High power electrical connector contact
A high power, single pole male electrical connector with a reduced surface area contact is disclosed. The male connector is configured for insertion into a female connector of standard design. The reduced surface area of the contact region of the male connector results in less surface contact between the male and female connectors.
1. A core conductor for a male, single-pole electrical connector comprising:
a generally cylindrical body with a minimum radius r 1 and a minimum cross-sectional area a 1 ;
an electrical contact region having an approximate total surface area A C ; and,
an electrical contact surface area A Ceff within the electrical contact region, wherein: 0.75 A C ≧A Ceff ≧0.75 a 1 .
2. The core conductor of claim 1 , wherein 0.5 A C ≧A Ceff ≧a 1 .
3. The core conductor of claim 1 , wherein 0.5 A C ≧A Ceff ≧0.9 a 1 .
4. The core conductor of claim 1 , wherein the electrical contact region further comprises a non-contact area A REM , which is defined as A REM =A C −A Ceff .
5. The core conductor of claim 4 , wherein the non-contact area has a diameter approximately equal to the diameter of the electrical contact surface area.
6. The core conductor of claim 5 , wherein the non-contact area comprises a region from which the surface layer of the core conductor has been removed.
7. The core conductor of claim 5 , wherein the non-contact area comprises grooves cut into the surface of the core conductor.
8. The core conductor of claim 5 , wherein the non-contact area comprises shallow holes in the surface of the core conductor.
9. The core conductor of claim 1 , wherein
the electrical contact region has a total length l Cfull ;
the electrical contact surface area is generally smooth with a length l C and a diameter d C , wherein the following are true:
d C >2 r 1 ; and,
0.75 l Cfull ≧l C ≧0.75 r 1 2 /d C .
10. The core conductor of claim 9 , wherein the electrical contact surface area is continuous.
11. The core conductor of claim 9 , wherein the electrical contact surface area in not continuous, but comprises two or more distinct contacts.
12. The core conductor of claim 9 , wherein 0.5 l Cfull ≧l C ≧r 1 2 /d C .
13. The core conductor of claim 1 , wherein the conductor is rated for 1,000 A or more.
14. A single-pole, male electrical connector contact, comprising:
a generally cylindrical core having a minimum radius of r 1 and a length of l Cfull ;
an electrical contact surface area having a length l C and a diameter d C , wherein the following are true:
d C >2 r 1 ; and,
0.75 l Cfull ≧l C ≧0.75 r 1 2 /d C .
15. The contact of claim 10 , wherein 0.5 l Cfull ≧l C ≧0.9 r 1 2 /d C .
16. The contact of claim 10 , wherein 0.5 l Cfull ≧l C ≧r 1 2 /d C .
17. A single-pole, male electrical connector comprising:
a generally cylindrical core conductor with a minimum cross-sectional area a 1 , an electrical contact region having an approximate total surface area A C , and an electrical contact surface area A Ceff within the electrical contact region, wherein: 0.75 A C ≧A Ceff ≧0.75 a 1 ; and,
an insulator positioned around the core conductor.
18. The connector of claim 17 , wherein the core conductor has a cable crimp region configured for secure attachment to an electrical supply cable.
19. The connector of claim 17 , further comprising a rigid housing positioned around the insulator and a flange for mounting the housing to a panel.