Multi-Plane Sheet Connector for Thermal Stress Relief
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Solution Overview
Problem
Existing electrical connections in electronic assemblies, such as inverters, are prone to damage due to thermal and mechanical stresses, leading to reduced longevity and reliability.
Innovation Solution
A connection element with two separate connection regions on different planes and a transition region, featuring slots and relief recesses, provides mechanical flexibility and high electrical conductivity to withstand such stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a sheet metal connector is used to connect electronic elements, then electrical conductivity is achieved, but thermal and mechanical stresses cause damage to the electrical connection
Solution Approach 1:
The connection element is divided into multiple connection regions (first connection region, second connection region) located on different planes, with deflection regions between them. This segmentation allows each region to independently accommodate thermal and mechanical stresses, preventing stress concentration and connection damage.
Solution Approach 2:
The connection element transitions from a single-plane sheet metal connector to a multi-plane structure with connection regions on different planes. This dimensional change enables the connector to absorb thermal expansion and mechanical stresses in multiple directions, significantly improving reliability under stress conditions.
2Stability of the object's composition
If a rigid sheet metal connector is used, then structural stability is provided, but flexibility to compensate for thermal and mechanical stresses is reduced
Solution Approach 1:
The connection element incorporates deflection regions that enable dynamic adaptation to thermal and mechanical stresses. These regions allow the connector to flex and deform elastically in response to stress, maintaining structural stability while adapting to changing conditions.
Solution Approach 2:
The connection element uses a thin sheet-like structure with strategically placed deflection regions that provide flexibility. This flexible design allows the connector to accommodate thermal expansion and mechanical stresses while maintaining its structural integrity and electrical conductivity.
3Adaptability or versatility
If the connection element geometry is customized for different electronic elements, then adaptability is improved, but manufacturing complexity increases
Solution Approach 1:
The multi-plane connection element design serves multiple functions: it provides electrical connectivity, accommodates thermal stresses, absorbs mechanical stresses, and adapts to different electronic element geometries. This universal design approach allows a single connector type to be used across various applications without increasing manufacturing complexity.
Solution Approach 2:
The connection element's geometry can be adjusted by modifying parameters such as the distance between connection planes, the number and position of deflection regions, and the overall shape. These parameter changes allow customization for different electronic elements while maintaining the same basic manufacturing process and structure.
Data Source
AI summary
The invention relates to a connection element (10) for electrically connecting electronic elements (11, 12), comprising a first connection region (1), which is designed for connection to a first electronic element (11), and a second connection region (2) which is designed for connection to a second electronic element (12), wherein each connection region (1, 2) is in the form of a sheet, wherein the first connection region (1) is in a first connection plane (21), and wherein the second connection region (2) is located at a distance from the first connection plane (21).