Power Module Positioning Structures for Board Terminal Alignment
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Solution Overview
Problem
Existing power modules face challenges in precise mechanical and electrical connection to control electronics due to difficulties in aligning terminals with assembly boards, often resulting in bent or displaced terminals that do not fit properly into contact holes.
Innovation Solution
The power module incorporates positioning structures on its side surface that can receive an alignment tool, allowing for controlled vertical and lateral movement, ensuring exact alignment with assembly boards through complementary alignment structures, facilitating secure electrical interconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional alignment methods are used without positioning structures, then the assembly process is simpler in terms of tooling, but the alignment precision between power module terminals and assembly board contact holes deteriorates, resulting in bent or displaced terminals
Solution Approach 1:
Positioning structures are pre-integrated into the power module housing before assembly, establishing predetermined alignment references that guide the alignment tool and ensure precise terminal-to-contact-hole alignment during the assembly process
Solution Approach 2:
An alignment tool serves as an intermediary device that bridges the power module and assembly board, utilizing the positioning structures to transmit alignment information and enable precise positioning during the assembly operation
2Manufacturing precision
If manual alignment methods are used, then the equipment complexity is reduced, but the manufacturing precision of terminal alignment deteriorates, causing terminals to be bent or displaced and not fit properly into contact holes
Solution Approach 1:
Alignment features are pre-configured into the power module housing and alignment tool before assembly, establishing a predetermined alignment pathway that ensures precise terminal positioning when the alignment tool is used during assembly operations
Solution Approach 2:
The positioning structures on the power module housing automatically guide the alignment tool into the correct position, enabling the system to self-align without requiring complex external alignment equipment or sophisticated manual alignment procedures
Data Source
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AI summary
A power module (10) comprising at least one module component (12) is provided, wherein - the power module (10) has a side surface (10S), - the side surface (10S) of the power module (10) comprises positioning structures (13), and - at least one of the positioning structures (13) has a geometrical form configured for receiving an alignment tool (20) and further configured for vertically moving the power module (10) when sliding the alignment tool (20) along a lateral direction. Moreover, an alignment tool (20) and a method using the alignment tool (20) for positioning and aligning the power module (10) are provided.