Low-Profile Power Connector for Bus Bar
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Solution Overview
Problem
There is a need for a low-profile, high current power connector that can have a separable mating interface with a bus bar and be variably positionable along the bus bar to accommodate system design flexibility, particularly in systems requiring high power connections such as up to 500 amps.
Innovation Solution
A power connector design featuring a housing with terminal channels for power terminals, which include contact arrays that provide a separable mating interface with bus rails, allowing for high current transmission while maintaining a low profile and flexibility in positioning along the bus bar.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a power connector is designed for high current transmission (500 amps or more), then the current carrying capacity is improved, but the profile height increases and may not fit within rack unit height requirements
Solution Approach 1:
The power connector is divided into multiple terminal channels (first terminal channel and second terminal channel) that can be independently configured. Each channel can accommodate power terminals with contact arrays of different sizes and configurations, allowing the overall connector height to be reduced while maintaining high current capacity through parallel current paths across multiple channels.
Solution Approach 2:
Instead of increasing height to accommodate more contacts for high current, the design utilizes the horizontal dimension by providing multiple terminal channels arranged side-by-side. The contact arrays are configured to extend along the length of the bus bar interface, distributing the current-carrying contacts across a larger surface area in the horizontal plane rather than stacking them vertically.
2Ease of manufacture
If a power connector is designed with fixed positioning, then manufacturing simplicity is improved, but system design flexibility is reduced
Solution Approach 1:
The power connector incorporates a mating slot that allows the connector to be positioned at various locations along the bus bar. The slot geometry and contact array configuration enable the connector to accommodate different positioning requirements while maintaining reliable electrical connection, providing adaptability for various system designs without complicating the manufacturing process.
Solution Approach 2:
The power connector is designed with universal features including the mating slot configuration and terminal channel arrangement that can accommodate different bus bar positions and orientations. The same connector design can be used in multiple system configurations, making it versatile for different rack unit arrangements and power distribution scenarios.
3Ease of operation
If a power connector uses a separable mating interface with bus bar, then installation flexibility is improved, but connection reliability may be compromised
Solution Approach 1:
The contact arrays are pre-configured within the terminal channels to engage with the bus bar rails in a predetermined manner. The mating slot geometry guides the connector into proper alignment with the bus bar before final engagement, ensuring reliable electrical connection while maintaining the benefit of separable installation. The contact springs are pre-loaded to provide consistent contact pressure upon engagement.
Data Source
AI summary
A power connector includes a housing having a mating slot at a front having terminal channels holding power terminals between the slot and the corresponding side of the housing. Each power terminal includes a plate extending from the slot through a rear of the housing to an exterior of the housing for termination to a corresponding power element. The power terminal has a contact array of contacts discrete from and coupled to the plate. Each contact has a plate interface electrically coupled to the plate and a bus bar interface configured to be electrically coupled to a corresponding rail of the bus bar. The contacts are arranged along a corresponding side of the slot for interfacing with the bus bar.