Low-Profile Power Connector for High-Current Bus Bar Systems
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Solution Overview
Problem
There is a need for a low-profile, high-current power connector with a separable mating interface and variable positioning along a bus bar to accommodate system design flexibility, particularly in high-power systems requiring connections up to 500 amps or more.
Innovation Solution
The power connector features a housing with first and second power terminals, each comprising a contact stack and plate, where the mating beams of the power terminals oppose each other across a mating slot to engage bus rails on a bus bar, allowing for secure and flexible electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the power connector is designed for high current connections (500 amps or more), then the power transmission capability is improved, but the connector height increases and may not meet rack unit height requirements
Solution Approach 1:
The power connector is divided into multiple contact stacks (first contact stack and second contact stack) with separate plates and contacts for each terminal. This segmentation allows the current path to be distributed through multiple parallel contacts, achieving high current capacity (500 amps or more) while keeping each individual contact and the overall connector height compact and suitable for rack unit installations.
2Ease of manufacture
If the power connector uses a fixed position design, then the manufacturing simplicity is improved, but the system design flexibility is reduced
Solution Approach 1:
The power connector incorporates a variable position design where the connector can be positioned at different locations along the bus bar while maintaining proper electrical connection. The contact stacks and mating beams are designed to accommodate positional variation, allowing the same connector design to be used in multiple configurations without requiring custom manufacturing, thus providing system design flexibility while maintaining manufacturing simplicity.
3Reliability
If the power connector uses an integrated design with bus bar, then the connection reliability is improved, but the separability and reconfigurability are reduced
Solution Approach 1:
The power connector features a preliminary engagement design where the mating beams make initial contact with the bus bar rails before full connection is achieved. This preliminary action ensures proper alignment and establishes reliable electrical connection progressively, while still allowing the connector to be separated and repositioned if needed, thus maintaining both connection reliability and separability.
Data Source
AI summary
A power connector includes first and second power terminals having first and second contact stacks and first and second plates for termination to corresponding power element. The contact stacks have contacts separate and discrete from each other and from the plate. Each contact has a base and a mating beam. The bases are aligned and mechanically and electrically coupled to the plate. A housing has an end wall and a fastener that mechanically and electrically couples the bases to the plate. The power terminals are arranged such that the first and second mating beams oppose each other across a mating slot that receives a bus bar with the first mating beams mechanically and electrically engaging a first bus rail at a first side of the bus bar and the second mating beams mechanically and electrically engaging a second bus rail at a second side of the bus bar.