PCB Power Module Press-Fit Pin Assembly for Vibration Stability
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Solution Overview
Problem
Existing power electronics arrangements face challenges with inadequate electrical contacting and mechanical stability due to soldered connections, which are prone to failure under vibrations, and require precise alignment and costly soldering processes, as well as the need for complex pressing-in tools in press-fit connections.
Innovation Solution
A power electronics arrangement using a linear, perpendicular electrically conductive pin supported by a buttress section formed from potting compound, enabling a stable press-fit connection without soldering and eliminating the need for alignment tools, with the pin being fastened via adhesive or weld for enhanced mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldered connections are used for electrical contacting, then electrical connection is achieved, but mechanical stability deteriorates due to susceptibility to vibration failure
Solution Approach 1:
The patent replaces the soldered mechanical connection with a press-fit mechanical connection using L-shaped contacting pins. The pins are pressed into recesses in the printed circuit board, creating a mechanically robust connection that is resistant to vibration and mechanical stress, thereby resolving the contradiction between electrical connection reliability and mechanical stability.
Solution Approach 2:
The contacting pin is segmented into two perpendicular sections: a lateral section that provides mechanical support and an end section that makes electrical contact. This segmentation allows the pin to function both as a mechanical support element and an electrical conductor, simultaneously achieving mechanical stability and electrical connection reliability.
2Reliability
If selective soldering process is used, then electrical contacting is achieved, but manufacturing cost increases due to required soldering devices
Solution Approach 1:
The patent replaces the soldering process with a press-fit mechanical insertion process. The L-shaped contacting pins are simply pressed into corresponding recesses in the printed circuit board, eliminating the need for expensive soldering devices and complex soldering processes, thereby reducing manufacturing costs while maintaining electrical contacting reliability.
3Strength
If press-fit connection with L-shaped pins is used, then mechanical stability is improved, but alignment precision requirements increase
Solution Approach 1:
The contacting pin is divided into a lateral section and an end section at right angles to each other. The lateral section is inserted into a support recess that provides alignment and mechanical support, while the end section extends perpendicular to the board surface for electrical contact. This segmentation allows the alignment function to be separated from the electrical contact function, reducing overall alignment precision requirements.
Solution Approach 2:
The support recess in the printed circuit board acts as an intermediary element that receives and aligns the lateral section of the contacting pin. This intermediary structure provides mechanical guidance and positioning, thereby reducing the alignment precision requirements for the overall assembly process.
4Strength
If pressing-in support with shoulders is used, then pin support during pressing is achieved, but device complexity increases
Solution Approach 1:
The printed circuit board itself provides the pressing-in support function through its integrated support recess. The recess is designed with shoulders that naturally support the lateral section of the contacting pin during the pressing operation, eliminating the need for external pressing-in supports or complex tooling, thereby reducing device complexity.
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 solution provides a reliable, mechanically stable electrical contact with increased service life, reduced production costs, and simplified production processes by avoiding soldering and complex tooling requirements, while ensuring protection of electronic components from external influences.
Implementation Method 1
the pin is supported by a buttress section which is formed from the potting compound and has the module connecting point
Implementation Method 2
a base section of the pin is fastened on the module connecting point or on the board connecting point
Data Source
AI summary
Power electronics arrangement including a printed circuit board and at least one power module fastened on the printed circuit board, which has one or more electronic components potted by a potting compound. At least one module connecting point of the power module is electrically contacted with at least one board connecting point of the printed circuit board by an electrically conductive pin. A base section of the pin is fastened on the module connecting point or on the board connecting point, and the end of the pin opposite to the base section is pressed in the installation position into a contacting opening assigned or assignable to the respective other connecting point.