Shunt Resistor Terminal Connection Structure for Compact Modules
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Solution Overview
Problem
In compact electronic modules, such as intelligent power modules, it is challenging to directly weld lead wires to shunt resistors for voltage detection due to their small size and low resistance values, making it difficult to arrange wiring for voltage detection.
Innovation Solution
A terminal connection structure for shunt resistors that uses a connector base made of insulating material with an electrically conductive section, which fits onto the resistor body between the electrodes, eliminating the need for welding and allowing for easy and compact connection of lead wires for voltage detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If lead wire is directly welded to electrodes for voltage detection, then electrical connection is achieved, but welding operation becomes difficult and time-consuming in narrow modules with small components
Solution Approach 1:
The patent introduces a connector base as an intermediary component between the lead wire and the electrode. This connector base includes a connection portion that fits onto the resistor body and a terminal portion that provides the electrical connection, eliminating the need for direct welding of lead wires to small electrodes in narrow modules.
2Volume of moving object
If module size is reduced to achieve compact electronic equipment, then space efficiency improves, but arranging lead wire for voltage detection becomes difficult
Solution Approach 1:
The connector base is designed to fit onto the resistor body in a nested manner, with the connection portion mounting on the resistor body and the terminal portion extending outward. This nested structure allows compact arrangement within narrow modules while providing adequate space for lead wire connection.
3Area of moving object
If resistor size is reduced to achieve compact design, then space efficiency improves, but direct welding of lead wire to electrodes becomes difficult
Solution Approach 1:
The connector base serves as a mediator that bridges the gap between the reduced-size electrode and the lead wire. The connection portion fits onto the small resistor body while the terminal portion provides a larger, more accessible area for lead wire connection, making manufacturing feasible even with miniaturized components.
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 accurate detection of voltage and current across shunt resistors with reduced influence from magnetic flux, allowing for precise current monitoring in both direct and high-frequency applications, while maintaining stability and compactness in narrow modules.
Implementation Method 1
an electrically conductive section formed on the connector base; wherein the connector base is fit onto the shunt resistor such that the electrically conductive section is electrically connected to the electrodes
Data Source
AI summary
Provided is a connection structure for a detection terminal of shunt resistor that allows a lead wire, that is to be connected to an electrode of the shunt resistor and is for detecting electrical current, to be easily and compactly connected to the electrode within a narrow and small module. A terminal connection structure for a resistor, which connects a detection terminal to an electrode, comprises a shunt resistor (13) that has a pair of electrodes (12) at both ends of a resistor body (11); a connector base (14) formed of insulating material; and an electrically conductive section (15a) formed on the connector base (14); wherein the connector base (14) is fit onto the shunt resistor (13) such that the electrically conductive section (15a) is electrically connected to the electrodes (12). The connector base (14) is provided with a joint section (C) that can be fit onto the resistor body (11). The resistor body (11) and the electrode (12) is provided with a level difference and the connector base (14) is fit into between the electrodes (12,12).