Compact Power Connector Busbar Segmentation
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Solution Overview
Problem
As equipment density increases, there is a growing need for a compact pluggable power connector that can efficiently connect busbars to electrical systems while minimizing space requirements and enhancing airflow, as traditional receptacle-type clamping connectors obstruct airflow and require more space due to their design.
Innovation Solution
A compact connector design with pins on opposed sides of a contact tip that engages with two busbars, allowing for reduced connector width and improved airflow by eliminating the need for dual receptacle-type clamping connectors, and accommodating busbars of various thicknesses without constraining them to a specific width.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional receptacle-type clamping connectors are used to connect busbars, then reliable electrical connections are established, but the connector width increases and airflow is obstructed
Solution Approach 1:
The connector is segmented into two independent contact tips instead of a single receptacle structure. Each contact tip independently engages with a busbar, allowing the connector to maintain compact dimensions while establishing reliable electrical connections. This segmentation eliminates the need for a wide receptacle housing that would obstruct airflow.
Solution Approach 2:
The contact tips are arranged in a vertical stacking configuration rather than a horizontal side-by-side arrangement. This dimensional reorganization allows the connector to achieve its compact form factor in the horizontal plane (reducing width for airflow) while utilizing the vertical dimension to accommodate both contact points, thereby reducing overall connector volume without compromising connection reliability.
2Reliability
If traditional receptacle-type clamping connectors are used, then busbars can be securely clamped, but the connector requires more space and obstructs airflow
Solution Approach 1:
The single receptacle structure is divided into two separate contact tips that can be independently positioned and sized. Each contact tip is optimized to engage with its corresponding busbar, providing secure clamping force. This segmentation allows the overall connector footprint to be minimized while maintaining stable connections through proper distribution of contact forces.
Solution Approach 2:
Each contact tip is designed with localized engagement features optimized for its specific busbar interface. The contact tips can have different geometries, contact areas, and clamping mechanisms tailored to their respective positions, allowing the connector to achieve stable connections with minimal overall footprint by concentrating connection functionality at specific local points rather than distributing it across a large receptacle structure.
3Productivity
If equipment density is increased, then space utilization improves, but traditional connectors become too large and obstruct airflow
Solution Approach 1:
By transitioning from a horizontal side-by-side arrangement to a vertical stacking configuration, the connector achieves superior space utilization in the horizontal plane. This dimensional change reduces the connector's footprint area, allowing higher equipment density in data centers while simultaneously creating channels for improved airflow between and around connectors, thereby eliminating the harmful effect of airflow obstruction.
Solution Approach 2:
The segmented contact tip design allows each component to be independently optimized for compact dimensions. This segmentation enables the connector to achieve a compact overall form factor that maximizes equipment density while the gaps between the vertically-stacked contact tips create natural airflow passages, reducing airflow obstruction without sacrificing connection reliability.
Data Source
AI summary
A compact connector is provided. The compact connector includes a connector body having a first group of one or more pins on a first face of a contact tip and a second group of one or more pins on an opposed second face of the contact tip. The first group of one or more pins engages with a first busbar, and the second group of one or more pins engages with a second busbar, wherein when the connector engages with the busbars the contact tip is disposed between the first and second busbars. A method of using a connector is also provided.