Terminal Base Connects Power Module Pins to Wire Bypassing PCB Copper
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Solution Overview
Problem
Conventional printed circuit boards face challenges in handling high-current ratings due to limitations in copper foil width expansion, leading to increased temperature and cost issues, especially when integrating high-power modules with narrow terminal pin spacing.
Innovation Solution
A connecting member is introduced that directly connects terminal pins of a power module to an electrical wire, bypassing the copper foil on the printed circuit board, allowing for high-current transmission without expanding the copper foil width, and includes a terminal base configuration with a plate-like section and leg sections for heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the width of copper foil is expanded to lower resistance for high current, then the resistance value decreases, but the printed circuit board size increases
Solution Approach 1:
The invention divides the current path into two segments: a narrow copper foil trace on the printed circuit board for signal routing, and a separate terminal base with large cross-sectional area for high-current transmission. This segmentation allows the PCB to maintain small size while the terminal base handles the high current with low resistance
Solution Approach 2:
The terminal base acts as an intermediary component between the copper foil trace and the external electrical wire. It receives current from the narrow copper foil and transfers it to the thick electrical wire, providing a low-resistance path for high current without requiring the PCB itself to be large
2Power
If the width of copper foil is expanded to apply high current, then the current carrying capacity increases, but the space between terminal pins cannot be reduced
Solution Approach 1:
The current path is segmented such that the narrow copper foil on the PCB handles only low current for control signals, while the terminal base and external wire handle the high current. This allows terminal pins to be closely spaced on the PCB without requiring wide copper traces
Solution Approach 2:
The invention moves the high-current conduction function from the two-dimensional PCB surface to a three-dimensional terminal base structure that extends vertically and provides large cross-sectional area for current flow, decoupling the current carrying capacity from the PCB footprint
3Power
If the thickness of copper foil is increased to apply high current, then the current carrying capacity increases, but the manufacturing cost increases
Solution Approach 1:
The invention uses a standard thickness copper foil (approximately 35 μm) that is inexpensive and easily manufactured, rather than using thick copper foil which would be costly. The terminal base provides the necessary current carrying capacity without requiring expensive thick copper foil on the PCB
Solution Approach 2:
The invention changes the geometry of the current path by introducing a terminal base with large cross-sectional area, rather than changing the thickness parameter of the copper foil. This allows high current capacity to be achieved through dimensional changes in the terminal base rather than through expensive material changes
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 high-current ratings without increasing the printed circuit board size or cost, reduces heat generation, and allows for efficient heat dissipation, effectively utilizing a low-cost, thin-film printed circuit board.
Implementation Method 1
a cross-sectional area of a current path can be expanded by using such terminal bases, and therefore a resistance value can be lowered for the terminal base to decrease an amount of heat generation
Implementation Method 2
the plate-like terminal connecting section is formed in a position corresponding to a hole of the printed circuit board
Implementation Method 3
current supplied through terminal pins of the power module flows through copper foil of a main circuit of a printed circuit board
Implementation Method 4
a resistance value can be lowered for the terminal base to decrease an amount of heat generation
Data Source
AI summary
A connecting member such as a terminal base is used in connection with a printed circuit board unit in which circuit elements such as a power module are mounted on a printed circuit board. The connecting member connects the circuit element of an electrical circuit including the printed circuit board, to an electrical wire. The connecting member includes a terminal connecting section to be directly connected to terminal pins of the circuit element; a wire connecting section to be connected to the electrical wire; and attachment sections for attaching the connecting member to the printed circuit board.