Power Module Alignment Slot Structure for Terminal Bending Prevention
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Solution Overview
Problem
Existing power modules face challenges in accurately positioning and mechanically supporting terminals for efficient electrical connection to assembly boards, leading to potential misalignment and bending of terminals during insertion into contact holes.
Innovation Solution
A power module design incorporating an alignment part with recessed portions and holding structures that provide precise lateral alignment and mechanical support for terminals, allowing safe and efficient insertion into contact holes on assembly boards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If terminals are directly inserted into contact holes without alignment part, then the structure is simpler, but terminal misalignment and bending occur during insertion
Solution Approach 1:
An alignment part is introduced as an intermediary component between the terminal and the contact hole. This alignment part includes a recessed portion that receives and positions the terminal, and a holding structure that supports the terminal during insertion. The intermediary alignment part ensures precise alignment and prevents terminal bending, resolving the contradiction between alignment precision and structural simplicity.
2Reliability
If alignment part with holding structure is added, then terminal mechanical support is improved, but device complexity increases
Solution Approach 1:
The alignment part is segmented into distinct functional elements: a recessed portion for receiving the terminal and a holding structure for mechanical support. This segmentation allows each element to perform its specific function efficiently while keeping the overall design manageable. The recessed portion provides positional accuracy, while the holding structure provides mechanical support, together improving insertion reliability without excessive complexity.
3Manufacturing precision
If terminal is fully enclosed in recessed portion, then lateral alignment is improved, but vertical insertion is hindered
Solution Approach 1:
The alignment part's recessed portion is designed with selective openness: it is open in lateral directions to provide precise lateral alignment and positioning, while remaining open or accessible in the vertical direction to allow easy insertion. This dimensional differentiation resolves the contradiction by providing tight lateral constraints while maintaining vertical freedom of movement for insertion.
Data Source
AI summary
A power module having an alignment part fixed on a lateral top surface (10T) of a semiconductor module component. The semiconductor module component has at least one terminal which—at least in places—is orientated vertically with respect to the lateral top surface of the semiconductor module component and for the purpose of alignment along lateral directions, is located at least partly within the at least one recessed portion. Along a vertical direction, the at least one terminalprotrudes beyond the at least one recessed portion. The at least one recessed portion is located on a side surface of the alignment part, wherein the at least one recessed portion is a vertical slot being an open recess on the side surface of the alignment part, and wherein the slot is not a through-hole being completely surrounded by inner walls of the at least one recessed portion in lateral directions.