Press-Fit Contact Sleeve Structure for Expansion-Stable Module Connections
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Solution Overview
Problem
Existing press-fit contact elements and power semiconductor assemblies face challenges in achieving a reliable and stable electrical and mechanical connection with substrates, particularly in managing longitudinal movement and linear expansion.
Innovation Solution
A press-fit contact element with a press-in section, a connecting section, a compensating section, and a blocking section, integrated with a sleeve having a receiving section and a foot section, where the compensating section is elastic to compress and reduce linear expansion, and the blocking section limits longitudinal movement by engaging with the sleeve's blocking counter surface, ensuring a cohesive fastening on the substrate's conductor track.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the press-in contact element is rigid to ensure structural strength, then mechanical strength is improved, but longitudinal expansion during pressing increases causing connection instability
Solution Approach 1:
The press-in contact element is divided into multiple functional sections: a rigid press-in section for structural strength, a compliant section with reduced cross-sectional area for expansion accommodation, and a blocking section for movement limitation. This segmentation allows different parts to serve different functions, resolving the contradiction between overall strength and local stability.
Solution Approach 2:
The cross-sectional area of the press-in contact element is varied along its length, with the compliant section having a reduced cross-sectional area compared to the press-in section. This parameter change allows the compliant section to expand longitudinally during pressing while the overall element maintains structural integrity through the rigid press-in section.
2Adaptability or versatility
If the press-in contact element allows longitudinal movement to accommodate expansion, then connection flexibility is improved, but electrical connection reliability deteriorates due to excessive movement
Solution Approach 1:
The blocking section is separated from the press-in section by the compliant section, creating distinct functional zones. The compliant section provides necessary flexibility for expansion, while the blocking section provides hard stops to limit excessive movement, thereby maintaining electrical connection reliability.
Solution Approach 2:
The blocking section with its blocking surface is positioned in advance to counteract excessive longitudinal movement before it can occur. During the pressing process, the blocking surface engages with the counter-blocking surface on the substrate to prevent over-movement, ensuring the electrical connection remains within reliable limits.
3Ease of manufacture
If the press-in contact element has a simple structure for ease of manufacture, then manufacturing complexity is reduced, but the ability to manage longitudinal expansion and movement deteriorates
Solution Approach 1:
The press-in contact element is segmented into distinct functional sections (press-in section, compliant section, blocking section) that can be manufactured using standard processes. Each section has a clear geometric definition that simplifies manufacturing while collectively providing the complex functionality needed for expansion management.
Solution Approach 2:
The compliant section features an arc-shaped cross-section that provides elastic compliance for managing longitudinal expansion. This curved geometry is straightforward to manufacture using conventional forming processes while effectively providing the needed flexibility and expansion accommodation.
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 enhances the electrical and mechanical connection by reducing linear expansion and limiting longitudinal movement, thereby improving the stability and reliability of the press-fit contact element with the substrate, suitable for various substrate types including insulating ceramic and flexible circuit boards.
Implementation Method 1
the compensating section (4) is designed elastically and is designed to be compressed towards the insertion section (5) during a longitudinal movement of the press-in section (2) in a longitudinal direction, and thus to reduce its longitudinal expansion
Implementation Method 2
the blocking section (6) is designed to support itself with a blocking surface (600) on the blocking counter surface (700) of the sleeve (7) and to limit the longitudinal movement of the press-in section (2) in the direction of the plug-in section (5)
Implementation Method 3
the fastening section (76) is designed to be arranged in a materially bonded manner on a conductor track (80) of a substrate (8)
Data Source
Figure 1a~1c
Figure 2a~2c
Figure 3
AI summary
An arrangement is presented comprising a press-fit contact element and a sleeve, wherein the press-fit contact element has a press-fit section, a connecting section, a compensating section, an insertion section, and a locking section, wherein the compensating section is elastically designed and configured to be compressed towards the insertion section during a longitudinal movement of the press-fit section in a longitudinal direction of the press-fit contact element, thus reducing its longitudinal expansion, and wherein the sleeve has a receiving section and a base section comprising a locking surface and a fastening section, wherein the insertion section is configured to be arranged in the receiving section, wherein the fastening section is configured to be materially bonded to a conductor track of a substrate, and wherein the locking section is configured toto brace itself with a blocking surface on the blocking surface of the sleeve and to limit the longitudinal movement of the press-in section towards the insertion section.