PCB Filter Component With Press-Fit Bus Bar Connection
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Solution Overview
Problem
Existing filter components, particularly EMC filters, face challenges in achieving a compact design due to the need for high-current carrying capabilities and the inability to use soldered connections, which are hindered by strong soldering heat dissipation.
Innovation Solution
The filter component incorporates a printed circuit board with a low-pass filter circuit, a bus bar for high-current operation, and a clamping plug-in connector with an electrically conductive pin that forms a force-locked, electrically conductive connection with the bus bar through a press-fit mechanism, allowing for a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a soldered connection is used between the bus bar and the filter component, then the electrical contact is reliable, but the soldering heat dissipation is too strong making the connection impossible
Solution Approach 1:
The patent replaces the thermal-based soldering process with a mechanical press-fit connection system. The clamping plug-in connector uses mechanical pressure to create an electrically conductive connection between the bus bar and the printed circuit board, eliminating the need for soldering heat and resolving the contradiction between connection reliability and heat dissipation issues.
2Reliability
If a screw connection is used between the bus bar and the filter component, then the electrical contact is achieved, but the design becomes less compact
Solution Approach 1:
The patent merges the electrical connection function and the mechanical clamping function into a single integrated clamping plug-in connector. This consolidation eliminates the need for separate screw connections and mounting structures, achieving both reliable electrical contact and a compact filter component design.
Solution Approach 2:
The clamping plug-in connector serves multiple functions simultaneously: it provides mechanical support, establishes electrical contact, and secures the bus bar to the printed circuit board. This multi-functionality reduces the overall component count and volume while maintaining connection reliability.
3Volume of moving object
If the filter component is designed to be compact, then the space efficiency is improved, but the high-current carrying capability and connection reliability become challenging
Solution Approach 1:
The patent transitions from traditional planar mounting to a three-dimensional press-fit connection approach. The clamping plug-in connector extends vertically from the printed circuit board to clamp the bus bar, utilizing the vertical dimension to achieve compact horizontal footprint while maintaining robust electrical contact for high-current applications.
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 configuration enables a compact filter component capable of effectively suppressing high-frequency interference signals while supporting high operating currents, without the limitations of soldered connections.
Implementation Method 1
The clamping plug-in connector comprises an electrically conductive pin that is pressed into a hole in the bus bar, such that a force-locked, electrically conductive connection is established between the electrically conductive pin and the bus bar.
Data Source
AI summary
In an embodiment a filter component includes a printed circuit board with an electrical circuit arranged thereon, a bus bar and a clamping plug-in connector, wherein the clamping plug-in connector, arranged on the printed circuit board, is electrically connected to the electrical circuit and is configured for electrically contacting the electrical circuit with the bus bar.