Integrated Electrical Panel Connection Using Conductive Adhesive
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Solution Overview
Problem
Current methods for electrical contacting of metal circuit boards, such as soldering, crimping, or edge connectors, are not suitable for power applications and require significant effort and specialized training, making it difficult to integrate reliable and cost-effective electrical connections into metal components with integrated electrical functionality.
Innovation Solution
A plate with a metal circuit board and an insulation layer, featuring an electrical functional layer with conductor tracks and contact points, uses a conductive adhesive to connect a metal pad to the contact point, along with a connection element and an adhesive area for secure attachment to an external line, allowing for easy and reliable electrical connection suitable for power applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard contacting processes (soldering, crimping, edge connectors) are used, then electrical connection is achieved, but the process complexity increases and requires specialized training and equipment
Solution Approach 1:
The patent introduces an adhesive area as an intermediary element between the electrical connection and the plate. This adhesive area mediates the bonding process, eliminating the need for complex soldering or crimping operations while ensuring reliable electrical contact through the conductive adhesive that transfers both mechanical and electrical connection.
Solution Approach 2:
The electrical connection is designed with an integrated adhesive area that enables self-adhesion to the plate. The connection element with conductive adhesive automatically bonds to the contact point when pressed together, eliminating the need for external soldering equipment, specialized tools, or highly trained personnel, thus simplifying the contacting process while maintaining reliability.
2Reliability
If soldering processes are integrated into existing production lines, then electrical connection is achieved, but additional effort and specialized personnel are required
Solution Approach 1:
The adhesive area with conductive adhesive enables the electrical connection to bond itself to the plate through simple pressure application. This self-service mechanism eliminates the need for soldering processes, additional manufacturing equipment, and specialized personnel, making the manufacturing process easier and more accessible to existing production lines without requiring additional effort or training.
3Ease of operation
If adhesive area is added to electrical connection, then assembly simplicity increases, but device structure becomes more complex
Solution Approach 1:
The patent merges the adhesive function and the electrical connection function into a single integrated component. The adhesive area is combined with the connection element and conductive adhesive to form one unified electrical connection assembly, eliminating the need for separate adhesive application steps and reducing overall structural complexity while greatly simplifying assembly operations.
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 solution enables simple, cost-effective, and reliable electrical connections that can handle high currents and voltages, providing a stable and secure attachment that protects the conductive adhesive during handling and processing, and can be easily integrated into existing production lines without specialized training.
Implementation Method 1
The electrical connection comprises a metal pad that is electrically conductively bonded to the contact point by means of an electrically conductive adhesive
Implementation Method 2
an adhesive area located laterally adjacent to the electrically conductive adhesive, which pre-fixes the electrical connection to the plate during assembly
Data Source
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AI summary
A plate 100 with integrated electrical functionality and an electrical connection 400 attached to the plate is described. The plate 100 comprises a metal circuit board 110, at least one insulating layer 120 arranged over a main surface of the metal circuit board, and an electrical functional layer arranged over the insulating layer. The electrical functional layer has at least one electrical conductor and a contact point 144 for electrically connecting the electrical conductor to the electrical connection 400.The electrical connection comprises a metal pad 320, which is electrically connected to the contact point by means of an electrically conductive adhesive 340, a connection element 350 connected to the metal pad, which is designed to couple the electrical connection to an external electrical line, and an adhesive area 360, which is located laterally adjacent to the electrically conductive adhesive 340 and fixes the electrical connection to the plate.