Current-Sensing Resistor Assembly With Integrated PCB Contact Pins
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Solution Overview
Problem
Existing methods for measuring current strengths in electronic circuits require additional components and materials, leading to increased effort and cost, and can result in unwanted contact voltages that distort the voltage signal.
Innovation Solution
A method involving a resistance arrangement with connection elements and a resistance element made of different conductive materials, where contact pins are formed from the connection element material and laterally widened to protrude through a circuit board, establishing a monolithic connection that eliminates the need for separate components and reduces contact voltages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate contact pins are used to tap the voltage drop across the measuring resistor, then the voltage can be measured, but additional components and materials are required, increasing effort and cost
Solution Approach 1:
The contact pins are integrated directly into the connection elements of the resistor arrangement, forming a single monolithic component. This merging eliminates the need for separate contact pin components, reducing both the number of parts and manufacturing complexity while maintaining the voltage tapping function.
Solution Approach 2:
The connection elements serve dual functions: they provide electrical connection to the measuring resistor and simultaneously form the contact pins for voltage measurement. This multi-functionality reduces the overall component count and simplifies the device structure.
2Measurement precision
If separate contact pins are used to tap the voltage drop, then voltage measurement is possible, but contact voltages occur at the contact points that can distort the voltage signal
Solution Approach 1:
By integrating the contact pins into the connection elements as a monolithic structure, the invention eliminates contact interfaces between separate components. This removes the source of contact voltages and signal distortion, improving measurement precision.
3Ease of manufacture
If additional components are used for voltage tapping, then the measurement function is achieved, but expense increases
Solution Approach 1:
The integration of contact pins into the connection elements reduces the total number of components that need to be manufactured, procured, and assembled. This directly reduces production costs and material expenses.
Solution Approach 2:
The connection elements perform multiple functions (electrical connection and voltage tapping) simultaneously, eliminating the need for separate dedicated contact pin components and reducing overall device cost.
4Ease of manufacture
If contact pins are formed from connection element material and laterally widened, then the circuit board is mechanically fixed and electrical connection is established, but deformation process is required
Solution Approach 1:
The contact pins are pre-formed as integral parts of the connection elements during the resistor arrangement manufacturing process. The lateral widening deformation is then applied to simultaneously achieve both mechanical fixation and electrical connection, reducing subsequent assembly steps.
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 approach simplifies and cost-reduces the production of current measurement devices by integrating contact pins directly from the connection elements, avoiding additional components and materials, and ensuring accurate measurements without signal distortion.
Implementation Method 1
Laterally widening the contact pin at least in the region of its projection by deforming the material, so that the circuit board is mechanically fixed to the resistor arrangement
Data Source
Figure 1~2
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Figure 5~6
AI summary
The invention relates to a method for manufacturing a device (1) for measuring currents, the method comprising the following steps: a) providing a resistor arrangement (2) comprising at least two terminal elements (3) and at least one resistor element (4) arranged with respect to the direction of current flow between the terminal elements (3), wherein the at least one resistor element (4) on the one hand and the terminal elements (3) on the other hand consist of different electrically conductive materials, b) forming at least one contact pin (5) from the material of at least one terminal element (3), c) positioning a printed circuit board (8) having at least one conductor track and at least one through-hole (9) on the resistor arrangement (2) such thatthat the at least one contact pin (5) projects through the through-hole (9) and has a projection (6) beyond the printed circuit board (8) on the side of the printed circuit board (8) facing away from the resistor assembly (2), d) Lateral widening of the contact pin (5) at least in the area of its projection (6) by deformation of the material, so that the printed circuit board (8) is mechanically fixed to the resistor assembly (2), e) Establishing an electrically conductive connection between the contact pin (5) and at least one conductor track of the printed circuit board (8). The invention further comprises a device for measuring current intensities.