Pivotable Power Connector Tolerating Busbar Misalignment
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Solution Overview
Problem
As electronic systems become smaller and more complex, they require tighter tolerances for signal and ground conductor positioning, making it more expensive to manufacture components that meet these tighter specifications, and existing connectors struggle to maintain low resistance electrical contact with greater misalignment between components.
Innovation Solution
The development of a power connector with a pivotable member and conductive elements featuring compliant beams that can tolerate misalignment up to 2 mm, allowing for low resistance electrical contact between busbars and printed circuit boards, even when components are not in their nominal positions, and capable of carrying high currents without excessive temperature rise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If tighter tolerances are required for conductor positioning to maintain low resistance contact, then manufacturing precision must be improved, but manufacturing cost increases
Solution Approach 1:
The connector employs a pivotable member that can rotate about an axis, transforming a static rigid connection into a dynamic adjustable one. This allows the connector to adapt to misalignment between busbars and PCBs without requiring tight manufacturing tolerances, thereby reducing manufacturing costs while maintaining low resistance electrical contact
Solution Approach 2:
The invention changes the positional parameter of the conductive elements through rotation of the pivotable member. By allowing the mating portion to rotate and adjust its position, the system can compensate for misalignment variations without needing precise manufacturing tolerances, thus resolving the contradiction between precision and manufacturing cost
2Adaptability or versatility
If pivotable member with compliant beams is used to tolerate misalignment, then adaptability to misalignment is improved, but device complexity increases
Solution Approach 1:
The connector is divided into distinct functional segments: a housing, a pivotable member with conductive elements, and compliant beams. This segmentation allows each part to perform its specific function - the pivotable member handles misalignment through rotation, while the compliant beams provide additional flexibility and contact force, achieving high adaptability without excessive overall complexity
Solution Approach 2:
The pivotable member acts as an intermediary between the rigid housing and the busbars/PCBs. It mediates the misalignment issue by providing a rotation joint that absorbs positional deviations, while the compliant beams serve as intermediaries that provide flexible electrical contact, thereby achieving adaptability with controlled complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The connector provides reliable, low-resistance connections with improved tolerance for misalignment, enabling efficient power distribution in complex electronic systems while maintaining high current-carrying capacity without significant heating.
Implementation Method 1
a first conductive element having a body and a mating portion extending from the body, where the mating portion comprises a plurality of beams configured to pivot about a pivot axis
Implementation Method 2
the plurality of beams may be configured to carry in excess of 350 A with a temperature rise of no greater than 30° C.
Implementation Method 3
capable of carrying high currents without excessive temperature rise
Data Source
AI summary
A power connector that provides a large tolerance for mating to a busbar. The connector has compliant mating contacts supported by a pivoting member. Upon insertion between two busbars, the compliant mating contacts compensate for a first amount of misalignment between the connector and the busbars. The contacts may pivot, compensating for an additional amount of misalignment.