Power Connector Biasing Pin Compression Fit
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Solution Overview
Problem
Existing power connectors for bus bars face issues with maintaining reliable electrical conductivity, preventing oxidation, and withstanding insertion and removal forces, especially during blind mating and hot-plugging, which can lead to arcing and increased resistance.
Innovation Solution
A power connector design featuring a conductive support structure with a biasing pin that creates a compression fit, providing an airtight contact and mechanical stop, and an electrical contact with deformable portions to minimize arcing, coupled directly to a bus bar or backplane, reducing resistance and oxidation risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contact members are soldered or screwed to a backplane, then electrical connection is established, but oxidation risk increases and manufacturing complexity increases
Solution Approach 1:
The conductive support structure merges the electrical contact and backplane into a single integrated component. The electrical contact is directly formed as part of the conductive support structure, eliminating the need for separate soldering or screwing operations and removing the backplane interface that is susceptible to oxidation.
Solution Approach 2:
The invention extracts and eliminates the backplane component from the traditional connector design. By directly forming the electrical contact within the conductive support structure, the patent removes the intermediate backplane that creates oxidation risks and manufacturing complexity.
2Ease of operation
If conventional power connectors are used, then electrical connection is provided, but arcing occurs during hot-plugging and insertion forces cause damage
Solution Approach 1:
The biasing pin applies pre-compression force to the electrical contact before bus bar insertion, creating a cushioning effect. This pre-compression ensures optimal contact pressure is already established, preventing arcing during hot-plugging and protecting against damage from insertion forces.
Solution Approach 2:
The invention changes the electrical contact's mechanical parameters by making it deformable under compression. The electrical contact can deform to accommodate insertion forces while maintaining electrical conductivity, and the biasing pin dynamically adjusts contact pressure to prevent arcing during hot-plugging operations.
3Reliability
If electrical contact is deformable to minimize arcing, then conductivity is maintained, but manufacturing precision requirements increase
Solution Approach 1:
The electrical contact is designed to be self-deforming under the biasing pin's compression. Rather than requiring precise pre-formed geometry, the contact material itself deforms to achieve optimal contact pressure and geometry, with the biasing pin providing the necessary compressive force to maintain this self-adjusting mechanism.
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 solution ensures low resistance and reduced risk of oxidation, preventing overheating and damage from arcing, while allowing for reliable high-force insertion and removal without over-insertion, maintaining conductivity across multiple cycles.
Implementation Method 1
The biasing pin 106 engages the electric contact 104 and biases a first portion 110 of the electrical contact 104 against the conductive support structure 102
Implementation Method 2
The conductive support structure 102 and the electrical contact 104 form a compression fit
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A power connector for mating with a bus bar includes a conductive support structure defining at least a first slot, an electrical contact positioned within the first slot, and a biasing pin positioned within the first slot and engaging the electrical contact The biasing pin biases at least a first portion of the electrical contact against the conductive support structure to maintain electrical conductivity between the conductive support structure and the electrical contact. At least a second portion of the electrical contact engages a bus bar when the bus bar is received in the first slot.