Segmented Line Element for PCB Power Integration
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Solution Overview
Problem
Conventional electrical contacting arrangements for high-current power components in motor vehicles are technically complex, costly, and require significant installation space, making them unsuitable for PCB-based integration due to thermal loading issues.
Innovation Solution
The line element is produced separately from the printed circuit board and includes a fastening portion and electrical connection contact, allowing for low-cost, low-complexity integration with thermal decoupling to reduce heat development and enable high-current carrying capacity, using materials like aluminum or copper for low resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If busbars are used for high-current applications, then current carrying capacity is improved, but device complexity and installation space increase
Solution Approach 1:
The busbar structure is segmented into a main body portion and a fastening portion. The main body carries high current with low resistance, while the fastening portion is thermally decoupled and can be soldered to the PCB without exposing the solder joint to excessive thermal loading. This segmentation allows the system to achieve high current carrying capacity while reducing device complexity compared to traditional busbar implementations.
2Area of stationary object
If PCB-based integration is used, then installation space is reduced, but thermal loading increases
Solution Approach 1:
The fastening portion is extracted as a separate functional element from the main current-carrying body. This allows the fastening portion to be attached to the PCB via soldering while the main body remains thermally decoupled, carrying high current without transferring excessive heat to the PCB. The extraction enables PCB-based integration with reduced thermal loading on the board.
3Ease of manufacture
If line element is produced separately, then manufacturing cost is reduced, but assembly complexity increases
Solution Approach 1:
The line element is segmented into a main body and a fastening portion that can be produced separately using cost-effective methods like stamping. The segmentation enables each part to be optimized for its specific function and manufactured independently at low cost. The separate production is compensated by the simple geometry of each segment, which facilitates straightforward assembly through standard soldering processes.
4Reliability
If fastening portion carries high current, then electrical connection is improved, but thermal loading of solder joint increases
Solution Approach 1:
The fastening portion is extracted as a separate element dedicated to mechanical attachment and electrical connection to the PCB, while the main body handles high current transmission. This extraction ensures that the solder joint connects only to the fastening portion, which has minimal current flow, thereby avoiding excessive thermal loading on the solder joint while maintaining reliable electrical connection.
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 enables low-cost, low-complexity integration of power components on a printed circuit board with reduced thermal loading, allowing for modular and efficient electrical and thermal connections, thereby reducing installation space requirements and increasing reliability.
Implementation Method 1
the main body has an electrical connection contact, in order to electrically contact the line element with respect to the printed circuit board or one of the electrical components
Implementation Method 2
the line element can be thermally decoupled from the printed circuit board, so that the thermal loading of the printed circuit board can be reduced
Data Source
AI summary
An electrical contact-making arrangement for electrical power components, having a printed circuit board for mounting the electrical power components, and a line element which is fixed to the printed circuit board. The line element has a metal main body and the main body has an electrical connection contact in order to electrically contact-connect the line element to the printed circuit board or one of the electrical components. The main body has a fastening section in order to fix the line element to the printed circuit board. The line element is produced separately from the printed circuit board, and the electrical connection contact and the fastening section are formed separately from one another.