Busbar Contact Assembly Using Pressed Galvanic Contacts
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Solution Overview
Problem
Existing power module arrangements require costly laser welding for connections, which results in large clearances and potential short circuits due to conductive particles.
Innovation Solution
A contact device with busbars arranged in an insulated manner, featuring contact regions with contact elements, and a force-loaded galvanic system contact to establish electrical connections without welding, using stamped and bent busbars for cost-effective production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If laser welding is used to produce welded connections between power modules and functional components, then reliable electrical contact is achieved, but the device complexity and cost increase due to required large clearances and expensive laser welding devices
Solution Approach 1:
The patent replaces the laser welding process (thermal/optical system) with a mechanical pressing system. Contact elements with contact forces mechanically press against contact surfaces to establish electrical connections, eliminating the need for laser welding devices and large clearances while maintaining reliable electrical contact.
Solution Approach 2:
The patent introduces contact elements as intermediary components between power modules and functional components. These contact elements transmit electrical current through mechanical contact rather than direct welding, simplifying the connection process and reducing equipment requirements.
2Reliability
If laser welding is used to produce welded connections, then electrical contact is established, but conductive particles are generated that can cause short circuits
Solution Approach 1:
The patent replaces the laser welding process that generates conductive particles with a mechanical pressing system. Contact elements establish electrical connections through controlled mechanical contact forces without melting or vaporizing materials, thereby eliminating the generation of harmful conductive particles.
3Ease of manufacture
If stamped and bent busbars are used instead of welded connections, then cost-effective mass production is enabled, but contact reliability may be compromised
Solution Approach 1:
The patent employs elastic contact elements that can dynamically adapt to contact surfaces. These elements are designed to deflect and apply controlled contact forces, ensuring reliable electrical contact while accommodating manufacturing tolerances and assembly variations in stamped and bent busbars.
Solution Approach 2:
The patent optimizes parameters such as contact force magnitude, contact element geometry, and material properties to ensure reliable electrical contact. By carefully controlling these parameters, the system achieves both manufacturing ease with stamped busbars and contact reliability comparable to welded connections.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a cost-effective, low-inductance, and rigid electrical connection with low resistance and high current carrying capacity, eliminating the need for expensive laser welding and reducing the risk of short circuits.
Implementation Method 1
The electrical contacting of the contact element of at least one contact region with at least one contact surface of a functional element can be formed in the form of a force-loaded galvanic system contact in that the contact device has means which, in the contacting state of the contact device with at least one of the functional elements, effect a pressure force perpendicular to the contact surface as a contact force on the at least one contact element
Implementation Method 2
When the contact device is operated in current mode with a current flowing through the two busbars, the additional side rail portions result in a very low-inductance overall behavior of the contact device. In particular, inductances that occur when the two busbars are at different potentials compensate one another
Data Source
AI summary
A contact device. The contact device includes at least a first and a second busbar, which are arranged at a distance from one another in an electrically insulated manner. Each busbar includes at least a first and a second contact region, each of which has at least one contact element. The contact device is configured such that, when the functional elements are electrically contacted with, in each case, two busbars on contact elements of different contact regions in switching operation, a current path is formed in each case between the first and the second contact region within the two busbars. The electrical contacting of the contact element of at least one contact region with at least one contact surface of a functional element can be formed in the form of a force-loaded galvanic system contact.