Isolated Sense Connector Layout for Arc-Free Power Mating
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Solution Overview
Problem
Existing power connector systems face challenges in preventing electrical arcing during mating and un-mating due to the inability to isolate sense contacts from metal shells, which can lead to electrical connections and potential damage.
Innovation Solution
A power connector system with a separate and discrete sense connector that includes a housing to electrically isolate the sense contact from the shell, allowing for accurate sensing of the mating state without electrical connection to the power contacts or metal shell, thereby controlling power supply to prevent arcing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal shell is used in the power connector, then the structural strength and shielding are improved, but the sense contact cannot be electrically isolated from the shell
Solution Approach 1:
The connector is divided into two separate connectors: a power connector with the metal shell and power contacts, and a sense connector with the sense contact. This segmentation allows the power connector to maintain its metal shell structure for strength while the sense connector provides electrical isolation for reliable sensing without interference from the metal shell
Solution Approach 2:
The sense contact function is extracted from the power connector and placed in a separate sense connector. This extraction resolves the conflict by allowing the power connector to focus on power transmission with its metal shell while the sense connector handles sensing with proper electrical isolation
2Device complexity
If sense contacts are included within the power connector housing, then the integration is improved, but electrical connection to power contacts or metal shell cannot be prevented
Solution Approach 1:
The system is segmented into separate power and sense connector units. The sense connector is mounted adjacent to the power connector on the power substrate, providing integrated functionality while maintaining physical and electrical separation to prevent unwanted connections
Solution Approach 2:
The housing in the sense connector acts as an intermediary structure that electrically isolates the sense contact from the metal shell while still allowing the sense contact to perform its sensing function. This intermediary structure resolves the conflict between integration and electrical isolation
3Reliability
If hot swap circuitry is used to prevent arcing, then power control is improved, but additional complexity in the power connector is added
Solution Approach 1:
The hot swap control function is segmented from the power connector and implemented in the sense connector. The sense contact detects mating state and provides signals to control power flow, separating the sensing function from the power transmission function and reducing power connector complexity
Solution Approach 2:
The sense contact detects the mating state before power is applied to the power contacts. This preliminary detection allows the control circuit to prepare for safe power connection, preventing arcing by ensuring proper mating before power flow begins
Data Source
AI summary
A connector assembly includes a power connector having first and second power interfaces that interface with first and second power components. The power connector includes a shell forming a cavity and having a shell slot at the first power interface to receive the first power component. A power contact is received in the cavity that extends between the first power interface and the second power interface to electrically connect the first power component to a power circuit of the second power component. The connector assembly includes a sense connector separate and discrete from the power connector. The sense connector includes first and second sense interfaces configured to interface with the first and second power components. The sense connector includes a housing holding a sense contact and electrically isolating the sense contact from the shell. The sense contact electrically connect the first power component to a sense circuit of the second power component.