Patent Grant
12132285
The subject matter herein relates generally to power connector systems.
Power connectors are used to electrically connect components, such as a printed circuit board with a busbar to supply power to the printed circuit board. When the power connector mates to the power source, such as the busbar, the potential exists for power to arc across the interface as the power connector is mated or unmated. Some systems use hot swap circuitry to prevent arcing by delaying power on until the power contacts are fully and reliably mated and powering off the power contacts before the power contacts are unmated. Some known power connectors include sense contacts that are included within the power connector, such as held in the housing of the power connector adjacent the power contacts. However, some known power connectors include metal shells. Such power connectors cannot hold sense contacts therein because the sense contacts may be electrically connected to the power contacts or the metal shell.
A need remains for a power connector system having a sense module for sensing a mating state of the power connector within the power connector system.
In one embodiment, a connector assembly is provided and includes a power connector including a first power interface configured to interface with a first power component and a second power interface configured to interface with a second power component. The power connector includes a shell having a first wall and a second wall forming a cavity. The shell has a shell slot at the first power interface to receive the first power component. The power connector includes a power contact received in the cavity. The power contact 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 a first sense interface configured to interface with the first power component and a second sense interface configured to interface with the second power component. The sense connector includes a housing holding a sense contact. The housing electrically isolates the sense contact from the shell. The sense contact extends between the first sense interface and the second sense interface to electrically connect the first power component to a sense circuit of the second power component.
In another embodiment, a power connector system is provided and includes a power substrate including a power circuit. The power connector system includes a power connector mounted to the power substrate. The power connector includes a first power interface configured to interface with a power component and a second power interface electrically connected to the power circuit of the power substrate. The power connector includes a shell having a first wall and a second wall forming a cavity. The shell has a shell slot at the first power interface to receive the first power component. The power connector includes a power contact received in the cavity. The power contact extends between the first power interface and the second power interface to electrically connect the first power component to the power circuit of the power substrate. The power connector system includes a sense connector separate and discrete from the power connector. The sense connector is mounted to the power substrate. The sense connector includes a first sense interface configured to interface with the first power component. The sense connector includes a housing holding a sense contact. The housing electrically isolates the sense contact from the shell. The sense contact electrically connects the first power component and a sense circuit configured to control power supply between the first power component at the power circuit.
In a further embodiment, a power connector system is provided and includes a power substrate having a first side and a second side. The power connector system includes a power connector mounted to the first side of the power substrate. The power connector includes a first power interface configured to interface with a power component and a second power interface electrically connected to the first side of the power substrate. The power connector includes a shell having a first wall and a second wall forming a cavity. The shell has a shell slot at the first power interface to receive the first power component. The power connector includes a power contact received in the cavity. The power contact extends between the first power interface and the second power interface to electrically connect the first power component to the power substrate. The power connector system includes a sense connector separate and discrete from the power connector. The sense connector mounted to the power substrate. The sense connector includes a first sense interface configured to interface with the first power component. The sense connector includes a housing holding a sense contact. The housing electrically isolates the sense contact from the shell. The sense connector includes a sense wire terminated to the sense contact. The sense wire extends from the housing to electrically connect the first power component to a sense circuit to control power supply between the first power component and the power substrate.
In an exemplary embodiment, the connector assembly 102 of the power connector system 100 includes a sense module for sensing the mated state of the connector assembly 102 between the first and second power components 104, 106 to control power supply between the first and second power components 104, 106. For example, the sense module senses when the connector assembly 102 is mated to the first and second power components 104, 106 and senses when the connector assembly 102 is unmated from the first power component 104 and/or the second power component 106. The sense module may be used to control the power supply, such as by switching the power supply on and off based on the mating state of the connector assembly 102, such as to prevent electrical arcing or damage to the components during mating to and unmated. The sense module prevents arcing by delaying power on until the power contacts are fully and reliably mated and powering off the power contacts before the power contacts are unmated.
In an exemplary embodiment, the first power component 104 includes a power substrate 111 having a power circuit. In the illustrated embodiment, the power substrate 111 defining the first power component 104 is a busbar 110. In the illustrated embodiment, the first power component 104 includes a pair of the busbars 110. However, greater or fewer busbars 110 may be provided in alternative embodiments. Each busbar 110 is a metal plate configured to supply power to one or more of the second power components 106 through the connector assembly(ies) 102. The busbar 110 includes a first side 112 and a second side 114 opposite the first side 112. The busbar 110 includes an edge 116 at the front of the busbar 110. In an exemplary embodiment, the edge 116 is configured to be plugged into the connector assembly 102. The connector assembly 102 is configured to be mated to the first side 112 and/or the second side 114 to electrically connect to the busbar 110. In an exemplary embodiment, the connector assembly 102 is coupled to the busbar 110 at a separable mating interface. For example, the busbar 110 may be plugged into and unplugged from the connector assembly 102.
In various embodiments, the busbar 110 may include a cap 118 along the edge 116. The cap 118 may be intuitive, such as plastic or rubber, to prevent inadvertent touching of the edge 116 of the busbar 110. In various embodiments, a housing (not shown) may surround the busbar 110, such as along the first side 112 and/or the second side 114, to prevent inadvertent touching of the busbar 110.
In an alternative embodiment, the first power component 104 may be another type of electrical component, such as a printed circuit board having one or more circuits on the printed circuit board. The printed circuit board may be used to supply power to the second power component 106 through the connector assembly 102. However, in alternative embodiments, the printed circuit board may receive power from the second power component 106 through the connector assembly 102.
In an exemplary embodiment, the second power component 106 includes a power substrate 121 having a power circuit. In the illustrated embodiment, the power substrate 121 defining the second power component 106 is a printed circuit board 120. In the illustrated embodiment, a single printed circuit board 120 is shown coupled to the busbars 110; however, additional printed circuit boards 120 may be coupled to the busbars 110 along the mating faces of the busbars 110. Other components (not shown) may be mounted to the printed circuit board 120 connected to the power circuit of the printed circuit board 120. The power supplied to the printed circuit board 120 through the connector assembly 102 is supplied to the other components through the power circuit. For example, a processor or other electrical component may be mounted to the printed circuit board 120 and powered by the power circuit.
The printed circuit board 120 includes a first side 122 and a second side 124 opposite the first side 122. The printed circuit board 120 includes an edge 126 at the front of the printed circuit board 120. In an exemplary embodiment, the connector assembly 102 is mounted to the printed circuit board 120 at the edge 126. For example, components of the connector assembly 102 may be mounted to the first side 122 and/or the second side 124. The components of the connector assembly 102 may extend forward of the edge 126 for mating with the busbars 110. In various embodiments, the components of the connector assembly 102 may be soldered to the printed circuit board 120. In other various embodiments, the components of the connector assembly 102 may be connected to the printed circuit board 120 by a press-fit connection. In alternative embodiments, the components of the connector assembly 102 may be connected to the printed circuit board 120 at a separable interface. In an exemplary embodiment, the components of the connector assembly 102 are connected to the printed circuit board 120 using fasteners 130, such as bolt or screws.
In an alternative embodiment, the second power component 106 may be another type of electrical component, such as a busbar. In various embodiments, the second power component 106 may be used to supply power to the first power component 104 through the connector assembly 102.
In an exemplary embodiment, the connector assembly 102 includes a power connector 200 and a sense connector 300 separate and discrete from the power connector 200. The sense connector 300 provides a sense module within the system without the need for redesigning or retooling the power connector 200. The sense connector 300 provides a sense contact that is electrically isolated from the power connector 200. The sense module 300 may be used to retrofit existing systems. The power connector 200 and the sense connector 300 are configured to be electrically connected to the first and second power components 104, 106. In the illustrated embodiment, multiple power connectors 200 and multiple sense connectors 300 are provided, each being electrically connected to the corresponding busbar 110 in printed circuit board 120. The power connector 200 supplies power between the first and second power component 104, 106. The sense connector 300 senses a mating state of the connector assembly 102 with the first power component 104 and/or the second power component 106. Optionally, a power control circuit may be controlled based upon the mating state sensed by the sense connector 300. For example, the power control circuit may turn the power supply on and off based upon the mating state. In other embodiments, the power control circuit may control a switch to control (for example, open/close) the power circuit of the first power connector 104 and/or the second power connector 106 based upon the mating state.
The power connector 200 includes a first power interface 204 configured to interface with the first power component 104 and a second power interface 206 configured to interface with the second power component 106. In various embodiments, the first power interface 204 is a separable interface. In various embodiments, the second power interface 206 is a permanent interface, such as a solder or press-fit connection. However, in alternative embodiments, the second power interface 206 may be a separable interface.
In an exemplary embodiment, the power connector 200 includes a shell 210 and the power contact 212 received in the shell 210. The shell 210 and/or the power contacts 212 are configured to be electrically connected to the printed circuit board 120 and are configured to be electrically connected to the corresponding busbar 110. In an exemplary embodiment, the shell 210 is electrically conductive and electrically connected to the power contact 212. The current and/or voltage transmitted through the power connector 200 may be based on the size and/or the shape and/or the material of the shell 210 and the power contacts 212, may be based on the points of contact (number and locations) between the shell 210 and the power contact 212, and may be based on the points of contact between the power connector 200 and the busbar 110 and the printed circuit board 120.
The sense connector 300 includes a first sense interface 304 configured to interface with the first power component 104 and a second sense interface 306 configured to interface with the second power component 106, such as with a sense circuit of the second power component 106. The sense circuit may be a hot swap circuit. The sense circuit may include a processor or electrical components that control the power supply through the power connector system. The sense circuit may be operably connected to the power source, such as the power supply. The sense circuit may be operably connected to the power circuit of the second power component 106 to control power flow through power circuit (for example, to open and close the power circuit, such as by controlling a switch of the power circuit). In various embodiments, the first sense interface 304 is a separable interface. In various embodiments, the second sense interface 306 is a separable interface. However, in alternative embodiments, the second sense interface 306 may be a permanent interface, such as a solder or press-fit connection.
In an exemplary embodiment, the sense connector 300 includes a housing 310 and a sense contact 312 (shown in
The housing 310 includes a housing slot 330 at the front 320. The housing slot 330 is configured to receive the busbar 110. In an exemplary embodiment, the housing slot 330 includes chamfered surfaces 332 at the front 320 to widen the housing slot 330 at the front 320. The chamfered surfaces 332 guide the busbar 110 into the housing slot 330. In an exemplary embodiment, the housing 310 includes a pair of silos 335 at the front 320 on opposite sides of the housing slot 330. Portions of the sense contact 312 extend into the corresponding silos 335 on opposite sides of the housing slot 330 to interface with the busbar 110. The housing slot 330 is defined by side walls 334, 336 and an end wall 338. The side walls 334, 336 oppose each other on opposite sides of the housing slot 330. The side walls 334, 336 are configured to face opposite sides of the busbar 110. The sense contact 312 extends to the housing slot 330 to interface with the busbar 110. For example, the sense contact 312 may be exposed along the side walls 334, 336 to interface with the busbar 110.
The housing 310 includes a pocket 340 along the first side 324. The pocket 340 is configured to receive the printed circuit board 120. A lip 342 is located forward of the pocket 340. The pocket 340 may be open between the lip 342 and the rear 322 of the housing 310. The pocket 340 may be open between the edges 328. In an exemplary embodiment, the housing 310 includes locating posts 344 extending into the pocket 340. The locating posts 344 are used to locate the sense connector 300 relative to the printed circuit board 120. The locating posts 344 may be received in openings in the printed circuit board 120. Optionally, the locating posts 344 may be sized differently or shaped differently for keyed mating with the printed circuit board 120. Any number of the locating posts 344 may be provided in various embodiments.
In an exemplary embodiment, the housing 310 includes openings 346 extending between the first side 324 and the second side 326. The openings 346 are configured to receive the fasteners 130 (shown in
The sense contact 312 is a conductive contact configured to be electrically connected to the busbar 110 and electrically connected to the printed circuit board 120. In an exemplary embodiment, the sense contact 312 is a stamped and formed contact. The sense contact 312 may be overmolded by the housing 310 such that the housing 310 covers portions of the sense contact 312 to electrically isolate the sense contact 312 from the power connector 200 (shown in
The sense contact 312 includes a main body 350 (shown in phantom) extending between a mating end 352 and a terminating end 354. The mating end 352 is configured to be coupled to the busbar 110. In the illustrated embodiment, the mating end 352 includes a pair of mating beams 356 extending forward of the main body 350. The mating beams 356 extend along opposite sides of the housing slot 330. The mating beams 356 have mating interfaces 358 at or near distal ends of the mating beams 356. The mating interfaces 358 are configured to directly engage the busbar 110. Optionally, the mating beams 356 may be curved at the mating interfaces 358. The mating interfaces 358 may define separable interfaces configured to be mated to and unmated from the busbar 110. For example, the mating interfaces 358 may slide along the busbar 110 during mating with and unmated from the busbar 110. Other types of mating elements may be provided at the mating end 352, such as spring beams, blades, pins, sockets, compliant pins, solder tabs, and the like.
The terminating end 352 is configured to be terminated to the printed circuit board 120. In the illustrated embodiment, the terminating end 354 includes a spring beam 360 extending rearward from the main body 350. The spring beam 360 is configured to be spring biased against the printed circuit board 120. For example, the spring beam 360 may be deflected when mated to the printed circuit board 120 creating an internal spring biasing force that maintains reliable mechanical and electrical connection to the printed circuit board 120. Other types of mating elements may be provided at the terminating end 354, such as fixed beams, blades, pins, sockets, compliant pins, solder tabs, and the like. In an exemplary embodiment, the terminating end 354 extends to an exterior of the housing 310 for electrical connection to the printed circuit board 120. For example, the terminating end 354 extends rearward from the rear 322 of the housing 310. The sense contact 312 may include multiple spring beams 360 in alternative embodiments creating multiple points of contact with the printed circuit board 120.
In an exemplary embodiment, the shell 210 is electrically conductive. For example, the shell 210 may be manufactured from a metal material. In an exemplary embodiment, the shell 210 is stamped and formed from a metal sheet. The shell 210 forms a cavity 214 that receives the power contact 212. The power contact 212 is electrically conductive and configured to be electrically connected to the shell 210. The power contact 212 is configured to be electrically connected to the busbar 110 to electrically connect the shell 210 to the busbar 110. The power contact 212 is configured to be electrically connected to the printed circuit board 120 to electrically connect the shell 210 to the printed circuit board 120.
The shell 210 extends between a front 220 and a rear 222. The shell 210 includes a first side 224 and a second side 226. The shell 210 includes a top 228 and a bottom 229. The shell 210 includes a shell slot 230 at the front 220. The shell slot 230 is configured to receive the busbar 110. The shell slot 230 is open at the top 228 and the bottom 229 to allow the busbar 110 to pass through the shell 210. In an exemplary embodiment, the shell slot 230 includes chamfered surfaces 232 at the front 220 to widen the shell slot 230 at the front 220. The chamfered surfaces 232 guide the busbar 110 into the shell slot 230.
The shell slot 230 is defined by side walls 234, 236. The side walls 234, 236 oppose each other on opposite sides of the shell slot 230. The side walls 234, 236 are configured to face opposite sides of the busbar 110. The power contact 212 is located in the cavity 214 and extends along the side walls 234, 236. The power contact 212 is exposed within the shell slot 230 to interface with the busbar 110. In an exemplary embodiment, the shell 210 includes latch pockets 240 in the side walls 234, 236 that receive latching features of the power contact 212 to hold the power contact 212 in the cavity 214.
In an exemplary embodiment, the shell 210 is secured to the printed circuit board 120 using the fasteners 130. For example, the fasteners 130 may be threadably coupled to the shell 210. In various embodiments, the shell 210 may include mounting tabs (not shown) or other features for mounting the shell 210 to the printed circuit board 120. For example, the mounting tabs may be solder tabs configured to be soldered to the first side 122 of the printed circuit board 120. In other various embodiments, the mounting tabs may be compliant pins configured to be press-fit into the printed circuit board 120 to mechanically and electrically connect the shell 210 to the printed circuit board 120.
The power contact 212 is a conductive contact configured to be electrically connected to the busbar 110 and electrically connected to the printed circuit board 120. In an exemplary embodiment, the power contact 212 is a stamped and formed contact. In various embodiments, the power contact 212 may be manufactured from a different material than the shell 210 or may be plated with a different material than the shell 210. In various embodiments, the power contact 212 is stamped from a metal sheet having a different thickness than the metal sheet used to form the shell 210. The power contact 212 may be loaded into the cavity 214, such as through the rear 222 or the bottom 229 of the shell 210. Alternatively, the shell 210 may be formed around the power contact 212.
The power contact 212 includes a main body 250 extending between a mating end 252 and a terminating end 254. In an exemplary embodiment, the power contacts 212 is a right-angle contact having the mating end 252 perpendicular to the terminating end 254. For example, the mating end 252 may be provided at the front of the power contact 212 and the terminating end 254 may be provided at the bottom of the power contact 212. Other orientations are possible in alternative embodiments, including having the mating end 252 and the terminating end 254 at opposite ends of the main body 250.
The mating end 252 is configured to be coupled to the busbar 110. In the illustrated embodiment, the mating end 252 includes a plurality of mating beams 256 extending forward of the main body 250. In an exemplary embodiment, the mating beams 256 are deflectable mating beams, such as spring beams configured to be compressed when engaging the busbar 110. The mating beams 256 extend toward the front 220 of the shell 210 and are located along opposite sides of the shell slot 230, such as to mate with opposite sides of the busbar 110. The mating beams 256 have mating interfaces 258 at or near distal ends of the mating beams 256. The mating interfaces 258 are configured to directly engage the busbar 110. Optionally, the mating beams 256 may be curved at the mating interfaces 258. The mating interfaces 258 may define separable interfaces configured to be mated to and unmated from the busbar 110. For example, the mating interfaces 258 may slide along the busbar 110 during mating with and unmated from the busbar 110. Other types of mating elements may be provided at the mating end 252, such as blades, pins, sockets, compliant pins, solder tabs, and the like.
The terminating end 252 is configured to be terminated to the printed circuit board 120. In the illustrated embodiment, the terminating end 254 includes a solder tab 260 extending along the bottom of the power contact 212. The solder tab 260 is configured to be soldered to the power circuit of the printed circuit board 120. Other types of terminating elements may be provided at the terminating end 254, such as spring beams, blades, pins, sockets, compliant pins, and the like. In an exemplary embodiment, the terminating end 254 extends to an exterior of the shell 210 for electrical connection to the printed circuit board 120. For example, the terminating end 254 extends downward from the bottom 229 of the shell 210. The terminating end 254 may be located proximate to the rear 222 of the shell 210.
In an exemplary embodiment, the power contact 212 includes a latch 262 extending from the main body 250. The latch 262 is received in the corresponding latch pocket 240 of the shell 210. The latch 262 secures the power contact 212 relative to the shell 210.
During assembly, the power connectors 200 are aligned with corresponding mating areas at the first side 122 of the printed circuit board 120 and the sensor connectors 300 are aligned with corresponding mating areas at the second side 124 of the printed circuit board 120. The sensor connectors 300 are aligned with the power connectors 200. For example, the housing slots 330 of the housing 310 may be aligned with the shell slots 230 of the shells 210 to receive the corresponding busbars 110.
During assembly, the pocket 340 of the housing 310 is aligned with the printed circuit board 120 such that the lip 342 is located forward of the edge 126 of the printed circuit board 120. The locating posts 344 are aligned with locating openings 144 in the printed circuit board 120. During mating, the locating posts 344 may be loaded into the locating openings 144. The housing 310 is held against the second side 124 of the printed circuit board 120. The front end of the housing 310 extends forward of the printed circuit board 120.
During assembly, the power connectors 200 are mounted to the first side 122 of the printed circuit board 120. Locating features, such as pins or other protrusions, of the power connectors 200 may be received in the locating openings 144. The mounting features of the power connectors 200 may be mounted to the printed circuit board 120. For example, solder tabs of the power connectors 200 may be soldered to the printed circuit board 120.
During assembly, the fasteners 130 pass through the openings 346 and pass-through openings 146 in the printed circuit board 120 to secure the sensor connectors 300 to the printed circuit board 120. In an exemplary embodiment, the fasteners 130 pass through the printed circuit board 120 to couple to the power connectors 200. For example, the fasteners 130 may be threadably coupled to the power connectors 200. As such, the same fasteners 130 may be used to secure both the sensor connectors 300 and the power connectors 200 to the printed circuit board 120. However, in alternative embodiments, separate fasteners may be used for the sensor connectors 300 and the power connectors 200.
The mating ends 352 of the sense contacts 312 are located rearward of the mating ends 252 of the power contacts 212. For a time during the mating process, after initial connection of the power contacts 212 to the busbar 110, the sense contacts 312 are not connected to the busbar 110. The sense circuit is inactive prior to the sense contacts 312 being electrically connected to the busbar 110. As such, the power circuit is deactivated, and power is unable to flow through the power connector system 100 when the sense contacts 312 are not connected to the busbar 110. Similarly, during un-mating, when the connector assembly 102 is in the positioner illustrated in
In the illustrated embodiment, the second power component 106 includes a power substrate 421 including a busbar 420. Other components (not shown) may be connected to the busbar 420. For example, a power take-off connector or power cable may be coupled to the busbar 420. Power is supplied to the busbar 420 through the connector assembly 102, such as through the power connector 200. However, in alternative embodiments, the power substrate 421 may include a printed circuit board similar to the printed circuit board 120.
The busbar 420 includes a first side 422 and a second side 424 opposite the first side 422. The busbar 420 includes an edge 426 at the front of the busbar 420. In an exemplary embodiment, the connector assembly 102 is mounted to the busbar 420 at the edge 426. For example, the power connector 200 is mounted to the first side 422 and the sense connector 300 is mounted to the second side 424. In various embodiments, the connector assembly 102 is secured to the busbar 420 using fasteners 430.
During assembly, the power connectors 200 are aligned with corresponding mating areas at the first side 422 of the busbar 420 and the sensor connectors 300 are aligned with corresponding mating areas at the second side 424 of the busbar 420. The sensor connectors 300 are aligned with the power connectors 200. For example, the housing slots 330 of the housing 310 may be aligned with the shell slots 230 of the shells 210 to receive the corresponding busbars 110. The fasteners 430 pass through the openings 346 and pass-through openings 446 in the busbar 420 to secure the power connectors 200 and the sensor connectors 300 to the busbar 420.
It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely exemplary embodiments. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means-plus-function format and are not intended to be interpreted based on 35 U.S.C. § 112(f), unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.
| Number | Name | Date | Kind |
|---|---|---|---|
| 2701346 | Powell | Feb 1955 | A |
| 5190462 | Lauchner | Mar 1993 | A |
| 9431783 | Costello | Aug 2016 | B1 |
| Number | Date | Country | |
|---|---|---|---|
| 20230387637 A1 | Nov 2023 | US |
