Patent ID: 12224537

DETAILED DESCRIPTION OF THE INVENTION

FIG.1illustrates an electrical connector system100in accordance with an exemplary embodiment. The electrical connector system100includes an electrical connector200configured to be electrically connected to a mating electrical connector104. In an exemplary embodiment, the electrical connector200is a panel-mount electrical connector configured to be mounted to a panel102(shown in phantom). In various embodiments, the electrical connector200is a cable connector provided at an end of a cable. In the illustrated embodiment, the mating electrical connector104is a power connector configured to supply power to the electrical connector200. For example, the mating electrical connector104includes a busbar assembly120supplying power to the electrical connector200. In an exemplary embodiment, the mating electrical connector104is additionally used to transmit data signals between the electrical connector200and the mating electrical connector104.

The panel102may be a chassis, a frame, a housing, or other component of the electrical connector system100. In various embodiments, the panel102may be a panel of a server rack, such as a single rack unit and the electrical connector200is used to power the rack unit. The busbar assembly120may be used to power multiple rack units within the server rack.

In an exemplary embodiment, the panel102is planar having a front surface110and the rear surface112. In various embodiments, the panel102is electrically conductive and may be electrically grounded. For example, the panel102may be a piece of sheet metal. The electrical connector200may be electrically commoned with the panel102. The panel102includes a panel opening therethrough. For example, a portion of the electrical connector200may pass through the panel opening for mating with the mating electrical connector104. In an exemplary embodiment, a portion of the electrical connector200is coupled to the rear surface112and a portion of the electrical connector200is coupled to the front surface110. In an exemplary embodiment, the electrical connector200may be latchably coupled to the panel102. For example, the electrical connector200includes one or more latching features that are latchably coupled to the panel102.

The busbar assembly120includes a busbar housing122holding a busbar130. The busbar housing122is manufactured from a dielectric material, such as a plastic material. The busbar housing122includes a first side wall123and a second side wall124forming a busbar cavity125. The busbar130is located in the busbar cavity125between the first and second side walls123,124. In an exemplary embodiment, the busbar housing122includes a mid-wall126between the first and second side walls123,124. The mid-wall126extends into the busbar cavity125. The mid-wall supports the busbar130. The mid-wall126includes a cap127at a front or distal end of the mid-wall126. The cap127is located forward of the busbar130. The cap127is a touch-proof feature of the busbar assembly120that prevents inadvertent touching of the busbar130.

The busbar130includes a first busbar contact132and a second busbar contact134. The first busbar contact132may be a positive contact and the second busbar contact134may be a negative contact. The first busbar contact132may be a cathode and the second busbar contact134may be an anode. In an exemplary embodiment, the busbar contacts132,134are metal plates. The busbar contacts132,134are separated by the mid-wall126. The busbar contacts132,134are exposed in the busbar cavity125for mating with the electrical connector200. In various embodiments, the mid-wall may be stacked with the busbar contacts132,134, separate from the busbar housing122, and coupled to the base wall of the busbar housing122.

In an exemplary embodiment, the busbar cavity125is divided into a first pocket136and a second pocket138. The first pocket136is defined between the mid-wall126and the first side wall123. The second pocket138is defined between the mid-wall126and the second side wall124. The first busbar contact132is exposed in the first pocket136for mating with the electrical connector200. The second busbar contact134is exposed in the second pocket138for mating with the electrical connector200.

In an exemplary embodiment, the busbar assembly120includes a first conductive structure140in the busbar cavity125and a second conductive structure142in the busbar cavity125. The first conductive structure140is located in the first pocket136for mating with the electrical connector200. The first conductive structure140may be a printed circuit board in various embodiments. In other embodiments, the first conductive structure140may be a connector, a contact, or other conductive structure. In an exemplary embodiment, the first conductive structure140is coupled to an interior surface of the first side wall123. The first conductive structure140faces the first busbar contact132across the first pocket136. The first conductive structure140includes first conductors144. The first conductors144are circuits or contacts. The first conductors144may be pads, traces, vias or other circuit components. In various embodiments, the first conductors144are signal conductors; however, the first conductors144may additionally or alternatively be ground conductors or power conductors in alternative embodiments. In the illustrated embodiment, the first conductive structure140includes a plurality of the first conductors144, such as three first conductors144, arranged at a predetermined pitch.

The second conductive structure142is located in the second pocket138for mating with the electrical connector200. The second conductive structure142may be a printed circuit board in various embodiments. In other embodiments, the second conductive structure142may be a connector, a contact, or other conductive structure. In an exemplary embodiment, the second conductive structure142is coupled to an interior surface of the second side wall124. The second conductive structure142faces the second busbar contact134across the second pocket138. The second conductive structure142includes second conductors146. The second conductors146are circuits or contacts. The second conductors146may be pads, traces, vias or other circuit components. In various embodiments, the second conductors146are ground conductors; however, the second conductors146may additionally or alternatively be signal conductors or power conductors in alternative embodiments. In the illustrated embodiment, the second conductive structure142includes a plurality of the second conductors146, such as three second conductors146, arranged at a predetermined pitch. In alternative embodiments, the second conductive structure142may be a sheet of metal defining a ground plane or ground contact.

FIG.2is a front perspective view of the electrical connector200in accordance with an exemplary embodiment. The electrical connector200includes a connector housing202holding a first power contact204(shown inFIG.1) and a second power contact206. In an exemplary embodiment, the electrical connector200includes a cable connector assembly300coupled to the connector housing202. In an exemplary embodiment, the electrical connector200includes a ground element400coupled to the connector housing202.

The first and second power contacts204,206are configured to be electrically connected to the mating electrical connector104(shown inFIG.1). For example, the power contacts204,206are electrically connected to the first and second busbar contacts132,134of the busbar assembly120(shown inFIG.1). In an exemplary embodiment, the power contacts204are provided at ends of power cables205,207extending from the connector housing202. In an exemplary embodiment, each power contact204,206includes a mating end208and a cable end (not shown). The mating end208may include spring beams or other types of contacts defining a mating interface for mating with the busbar assembly120. The cable end is configured to be terminated to the power cable205,207, such as being welded or crimped to the end of the power cable205,207.

The cable connector assembly300is configured to be electrically connected to the mating electrical connector104. For example, the cable connector assembly300is electrically connected to the first conductive structure140(shown inFIG.1) of the busbar assembly120.

The ground element400is configured to be electrically connected to the mating electrical connector104. For example, the ground element400is electrically connected to the second conductive structure142(shown inFIG.1) of the busbar assembly120.

The connector housing202includes a front210and a rear212. The front210defines a mating end214configured to be mated with the mating electrical connector104. The cables205,207extend from a cable end of the connector housing202. In the illustrated embodiment, the rear212defines the cable end. However, the electrical connector200may be a right angle connector with the cables extending from a top216or a bottom218of the connector housing202or extending from a first side220or a second side222of the connector housing202.

In an exemplary embodiment, the connector housing202includes a base230at the rear212and a plug232at the front210. The connector housing202includes a flange234extending from the base230. In various embodiments, the flange234may extend from the base230at the sides220,222. In other various embodiments, the flange234may extend from the base230at the top216and/or the bottom218. The flange234is used for mounting the electrical connector200to the panel102. For example, the flange234may face the rear surface112of the panel102. The base230is located rearward of the flange234, and is thus configured to be located behind the panel102. The plug232extends forward of the flange234, and thus is configured to be located forward of the panel102. For example, the plug232is configured to extend through the panel opening for mating with the busbar assembly120.

In an exemplary embodiment, the connector housing202includes contact channels236that receive the power contacts204,206. The contact channels236extend into the base230and into the plug232. The contacts204,206are configured to be terminated to the cable205,207in the base portion of the contact channels236. The contacts204,206are configured to be mated with the busbar assembly120in the plug portion of the contact channels236.

In an exemplary embodiment, the plug232includes a first plug wall240and a second plug wall242forming a slot244therebetween. Each of the plug walls240,242include an interior surface246and an exterior surface248. The interior surface246faces the slot244. The slot244is open at the front210to receive the busbar130. The contacts204,206are exposed within the slot244for mating with the corresponding first and second busbar contacts132,134of the busbar130. For example, the contacts204,206extend along the interior surfaces246of the corresponding plug walls240,242. In the illustrated embodiment, the slot244extends vertically from the top216to the bottom218. For example, the slot244is open at the top216and open at the bottom218. The slot244may have other shapes in alternative embodiments. In other alternative embodiments, a plurality of the slots244may be provided, such as individual slots for each of the contacts204,206. In the illustrated embodiment, the plug walls240,242are oriented vertically and provided at the first side220and the second side222of the plug232. Additional plug walls may be provided in alternative embodiments.

The cable connector assembly300is coupled to the first plug wall240. For example, the cable connector assembly300extends along the exterior surface248of the first plug wall240for mating with the first conductive structure140of the busbar assembly120.

The ground element400is coupled to the second plug wall242. For example, the ground element400extends along the exterior surface248of the second plug wall242for mating with the second conductive structure142of the busbar assembly120. The ground element400is configured to be electrically connected to the panel102. For example, the ground element400is used to electrically common the panel102and the busbar assembly120.

With additional reference back toFIG.1, the ground element400is electrically conductive. In an exemplary embodiment, the ground element400is stamped and formed from a metal sheet. In the illustrated embodiment, the ground element400includes a plug wall402extending along the plug232and a flange wall404extending along the flange234. The ground element400includes one or more panel tabs406extending from the flange wall404configured to engage the rear surface112of the panel102. The panel tabs406are deflectable and extend out of the plane of the flange wall404to interface with the panel102. The ground element400includes one or more ground beams408extending from the plug wall402configured to engage the busbar assembly120. The ground beams408are deflectable and extend out of the plane of the plug wall402to interface with the busbar assembly120. In the illustrated embodiment, three ground beams408are provided; however, greater or fewer ground beams408may be provided in alternative embodiments. The ground beams408including mating interfaces for mating with the busbar assembly120. The mating interfaces may be outward facing to engage corresponding conductors146of the second conductive structure142. The ground element400may be secured to the connector housing202using clips, brackets, fasteners, heat stakes, adhesive, or other securing elements. The ground element400may have other sizes, shapes, and/or features in alternative embodiments.

FIG.3is a rear perspective view of the cable connector assembly300in accordance with an exemplary embodiment.FIG.4is a rear perspective view of a portion of the cable connector assembly300in accordance with an exemplary embodiment.

The cable connector assembly300includes a cable connector housing302holding signal contacts304electrically connected to corresponding signal cables306. In an exemplary embodiment, the cable connector assembly300includes a cable connector350removably coupled to the cable connector housing302to mate to and un-mate from the signal contacts304at a separable mating interface. The signal cables306are part of the cable connector350. The signal cables306are electrically connected to the signal contacts304through the cable connector350. However, in alternative embodiments, the signal cables306may be terminated directly to the signal contacts304, such as by a solder connection, a crimp connection, or another termination method without the use of the cable connector350.

The cable connector housing302includes a front portion310at a front312of the cable connector housing302and a rear portion314at a rear316of the cable connector housing302. A shoulder318is defined between the front and rear portions310,314. In an exemplary embodiment, the cable connector housing302may be overmolded over the signal contacts304. Alternatively, the cable connector housing302may be pre-molded and the signal contacts304are loaded into the cable connector housing302. The signal contacts304may extend from the cable connector housing302for mating with the busbar assembly120. The signal contacts304may extend from the cable connector housing302for connection to the signal cables306.

The cable connector housing302includes a receptacle320at the rear portion314. The receptacle320receives the cable connector350and/or the signal cables306. The signal contacts304extend into the receptacle320for connection with the cable connector350and/or the signal cables306. In an exemplary embodiment, the cable connector housing302includes a latching feature322for latchably securing the cable connector350in the receptacle320. The cable connector housing302includes an inner surface324. The inner surface324is configured to face the connector housing202(shown inFIG.2). In the illustrated embodiment, the cable connector housing302is a single piece housing. However, the cable connector housing302may be a multi-piece housing in alternative embodiments.

In an exemplary embodiment, the signal contacts304are stamped and formed contacts. The signal contacts304may be formed from a leadframe and the cable connector housing302may be overmolded over the leadframe. Each signal contact304extends between a mating end330and a terminating end332(FIG.4). The mating end330is configured for mating with the busbar assembly120. In the illustrated embodiment, the signal contact304includes a spring beam334at the mating end330. The spring beam334extends forward of the front312of the cable connector housing302. The spring beam334is deflectable. The spring beam334includes a mating interface for mating with the corresponding conductor144of the first conductive structure140(shown inFIG.1). The mating interface may be provided proximate to the distal end of the spring beam334. The mating interface is outward facing. The signal contacts304may extend from the cable connector housing302for connection to the signal cables306. In the illustrated embodiment, the signal contact304includes a pin336at the terminating end332. The pin336is located in the receptacle320. The pin336is configured to be mated with the cable connector350. Other types of terminating ends may be provided in alternative embodiments, such as a socket, a solder pad, and the like.

FIG.5is a front perspective view of the cable connector assembly300in accordance with an exemplary embodiment. In the illustrated embodiment, the cable connector assembly300is provided without the cable connector350(shown inFIG.3). Rather, the cables306are terminated directly to the terminating ends332of the signal contacts304. In the illustrated embodiment, the signal contacts304include solder pads338at the terminating ends332. The cables306are soldered to the solder pads338. The solder pads338may be exposed at the outer surface of the cable connector housing302. Alternatively, the solder pads338may be surrounded or enclosed within the cable connector housing302, such as in a receptacle or due to the cable connector housing302being overmolded over the terminating ends332and the cables306.

FIG.6is an exploded view of the electrical connector200in accordance with an exemplary embodiment.FIG.6shows the embodiment of the cable connector assembly300shown inFIG.3including the cable connector350. The cable connector350includes a housing352holding cable connector contacts354. The cable connector contacts354are electrically connected to the signal cables306. For example, the cable connector contacts354may be crimped or soldered to the ends of the signal cables306. The cable connector contacts354may be sockets configured to receive the pins336of the signal contacts304. The housing352includes a latch356configured to be latchably coupled to the latching feature322of the cable connector housing302.

In an exemplary embodiment, the cable connector housing302includes a connector port340that receives the cable connector assembly300. The cable connector assembly300is removable from the connector housing202, such as to repair or replace components of the electrical connector200. The connector port340is open along the base230and the plug232. In the illustrated embodiment, the connector port340extends through the flange234. The cable connector assembly300is received in the connector port340to extend along the exterior surface248of the first plug wall240. For example, the inner surface324of the cable connector housing302is configured to be coupled to the exterior surface248. The spring beams334are configured to be coupled to the exterior surface248of the first plug wall240to interface with the signal conductors144of the busbar assembly120(shown inFIG.1) when the plug232is plugged into the busbar assembly120.

When assembled, the first plug wall240is located between the signal contacts304and the first power contact204. The first plug wall240electrically separates the signal contacts304and the first power contact204. In an exemplary embodiment, the spring beams334are configured to be received in a pocket237at the exterior of the first plug wall240. The distal end of the first plug wall240may include guide surfaces238,239that guide the first plug wall240into the pocket136of the busbar assembly120. The guide surface238blocks the pocket237, such as to protect the distal ends of the signal contacts304from stubbing during mating of the electrical connector200with the busbar assembly120. When assembled, the spring beams334are configured to be mated with the signal conductors144of the busbar assembly120to send data signals between the electrical connector200and the busbar assembly120. Signals, such as proximity or control signals may be transmitted through the cable connector assembly300to ensure that the electrical connector200is fully mated with the busbar assembly120to control the power circuit, such as to turn the power circuit on/off based on the mating status of the electrical connector200with the busbar assembly120. For example, the power circuit may be off until the data signals are transmitted through the system. In an exemplary embodiment, the spring beams334are compressible toward the exterior surface248of the first plug wall240when mated to the busbar assembly120.

FIG.7is an exploded view of the electrical connector200in accordance with an exemplary embodiment showing the cable connector assembly300as a multi-piece assembly.FIG.8is a rear perspective view of the electrical connector200in accordance with an exemplary embodiment showing the cable connector assembly300poised for loading into the connector housing202.FIG.9is a rear perspective view of the electrical connector200in accordance with an exemplary embodiment in an assembled state.

The connector housing202includes the connector port340that receives the cable connector assembly300. The connector port340passes through the base230and the flange234. In an exemplary embodiment, the connector port340is open to the contact channel236. In an exemplary embodiment, the cable connector assembly300forms part of the contact channel236.

In an exemplary embodiment, the cable connector housing302of the cable connector assembly300is a multi-piece housing. For example, the cable connector housing302includes an inner shell326and an outer shell328. The inner shell326is coupled to the outer shell328. In an exemplary embodiment, the inner shell326includes a pocket327at the inner side. The pocket327may form part of the contact channel236. For example, the pocket327may receive a portion of the power cable coupled to the power contact204. The outer shell328may hold the signal contacts304. For example, the outer shell328may be overmolded over the signal contacts304. The inner shell326and/or the outer shell328form the receptacle320. In an exemplary embodiment, the outer shell328includes latches329to secure the cable connector housing302in the connector housing202.

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.