WO2008026938A2

WO2008026938A2 - A connector, a connector assembly and an edge connector

Info

Publication number: WO2008026938A2
Application number: PCT/NZ2007/000216
Authority: WO
Inventors: Michael John Harrison; Hugh Joseph Fitzgerald Moore
Original assignee: Eaton Power Quality Company
Priority date: 2006-08-29
Filing date: 2007-08-13
Publication date: 2008-03-06
Also published as: WO2008026938A3

Abstract

A connector configured to engage with a PCB edge connector of a power component having contacts positioned to make electrical connection with tracks of a PCB edge connector when engaged therewith; and terminals electrically connected to the contacts and configured to enable direct connection to individual conductors. There is also provided a power component having a PCB edge connector for engaging with a complementary power connector having a plurality of tracks extending to or near the edge of the PCB edge connector in which at least one power track is relatively displaced with respect to another track so that when inserted into a complementary power connector electrical connection is made with one track before engagement with the other track.

Description

A CONNECTOR, A CONNECTOR ASSEMBLY AND AN EDGE CONNECTOR

FIELD OF THE INVENTION

This invention relates to a connector, a connector assembly and an edge connector. More particularly, although not exclusively, the invention relates to a connector, a connector assembly and an edge connector suitable for use in power converters.

BACKGROUND OF THE INVENTION

In many power applications there is a need to provide assemblies of power components to provide the required capacity. Typically one or more magazine containing a number of power components, such as rectifier modules, is provided.

The connectors for each module are typically specifically wired to supply lines for a specific application.

A common approach is to provide a printed circuit board (PCB) at the rear of the magazine having a number of connectors soldered to the PCB. The power components are provided with complementary connectors which engage with the connectors soldered to the PCB. This approach is expensive, requiring a lot of expensive PCB and expensive connectors on both sides. The PCB also obstructs ventilation.

It would be desirable to provide a connector, edge connector and connector assembly that is simple and inexpensive whilst providing good ventilation.

It is an object of the invention to provide a solution satisfying these demands or to at least provide the public with a useful choice. SUMMARY OF THE INVENTION

According to a first aspect there is provided a connector configured to engage with a PCB edge connector of a power component comprising: a. a body adapted to receive a PCB edge connector; b. contacts positioned to make electrical connection with tracks of a PCB edge connector when engaged therewith; and c. terminals electrically connected to the contacts and configured to enable direct connection to individual conductors.

According to a further aspect there is provided a connector assembly comprising a plurality of units as hereinbefore described wherein a common bus bar is connected between terminals of the connectors

According to a further aspect there is provided a power component having a PCB edge connector for engaging with a complementary power connector having a plurality of tracks extending to or near the edge of the PCB edge connector wherein at least a first track is relatively displaced with respect to another track so that when inserted into a complementary power connector electrical connection is made with the first track before engagement with the other track.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings which are incorporated in and constitute part of the specification, illustrate embodiments of the invention and, together with the general description of the invention given above, and the detailed description of embodiments given below, serve to explain the principles of the invention.

Figure 1 shows a front perspective view of a connector and PCB edge connector according to one embodiment;

Figure 2 shows a rear perspective exploded view of the connector shown in figure 1 ; Figure 3a shows an integrated contact and terminal according to one embodiment;

Figure 3b shows integrated contacts and a terminal according to another embodiment;

Figure 4 shows a rear perspective view of a power component having a PCB edge connector extending therefrom;

Figure 5 shows a magazine for receiving a plurality of power components including an assembly of connectors;

Figure 6 shows a wiring arrangement for an assembly of connectors; and

Figures 7 to 9 show possible AC bus arrangements.

DESCRIPTION OF EMBODIMENTS OF THE INVENTION

Figure 1 shows a perspective view of a connector 1 according to one exemplary embodiment. In this embodiment a number of pairs of integrated contacts and terminals 3e (see figure 3a) are inserted into body 2 of connector 1 as opposing pairs. Opposing pairs of contacts 3a and 4a are provided to provide electrical connection between track 5a (and a corresponding track on the other side) of PCB edge connector 6 of a power component 7 and terminals 3b and 4b. Contacts 3a and 4a may be formed as a series of resilient metal strips to bias the contacts into engagement with a track.

Terminals 3b and 4b may overlap so that apertures in the terminals (see 3c in figure 3a) are aligned and a bolt may secure a conductor to the terminals. The terminals 3b and 4b are preferably angled (preferably more than 30°) to the face of body 2 so that DC bus bars may be oriented to assist ventilation. Contacts 8a and 9a and terminals 8b and 9b are similarly arranged. In this way the contacts can engage with tracks on both sides of PCB 6. This allows higher current handling capacity and/or redundancy in case of a poor contact with one set of contacts. The terminals 3b, 4b, 8b and 9b may be bolted directly to DC bus bars as will be described later.

Figure 3b shows an alternative arrangement in which the contacts 3c and 4c and terminal 3d are formed from a single strip of metal. An aperture may be provided in the end of terminal 3d or in the sides to allow connections to be made at a variety of orientations.

Similar pairs of contacts 10a, 11a, 12a, 13a, 14a and 15a and terminalsl Ob, 1 1 b, 12b, 13b, 14b and 15b may be provided to provide connections between AC supply lines and tracks 16, 17 and 18 (and corresponding tracks on the other side) providing an AC supply to power component 7. In this case the contacts and tracks are smaller as the current carrying requirements are lower. However, it will be appreciated that the size, number and arrangement of contacts will be selected according to the requirements for a given application.

In this embodiment contacts 19a and 20a may be connected to respective terminals 19b and 20b of an insulation displacement connector (IDC) 21. Track 22 and its mirror on the other side may connect to contacts 19a and 20a to provide two separate paths of conduction so that data may be communicated between the power component 7 and data lines connected to terminals 19b and 20b. The data lines may be simple plastic sheathed data lines.

Referring now to figure 5 a magazine having an assembly of such connectors is shown. DC bus bars 23 and 24 are connected to terminals 3b, 4b, 8b and 9b of respective connectors by bolts 25, although any suitable electrical connecting method may be employed. This technique allows low cost copper rod to be used instead of expensive PCB conductors and allows good ventilation.

Plastic sheathed data lines may be connected to respective terminals of IDC connectors 21 to provide a common data bus between a control module connected to one connector and the other power components. A power component 7 is shown inserted within the magazine. A screw 26 may be provided which screws into power component 7. Fastening of screw 26 may draw PCB edge connector 6 of power component 7 into engagement with connector 1. This may be used to gradually engage PCB edge connectors 6 with a connector 1. PCB edge connector 6 may include a pre-charging track 27 which connects the DC buss to large capacitors of the power component 7 to pre- charge the capacitors before track 5 connects the main circuit to the DC bus. It will be appreciated that tracks may be offset to provide a desired sequence of connection and that multiple tracks may be provided to provide sequential connections to circuit components. It will be appreciated that other mechanisms may be used to provide controlled engagement of connectors.

Figure 6 shows a wiring arrangement for the AC terminals of an assembly of connectors 1. In this assembly terminals 10b and 11 b of respective connectors 1 are connected together by a conductor 34, every third pair of terminals 12b and 13b is connected to a respective conductor 28, 29 or 30 and every third pair of terminals 14b and 15b is connected to a respective conductor 31 , 32 or 33. To provide such connections individual wires may be used or a conductor assembly may be employed. Using three elements 38 as shown in figure 7 they may be stacked with insulation between and offset to form an assembly of elements 28, 29 and 30 as shown in figure 8. Alternatively spiral conductors 35 to 37, shown in figure 9 appropriately insulated, may be used.

There is thus provided a simple and inexpensive connector allowing direct connection to inexpensive DC bus bars, providing improved current handling and redundancy whilst allowing good ventilation. The terminals of the connector allow great flexibility of connection to conductors including the use of lugs, bolts etc. The construction is robust and avoids failure due to connections to a PCB or in the PCB itself.

While the present invention has been illustrated by the description of the embodiments thereof, and while the embodiments have been described in detail, it is not the intention to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details, representative apparatus and method, and illustrative examples shown and described. Accordingly, departures may be made from such details without departure from the spirit or scope of the Applicant's general inventive concept.

Claims

1. A connector configured to engage with a PCB edge connector of a power component comprising: a. a body adapted to receive a PCB edge connector; b. contacts positioned to make electrical connection with tracks of a

PCB edge connector when engaged therewith; and c. terminals electrically connected to the contacts and configured to enable direct connection to individual conductors.

2. A connector as claimed in claim 1 wherein the terminals and contacts are integrally formed.

3. A connector as claimed in claim 1 or claim 2 wherein the terminals are in the form of lugs.

4. A connector as claimed in any preceding claim wherein the terminals include apertures to receive bolts.

5. A connector as claimed in any preceding claim wherein the terminals are in the form of a loop.

6. A connector as claimed in any preceding claim wherein the terminals include elements to assist soldering.

7. A connector as claimed in any preceding claim wherein at least some of the terminals are push fit IDC terminals.

8. A connector as claimed in claim 7 wherein the push fit IDC terminals are data terminals.

9. A connector as claimed in claim 7 or claim 8 wherein the push fit IDC terminals are power terminals.

10. A connector as claimed in any preceding claim wherein the contacts are in the form of opposing pairs of contacts.

1 1. A connector as claimed in claim 10 wherein terminals of the opposing pairs of contacts are adjacent one another.

12. A connector as claimed in any preceding claim wherein the terminals are provided at an angle to the face of the connector that receives a PCB edge connector.

13. A connector as claimed in any preceding claim wherein terminals are disposed at an angle greater than 30°.

14. A connector assembly comprising a plurality of connectors as claimed in any preceding claim wherein a common bus bar is connected between terminals of the connectors.

15. A connector assembly as claimed in claim 14 wherein multiple bus bars are connected between common terminals of the connectors.

16. A connector assembly as claimed in claim 15 wherein two DC bus bars are connected between common terminals of the connectors.

17. A connector assembly as claimed in claim 14 wherein two AC terminals are connected to terminals of each connector.

18. A connector assembly as claimed in claim 17 wherein each connector includes a first and a second AC terminal and every third respective first AC terminal is connected to a common AC line and every third respective second AC terminal is connected to a common AC line, different to the first AC terminal.

19. A connector assembly as claimed in claim 18 wherein a multilayer AC bus interconnects the AC terminals.

20. A connector assembly as claimed in claim 18 wherein a spiral AC bus interconnects the AC terminals.

21. A power component having a PCB edge connector for engaging with a complementary power connector having a plurality of tracks extending to or near the edge of the PCB edge connector wherein at least a first track is relatively displaced with respect to another track so that when inserted into a complementary power connector electrical connection is made with the first track before engagement with the other track.

22. A power component as claimed in claim 21 wherein the first track is connected to a pre-charging circuit of the power component.

23. A power component as claimed in claim 21 or claim 22 wherein multiple tracks are provided within a region of engagement with a set of contacts of a complementary connector arranged so that one track engages with the contacts prior to the other track.

24. A power component as claimed in any one of claims 21 to 23 including an advancement mechanism to control the rate of engagement of the PCB edge connector with a complementary connector.

25. A power component as claimed in claim 24 wherein the advancement mechanism is a screw.