PCB Connection Clamp With Elastic Coupling for Thermal Cycling

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing methods for mounting electronic components like MOSFETs to PCBs fail to establish reliable mechanical, electrical, and thermal connections, particularly in applications with significant thermal cycling, due to issues with solder fatigue and thermal expansion.

Innovation Solution

A connection clamp assembly with a rigid clamp portion and lid elastic element that secures electrical leads to PCB connections, using fasteners offset from the component centerline to allow access for cooling systems, and includes baseplate elastic elements for additional electrical connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If solder connections are used to connect electrical leads to PCB, then electrical connection is formed, but the connection becomes vulnerable to fatigue and failure due to thermal cycling

Engineering Contradiction:

Improveconnection reliabilityVSAvoidservice life under thermal cycling

Core Design Contradiction:

ReliabilityVSDuration of action of moving object

Solution Approach 1:

The patent replaces the solder-based mechanical connection system with an elastic element-based mechanical connection system. The elastic element (compression spring) provides mechanical pressure to maintain electrical contact between the electrical lead and PCB contact point, eliminating the thermal cycling vulnerability of solder joints while maintaining electrical connectivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the connection mechanism from a rigid solder joint to a compliant elastic element that can dynamically adjust to thermal expansion and contraction. The elastic element's force parameter varies with compression distance, allowing it to accommodate thermal cycling while maintaining reliable electrical contact.

Inventive Principle:

Principle #35Parameter changes

2Strength

If packaged MOSFETs are mounted directly to cooling device by screws, then mechanical connection is achieved, but adequate thermal bond line is not formed

Engineering Contradiction:

Improvemechanical connection strengthVSAvoidthermal bond quality

Core Design Contradiction:

StrengthVSTemperature

Solution Approach 1:

The patent introduces an elastic element as an intermediary component between the electrical lead and the PCB contact point. This elastic element serves dual functions: providing mechanical connection strength through elastic pressure and enabling thermal contact by accommodating dimensional changes during thermal cycling, thus forming both mechanical and thermal bonds simultaneously.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If fasteners are positioned at centerline of component, then symmetric mounting is achieved, but access for cooling systems is blocked

Engineering Contradiction:

Improvesymmetric mountingVSAvoidcooling system access

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The patent employs asymmetric positioning of fasteners relative to the component centerline. By offsetting the fastener location, the design sacrifices perfect symmetry to enable access for cooling systems and other components, demonstrating how asymmetric design can resolve conflicts between manufacturing ease and operational accessibility.

Inventive Principle:

Principle #4Asymmetry

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

Enables reliable mechanical, electrical, and thermal coupling of electronic devices to PCBs, improving connection reliability and functionality, especially in thermally cycled environments.

Implementation Method 1

a lid elastic element received by the rigid clamp portion, the lid elastic element configured to elastically press on the electronic device

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS12457701B2Mechanical and electrical connection clamp

Publication Date: 2025.10.28 ADVANCED ENERGY IND INC

AI summary

A connection clamp assembly and an electrical system including a connection clamp assembly are disclosed. The connection clamp assembly includes a rigid clamp portion with one or more protrusions configured to mechanically secure one or more electrical leads of an electronic device to one or more electrical connection points on a printed circuit board assembly forming an electrical connection. One or more fasteners pass through the rigid clamp portion and are configured to couple the connection clamp assembly to the printed circuit board assembly. A lid elastic element is received by the rigid clamp portion and is configured to elastically press on the electronic device, mechanically and thermally coupling the electronic device to the printed circuit board assembly.