Contact Spring and Spring Shaft Layout for Twisted High-Current Contact
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Solution Overview
Problem
Existing power semiconductor modules face challenges in achieving optimal electromagnetic compatibility and flexible contact arrangements for high-current contact elements, particularly in accommodating different installation positions and ensuring secure retention within the spring shaft.
Innovation Solution
The design incorporates an electrically conductive contact spring with orthogonal main planes, allowing for symmetric and asymmetric configurations within the spring shaft, featuring a peg and narrowing as retaining means to secure the contact spring in two distinct positions, enabling captive retention and flexible contact with traces on the substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the contact spring is designed with asymmetric configuration relative to the second main plane, then the contact spring can be arranged in two different positions (non-twisted and twisted) within the spring shaft, but the complexity of the contact spring structure increases
Solution Approach 1:
The contact spring is designed with asymmetric configuration relative to the second main plane (x-y plane) while maintaining symmetry relative to the first main plane (x-z plane). This asymmetric design enables the contact spring to be arranged in two distinct positions (non-twisted and twisted) within the spring shaft, providing adaptability for different substrate trace connections without requiring multiple different contact spring designs.
2Reliability
If retaining means (peg and narrowing) are added to secure the contact spring in two positions, then the contact spring retention reliability improves, but the manufacturing complexity of the spring shaft increases
Solution Approach 1:
The retaining means consist of a peg and a narrowing that are integrated into the spring shaft as a single structural unit. The peg protrudes from the first end of the spring shaft and the narrowing is formed within the spring shaft, both serving together to retain the contact spring in two distinct positions. This merged design provides reliable retention while avoiding the need for separate retaining components, thus simplifying the manufacturing process.
3Manufacturing precision
If the contact spring is made captive within the spring shaft, then the contact spring positioning precision improves, but the ease of assembly decreases
Solution Approach 1:
The spring shaft is pre-configured with the peg and narrowing retaining means during manufacturing. These retaining features are built into the spring shaft structure before assembly, creating a captive arrangement that precisely positions the contact spring in two specific orientations. The contact spring can be inserted in either non-twisted or twisted position and will be automatically retained, eliminating the need for additional positioning steps during assembly.
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
This configuration allows for secure, high-current contact in both non-twisted and twisted positions, enhancing electromagnetic compatibility and accommodating various substrate trace connections, while maintaining production feasibility with conventional methods.
Implementation Method 1
resilient connecting elements are pressure-contacted between the first and the second traces by means of a dimensionally stable pressure body
Data Source
AI summary
An arrangement having a housing and an electrically conductive contact spring is presented, wherein the contact spring has a first and a second orthogonal main plane along its specified spring direction, wherein it is formed so as to be symmetric with respect to the first main plane, x-z plane, and asymmetric with respect to the second main plane, x-y plane, and also with respect to a rotation through 180° about the specified spring direction. The housing has a spring shaft for receiving the contact spring, and wherein this spring shaft likewise has a first and a second main plane, which coincides with the respective main plane of the contact spring, and wherein the spring shaft is formed so as to be symmetric relative to both main planes. And a power semiconductor module having such an arrangement.