] In some embodiments, the insertion pin 103 has a chamfered section 109 to aid in lining up the insertion pin 103 with the sleeve 102 as the pin 103 is first being inserted. In some forms, the chamfered section 109 runs around the edge of the distal end 107 of insertion pin 103 and is typically angled at 45° + / - 15° from the flat middle portion of distal end 107. Some implementations of insertion pin 103 may have a rounded edge rather than a chamfered section 109. In some forms, the chamfered section 109 may be extended from the distal end 107 a distance of at least 10% the full pin diameter 1 13 of insertion pin 103.

[0107] In some forms, the tapered section 105 extends from the edge of the chamfered section 109 in the proximal direction a length of at least one-half but no greater than ten times the full pin diameter 1 13. In some typical implementations, the tapered section 105 extends in the proximal direction a length of between one and ten times the full pin diameter 113 of insertion pin 103. In one implementation the tapered section 105 extends in the proximal direction a length of 4.0 + / - 3.5 times the full pin diameter 1 13.

[0108] The tapered section 105 preferably slopes gradually such that the pin edge diameter 129 at the edge of chamfered section 109 is less than the full pin diameter 1 13 further along the pin 103 in the proximal direction. A typical angle of slope of the chamfered section 109 — the taper angle 1 15 — is 1 .0° + / - 0.5°. A taper angle 1 15 of 1 .0° will significantly lower the insertion force by allowing the pin to encounter less friction from the spring during lateral force insertion. In other implementations the taper angle 1 15 may be: is 1 .5° + / - 0.75°; 1 .5° + / - 1 .0°; 2.0° + / - 1 .5°; 2.5° + / - 2.0° or any other angle of slope or range between 0.35° and 5.5°. Choosing an optimal taper is well within the ability of one of ordinary skill in the art armed with the present specification through routine experimentation taking into account the size of the connector and the spring force to be encountered.

[0109] FIG. 4B is a cutaway view depicting a pin-and-sleeve connectivity device 100 with a reduced spring element engagement, in accordance with various embodimentsdisclosed herein. Reducing the engagement of the spring element 104 inside the female sleeve 102 is another design characteristic that aids in reducing the pin insertion force. This may be done by slightly increasing the inside diameter (ID) 114 of spring element 104 so it fits more loosely around the insertion pin 103, or by using a spring element 104 with less spring force so that it gives more easily as the insertion pin 103 slides into it. Reducing the engagement of the spring element 104 inside the female sleeves 102 reduces the force needed to mate the pins 103 into the sleeves 102. In at least one embodiment, the spring has an inside diameter of 0.353 inches (as illustrated in FIG. 4B). Increasing the spring inside diameter to greater than 0.353 inches — e.g., to 0.383 inches — achieves the desired reduction in pin insertion force.

[0110] FIG. 4G is a cutaway view depicting a pin-and-sleeve connectivity device 100 with multiple spring elements 104 in the insertion sleeve 102, in accordance with various embodiments disclosed herein. The multiple spring elements 104 are used to overcome reduced engagement of using one spring element, the reduced engagement may increase the contact resistance through the pin-spring mating interface, causing a temperature increase of the pin-and-sleeve connectivity device 100 when under a current load. Although FIG. 4G illustrates devices 100 with two springs 104 and three springs 104, it is to be appreciated the number of springs may be varied to achieve a desired effect.

[0111] Each spring element 104 creates a fixed number of “asperity spots”, also referred to as A-spots, for current to pass through. Multiple spring elements 104 create more A-spots. The more A-spots there are, the lower contact resistance and temperature rise. The use of additional spring elements 104 can help reduce the increased temperatures within the sleeve 102 by increasing the number of contact spots for the current to pass through, thus increasing the electrical conductivity which results in lowering of the temperature.

[0112] With a single spring, when inserting a pin into a sleeve, there’s an initial peak insertion force when the leading edge of the pin first engages with and deforms the spring 104. After the spring is opened up to the pin’s full diameter (e.g., diameter 1 13), then the subsequent insertion force is just the sliding friction which is less than the peak insertion force. When a pin is removed from the sleeve, only the lower sliding force is experienced.

[0113] With multiple springs, the peak insertion force does not increase proportionally with the number of springs. For example, when two springs are present, the peak insertion force is not two times greater than that of a single spring. In both cases, the tip 107 of the pin 103 will only encounter one spring 104 at a time. Having multiple springs 104 does increase the sliding friction between the pin 103 and the spring 104. But this can be tuned by increasing the spring ID 114. The spring ID 114 can be increased quite significantly to have a “light touch” with the pin which results in lower sliding friction. This decreased normal force between spring and pin may increase the contact resistance of each touch point. But having multiple springs will offset the increases contact resistance by creating many more touch points.

[0114] In operation, the effort is to maximize the number of touch points between the spring and the sleeve while minimizing the normal force at each touch point. Thus, one of ordinary skill in the art can optimize for pin insertion and withdrawal force and for low temperature rise, by controlling the number of springs and the spring ID using only routine experimentation.

[0115] When pins 103 insert into springs 104, the springs 104 extend and become longer from pin insertion as the spring arms lengthen. For a single spring 104, only two ends 121 of the spring engage into a single sleeve pocket 123. By contrast, the multiple spring design, e.g., the three spring design as shown in FIG. 4G, has 6 spring ends 121 and the 3 inward facing ends 125 will all extend inward when a pin is engaged. As the sharp edges of the springs (i.e., ends 121 ) can dig into the sleeve pockets 123, it creates some friction and adds to insertion force.

[0116] Variations in the installed condition of multiple springs may be minimized by configuring multiple springs as a single spring 130, 140 as shown in FIG. 4D(a)-(d). With the spring convolutions 132 connected by the center spring bands 134, 136, the entire spring 130 can deflect in unison and makes pin insertion forces more uniform. It is to be appreciated that a single spring will also have more consistent performance and uniformity of radial force.

[0117] In operation, the pin taper angle is another variable that may be optimized according to the present disclosure. In sum, any desired optimization to minimize the peak insertion force, to minimize the sliding force, and / or to minimize the temperature riseby controlling the pin tip shape and taper, the spring ID, the number of springs, and / or optionally adding highly conductive plating are all well within the ability of one of ordinary skill in the art armed with the present disclosure using only routine experimentation.

[0118] Pin and sleeve contacts with high current rating typically have high insertion forces. This makes it difficult for operators to mate a plug with a connector or receptacle. In accordance with an embodiment of the present disclosure, the pin tip taper may be optimized to minimize insertion force. For example, referring to FIG. 4E, a pin tip with a blended radii is illustrated. The tip of pin 103 includes a first chamfered portion 114 and a second chamfered portion 1 16. The first chamfered portion 114 is at an angle of 15 degrees. The combination of the first and second chamfered portions 1 14, 116 creates a decreasing radius of the tip as the tip extends to the distal end. The blended radii makes the angle transition less severe which reduces insertion force. It is to be appreciated that the more gradual the angle the better to lower insertion force. A large transition radii also benefits lower insertion forces. It is further to be appreciated that although a 15 degree angle is described and shown other angles are contemplated to be within the scope of the present disclosure. For example, in one embodiment, an insertion pin may include a fully rounded or semi-spherical tip. In this embodiment, the rounded or semi-spherical tip minimizes corners which are unfavorable for arcing performance.

[0119] In addition to multiple springs, in some forms, a sleeve may be configured to make sure one or more or pairs of half-round spring members 120 as shown in FIG. 4F. In an embodiment depicted in FIG. 4G, one or more pairs of cooperating half-round spring members 120A, 120B are disposed in a sleeve 102 and squeezed between the half-round spring elements 120A, 120B. With this configuration, dimensional variations among pins are easily accommodated in a given connector. As will be appreciated, the multiple individual spring elements ensure constant contact pressure on the pin.

[0120] In addition to multiple springs, in some forms, a split sleeve contact may be configured to increase a number of A-spots between the sleeve and pin. Referring to FIGS. 5A and 5B, perspective views of a split sleeve contact 200 are illustrated, where FIG. 5C is a cross-sectional view of the split sleeve contact 200. The split sleeve contact 200 has a first end 202 and a second end 204 and includes a termination portion 203 and sleeve portion 205. The termination portion 203 includes a first aperture 206 for receivingan end of a conductor and a second aperture 208 for receiving a set screw for securing the end of the conductor in the first aperture 206. A channel 210 runs along the longitudinal axis of the contact 200 from the first end 202 to the second end 204. The sleeve portion 205 includes a plurality of contact members 212 separated by a plurality of slits 214. The contact members 212 are concentrically arranged around the channel 210 to receive a pin (not shown). Each contact member 212 is individually coupled to the termination portion 203 such that each contact member 212 may individually flex upon receiving the pin.

[0121] Referring to FIG. 5C, each contact member 212 is configured to include a plurality of contact points 216 on an inner surface of the formed channel 210. Each contact member 212 includes a slot 218 disposed on an outer surface of the contact member 212. Respective slots 218 on each contact member 212 align to receive a generally circular ring spring 220. When a pin is inserted into the channel 210 via the second end 204, the springs 220 will apply a force on the contact members 212 to urge the contact points 216 toward the center of the channel 210 and maintain contact with the pin. Each contact point 216 will create an A-spot, the more contact points 216 the better electrical performance, e.g., reduce contact resistance and temperature rise.

[0122] FIG. 6A is an oblique view depicting a pin-and-sleeve connectivity device 300 with silver plating on key surface areas, in accordance with various embodiments disclosed herein. The conductivity of the pin and sleeve contacts can be increased by plating the surfaces with a high conductivity material such as silver. The use of selective plating, utilizing silver on all interfacing surfaces, is added to the electrical contacts as shown in FIG. 6A. These areas include the surface where the spring 104 touches the sleeve 102 and the surface of the pin 103 that touches the spring 104. Referring to FIG. 6A, an insertion pin 300 is shown. The surface 340 of the pin 300 that contacts the inner surface of a spring is plated with a highly conductive material. Additionally, the conductor receiving portion 342 of the termination portion 344 of pin 300 may be plated. The thickness of silver is optimized to maximize electrical efficiency, thereby minimizing resistance that generates unwanted heat that has to be managed and removed, increasing operating cost.

[0123] In some implementations the plating 340, 342 is only be applied to critical areas where contact is made in order to save on material costs. In other implementations, entire contact is plated to streamline the manufacturing process.

[0124] It is to be appreciated that the conductivity of silver being 4x copper means that an additional conductive component can create more efficient heat transfer between the copper conductor and the copper termination sleeve. A silver-plated ferrule may be more cost effective and an easier alternative to silver plating the pin contact or the sleeve contact. A silver ferrule adds a highly conductive path between the wire and the terminal. For this to happen, the additional component layer (i.e., a sliver plated ferrule) must be fully compressed radially against the conductor and the sleeve bore.

[0125] Referring to FIGS. 6B-6D, a sliver-plated ferrule 352 disposed in a termination portion 354 of a sleeve contact 356 is illustrated. The silver-plated ferrule 352 is generally cylindrical with a flared end 353, wherein a diameter of the flared end 353 is larger than a diameter of the cylindrical portion 355 of the ferrule 352. The cylindrical portion 355 of sliver-plated ferrule 352 is disposed in the termination portion 354 and an end of a conductor 358 is then disposed in the flared end 353 of the ferrule 352. Screws 360, 362 are then tightened to compress the ferrule 352 against the conductor 358 and the sleeve bore 364.

[0126] To maximize performance of the ferrule 352, certain design considerations must be implemented. Control of ferrule diameters, both outer diameter (OD) and inner diameter (ID) are extremely important. Minimal clearances are necessary to minimize the effect of the conductor 358 extruding into the terminal bore 364 where it is not in the current path. Only if the conductor 358 makes physical contact with the terminal bore 364 is the current path maximized. The ferrule 352 limits the amount that the conductor 358 can extrude away from the terminal bore 364. As the conductor 358 extrudes, the ferrule 358 also extrudes and continues to make contact with both the conductor 358 and the terminal bore 364.

[0127] In further implementations, the pin and / or sleeve contact may be made of highly conductive contact materials. Contacts heat up while carrying a high current. Existing pin- and-sleeve connectors use brass for the contacts. Typically, brass has an electrical conductivity ranging from 23% to 44% IACS, depending on the specific type of brass. Forreference, the conductivity of copper is 100% IACS. In one embodiment, the pin and sleeve contacts are constructed from Tellurium Copper (C14500: 99.2 to 99.596% copper, 0.4 to 0.7% tellurium, and 0.004 to 0.012% phosphorus) with electrical conductivity of about 90% IACS. Other material may include but are not limited to Copper Chromium (C18200: nominal composition of 99.1 % copper and 0.9% chromium, the chromium content typically falls within a range of 0.6% to 1 .2%.; -80% IACS) and Copper Zirconium (C15000: 99.8% min copper and 0.1 -0.2% zirconium; -80% IACS). By employing such materials for pin and sleeve connectors lower temperature rise and improved resistance to arcing can be achieved. It is to be appreciated that the pin and sleeve contacts may be made from bar stock of a cooper alloy by several machining methods, including CNC machining, milling machining, turning machining, grinding and drilling. In another embodiment, the pin and sleeve contacts may be configured from a copper alloy specifically design to enhance electrical and thermal conductivity by a copper casting process, for example, sand casting shell mold casting, investment casting, centrifugal casting, continuous casting, etc. In a further embodiment, the pins and sleeve contacts may be configured from a copper alloy using a metal injection molding process or 3D printing process.

[0128] In operation, when a user desires to make an electrical connection using a pin- and-sleeve configuration of the types described above, the male end and female ends are brought into proximity. The pins of the male end are aligned with the respective pin receptacle openings of the female end. The alignment may be facilitated by the chamfered section as described above. The pins are then fictionally fit into the receptacles and lateral force is exerted to flex the springs radially to allow the pins to move laterally until the full length of the pins are received in the female receptacles and secured from the outside environment. The insertion force of the connection is eased by the tapering of the distal ends of the pins reducing the force necessary for insertion. The force may also or alternatively be reduced by providing one or more springs providing less radial spring force against the pins.

[0129] In various embodiments and uses, the female receptacles may make use of multiple springs to provide additional retention force, additional contact points for heatmitigation, or for other advantageous reasons. Likewise, the connector may use a sliver coating in areas of contact or throughout to provide additional conductivity benefits.

[0130] Terminal screws are typically used to connect a wire or conductor to a pin or sleeve connector. FIG. 7A illustrates a conventional connector 400. The connector 400 may be a sleeve connector or a pin connector. The connector 400 includes a termination portion 403 having a first aperture or cavity 406 for receiving a wire or conductor and a second aperture 408 for receiving a screw 409 for compressing and securing the wire or conductor in the first aperture or cavity 406. The possibility of stress relaxation of the compressed wire under a screw is a known phenomenon, which effects reliable power distribution that may be mission-critical in data centers.

[0131] By providing multiple termination screws, the possibility of stress relaxation can be reduced while increasing the high-pressure connection area between the wire and terminal to reduce contact resistance and temperature rise. Referring to FIGS. 7B and 7C, a connector 420 is illustrated in accordance with an embodiment of the present disclosure. The connector 420 includes a termination portion 423 having a first aperture or cavity 426 for receiving a wire or conductor. The connector 420 further includes second and third apertures 428, 430 for receiving screws 429, 432 respectively. By employing multiple screws 429, 432, the high-pressure connection area 434 of cavity 426 between the wire 436 and terminal 438 is increased as compared to conventional connector.

[0132] Further to the goal of reducing unwanted heat rise, the present disclosure provides alternative ways to terminate conductors. Conventionally, terminal screws are employed to engage terminal conductors. Conductivity relies on the screws pressing the conductor against the opposite wall in the terminal bore. Approximately half of the conductor surface area makes contact with the highly conductive sleeve material. Terminal screws are typically made from stainless steel and less conductive. In addition, the terminal bores are typically smooth. Adding points of asperity inside the terminal bore or cavity using threads or ribs creates predictable points of contact to the conductor to decrease contact resistance between the wire and the terminal. This will decrease joule heating.

[0133] Referring to FIG. 7D, a connector 450 is illustrated in accordance with an embodiment of the present disclosure. The connector 450 includes a termination portion452 having a first aperture 454 for receiving a wire or conductor. The connector 450 further includes second and third apertures 456, 458 for receiving screws 460, 462 respectively. As described above, a bore or cavity 464 of the termination portion 452 receives a conductor (not shown). The conductor is pressed into engagement of a surface of the bore or cavity 464. In this embodiment, the surface of the bore or cavity 464 is configured with threads 466 to create predictable points of contact to the conductor to decrease contact resistance between the conductor and the termination portion 452 of the contact 450. The decrease in contact resistance will decrease joule heating, as shown in FIG. 7E. FIG. 7E is an exemplary graph 470 comparing the temperature of a contact with no threads in the bore of the termination portion versus a contact with threads in the bore of termination portion. As can be seen in FIG. 7E, experimental results indicate that contacts having threads in the bore of the termination portion of the contact generate a lower temperature, i.e., due to decreased joule heating, then contacts with no threads.

[0134] Further to the goal of reducing unwanted heat rise, the present disclosure provides alternative ways to terminate conductors. Conventionally, terminal screws are employed to engage terminal conductors. Conductivity relies on the screws pressing the conductor against the opposite wall in the terminal bore. Approximately half of the conductor’s surface area makes contact with the highly conductive sleeve material. Terminal screws are typically made from stainless steel and less conductive, with a typical conductivity of 2-3% IACS. To further reduce contact resistance at the wire or conductor terminal, the terminal screws may be made from significantly more conductive materials that are sufficiently strong. For example, beryllium copper with 15- 30% IACS may be used in terminal screws (Beryllium copper C17200: copper 98%, beryllium 1 .8% to 2.0%, Cobalt + Nickel 0.2% combined minimum, Ni + Co + Fe 0.6 max, Al 0.20 max, Si 0.20 max). By doing so, the electrical path from the wire or conductor through the screw to the contact terminal is enhanced. In addition to beryllium copper, other high strength copper alloys exist, such as Copper-Titanium (CuTi) (e.g., C1990 Titanium Copper: 2.90-3.50% titanium and the remainder copper).

[0135] It is to be appreciated that the screws may be made from bar stock of a cooper alloy by several machining methods, including CNC machining, milling machining, turning machining, grinding and drilling. In another embodiment, the screws may be configuredfrom a copper alloy specifically design to enhance electrical and thermal conductivity by a copper casting process, for example, sand casting shell mold casting, investment casting, centrifugal casting, continuous casting, etc. In a further embodiment, the screws may be configured from a copper alloy using a metal injection molding process or 3D printing process.

[0136] In a further embodiment of the present disclosure, connectors not utilizing terminal screws are provided. Referring to FIGS. 8A-8D, a connector 500 includes a threaded split bushing 502 that engages into a threaded sleeve 504. The split bushing 502 includes at least four members 510 that extend from a hex driver 512, as shown in FIG. 8A. The member 510 are arranged to form a channel 514 for receiving a conductor 508. Each member 510 includes a first end 516 coupled to the hex driver 512 and a second free end 518. At least a portion of the first end 516 includes a threaded outer surface 520. Additionally, at least a portion of the second end 518 includes a threaded internal surface 522. Referring to FIG. 8B, the sleeve 504 includes a sleeve portion 530 configured to receive a pin and an engagement portion 532. As shown in FIGS. 8B and 8D, the engagement portion 532 includes a bore or channel 533 that includes a threaded portion 534 and a tapered portion 536. The taper on the sleeve bore 533 ensures that advancement of the split bushing 502 reduces the bushing diameter and compresses the conductor 508, as will be described below. Although the engagement portion 532 is shown as generally rectangular, it is contemplated that other shapes may be used and still be within the scope of the present disclosure, e.g., cylindrically shaped.

[0137] It is to be appreciated the split bushing 502 works like a ferrule, compressing around the conductor 508 inside the terminal bore 533. To create the compression, the external threads 520 of the split bushing 502 engage the internal threads 533 in the sleeve 504. The sleeve bore 533 is tapered so that the further the bushing 502 enters the bore 533, the more the members 510 of the bushing 502 collapses and the more the members 510 compresses the conductor 508. In addition, the threads or ribs 522 on the inside diameter the split bushing 502 create multiple points of asperity to decrease contact resistance between the wire and the terminal. The decrease in contact resistance will decrease joule heating.

[0138] It is to be appreciated that the bushing engages most of the outer surface area of the conductor, and, if the length of engagement can be maximized, contact resistance will be reduced. It is to be further appreciated that the split bushing inner diameter (ID) must sized closely to the expected diameter of the conductor to yield the best compression.

[0139] In another embodiment, a termination connector utilizes a split sleeve with .5 degree taper on OD threads and ID threads for asperity points on the conductor. Referring to FIGS. 9A-9G, a termination connector 600 is illustrated. Connector 600 includes a capture nut 602 and a sleeve 604. The capture nut 602 includes a hex driver 606 and a cylindrical portion 609. The sleeve 604 includes a receiving portion 610 comprised of flexible members 612 that are configured to create a channel 614. The sleeve 604 includes threads on an outside surface of the receiving portion and the receiving portion has slots which enable the flexible members 612 to directly compress against the conductor 608.

[0140] Referring to FIG. 9E, sleeve 604 includes a threaded portion 620 and a smooth, or non-threaded, cylindrical portion 622. The smooth surface 622 is configured with a 0.5 degree taper all of the surfaces of each member 612. The slotted sleeve beams or members 612 will deflect but the members 612 need to deform to become coincident and concentric w / the conductor when nut 602 is tightened. The termination process would require a stripped conductor to install through the nut 602 as shown in FIG. 9F. Then, both the capture nut 602 and conductor 608 can be loaded into the sleeve. As shown in FIG. 9G, a surface 624 on the leading edge 626 of the capture nut 602 will make contact w / the taper on the sleeve 604. Surface 624 will interfere with the members 612 of the sleeve 604 to collapse sleeve when nut 602 is tightened.

[0141] Further to the goal of reducing unwanted heat rise, the present disclosure provides alternative ways to dissipate heat from conductors and / or contacts.

[0142] Joule heating of contacts contributes to temperature rise while a device carries current. In one embodiment, a heat sink may be applied to a contact to buffer against heat spikes from transient high current draw. Referring to FIGS. 10A-10B, a sleeve contact 700 is provided for reducing a peak temperature rise from transient high current draw. Sleeve contact 700 has a first end 702 and a second end 704 and includes atermination portion 703 and sleeve portion 705. The sleeve portion 705 includes a plurality of fins 707 that extend radially from a longitudinal axis of the sleeve contact 700. It is to be appreciated that the heat sink fins 707 may be attached as a separate component (e.g., a sleeve component) or may be integral to the sleeve portion 705. The heat sink fins 707 will draw heat generated inside the sleeve portion 705, e.g., at contact points between a spring and conductor, away from the conductor.

[0143] In a further embodiment, a connector 800 is provided with venting slots 810 as shown in FIG. 1 1 A. Sleeve contact 800 has a first end 802 and a second end 804 and includes a termination portion 803 and sleeve portion 805. The sleeve portion 805 includes a plurality of venting slots 810 which enable heat dissipation at contact points between a spring and conductor. In one embodiment, each venting slot 810 is aligned with an internally disposed spring contact 812 such that contact points that are created at the concave portions of the spring contact are exposed through the venting slots 810. Although the venting slots 810 are shown in FIG. 11 A on one side of the sleeve portion 805, it is to be appreciated that the venting slots 810 may be disposed on both side of the sleeve portion 805 or in any other position on the sleeve portion 805.

[0144] In another embodiment, a modified version of contact 200 described above in relation to FIGS. 5A-5B is provided to have improved heat dissipation. Referring to FIG. 1 1 B, a split sleeve contact 850 has a first end 852 and a second end 854 and includes a termination portion 853 and sleeve portion 855. A channel 860 runs along the longitudinal axis of the contact 850 from the first end 852 to the second end 854. The sleeve portion 855 includes a plurality of contact members 862 separated by a plurality of slits 864. The contact members 862 are concentrically arranged around the channel 860 to receive a pin (not shown). Each contact member 862 is individually couped to the termination portion 853 such that each contact member 862 may individually flex upon receiving the pin. In this embodiment, portions of each contact member 862 includes at least one recess 866 along a respective slit 864 forming venting slots 868 with adjacent contact members 852.

[0145] Prior art housings, e.g., a plug and / or receptacle of a pin-and-sleeve connector, trap heat which contributes to temperature rise while device carries current. In one embodiment of the present disclosure, thermally conductive plastic may be used to makethe housings to help dissipate heat. In a further embodiment, venting elements in the housings may be provided. Referring to FIG. 12A, a contact carrier 900 with venting elements 902 is illustrated. The venting elements 902 are positioned on an outer surface of the contact carrier 900 to align with contact sleeves 904 with the carrier 902, i.e., to be parallel to the contact sleeves. The vents dissipate heat from within the wiring device. The dissipated heat is carried away from a data center’s cooling infrastructure.

[0146] In other embodiments, the housings of the wiring device are cooled by liquid circulation. In one embodiment, a contact carrier 910 includes a liquid circulation system 903 that circulates a dielectric (i.e., non-conductive) coolant through a wiring device’s interior, as shown in FIG. 12B. In this embodiment, the contact carrier 910 includes a plurality of ducts 905 that are arranged with the housing of the contact carrier 910. An input port 906 feeds the coolant to the ducts 905 and an output port 908 allows the coolant to exit the housing. The liquid cooling enables a wiring device to handle multiple times the current versus prior art. In another embodiment, a sealed liquid circulation module (e.g. “cold plate”) may be disposed within or on a wiring device. In one embodiment, a circulation module may be configured as a cylinder to be placed over the contact carrier. In another embodiment, the circulation module may be configured as a curve plate to be placed in contact with a portion of the contact carrier.

[0147] The above-described embodiments enable a plug / connector with 100A current rating but in the size of existing 60A pin-and-sleeve devices. Keying of 60A devices is standardized in IEC 60309-2 as “clock positions” - e.g. 1 o’clock, 2 o’clock etc. The IEC configurations are arranged like hour hands on a clock face where each configuration has 1 hour increments. The ground GND position is always synonymous with the location of the hour hand on the clock face. The novel 100A device must not have these standard clock positions to prevent mating with existing 60A devices.

[0148] The novel 100A design of the present disclosure has keys in the half-hour positions, e.g. 12:30 position, instead of the standard 12:00 position. By creating1 / 2 hour locations, the unique locations would not violate IEC configurations and would insure no intermating could every occur, i.e., the keying locations of the present disclosure would only allow mating of like plug and connector in terms of current / voltage rating. A 12:30 keyed device will reject mating with a 60A 12:00 or 1 :00 device, for example. Referring toFIG. 13A, a plug and receptacle are illustrated showing the pins 1302 and sleeves 1306, respectively, arranged in a circular manner about a center point 1304. A corresponding ground GND pin 1308 and ground GND sleeve 1310 are positioned at 11 :30 in accordance with an embodiment of the present disclosure. Referring to FIG. 13B, a plug and receptacle are illustrated showing the ground GND position at 12:30 in accordance with an embodiment of the present disclosure.

[0149] Referring to FIGS. 13C and 13D, a plug and receptacle combination are illustrated to show the magnitude of the 15 degree uniqueness between 1 hour and1 / 2 hour positions and how the new GND positions are incapable of mating with an IEC configuration. In FIG. 13C, the GND position 1320 of the receptacle is 12:00 while the plug has a GND position 1322 of 12:30. In FIG. 13D, the GND position 1324 of the receptacle is 12:00 while the plug has a GND position 1326 of 11 :30. The 15 degree shift in locations from the 1 hour positions to the1 / 2 position ensures no intermating of mismatched voltage / current occurs.

[0150] Advantageously, the half-hour keying enables a connector manufacturer to use existing injection mold tooling for 60A devices. The half-hour keying is accomplished with new mold inserts which are more cost effective and faster than building new molds.

[0151] FIGS. 14A-14B depict alternative configurations for electrical connectors for use in achieving various of the advantageous features of the present disclosure. With these embodiments, the connectivity devices use external latch mechanisms 1402 to facilitate mating and unmating of connectors 1400.

[0152] FIGS. 14A-14B depict an embodiment of a round connector 1400 having a male portion 1404 and a female portion 1406. In the embodiment shown, male portion 1404 include a plurality of conductive pins and the female portion 1406 includes a plurality of respective female pin receptacles. In order to facilitate insertion of the pins into the receptacles, the connector 1400 is provided with a latch member 1450. In some embodiments, the latch member 1450 comprises a latch body 1451 having a latch handle 1459, a pivot point hub 1452 having a pin opening 1453, and a clamping extension 1455 defining an arcuate latching groove 1456 with an open pin receiving end terminating in a cradle portion 1458. As depicted, in some forms, these features are provided on both sides of the latch body 1451 .

[0153] The latch body 1451 may be pivotably secured to either the male 1404 or female 1406 portion of the connector 1400 (shown in FIG. 14A-14B on the male portion for illustration purposes) by a pivot pin extending through the pin opening 1453 of the pivot point hub 1452. In some forms, the female portion 1406 is provided with mating bosses 1470 disposed in an area where upon partial or near entry of the pins into the receptacles. With this configuration, the latch body 1451 may be rotated downwardly such that the pin receiving end of the latching groove 1456 provided in the clamping extension 1455 engages the bosses 1470 when partially rotated downwardly (as best shown in FIG. 14B).

[0154] Once engaged by the clamping extension 1455, further force provided to rotate the handle 1459 to the closed position (best shown in FIG. 14A) provides force on the bosses 1470 that pulls the male 1404 and female 1406 portions together due to the curvature of the latching groove 1456 until the bosses 1470 reach the cradle 1458 of the groove 1456 and the handle 1459 is fully engaged in the closed position and the connection is fully made.

[0155] As will be appreciated, with this configuration, it is the relative spacing of the bosses 1470 and the cradle 1456 that allow the latch 1450 to be fully engaged and the connector 1400 fully secured from the outside environment. As will also be appreciated, the physics of a fulcrum and lever allow for this connection to be made by a user at a fraction of what a traditional force-fit by hand would require to secure the connector together.

[0156] In some embodiments, the lever action of the latching mechanism 1450 may result in difficulty separating the connector by hand. To facilitate disconnection, some latching connectors 1400 may be provided with spring loaded contacts. As shown in FIGS. 14C-E, a connectivity device may be provided with spring loaded contacts comprising a spring and a plunger assembly 1423 with spring member 1427 and plunger 1429.

[0157] In some forms, such as the depicted embodiment, a spring-loaded plunger 1423 is housed in the female connector which can push the male connector out and away from the female connector to make unmating easier. The spring loading applies force to ensure a good electrical connection between the male and female contacts. In operation,when a latch 1450 is released, the male device does not require much, if any, force to remove it since the spring-loaded plunger assembly 1423 pushes the male and female connectors apart.

[0158] In alternative forms making use of spring-loaded butt contacts 1499, the spring loaded plunger 1423 may not be necessary. FIG. 14D shows an embodiment of a connectivity device with spring loaded contacts in the released position 1499A. FIG. 14E shows a connectivity device with spring loaded contacts in the engaged position 1499B. The use of spring-loaded butt contacts (as shown in FIGs. 14D-E), aids in reducing unwanted heat generation by maintaining a larger force between the engaged contacts.

[0159] One of ordinary skill in the art armed with the present specification will readily appreciate that the exemplary pin-and-sleeve embodiments described above were provided for explanatory purposes and are not to be interpreted as limiting the present disclosure to any of the specific features, combinations, configurations, form factors, or other limitations described in connection with the embodiments depicted in the figures. It is to be appreciated that the various features shown and described are interchangeable, that is a feature shown in one embodiment may be incorporated into another embodiment.

[0160] Any known method to insure proper insertion of the male portion may be used in a given construction. For example, the pin openings and pins may be in a specific pattern ensuring only a single mirror image configuration for mating. Likewise, the central bore and / or pin openings may be keyed to match a profile of the central extension of the male connector.

[0161] While not shown in the various exemplary embodiments, the connectors disclosed herein may be provided with other mechanical friction connections or the like to visually or audibly ensure a full connection, and / or prevent inadvertent disconnection, and / or lock connectors in a closed position.

[0162] One of ordinary skill will appreciate that the exact dimensions and materials are not critical to the disclosure and all suitable variations should be deemed to be within the scope of the disclosure if deemed suitable for carrying out the objects of the disclosure.

[0163] One of ordinary skill in the art will also readily appreciate that it is well within the ability of the ordinarily skilled artisan to modify one or more of the constituent partsfor carrying out the various embodiments of the disclosure. Once armed with the present specification, routine experimentation is all that is needed to determine adjustments and modifications that will carry out the present disclosure.

[0164] The above embodiments are for illustrative purposes and are not intended to limit the scope of the disclosure or the adaptation of the features described herein to particular electrical connectors. Those skilled in the art will also appreciate that various adaptations and modifications of the above-described preferred embodiments can be configured without departing from the scope and spirit of the disclosure. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described.

Claims

WHAT IS CLAIMED IS:1 . A pin-and-sleeve electrical connectivity apparatus comprising: a male connector; an insertion pin of conductive material with a distal end and a proximal end configured as part of the male connector, the insertion pin having a full pin outside diameter; a tapered section of the insertion pin positioned towards the distal end of the insertion pin; a female connector; a sleeve configured as part of the female connector, the sleeve having a sleeve inside diameter; wherein the sleeve inside diameter is larger than the full pin outside diameter of the insertion pin; and wherein the sleeve is configured to receive the insertion pin to make an electrical connection.

2. The pin-and-sleeve electrical connectivity apparatus according to claim 1 , further comprising: a spring element configured as part of the female connector, the spring element having a spring inside diameter; wherein the spring inside diameter of the spring element in the released position is smaller than the full pin outside diameter of the insertion pin; and wherein the spring inside diameter of the spring element in the engaged position is at least as large as the full pin outside diameter of the insertion pin.

3. The pin-and-sleeve electrical connectivity apparatus according to claim 1 , further comprising two or more springs elements configured as part of the female connector, said two or more spring elements providing holding force for said insertion pin and providing multiple areas of electrical contact.

4. The pin-and-sleeve connectivity apparatus according to claim 3, further comprising silver plating in at least said areas of said electrical contact.

5. The pin-and-sleeve electrical connectivity apparatus according to claim 1 , further comprising: a chamfered section positioned between the distal end and the tapered section.

6. The pin-and-sleeve electrical connectivity apparatus according to claim 1 , wherein the chamfered section has an angle of 45.0° + / - 15.0°.

7. The pin-and-sleeve electrical connectivity apparatus according to claim 1 , wherein the tapered section has a taper angle of 2.5° + / - 2.0°.

8. The pin-and-sleeve electrical connectivity apparatus according to claim 7, wherein the tapered section extends away from the distal end of the insertion pin a distance at least equal to one-half the full pin outside diameter.

9. The pin-and-sleeve electrical connectivity apparatus according to claim 8, wherein the tapered section has a taper angle of 1 .5° + / - 0.75°.

10. The pin-and-sleeve electrical connectivity apparatus according to claim 9, wherein the tapered section extends away from the distal end of the insertion pin a distance at least equal to the full pin outside diameter.1 1 . The pin-and-sleeve electrical connectivity apparatus according to claim 1 , further comprising two or more springs elements configured as a single spring, each of the two or more springs include a first end and a second end with a convolution portion disposed therebetween, wherein a first end of a first spring is coupled to a second end of a second spring, the single spring disposed in the sleeve.

12. The pin-and-sleeve electrical connectivity apparatus according to claim 1 , wherein a tapered section of the insertion pin is configured in a semi-spherical shape.

13. The pin-and-sleeve electrical connectivity apparatus according to claim 1 , wherein the male connector and female connector include a termination portion for receiving a conductor, the termination portion including an internally threaded surface to reduce contact resistance with the conductor.

14. The pin-and-sleeve electrical connectivity apparatus according to claim 13, wherein the termination portion includes a cavity that receives the conductor and at least two apertures arranged circumferentially to the cavity, each aperture configured to receive a screw to secure the conductor in the cavity.

15. The pin-and-sleeve electrical connectivity apparatus according to claim 14, wherein the screw includes a high strength copper alloy.

16. The pin-and-sleeve electrical connectivity apparatus according to claim 15, wherein the high strength copper alloy includes at least one of beryllium copper and copper titanium.

17. The pin-and-sleeve electrical connectivity apparatus according to claim 1 , wherein the male connector and female connector include a termination portion for receiving a conductor, further comprising a silver-plated ferrule disposed between the conductor and an internal surface of the termination portion.

18. The pin-and-sleeve electrical connectivity apparatus according to claim 1 , wherein the sleeve includes a termination portion for receiving an end of a conductor and sleeve portion, the sleeve portion includes a plurality of contact members arranged concentrically to form a channel to receive the insertion pin, each contact member is individually coupled to the termination portion such that each contact member may individually flex upon receiving the insertion pin.

19. The pin-and-sleeve electrical connectivity apparatus according to claim 18, wherein each contact member is configured to include a plurality of contact points on an inner surface of the formed channel.

20. The pin-and-sleeve electrical connectivity apparatus according to claim 19, wherein each contact member includes a slot disposed on an outer surface of the contact member, the respective slots on each contact member align to receive a generally circular ring spring to urge the contact points toward a center of the channel and maintain contact with the insertion pin.21 . The pin-and-sleeve electrical connectivity apparatus according to claim 1 , wherein the insertion pin and sleeve include a copper alloy.

22. The pin-and-sleeve electrical connectivity apparatus according to claim21 , wherein the copper alloy includes at least one of tellurium copper, chromium copper and zirconium copper.

23. The pin-and-sleeve electrical connectivity apparatus according to claim 1 , wherein the male connector and female connector include a termination portion for receiving a conductor, the termination portion including an internally threaded surfaceconfigured to receive a split bushing, the split bushing configured to be disposed over the conductor and includes a plurality of members that compress the conductor when the split bushing is advanced into the internally threaded surface of the termination portion.

24. The pin-and-sleeve electrical connectivity apparatus according to claim 1 , wherein the male connector and female connector include a termination portion for receiving a conductor, the termination portion configured to be disposed over the conductor and includes a plurality of members having an externally threaded surface, the plurality of members compress the conductor when a capture nut is advanced onto the externally threaded surface of the termination portion.

25. The pin-and-sleeve electrical connectivity apparatus according to claim 1 , wherein the sleeve includes a termination portion for receiving an end of a conductor and a cylindrical sleeve portion, the cylindrical sleeve portion includes a plurality of fins that extend radially from a longitudinal axis of the cylindrical sleeve portion to draw heat generated inside the cylindrical sleeve portion away from the conductor.

26. The pin-and-sleeve electrical connectivity apparatus according to claim 1 , wherein the sleeve includes a termination portion for receiving an end of a conductor and a cylindrical sleeve portion, the cylindrical sleeve portion includes a plurality of fins that extend radially from a longitudinal axis of the cylindrical sleeve portion to draw heat generated inside the cylindrical sleeve portion away from the conductor.

27. The pin-and-sleeve electrical connectivity apparatus according to claim 1 , wherein the sleeve includes a termination portion for receiving an end of a conductor and a cylindrical sleeve portion, the cylindrical sleeve portion includes a plurality of venting slots which enable heat dissipation from the conductor.

28. The pin-and-sleeve electrical connectivity apparatus according to claim 2, wherein the sleeve includes a termination portion for receiving an end of a conductor and a cylindrical sleeve portion, the cylindrical sleeve portion includes a plurality of venting slots which enable heat dissipation at contact points between a spring element and conductor.

29. The pin-and-sleeve electrical connectivity apparatus according to claim 28, wherein each venting slot is aligned with an internally disposed spring element such thatthe contact points that are created at concave portions of the spring element are exposed through the venting slots.

30. The pin-and-sleeve electrical connectivity apparatus according to claim 18, wherein the plurality of contact members separated by a plurality of slits, portions of each contact member include at least one recess along a respective slit forming venting slots with adjacent contact members to facilitate heat dissipation from the conductor.31 . The pin-and-sleeve electrical connectivity apparatus according to claim 1 , wherein the male connector includes a first housing and the female connector includes a second housing, each of the first and second housings include thermally conductive plastic to dissipate heat.

32. The pin-and-sleeve electrical connectivity apparatus according to claim 1 , wherein the male connector includes a first housing and the female connector includes a second housing, at least one of the first and second housings include venting elements to dissipate heat.

33. The pin-and-sleeve electrical connectivity apparatus according to claim 1 , wherein the female connector includes a housing with venting elements to dissipate heat, the venting elements being positioned on an outer surface of the housing to align with and to be parallel to the sleeves.

34. The pin-and-sleeve electrical connectivity apparatus according to claim 1 , wherein the male connector includes a first housing and the female connector includes a second housing, at least one of the first and second housings include a liquid circulation system that circulates a dielectric coolant through an interior of the housing.

35. The pin-and-sleeve electrical connectivity apparatus according to claim 1 , wherein the male connector includes a first housing and the female connector includes a second housing, at least one of the first and second housings include a sealed liquid circulation module coupled to the housing.

36. The pin-and-sleeve electrical connectivity apparatus according to claim 1 , wherein the male connector includes a plurality of insertion pins arranged in a circular manner, at least one of the plurality of insertions pins being an electrical ground pin, the ground pin located at a half-hour position.

37. The pin-and-sleeve electrical connectivity apparatus according to claim 1 , wherein the male connector includes a plurality of insertion pins arranged in a circular manner, at least one of the plurality of insertions pins being an electrical ground pin, the ground pin located at a 15 degree increment from a center position based on a rating of the male connector.

38. The pin-and-sleeve electrical connectivity apparatus according to claim 1 , wherein the female connector includes a plurality of sleeves arranged in a circular manner, at least one of the plurality of sleeves designated as an electrical ground sleeve, the ground sleeve located at a half-hour position.

39. The pin-and-sleeve electrical connectivity apparatus according to claim 1 , wherein the female connector includes a plurality of sleeves arranged in a circular manner, at least one of the plurality of sleeves being an electrical ground sleeve, the ground sleeve located at a 15 degree increment from a center position based on a rating of the female connector.

40. A pin-and-receptacle electrical connectivity apparatus comprising: a male connector including a plurality of pins; an insertion pin of conductive material included among the plurality of pins, the insertion pin having a distal end and a proximal end configured as part of the male connector; a female connector including a plurality of receptacles; a sleeve receptacle included among the plurality of receptacles; a latch body hingedly affixed to one of the male connector or the female connector, the latch body including a clamping extension, an open boss receiving end, and a cradle section; a mating boss extending affix to the other of said male or said female connector; wherein in an engaged position the mating boss is in contact with the cradle section, and each one of the plurality of pins is fully inserted into a respective one of the plurality of receptacles.41 . The pin-and-receptacle electrical connectivity apparatus according to claim 40, wherein said latch body defines a pivot pin opening to receive a pivot pin thereby allowing the latch body to hingedly rotate around the pivot pin.

42. The pin-and-receptacle electrical connectivity apparatus according to claim41 , further comprising: a latch handle affixed to the latch body; said latch handle providing lever force to pull said male and female connectors into the engaged position.

43. The pin-and-receptacle electrical connectivity apparatus according to claim42, further comprising an arcuate latching groove section of the latch body positioned between the open pin receiving end and the cradle section and configured to receive said boss and draw said female and male connectors together as the boss travels the length of the arc during rotation of said latch body.

44. The pin-and-receptacle electrical connectivity apparatus according to claim43, wherein said boss is disposed on said female connector and is spaced a distance on said female connector to ensure complete insertion of said pins in said receptacles when said boss reaches the cradle section of said latch body hingedly disposed on said male connector to reach said engaged position.

45. The pin-and-receptacle electrical connectivity apparatus according to claim44, further comprising a spring-loaded plunger disposed in said female connector configured to push said male connector out and away from said female connector when said latch is released from said engaged position.

46. The pin-and-receptacle electrical connectivity apparatus according to claim 43, further comprising: at least one spring loaded butt contact.

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