Ablative Power Pin Structure to Prevent Hooked Connector Removal
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Solution Overview
Problem
Conventional electrical connectors in server racks can become damaged, leading to exposed high-power contacts when removed, posing a risk of shock or fire.
Innovation Solution
The use of electrical connectors with ablative tips that include support material on either side of the terminal edge to prevent bending and formation of hooks, combined with a female connector having a skirt that limits the removal of the connector body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional connectors are used without support material, then the connector structure is simple, but the connector body can be pulled off when damaged, exposing high-power contacts and creating safety hazards
Solution Approach 1:
The patent applies preliminary action by providing support material (such as a collar or reinforcement structure) around the connector body before damage occurs. This support material prevents the connector body from being pulled off when the ablative tip becomes damaged, thereby preventing exposure of high-power contacts and eliminating the need for complex post-damage interventions.
Solution Approach 2:
The patent employs composite materials by combining the connector body with support material made of different properties. The support material (which may be a collar, reinforcement structure, or different material composition) works together with the connector body to provide enhanced mechanical strength and prevent pull-off, resolving the contradiction between simplicity and safety.
2Reliability
If ablative tips without support material are used, then manufacturing is simpler, but the tips can bend and form hooks that damage connectors
Solution Approach 1:
The patent applies preliminary action by incorporating support material around the ablative tip during manufacturing. This support structure prevents the tip from bending into hooks during use, thereby protecting the connector from damage while being integrated into the manufacturing process itself.
Solution Approach 2:
The patent uses composite materials by combining the ablative tip with support material that has different mechanical properties. The support material prevents hook formation while the ablative tip maintains its protective function, creating a durable connector assembly that is manufactured as an integrated unit.
3Reliability
If connectors without retention mechanisms are used, then the connector design is simpler, but damaged connectors can be unintentionally removed, exposing high-power contacts
Solution Approach 1:
The patent applies preliminary action by incorporating a retention mechanism (such as a skirt or engagement feature) into the connector design before damage occurs. This mechanism prevents unintentional removal of damaged connectors, thereby maintaining safety without requiring complex active retention systems.
Solution Approach 2:
The patent employs composite materials by integrating the retention mechanism (skirt or engagement feature) with the connector body. The retention structure works together with the support material to provide comprehensive protection against connector removal, resolving the contradiction between simple design and reliable retention.
Data Source
AI summary
An electrical connector for transmitting electrical power includes at least one power pin with an ablative tip. The power pin has a body oriented in a direction of a longitudinal axis, and the ablative tip is at a terminal end along the longitudinal axis. The ablative tip includes a terminal edge and a support material positioned on a transverse side of the terminal edge that provides structural support to the terminal edge.