Laminated Busbar Slanted Connection Section for Soldering
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Solution Overview
Problem
The existing busbar manufacturing techniques face challenges in efficiently soldering or welding pins to conductive layers due to heat dissipation issues, which require recesses that affect electrical properties and complicate the process, especially in mass production.
Innovation Solution
A laminated busbar design with slanted connection sections within the plug-in regions allows for improved heat storage and reduced contact area, eliminating the need for recesses and simplifying access for soldering tools, enabling efficient welding or soldering connections without compromising electrical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If recesses are incorporated into the conductive layer to interrupt heat transfer, then heat storage for welding/soldering is improved, but electric properties of the conductive layer are affected and device complexity increases
Solution Approach 1:
The connection section is bent at an angle of 45-90 degrees relative to the main extension plane of the busbar, transitioning from a planar configuration to a three-dimensional structure. This spatial reorientation allows the connection section to protrude from the busbar surface, creating a localized heat retention zone without requiring recesses that would compromise the conductive layer's integrity or electrical properties.
2Use of energy by moving object
If recesses are created in the conductive layer for heat storage, then welding heat retention is improved, but manufacturing complexity and access for soldering tools are reduced
Solution Approach 1:
By bending the connection section to protrude from the busbar surface at an angle of 45-90 degrees, the design creates a three-dimensional structure that naturally concentrates welding heat without requiring complex recess geometries. This protruding configuration provides excellent accessibility for soldering irons and other welding tools, simplifying the manufacturing process while maintaining high welding energy efficiency.
3Productivity
If the connection section extends perpendicular to the main extension plane, then heat storage is maximized and tool access is simplified, but the structural complexity of the busbar increases
Solution Approach 1:
The busbar structure is segmented into distinct functional zones: the main extension plane for current distribution and the protruding connection section for localized welding operations. This segmentation allows each part to optimize its function independently - the flat main body maintains low structural complexity for efficient current flow, while the bent connection section provides the necessary heat retention and tool access for mass production welding processes.
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 design enhances the soldering or welding process by effectively storing heat energy, reducing energy consumption, and facilitating mass production techniques like wave soldering, while maintaining the busbar's electrical integrity.
Implementation Method 1
this arrangement or orientation of the first connection section is an alternative way to store heat, being produced and used during the welding or soldering process
Implementation Method 2
the desired storage of the heat energy is caused by the reduced contact between the pin or contact element on the one hand and the first connection section on the other hand
Data Source
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AI summary
A busbar (1), in particular a laminated busbar (1), configured for mounting an electronic component on the busbar (1), in particular a passive electronic component, comprising - at least one plug-in region (30) for inserting a contact element of the electronic component, in particular a pin (2) of the electronic component, into the busbar (1) and - a first conductive layer (10), extending parallel to a main extension plane (M) of the busbar (1) outside of the at least one plug-in region (30), wherein the first conductive layer (10) comprises a first connection section (11) within the at least one plug-in region (30), the first connection section (11) being bonded to the contact element in a mounted state, wherein the first connection section (11) extends in a direction being slanted, preferably being perpendicular, to the main extension plane (M).