Sheet-Metal Stack PCB Terminal for High-Current Space Constraints
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing high-current printed circuit board connections face challenges in flexibility and adaptation to available installation space, as well as in matching current carrying capacities for DC and AC interfaces, with current connecting elements being inflexible and difficult to adapt.
Innovation Solution
A high-current element formed from a sheet-metal stack with a terminal region, pin region, and connection region, where the metal sheets are connected via positive joining and the pins are arranged in a comb-like manner for easy contact with printed circuit boards, allowing flexible configuration and adaptation to installation space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If massive milled press-fit elements or sheet-metal elements are used for connecting high-current printed circuit boards, then the current carrying capacity is sufficient, but the flexibility and adaptability to installation space is very poor
Solution Approach 1:
The connecting element is divided into multiple metal sheets (at least two) that are connected to form a sheet-metal stack. This segmentation allows the structure to be more flexible and adaptable to different installation spaces while maintaining current carrying capacity through the stacked configuration.
Solution Approach 2:
The invention transitions from massive three-dimensional connecting elements to a flattened, multi-layer sheet-metal stack configuration. This dimensional change enables better adaptation to available installation space while maintaining electrical connectivity through the stacked layers.
2Ease of manufacture
If standard connecting elements are used for high-current printed circuit boards, then the connection is simple, but the adaptability to different current carrying capacities for DC and AC interfaces is difficult
Solution Approach 1:
Different regions of the sheet-metal stack are designed with different properties: the pin region has pins for contacting the PCB, the connection region has metal sheets connected to each other, and the terminal region is configured for external power terminals. This local differentiation allows adaptation to different current carrying capacities while maintaining manufacturing simplicity.
Solution Approach 2:
The sheet-metal stack structure allows for flexible configuration and adaptation to different current requirements. The metal sheets can be connected in various patterns and the terminal region can be configured differently to match specific DC and AC interface requirements.
3Reliability
If multiple layers of high-current printed circuit board are connected, then the electrical current carrying capacity is sufficient, but the complexity of connection increases
Solution Approach 1:
Multiple metal sheets are merged into a single sheet-metal stack structure that provides both mechanical support and electrical connectivity. This merging simplifies the connection process by combining multiple connection functions into a single integrated component that can connect multiple PCB layers simultaneously.
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
Enables simple electrical connection of multiple printed circuit board layers, providing the necessary current carrying capacity and allowing for space-saving designs by adapting to various current requirements.
Implementation Method 1
the metal sheets are connected to one another in the connection region by means of positive or materially bonded joining
Data Source
AI summary
A high-current element for high-current printed circuit boards is formed from at least two metal sheets which are connected to form a sheet-metal stack and which have a plurality of pins at least at an end region thereof, and wherein the sheet-metal stack has a terminal region, a pin region, and a connection region, and wherein the metal sheets are connected to one another in the connection region, and the pins are arranged in the pin region and formed for contacting with the high-current printed circuit board, and the terminal region is set up to be used as a terminal region for connecting the high-current element to external power terminals.