Threaded Sleeve Terminal Element for Simpler Power Module Connections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for forming terminal elements in power semiconductor module arrangements are cumbersome and cost-intensive, requiring complex connection techniques between the terminal elements and external connectors.
Innovation Solution
A method involving stamping a metal sheet to form a blank with specific sections, forming a thread on one section, and bending it to create a round sleeve with an opening facing vertically, allowing for easy integration into a power semiconductor module arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex connection techniques are used to connect terminal elements with external connectors, then connection reliability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines the terminal element body and the connection interface into a single integrated component. The U-shaped configuration directly forms both the terminal body and the connection interface, eliminating the need for separate connection techniques and multiple assembly steps between terminal elements and external connectors.
Solution Approach 2:
The terminal element is designed with self-connecting capabilities through its U-shaped configuration. The open ends of the U-shape naturally form connection interfaces that directly engage with external connectors, allowing the terminal element to serve its own connection function without requiring additional complex connection techniques or separate fastening components.
2Strength
If traditional terminal element formation methods are used, then structural strength is maintained, but manufacturing cost and time increase
Solution Approach 1:
The terminal element is divided into functional segments within the U-shaped configuration: the body portion and the connection interface portion. This segmentation allows each part to be optimized for its specific function while being formed in a single manufacturing process, maintaining structural strength while improving manufacturing efficiency.
Solution Approach 2:
The patent utilizes parameter changes in the forming process, specifically transforming a flat blank into a three-dimensional U-shaped structure through controlled bending and shaping. This parameter transformation enables the creation of a strong structural form from a simple flat material, achieving both structural integrity and manufacturing efficiency.
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
Facilitates the formation of terminal elements that can be easily and cost-effectively integrated into power semiconductor modules, providing a simple and efficient electrical connection with external connectors.
Implementation Method 1
stamping a blank from a metal sheet
Implementation Method 2
bending the first section around a cylinder axis to form a round sleeve
Data Source
Figure 1~2
Figure 3A~6
Figure 7A~9
AI summary
A method comprises stamping a blank from a metal sheet, the blank comprising a first section, and a second section, wherein the second section is an elongated section having a length in a vertical direction that is at least twice its width in a first horizontal direction, and the first section is a rectangular section having a width in the first horizontal direction that is greater than the width of the second section, forming a thread on a surface of the first section, and bending the first section to form a sleeve, wherein the sleeve comprises an opening facing in the vertical direction towards the second section.