Data center rack whip connector system

Abstract

An electric connector system that is suitable for use in data centers to power rack-mounted devices that face high electric power demands. The connector system is designed for supplying devices that are mounted in a rack and have a height of one rack unit. In particular, the connector system is designed to connect power cables with 2 AWG electrical wires that can supply an electric current up to 125 A at a voltage up to 600 V.

Description

[0001] Applicant: HARTING Electric Stiftung & Co. KG

[0002] Title: DATA CENTER RACK WHIP CONNECTOR SYSTEM

[0003] TECHNICAL FIELD

[0004] The present disclosure relates to power whips and electrical connectors for power whips to power rack-mounted devices in data centers.

[0005] BACKGROUND

[0006] In data centers, Power Distribution Units (PDUs) play a crucial role in managing and distributing electrical power to servers, networking equipment, and other critical infrastructure. PDUs ensure a stable and reliable power supply, helping to prevent downtime and optimize energy efficiency.

[0007] A rack unit (abbreviated U or RU) is a unit of measure defined as 1% inches (44.45 mm). It is most frequently used as a measurement of the overall height of 19-inch and 23-inch rack frames, as well as the height of devices that mount in these frames.

[0008] A 1U power shelf is a compact power distribution and conversion unit designed to fit within a 1 U rack space (1.75 inches in height) in a standard 19-inch or 23-inch server rack. It is commonly used in data centers, telecommunications, and industrial applications to provide efficient power management for IT equipment.

[0009] SUMMARY

[0010] The present application provides an electric connector system that is suitable for use in data centers to power rack-mounted devices that face high electric power demands. The connector system is designed for supplying devices that are mounted in a rack and have a height of one rack unit (about 44.5 mm). In particular, the connector system is designed to connect power cables with 2 AWG electrical wires that can supply anelectric current up to 125 A at a voltage up to 600 V in typical data center applications. In some configurations, the connector system may be used with 50 mm2or 1 AWG cables.

[0011] In North America, wire diameters are traditionally measured in American Wire Gauge (AWG), a logarithmic stepped standardized wire gauge system. A “2 AWG” wire has a diameter of about 6.544 mm, a cross-sectional area of 33.6 mm2, and can conduct up to 125 A. A 2 AWG cable is roughly equivalent to a 35 mm2cable used in other parts of the world.

[0012] The connector system may be used in a prefabricated cable, known as a power whip. A whip connector is a type of electrical connector used to attach a flexible cable, often called a “whip,” to an electrical system or device. Whip connectors can be pre-installed to power cables for easy installation. Whip connectors can be used to plug into data center devices, such as servers, networking equipment, and power management components.

[0013] High-power applications in data centers typically employ three-phase PDlls. In a Wye (Star) configuration, power whip connector systems therefore typically include five conductors: L1 (Line 1), L2 (Line 2), L3 (Line 3), Neutral, and Protective Earth (Ground). Alternatively, a power whip may be configured for a Delta connection, which typically includes four conductors: L1 , L2, L3, and Protective Earth.

[0014] Connecting a 2 AWG cable to a 1 U rack faces a particular challenge: A power cable with five 2 AWG conductors has a diameter that may exceed 45 mm. That is, the power cable alone has a diameter that exceeds the height of the rack-mounted device to be powered.

[0015] The present connector system solves this dilemma in a unique way. It provides a power whip for powering a 1 U rack-mounted device. The power whip includes a plurality of wires. Within a multiple conductor cable portion,the plurality of wires are surrounded by a common cable jacket. The whip also includes a parallel wire portion. There, the plurality of wires are arranged parallel one another without being surrounded by the common cable jacket. Instead, each of the plurality of wires is part of a single conductor cable. A breakout sleeve transitions the multiple conductor cable portion to the single conductor cable portion. A plug connector is arranged at an end of the single conductor cable portion away from the breakout sleeve. The plug connector includes a plug contact carrier with a plurality of contact chambers arranged in a single row.

[0016] The power whip uses a novel electrical connector. The electrical connector includes a contact carrier that extends along a longitudinal axis and comprises a plurality of contact carrier formations arranged adjacent one another in a row. The contact carrier formations include a first outer contact carrier formation, a second outer contact carrier formation, and a plurality of center contact carrier formations arranged between the first outer contact carrier formation and the second outer contact carrier formation. Each contact carrier formation defines a contact chamber configured to receive a respective electrical contact.

[0017] The contact carrier formations may be formed as protrusions extending in a plug-in direction of the electrical connector, with each protrusion including an internal cavity to locally reduce wall thickness. Alternatively, the contact carrier formations may be formed as recesses in a mating face of the electrical connector. In either case, the contact carrier formations are arranged such that the contact chambers are aligned in a single row along the longitudinal axis.

[0018] Each of the center contact carrier formations includes opposing first and second longitudinal walls extending parallel to the longitudinal axis, and opposing first and second lateral walls extending between the first longitudinal wall and the second longitudinal wall. The first lateral wall and the second lateral wall are spaced from one another along the longitudinalaxis and together define, with the longitudinal walls, a boundary of the respective center contact carrier formation.

[0019] The first lateral wall and the second lateral wall of each center contact carrier formation include a plurality of wall segments that are longitudinally offset from one another and connected by transition wall segments. As a result, each of the first lateral wall and the second lateral wall defines a stepped profile in the longitudinal direction. In some implementations, the wall segments are planar wall segments extending perpendicular to the longitudinal axis, and the transition wall segments include curved or arcuate portions to reduce stress concentrations and improve manufacturability.

[0020] The stepped profile of the first lateral wall and the second lateral wall may be identical, and non-symmetric with respect to a plane perpendicular to the longitudinal axis. The longitudinal walls and the lateral walls may be connected by smooth, continuous, and non-angular transitions, such that the walls together define a closed boundary around the contact chamber of each center contact carrier formation.

[0021] The first outer contact carrier formation and the second outer contact carrier formation may have cross-sectional shapes that differ from one another and that further differ from the cross-sectional shapes of the center contact carrier formations. One outer contact carrier formation may include opposing longitudinal walls and a planar outer wall extending perpendicular to the longitudinal axis, wherein the planar outer wall is connected to the longitudinal walls by arcuate transitions. Another outer contact carrier formation may include an outer wall having both a planar wall section and a beveled wall section connected by an arcuate transition.

[0022] Each contact chamber may include a central circular opening configured to receive a corresponding electrical contact. The contact carrier, including the contact carrier formations, may be integrally formed as a single moldedbody, for example by an injection molding process using an electrically insulating material.

[0023] The electrical connector may be incorporated into a power whip for supplying electrical power to a rack-mounted device having a height of one rack unit. In such configurations, the power whip includes a multipleconductor cable, a plurality of single-conductor cables arranged parallel to one another, and a breakout sleeve arranged between the multipleconductor cable and the plurality of single-conductor cables. The electrical connector is arranged at an end of the single-conductor cables at a distance from the breakout sleeve, such that each single-conductor cable is electrically connected to a respective contact received in one of the contact chambers of the electrical connector.

[0024] The following detailed description is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any theory presented in the preceding background or the following detailed description.

[0025] BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 shows an exploded view of a plug and socket connection system. FIG. 2 shows a power whip with a connector system.

[0026] FIG. 3 is a detailed view showing a plug connector of the power whip as in FIG. 2 plugged into a socket of a rack-mounted device.

[0027] FIG. 4 is a perspective front and top view of a plug contact carrier.

[0028] FIG. 5 is a perspective front and top view of a socket housing.

[0029] FIG. 6 is a plan view of a plug contact carrier.

[0030] FIG. 7 shows different views of a plug contact carrier.

[0031] FIG. 8 shows different views of a device contact carrier.

[0032] FIG. 9 is a perspective view showing several plug connectors stacked on top of one another to power different rack-mounted device in a rack.

[0033] FIG. 10 is a front view of a five-wide device contact carrier;FIG. 11 is a rear view thereof;

[0034] FIG. 12 is a left side view thereof;

[0035] FIG. 13 is a right side view thereof;

[0036] FIG. 14 is a top view thereof;

[0037] FIG. 15 is a bottom view thereof;

[0038] FIG. 16 is a top, front perspective view thereof;

[0039] FIG. 17 is a bottom, front perspective view thereof;

[0040] FIG. 18 is a top, rear perspective view thereof; and

[0041] FIG. 19 is a bottom, rear perspective view thereof.

[0042] FIG. 20 is a front view of a mating five-wide connector contact carrier; FIG. 21 is a rear view thereof;

[0043] FIG. 22 is a left side view thereof;

[0044] FIG. 23 is a right side view thereof;

[0045] FIG. 24 is a top view thereof;

[0046] FIG. 25 is a bottom view thereof;

[0047] FIG. 26 is a top, front perspective view thereof;

[0048] FIG. 27 is a bottom, front perspective view thereof;

[0049] FIG. 28 is a top, rear perspective view thereof, and

[0050] FIG. 29 is a bottom, rear perspective view thereof.

[0051] FIG. 30 is a front view of a four-wide device contact carrier;

[0052] FIG. 31 is a rear view thereof;

[0053] FIG. 32 is a left side view thereof;

[0054] FIG. 33 is a right side view thereof;

[0055] FIG. 34 is a top view thereof;

[0056] FIG. 35 is a bottom view thereof;

[0057] FIG. 36 is a top, front perspective view thereof;

[0058] FIG. 37 is a bottom, front perspective view thereof;

[0059] FIG. 38 is a top, rear perspective view thereof; and

[0060] FIG. 39 is a bottom, rear perspective view thereof.

[0061] FIG. 40 is a front view of a mating four-wide connector contact carrier; FIG. 41 is a rear view thereof;

[0062] FIG. 42 is a left side view thereof;

[0063] FIG. 43 is a right side view thereof;FIG. 44 is a top view thereof;

[0064] FIG. 45 is a bottom view thereof;

[0065] FIG. 46 is a top, front perspective view thereof;

[0066] FIG. 47 is a bottom, front perspective view thereof;

[0067] FIG. 48 is a top, rear perspective view thereof, and

[0068] FIG. 49 is a bottom, rear perspective view thereof.

[0069] DETAILED DESCRIPTION FIG. 1 shows an exploded view of a plug and socket connection system. The system includes a plug connector 100 and a socket connector 200.

[0070] The plug connector 100 includes a plurality of pin contacts 150. Pin contacts are sometimes referred to as male contacts. In the context of the present application, they should be more broadly understood to refer to a first type of contacts. In some applications, the plug connector 100 may use socket, orfemale, contacts 150. When in use, each of the pin contacts 150 is electrically connected to one wire of a cable. Contacts may be in the form of screw terminals, crimp terminals, cage-clamp terminals, or soldered terminals. The terms contact and terminal are used interchangeably. The pin contacts 150 are securely held within a plug insert 130. The plug insert 130 is in turn secured within a plug contact housing 110. The plug contact housing 110 may also be referred to as a hood. The plug contact housing 110 includes a cable entry opening 105, which can be arranged for rear entry or side entry of the cable. A cable entry protection 120 may be secured to the cable entry opening 105. The cable entry protection 120 can come in various configurations. The cable entry protection 120 can for example be a universal cable gland, a special cable clamp with strain relief, a bell mouthed cable fitting, or an anti-twist device. A cable gland may include one or multiple seals.

[0071] The plug connector 100 is configured to mate with a corresponding socket connector 200. The socket connector 200 includes a plurality of receptacle contacts 250. Receptacle contacts are sometimes referred to as femalecontacts. In the context of the present application, they should be more broadly understood to refer to a second type of contacts. In some applications, the socket connector 200 may use pin, or male, contacts 250. Each of the receptacle contacts 250 is configured to receive one of the pin contacts 150 to create an electrical connection. The receptacle contacts 250 are securely held within a socket insert 230. The socket insert 230 is secured within a socket housing 210.

[0072] The geometries of the plug insert 130 and the socket insert 230 are coordinated such that they can be plugged together. When being plugged together, portions of the plug insert 130 and the socket insert 230 overlap.

[0073] A locking mechanism may be provided to lock the plug connector 100 to the socket connector 200. The locking mechanism may include a lever 211 that is pivotally connected to the socket housing 210. The lever 211 may include a recess that engages a locking protrusion 111 of the plug contact housing 110. When engaged, the lever securely holds the plug connector 100 and the socket connector 200 together. The lever 211 can be pivoted into an unlocked position to disengage the locking protrusion 111 for removing the plug connector 100 from the socket connector 200.

[0074] FIG. 2 shows a power whip suitable for use in data centers to power a device that is installed within a 1 U rack space. The power whip includes a plug connector 100. The plug connector 100 is shown plugged into a device connector 200.

[0075] The plug connector 100 electrically connects a cable 401 to a

[0076] rack-mounted 1 U device 201. The device connector 200 is a power inlet of the rack-mounted device 201. The rack-mounted device 201 is powered by three-phase electric current through the power whip. In some configurations, the rack-mounted device 201 may alternatively be powered by single-phase alternating current, or direct current (DC).The cable 401 includes a multiple conductor cable portion 400 having a circular cross sectional shape. The cable 401 may be a power cable with five 2 AWG conductors. A diameter of the cable 401 in the multiple conductor cable portion 400 may exceed 40 mm. The diameter of the cable 401 in the multiple conductor cable portion 400 may even exceed 45 mm. The cable 401 may be a Type-W flexible 2 AWG 5 Conductors cable rated for 2000 volts and a temperature up to 90 °C.

[0077] Within the multiple conductor cable portion 400 of the cable 401 , five insulated wires are arranged within an outer jacket. The outer jacket has a circular cross sectional shape.

[0078] The multiple conductor cable portion 400 extends to a breakout sleeve 300. Within the breakout sleeve 300, the five wires of the multiple conductor cable 401 are fanned out into a parallel arrangement. The breakout sleeve 300 includes a cable opening 310. The multiple conductor cable 401, including the cable jacket, extend through the cable opening 310.

[0079] At the breakout sleeve 300, the multiple conductor cable portion 400 of the power whip transitions into a single conductor cables portion 410 with five single conductor cables. The five single conductor cables 411...415 extend through single conductor cable openings 311...315 of the breakout sleeve 300. In the single conductor cables portion 410, the single conductor cables 411...415 are not surrounded by a common jacket. In the single conductor cables portion 410 the single conductor cables 411...415 each include a conductor surrounded by an insulation. Each single conductor cable may include stranded bare copper conductors surrounded by synthetic EPDM rubber insulation. In the single conductor cables portion 410, the EPDM rubber insulation of each of the single conductor cables 411...415 is surrounded by an individual wire jacket. The individual wire jackets of the single conductor cables 411...415 may transition into the common outer jacket of the multiple conductor cable portion 400 within thebreakout sleeve 300. The breakout sleeve 300 transitions a multi-conductor cable 401 into five single-conductor cables 411...415.

[0080] In the single conductor cables portion 410, the single conductor

[0081] cables 411...415 are locally parallel to one another. The single conductor cables 411...415 form a flat bundle 416. Within the flat bundle 416, all single conductor cables are arranged in a plane. The flat bundle 416 resembles the shape of a ribbon cable.

[0082] The term “plane” as used above includes two-dimensional surfaces that may be curved through space, such as a cylinder wall. The single conductor cables 411...415 within the flat bundle 416 may be arranged in a curved plane as shown in FIG. 2. The flat bundle 416 may follow a curved path. For example, as illustrated in FIG. 2, the cable 401 may be oriented vertically. The cable 401 enters the breakout sleeve 300 in a vertical orientation. The single conductor cables 411...415 exit the breakout sleeve parallel one another in a vertical orientation. The flat wire bundle 416 includes a bend in which the single conductor cables 411...415 change from a vertical orientation to a horizontal orientation. The single conductor cables 411...415 enter the plug connector 100 in a horizontal orientation. The horizontal orientation matches an orientation of the rack-mounted device 201 in the rack.

[0083] At the plug connector 100, each of the single conductor cables is connected to a plug contact 150. The plug contacts 150 are held within a plug contact carrier 131. The plug contacts 150 may be receptacle (female) contacts.

[0084] The plug contact carrier 131 includes contact chambers. One of the plug contacts 150 is received in each of the contact chambers. Within the contact chambers, the plug contacts are arranged in a common plane.

[0085] Center axes of the plug contacts extend in the common plane parallel to one another. The plug connector 100 has a single row of contacts.As shown in FIG. 4, the plug contact carrier 131 includes five contact chambers 141...145. A respective plug contact 150 is arranged in each of the five contact chambers 141...145. Each of the plug contacts 150 extends parallel to an insertion axis of the plug connector 100. The plug contacts 150 are arranged equidistant from one another along a longitudinal axis 132 of the plug connector 100.

[0086] The plug contact carrier 131 includes five contact carrier

[0087] protrusions 151 ...155. The contact carrier protrusions 151 ...155 extend in a plug-in direction from a plug contact carrier body 156. The contact carrier protrusions 151 ...155 are one type of contact carrier formations.

[0088] The plug contact carrier 131 includes three center contact

[0089] chambers 142, 143, 144, a first outer contact chamber 141, and a second outer contact chamber 145. The three center contact

[0090] chambers 142, 143, 144 extend through three respective center contact carrier protrusions 152...154. The first outer contact chamber 141 extends through a first outer contact carrier protrusion 151. The second outer contact chamber 145 extends through a second outer contact carrier protrusion 155.

[0091] The cross sectional shape of the center contact carrier

[0092] protrusions 152, 153, 154 is different than the cross sectional shape of the first outer contact carrier protrusion 151. The cross sectional shape of the center contact carrier protrusions 152, 153, 154 is different than the cross sectional shape of the second outer contact carrier protrusion 155. The cross sectional shape of the first outer contact carrier protrusion 151 is different than the cross sectional shape of the second outer contact carrier protrusion 155. The different shapes of the contact carrier

[0093] protrusions 151...155 ensures that the plug connector 100 can be plugged into the mating device connector 200 in only one orientation.Each of the center contact carrier protrusions 152, 153, 154 includes a first longitudinal wall 161 and a second longitudinal wall 162. The first longitudinal wall 161 and the second longitudinal wall 162 extend longitudinally and in the insertion direction of the plug connector 100. The first longitudinal wall 161 and the second longitudinal wall 162 are parallel to one another at a lateral distance from each other. A length of the first longitudinal wall 161 and a length of the second longitudinal wall 162 are equal. The first longitudinal wall 161 is arranged longitudinally offset from the second longitudinal wall 162.

[0094] The first longitudinal wall 161 and the second longitudinal wall 162 are connected by a first lateral wall 163 and by a second lateral wall 164. The first lateral wall 163 and the second lateral wall 164 are arranged on opposite longitudinal ends of the respective contact carrier protrusion. The first lateral wall 163 and the second lateral wall 164 each include three wall segments 165, 166, 167 that are longitudinally offset from one another. A first lateral wall segment 165 of the three wall segments 165, 166, 167 is arranged proximal to the first longitudinal wall 161. A second lateral wall segment 167 of the three wall segments 165, 166, 167 is arranged proximal to the second longitudinal wall 162. A center lateral wall segment 166 is arranged between the first lateral wall segment 165 and the second lateral wall segment 167. The first lateral wall segment 165 is connected to the center lateral wall segment 166 by a curved step. The center lateral wall segment 166 is connected to the second lateral wall segment 167 by a curved step. The lateral walls 163, 164 have a generally slanted orientation that is non-parallel to a lateral axis 133 of the plug connector 100. The slanted orientation has an angle of about 13 degrees relative to the lateral axis 133. The slanted orientation may be between 10 degrees and 20 degrees relative to the lateral axis 133.

[0095] The center contact carrier protrusions 152, 153, 154 each have a generally octagonal shape with two steps formed in their lateral walls 163, 164. The first outer contact chamber 151 has a generally hexagonal shape with twosteps formed in its inner lateral wall 178 while its outer lateral wall 168 is flat. The second outer contact chamber 155 has a generally heptagonal shape with two steps being formed in its inner lateral wall 179 and one bend being formed in its outer lateral wall 169.

[0096] An inner lateral wall 178 of the first outer contact carrier protrusion 151 matches the stepped shape of the lateral wall 163 of the adjacent center contact carrier protrusion 152. An inner lateral wall 179 of the second outer contact carrier protrusion 155 matches the stepped shape of the lateral wall 164 of the adjacent center contact carrier protrusion 154.

[0097] An outer lateral wall 168 of the first outer contact carrier protrusion 151 is flat and extends parallel to the connector’s lateral axis 133. The outer lateral wall 168 extends from the first longitudinal wall 161 to the second longitudinal wall 162. The outer lateral wall 168 extends perpendicular to the first longitudinal wall 161. The outer lateral wall 168 extends perpendicular to the second longitudinal wall 162.

[0098] An outer lateral wall 169 of the second outer contact carrier protrusion 155 includes a parallel wall segment 170 arranged parallel to the lateral axis 133. The outer lateral wall 159 also includes a beveled wall segment 171. The beveled wall segment 171 extends at an angle of about 45 degrees (45° ± 10°) to both the lateral axis 133 and to the longitudinal axis 132 of the plug connector 100. The parallel wall segment 170 is connected to the beveled wall segment 171 by an arcuate transition wall section 176.

[0099] The contact carrier protrusions 151...155 may include hollowed out portions 158. The hollowed out portions 158 are also referred to as “core-outs” 158. The hollowed out portions 158 ensure that walls of the contact carrier protrusions 151...155 are not too thick so as to prevent a detrimental effect on moldability by injection molding.Additionally, the hollowed out portions 158 can receive finger protection bars 258 of the socket connector 200. The finger protection bars 258 are arranged in the contact carrier recesses 251...255 to prevent a human finger from inadvertently reaching the receptacle contacts 250 in the contact carrier recesses 251...255.

[0100] The following description reflects the orientation as shown in FIG. 6. Of course, the connector can be oriented differently when in use.

[0101] The cross sectional shape of the first outer contact carrier protrusion 151 on the left is generally hexagonal with six rounded comers. Each step formed in the lateral wall is considered a corner, even though each step is defined by two oppositely curved portions connected to one another by a short flat portion. Overall, the shape outlines a closed, nearly rectangular profile bounded by two longitudinal walls (top and bottom) and two lateral walls (left and right), with modifications concentrated along the right (inner) lateral wall. The top longitudinal wall is a straight horizontal segment connecting the upper-left corner to the upper-right, while the bottom longitudinal wall mirrors this as a straight horizontal edge spanning the full width. The left (outer) lateral wall is a continuous vertical segment running unbroken between the top and bottom longitudinal walls. The right (inner) lateral wall 178, however, deviates from a straight profile and is composed of a series of smoothly connected segments: an upper convex section near the top that curves outward, followed by a concave inward curvature forming a slight waist at mid-height, and finally a lower convex bulge that transitions into the bottom wall. The top-left and bottom-left comers are radiused, providing right-angle transitions. The right-side curvature introduces asymmetry into the form. The overall geometry retains a predominantly rectangular footprint, but the contoured inner lateral wall clearly distinguishes it from a strictly rectangular shape.

[0102] The cross sectional shape of the center contact carrier

[0103] protrusions 152, 153, 154 is generally octagonal. The shape defines aclosed, primarily rectangular outline enclosed by two longitudinal walls (top and bottom) and two lateral walls (left and right), with both lateral walls exhibiting non-linear profiles. The top longitudinal wall is a straight horizontal segment connecting the upper ends of the left and right lateral walls, and the bottom longitudinal wall mirrors this, extending horizontally across the base of the shape. The left lateral wall features a smooth, continuous contour consisting of three vertically arranged segments: an upper outward convex section, a concave inward recess forming a waist at mid-height, and a lower outward convex return to the base. The right lateral wall mirrors this structure, with an upper convex segment, a mid-height concave waist, and a lower convex segment leading into the bottom wall. All four comers are rounded or gently radiused, allowing for continuous transitions between adjacent walls. The resulting geometry maintains overall symmetry between the left and right sides, while the double-waisted lateral profile introduces a complex contour along both vertical edges.

[0104] The cross sectional shape of the second outer contact carrier protrusion 155 is generally heptagonal with seven rounded comers. The shape of the second outer contact carrier protrusion 155 represents a closed, generally rectangular profile defined by two longitudinal walls (top and bottom) and two lateral walls (left and right). The top longitudinal wall is a straight horizontal segment extending from the upper-left toward the right, terminating in a beveled edge that slopes downward and inward at approximately 45 degrees, replacing the typical top-right corner. The bottom longitudinal wall is also straight and horizontal, running from the lower-left to the lower-right comers. The right (outer) lateral wall includes a continuous vertical segment connecting the bottom corner to the end of the beveled segment. The inner lateral wall departs from a straight form and is composed of three smoothly connected sections: an upper convex segment that bows outward from the interior, a midsection forming a concave indentation or waist, and a lower convex curve that returns to the full lateral width at the bottom. The top-left corner is rounded, providing a smooth transition between the top wall and the contoured left wall, while the bottomcorners are sharp or minimally radiused. The resulting shape provides a keying or alignment feature, with the contoured left side and beveled topright edge enforcing orientation.

[0105] The device connector 200 includes a device contact carrier 231. Pin terminals 250 are held in the device contact carrier 231. The shape of the device contact carrier 231 mirrors that of the plug contact carrier 131. When in use, the plug contact carrier 131 is plugged into and overlaps the device contact carrier 231.

[0106] The device contact carrier 231 includes a device contact carrier body 256. Five contact carrier recesses 251 ...255 are formed in a plug-in side of the device contact carrier 231. The contact carrier recesses 251 ...255 are shaped to receive the contact carrier protrusions 151 ...155. Each of the contact carrier recesses 251 ...255 is delimited by a wall. The shape of the walls of the contact carrier recesses 251 ...255 mirrors the shape of the corresponding contact carrier protrusions 151 ...155.

[0107] The plug connector 100 is secured to the socket connector 200 by two latching levers 211. The latching levers are pivotally supported on the device contact carrier 231 by pivot pins 212, 213. Two upper pivot pins 212 are arranged on an upper side of the device contact carrier 231. The upper pins 212 are arranged above the contact carrier recesses 251 ...255. Two lower pivot pins 213 are arranged on a lower side of the device contact carrier 231. The lower pins 213 are arranged below the contact carrier recesses 251 ...255. One upper pivot pin 212 and one lower pivot pin 213 engage corresponding hinge barrels 217 of a latching lever 211.

[0108] Each latching lever 211 includes an operating arm 216. When the latching levers 211 are in a latched position their operating arms 216 are oriented in the plug-in direction parallel one another. A catch arm 215 extends substantially perpendicular to the operating arm.The lower pivot pins 212 and the upper pivot pins 213 may have a U-shaped cross sectional shape that is open towards a front of the device contact carrier 231. This allows the device contact carrier 231 to be injection molded as a single piece without the need for a slider in an injection molding tool.

[0109] When the plug connector 100 is latched to the corresponding socket connector 200, the latching levers 211 reach behind latching pins 112, 113. Two upper latching pins 112 are arranged on an upper side of the plug contact carrier 131. The upper latching pins 112 are arranged behind the contact carrier protrusions 151 ...155. Two lower latching pins 113 are arranged on a lower side of the plug contact carrier 131. The lower latching pins 113 are arranged behind the contact carrier protrusions 151 ...155. One upper latching pin 112 and one lower latching pin 113 are embraced by a corresponding slot of each latching lever 211. One slot extends within the catch arm 215 of each latching lever 211.

[0110] The lower latching pins 113 and the upper latching pins 112 may have a U-shaped cross sectional shape that is open towards a front of the plug contact carrier 131. This allows the plug contact carrier 131 to be injection molded as a single piece without the need for a slider in an injection molding tool.

[0111] The latching levers 211 may be further secured against release by screws. As shown in FIG. 3, a screw 174 may engage a thread formed in each latching lever 211. The screw extends through a slot 172 within a lateral wing 173 of the plug contact carrier 131. A head 175 of the screw 174 braces against the lateral wing 173 of the plug contact carrier 131 and so prevents the associated latching lever 211 to swing open.

[0112] The screw 174 may be designed with a security head 175 that requires a non-standard tool. This prevents unauthorized users from unplugging theplug connector 100. The screw head 175 may, for example, be a pin-in-torx, pin-in-hex, snake eye, tri-wing, or similar non-standard head.

[0113] A rear end of the plug connectors 100, facing away from the socket connector 200, may be formed by an overmolded hood 110. The overmolded hood 110 may cover a rear portion of the plug contact carrier 131 and the single conductor cables 411 ...415. The lateral wings 173 may extend laterally out of the overmolded hood 110.

[0114] A clamping mechanism may be arranged in or at the overmolded hood 110. The clamping mechanism may provide strain relief to transfer pull-forces acting on the single conductor cables 411...415 into the plug contact carrier 131, and not into the respective plug contacts 150. The clamping mechanism may include a clamped bar that is arranged perpendicular to the plug-in direction of the plug connector 100.

[0115] The plug connector 100 has a height of about 33 mm (33 ± 5 mm). The plug connector 100 can so be used to power 1 U rack-mounted devices. Within a stack of rack-mounted devices, multiple plug connectors 100 can be arranged one above another as shown in FIG. 9. The multiple plug connectors then have a clearance of about 10 mm (10 ± 5 mm) from one another. This clearance allows for inserting and removing a plug connector 100 within a stack of rack-mounted devices, if necessary.

[0116] The plug contact carrier 131 has a height, without the latching pins 113, of about 24 mm (24 ± 5 mm) and a width, not including the lateral wings 173, of about 88 mm (88 ± 15 mm).

[0117] The plug connector 100 is preferably wired such that the lines L1 , L2, and L3 of a three-phase power system are arranged in the first outer contact chamber 141 , the center contact chamber 143, and the second outer contact chamber 145. For example, L1 may be connected to the respective plug contact 150 in the second outer contact chamber 145. L2 may beconnected to the respective plug contact 150 in the center contact chamber 143. L3 may be connected to the respective plug contact 150 in the first outer contact chamber 141. Neutral may be connected to the respective plug contact 150 in the center-left contact chamber 142.

[0118] Protective earth (PE) may be connected to the respective plug contact 150 in the center-right contact chamber 144.

[0119] The PE plug contact 150 in the center-right contact chamber 144 may be longer than the adjacent plug contacts 150 to ensure that the plug connector 100 establishes a protective earth connection before establishing a power connection.

[0120] In some configurations, not all five contact chambers 141...145 are populated with contacts. For example, if the rack-mounted device 201 is powered by single-phase alternating current, or direct current (DC), fewer than five contacts 150 may be used and some of the contact chambers 141...145 remain empty.

[0121] FIGS. 10-19 show renderings of a five-wide device contact carrier as in FIG. 8. FIGS. 20-29 show renderings of a matching five-wide plug contact carrier as in FIG. 7. FIGS. 30-39 show renderings of a four-wide device contact carrier, and FIGS. 40-49 show renderings of a mating four-wide plug contact carrier. The five-wide embodiment is suitable for Wye (Star) configurations to connect L1 , L2, L3, Neutral, and PE wires. The four-wide configuration is suitable in Delta configurations to carry L1, L2, L3, and PE wires.

[0122] The four-wide device contact carrier and the four-wide plug contact carrier are derived from the five-wide embodiments described above and share a common overall design concept, material selection, manufacturing approach, and functional interaction. In particular, the four-wide embodiments retain the same general connector architecture, including a plug contact carrier configured to mate with a corresponding device contactcarrier, individual contact chambers arranged in a single row, keyed contact carrier protrusions to enforce a unique mating orientation, and latching features for securing the plug connector to the device connector. The fourwide embodiments are likewise configured to be used with high-current single-conductor cables arranged in a locally parallel, substantially planar bundle for connection to rack-mounted devices occupying a height of one rack unit.

[0123] As shown in FIGS. 30-39, the four-wide device contact carrier includes four contact chamber recesses arranged adjacent one another along a longitudinal axis, rather than five. Correspondingly, as shown in

[0124] FIGS. 4049, the mating four-wide plug contact carrier includes four contact chambers and four contact carrier protrusions. The four contact chambers are configured to receive four electrical contacts for carrying, for example, three phase conductors L1 , L2, and L3, and a protective earth conductor, as is common in Delta-configured power distribution systems. In this configuration, no neutral conductor is required, and the absence of the neutral contact allows the overall width of the connector to be reduced relative to the five-wide embodiment.

[0125] The shapes of the contact carrier protrusions and the corresponding contact carrier recesses in the four-wide embodiments follow the same keying principles as described above with respect to the five-wide embodiments. That is, the individual protrusions have mutually different cross-sectional shapes, such that the plug contact carrier can be inserted into the device contact carrier in only one permissible orientation. In particular, the two outer protrusions of the four-wide plug contact carrier have cross-sectional shapes that differ from one another and from the shapes of the two center protrusions. Likewise, the two center protrusions have cross-sectional shapes that differ from one another or are mirror images, depending on the embodiment, and are distinct from the outer protrusions. The corresponding recesses of the four-wide device contact carrier mirror these shapes to ensure correct alignment and mating.Except for the reduction in the number of contact chambers and the associated reduction in overall width, the four-wide plug contact carrier and device contact carrier may be identical or substantially identical to the fivewide embodiments in terms of wall thicknesses, draft angles, use of hollowed-out portions for moldability, finger protection features, latching interfaces, and contact retention structures. The same latching levers, pivot pins, latching pins, and optional screw-based secondary locking mechanisms described above with respect to the five-wide embodiments may be used unchanged in the four-wide embodiments.

[0126] Similarly, the four-wide connector system may be used with a power whip having a multiple conductor cable portion that transitions, via a breakout sleeve, into a single conductor cable portion in which four single-conductor cables are arranged locally parallel to one another in a flat bundle. The four single-conductor cables may be connected to the four contacts of the plug connector in the same manner as described above for the five-wide embodiment. Apart from the reduced number of conductors, the cable construction, insulation materials, current ratings, and mechanical routing advantages described above apply equally to the four-wide configuration.

[0127] Accordingly, the five-wide and four-wide embodiments represent closely related variants of the same connector system architecture, optimized for different power distribution topologies, while maintaining common handling characteristics, installation procedures, safety features, and suitability for powering high-current 1 U rack-mounted devices in data center environments.

[0128] While the present invention has been described with reference to exemplary embodiments, it will be readily apparent to those skilled in the art that the invention is not limited to the disclosed or illustrated embodiments but, on the contrary, is intended to cover numerous other modifications,substitutions, variations, and broad equivalent arrangements that are included within the spirit and scope of the following claims.

Claims

Applicant: HARTING Electric Stiftung & Co. KGTitle: DATA CENTER RACK WHIP CONNECTOR SYSTEMCLAIMSWhat is claimed is:

1. An electrical connector, comprising:a plurality of contact carrier formations arranged adjacent one another along a longitudinal axis of the electrical connector, including a first outer contact carrier formation;a second outer contact carrier formation; anda plurality of center contact carrier formations arranged between the first outer contact carrier formation and the second outer contact carrier formation,wherein each of the center contact carrier formations includesa first longitudinal wall extending parallel to the longitudinal axis, a second longitudinal wall extending parallel to the first longitudinal wall,a first lateral wall extending from the first longitudinal wall to the second longitudinal wall, anda second lateral wall extending from the first longitudinal wall to the second longitudinal wall at a distance from the first lateral wall, andwherein the first lateral wall and the second lateral wall each include a plurality of wall segments that are longitudinally offset from one another and connected to one another by transition wall segments, such that each of the first lateral wall and the second lateral wall defines a stepped profile in a longitudinal direction.

2. The electrical connector as in claim 1 ,wherein the wall segments of each of the first lateral wall and the second lateral wall are planar wall segments extending perpendicular to the longitudinal axis, andwherein each of the center contact carrier formations includes exactly three of the planar wall segments in each of the first lateral wall and the second lateral wall.

3. The electrical connector as in claim 1 ,wherein the transition wall segments include arcuate portions.

4. The electrical connector as in claim 1 ,wherein the first longitudinal wall and the second longitudinal wall are connected to the first lateral wall and the second lateral wall by four continuous and non-angular transitions.

5. The electrical connector as in claim 1 ,wherein the stepped profile is non-symmetric with respect to a plane perpendicular to the longitudinal axis.

6. The electrical connector as in claim 1 ,wherein the first longitudinal wall, the second longitudinal wall, the first lateral wall, and the second lateral wall together define a closed boundary of each center contact carrier formation.

7. The electrical connector as in claim 1 ,wherein the first outer contact carrier formation and the second outer contact carrier formation have cross-sectional shapes different from cross-sectional shapes of the center contact carrier formations.

8. The electrical connector as in claim 1 ,wherein the first outer contact carrier formation and the second outer contact carrier formation have different cross-sectional shapes from one another.

9. The electrical connector as in claim 1 ,wherein the first outer contact carrier formation includesa first longitudinal wall extending parallel to the longitudinal axis, a second longitudinal wall extending parallel to the first longitudinal wall, anda planar outer wall extending perpendicular to the longitudinal axis, the planar outer wall being connected to the first longitudinal wall and to the second longitudinal wall by arcuate transitions.

10. The electrical connector as in claim 9,wherein the second outer contact carrier formation includesa first longitudinal wall extending parallel to the longitudinal axis, a second longitudinal wall extending parallel to the first longitudinal wall, andan outer wall includinga planar outer wall section extending perpendicular to the longitudinal axis, anda beveled outer wall section connected to the planar outer wall section by an arcuate transition wall section.

11. The electrical connector as in claim 1 ,wherein the contact carrier formations are formed as protrusions extending in a plug-in direction of the electrical connector.

12. The electrical connector as in claim 11 ,wherein each protrusion includes an internal cavity configured to reduce wall thickness.

13. The electrical connector as in claim 1 ,wherein the contact carrier formations are formed as recesses formed in a mating face of the electrical connector.

14. The electrical connector as in claim 1,wherein each contact carrier formation defines a contact chamber configured to receive an electrical contact,wherein the contact chambers are arranged in a single row along the longitudinal axis, andwherein each contact chamber includes a central circular opening for receiving a contact.

15. The electrical connector as in claim 1 ,wherein the contact carrier formations are integrally formed as a single molded body.

16. A power whip for powering a 1 U rack-mounted device, comprising: a multiple-conductor cable;a plurality of single-conductor cables arranged parallel one another; a breakout sleeve arranged between the plurality of single-conductor cables and the multiple-conductor cable; andthe electrical connector as in claim 1 arranged at an end of the singleconductor cables at a distance from the breakout sleeve.

17. The power whip of claim 16,wherein the multiple-conductor cable has a circular cross-sectional shape and includes five insulated conductors surrounded by a common outer jacket,wherein the breakout sleeve includes a cable opening through which the multiple-conductor cable, including the common outer jacket, extends,wherein the breakout sleeve further includes a plurality of singleconductor cable openings, each single-conductor cable extending through a respective one of the single-conductor cable openings, and wherein, downstream of the breakout sleeve, the plurality of singleconductor cables are not surrounded by a common jacket.

18. The power whip of claim 16,wherein each of the single-conductor cables includes a conductor surrounded by insulation and an individual wire jacket.

19. The power whip of claim 16,wherein the plurality of single-conductor cables are arranged in a flat bundle in which the single-conductor cables are locally parallel to one another.

20. The power whip of claim 19,wherein the flat bundle lies substantially in a curved plane such that the flat bundle follows a curved path.

21. The power whip of claim 16,wherein the plurality of single-conductor cables include a bend between the breakout sleeve and the electrical connector, such that the single-conductor cables change orientation from a first direction to a second direction different from the first direction.

22. The power whip of claim 21,wherein the single-conductor cables extend vertically adjacent the breakout sleeve and extend horizontally as they enter the electrical connector during use.

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