Dual level contact design for an interconnect system in power applications

A header for a power interconnect system comprising:

• a first portion comprising a first width;
• a second portion comprising a second width;
• and
• a third portion situated between the first and second portions, and comprising a third width,
• wherein the first width is less than the second width and greater than the third width,
• wherein the third width is less than the first width and the second width,
• wherein the first portion is configured to contact a first contact area of a receptacle of a connector prior to the second portion contacting a second contact area of the receptacle, wherein the first contact area of the receptacle is situated further from an opening of the receptacle than the second contact area.

An interconnect system for power applications, the interconnect system comprising:

• at least one header;
• and
• at least one receptacle configured to engage the at least one header,
• wherein the header comprises
• a first portion;
• a second portion;
• and
• a third portion situated between the first and second portions,
• wherein the receptacle comprises
• a first conductive wall;
• at least a second conductive wall situated opposite the first conductive wall;
• a first end and a second end situated opposite the first end, wherein the first end is configured to receive the header;
• a first sacrificial contact area situated on the first conductive wall;
• at least a second sacrificial contact area situated on the second conductive wall and opposite the first sacrificial contact area;
• a first conductive contact area situated on the first conductive wall;
• and
• at least a second conductive contact area situated on the second conductive wall and opposite the first conductive contact area,
• wherein the first portion of the header is configured to contact the first and second sacrificial contact areas of the receptacle prior to the second portion of the header contacting the first and second conductive contact areas, wherein a distance between the first end and the first and second conductive contact areas is less than a distance between the first end and the first and second sacrificial contact areas.

An interconnect system for power applications, the interconnect system comprising:

• at least one connector comprising a housing, wherein the housing includes at least one receptacle, and wherein the receptacle comprises
• a first conductive wall;
• at least a second conductive wall situated opposite the first conductive wall;
• a first end and a second end situated opposite the first end, wherein the first end is configured to receive a corresponding header of a connector;
• a first sacrificial contact area situated on the first conductive wall;
• at least a second sacrificial contact area situated on the second conductive wall and opposite the first sacrificial contact area;
• a first conductive contact area situated on the first conductive wall;
• and
• at least a second conductive contact area situated on the second conductive wall and
• opposite the first conductive contact area,
• wherein a distance between the first end and the first and second conductive contact areas is less than a distance between the first end and the first and second sacrificial contact areas, and
• wherein the first and second sacrificial contact areas are configured to contact a sacrificial portion of the header prior to a conductive portion of the header contacting the first and second conductive contact areas.