Offset Connection Piece for Precise Power Module Contact Assembly
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Solution Overview
Problem
Existing connectors for electrical contacts in power modules are limited in application possibilities, often requiring additional equipment during production or assembly, which is expensive and not always feasible.
Innovation Solution
A connecting piece with a base plate and secondary plate offset in the z-direction, featuring tabs and electrical contact surfaces, allowing for easy and precise positioning and electrical contact, and compensating for height differences, facilitated by tabs and recesses for automatic assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If existing connectors are used for electrical contacts, then assembly is possible, but additional equipment and aids are required which increases cost and complexity
Solution Approach 1:
The connector is divided into distinct functional elements: a base plate with tabs for positioning, a transition piece for connection, and a secondary plate with contact surfaces. This segmentation allows each part to perform its specific function without requiring additional assembly aids.
Solution Approach 2:
The connector design incorporates self-positioning tabs and self-aligning contact surfaces that automatically guide the assembly process. The tabs engage with corresponding features on the circuit board, eliminating the need for external positioning equipment or alignment tools.
2Manufacturing precision
If connectors require additional assembly aids, then positioning may be improved, but manufacturing cost and process complexity increase
Solution Approach 1:
The tabs are designed with asymmetric geometries that provide precise positioning in specific directions. The first tab protrudes in the positive x-direction while the second tab protrudes in the negative x-direction, creating directional guidance that ensures accurate positioning without requiring additional alignment equipment.
Solution Approach 2:
The connector utilizes the z-direction (vertical dimension) with offset between the base plate and secondary plate to compensate for height differences. This dimensional approach allows precise positioning and contact surface alignment without requiring complex positioning aids in the horizontal plane.
3Reliability
If height differences are not compensated, then assembly is simpler, but electrical contact reliability decreases
Solution Approach 1:
The offset between the base plate and secondary plate creates a dynamic adaptation mechanism that automatically compensates for height variations in the electrical contacts. The connector structure flexes or adjusts to accommodate different contact heights, ensuring reliable electrical connection without requiring rigid precision matching.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a connecting piece (1) for connecting at least two electrical contacts, a power module (12) comprising at least one such connecting piece (1) and an electrical device (20) comprising at least one such power module (12). In particular, in order to provide a cost-effective and easy-to-assemble connecting piece (1), it is proposed that the connecting piece (1) comprises: • a base plate (2) which extends in the xy plane and has a thickness dg in the z direction, wherein the base plate (2) has at least in sections a first electrical contact surface (21), wherein the base plate (2) has two tabs (4a, 4b), of which the first tab (4a) protrudes in the positive x direction and the second tab (4b) in the negative x direction from the base plate (2), wherein the two tabs (4a, 4b) continue to protrude in the positive z direction from the base plate (2), • a transition piece (5),which is arranged in extension in the y-direction on the base plate (2), and • a secondary plate (6), wherein the secondary plate (6) is arranged in extension in the y-direction on the transition piece (5), wherein the secondary plate (6) is connected to the base plate (2) via the transition piece (5), wherein the secondary plate (6) extends in the xy-plane, is offset by an offset V in the positive z-direction relative to the base plate (2) and has a thickness dn in the z-direction, wherein the secondary plate (6) has at least in sections a second electrical contact surface (10).