Ribbon Connection with Supporting Shoulders for High-Current Power Electronics
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Solution Overview
Problem
Existing power electronics circuits connected to high-current electrical connections experience significant electrical losses due to multiple transitions (IMS/lead frame, lead frame/printed circuit board, printed circuit board/connector, connector/cable, cable/motor) leading to inefficiencies.
Innovation Solution
A high-current, low-impedance connection is achieved through a ribbon connection with an insulation displacement connection element and supporting shoulders, designed as a metal strip with a U-web bending point, allowing for easy assembly and high-force application without impermissible force introduction into the substrate, and a non-detachable connection is formed by material deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If multiple transitions (IMS/lead frame, lead frame/printed circuit board, printed circuit board/connector, connector/cable, cable/motor) are used to connect power electronics to electrical connections, then the connection can be established, but electrical losses increase significantly
Solution Approach 1:
The patent combines multiple separate connection transitions into a single integrated flat ribbon connection that directly links the substrate to the electrical connection. This merging eliminates the chain of intermediate transitions (lead frames, connectors, cables) and creates one continuous low-impedance path for high current flow, thereby reducing electrical losses while simplifying the overall connection structure.
2Loss of energy
If a flat ribbon connection is used to carry high currents, then electrical losses are reduced, but the connection must withstand high assembly forces without introducing impermissible forces into the substrate
Solution Approach 1:
The flat ribbon connection is segmented into functionally distinct zones: a rigid base portion that anchors to the substrate and a flexible free end portion that absorbs assembly forces. This segmentation allows the connection to maintain structural integrity at the substrate interface while providing force absorption capacity at the free end, enabling high-current carrying capability without transmitting damaging forces to the substrate.
Solution Approach 2:
Different portions of the flat ribbon connection are designed with different mechanical properties tailored to their specific functions. The base portion near the substrate is designed for rigid anchoring and low electrical impedance, while the free end portion is designed with greater flexibility to absorb assembly forces. This local differentiation of material or structural quality allows simultaneous optimization for both electrical performance and mechanical force absorption.
3Ease of manufacture
If the ribbon connection is designed as a metal strip, then high-current resistance and ease of production are improved, but deformability in the longitudinal direction is limited due to rectangular cross-section
Solution Approach 1:
The patent employs a thin-film metal strip structure with controlled thickness and cross-sectional geometry that balances rigidity for current carrying with flexibility for deformation. The thin-film design allows the ribbon to be bent and deformed in the longitudinal direction to accommodate assembly tolerances and misalignments, while maintaining sufficient mechanical strength and electrical conductivity for high-current applications. This flexible thin-film approach enables both ease of manufacture and adaptability.
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 results in a space-optimized power electronics device with low thermal resistance, capable of handling high currents (50-150 amperes) and ensuring reliable, high-current connections with minimal electrical losses.
Implementation Method 1
the ribbon connection can be deformed in the direction of its longitudinal extent by forming at least one bending point
Implementation Method 2
at least one support shoulder for absorbing a joining force when connecting to a counter-element in the area of its free end
Implementation Method 3
a high-current, low-impedance connection path is created... capable of carrying high currents (50-150 amperes)
Data Source
Figure 1~2
Figure 3~4
AI summary
The circuit has a connection (3) designed as a flat band connection (5) with an insulation displacement connection device (15) in the area of its free ends. A supporting shoulder (17) is provided for receiving the joining force during connection with a counter-unit. The flat band connection is designed as metal strip and sheet plate-punching part. The supporting shoulders are provided opposite to each other. The insulation displacement connection device is designed as an insertion slot (18) for an insertion rod of the counter unit. An independent claim is also included for a power electronics device with a power electronic circuit.