Pin-Connected Power Resistor Assembly for Stable Load Transfer
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Solution Overview
Problem
Existing power resistors require high manufacturing effort and complex mechanical securing measures due to flexible electrical conductors and bonding wires, which can impair stability and increase construction effort, especially under thermal expansion and mechanical loads.
Innovation Solution
A pin, either soldering or press-fit, is used as the electrical conductor, soldered to the contact electrode, eliminating the need for a separate electrical connection and providing a stable, frictional connection that absorbs mechanical loads and thermal expansion, enhancing the resistor's stability and simplifying the design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a power resistor is disposed in a housing with a heat dissipation fin and sealed with a gasket, then heat dissipation performance is improved, but assembly complexity and potential leakage risks increase
Solution Approach 1:
The housing integrates both heat dissipation fin structure and sealing gasket function into a single component. The housing includes a fin portion extending from the side wall for heat dissipation, and a groove portion formed in the housing that receives and secures the gasket, eliminating the need for separate assembly steps for fins and gaskets.
Solution Approach 2:
The housing structure provides self-contained heat dissipation and sealing functions. The fin portion automatically provides heat dissipation surface area, and the groove portion automatically secures the gasket in place, reducing dependency on additional fastening mechanisms or complex assembly procedures.
2Reliability
If a separate gasket is used for sealing the power resistor in the housing, then sealing performance is improved, but the number of components and assembly steps increase
Solution Approach 1:
The housing integrates both heat dissipation fin structure and sealing gasket function into a single component. The housing includes a fin portion extending from the side wall for heat dissipation, and a groove portion formed in the housing that receives and secures the gasket, eliminating the need for separate assembly steps for fins and gaskets.
3Reliability
If the power resistor is tightly sealed in the housing, then environmental protection is improved, but heat dissipation efficiency may deteriorate
Solution Approach 1:
The housing is segmented into distinct functional zones: a groove portion for sealing that creates an environmental barrier, and a fin portion for heat dissipation that maintains thermal exchange with the environment. This segmentation allows the sealing function to protect the power resistor while the fin portion remains exposed for efficient heat dissipation.
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 increases the stability and reliability of the power resistor by simplifying the electrical connection, reducing the risk of cable breaks, and allowing for even load distribution, resulting in a stable, secure, and easy-to-use connection.
Implementation Method 1
a cooling fin which extends from the side wall of the housing in the second direction, viewed in the first direction, overlapping with the power resistor when projected on a plane parallel to the first direction
Implementation Method 2
a cooling fin which extends from the side wall of the housing in the second direction
Implementation Method 3
a gasket arranged to seal between the power resistor and the housing
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
The invention relates to a power resistor (1) having at least one electrical connection (2.1, 2.2, 2.3) having a carrier substrate (3), which has at least one resistor element (4.1, 4.2) made of a thick film material and at least one contact electrode (5.1, 5.2, 5.3), to which the resistor element (4.1, 4.2) electrically connects, having at least one electrical conductor (7.1, 7.2, 7.3), which is soldered to the contact electrode (5.1, 5.2, 5.3) and produces an electrical connection between the contact electrode (5.1, 5.2, 5.3) and the electrical connection (2.1, 2.2, 2.3), and having a housing (8), filled at least in part with at least one casting compound (17), which receives the resistor element (4.1, 4.2) and contact electrode (5.1, 5.2, 5.3) in a cast manner, wherein the electrical conductor (7.1, 7.2, 7.3) protrudes through the casting compound (17). In order to create a power resistor (1) having a simple design and which is easy to handle, according to the invention, a pin, in particular a solder or press fit pin, forms the electrical conductor (7.1, 7.2, 7.3), said pin (9.1, 9.2, 9.3) being placed on the contact electrode (5.1, 5.2, 5.3) and soldered thereto, and forms the electrical connection (2.1, 2.2, 2.3) of the power resistor (1).