Threaded Sleeve Terminal Element for Low-Complexity Power Modules
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing power semiconductor module arrangements face challenges in forming terminal elements that are both cost-effective and easy to produce, as current connection techniques are cumbersome and expensive.
Innovation Solution
A method involving stamping a metal sheet into a blank with specific sections, forming a thread on one section, and bending it to create a sleeve with an opening, allowing for a simple and cost-effective production of terminal elements that can be easily integrated into power semiconductor modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connection techniques are used to form terminal elements, then reliable electrical connection is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent combines multiple functions into a single terminal element: the connection element integrates both the electrical connection function (via conductive material) and the mechanical fastening function (via integrated thread and sleeve structures). This eliminates the need for separate connection components, reducing manufacturing complexity while maintaining reliable electrical connection.
Solution Approach 2:
The terminal element is designed as a multi-functional component that performs multiple tasks: providing electrical conduction, mechanical fastening through threading, and structural support through the sleeve. This universal design reduces the number of parts needed and simplifies the overall manufacturing process while ensuring reliable connections.
2Strength
If traditional connection techniques are used to form terminal elements, then secure mechanical connection is achieved, but production cost increases
Solution Approach 1:
The mechanical fastening features (thread and sleeve) are integrated directly into the terminal element body rather than being separate components. This consolidation reduces the number of parts to manufacture and assemble, lowering production costs while maintaining secure mechanical connection through the threaded interface.
Solution Approach 2:
The terminal element uses parameter optimization in its geometric design (thread pitch, sleeve dimensions, material properties) to achieve strong mechanical connections through standard manufacturing processes. This allows secure fastening to be achieved with simpler, more cost-effective production methods compared to traditional techniques.
3Reliability
If complex terminal element structures are used, then connection reliability is improved, but manufacturing simplicity is reduced
Solution Approach 1:
The terminal element integrates multiple connection functions (electrical conduction, mechanical fastening, structural support) into a single component that can be manufactured as one piece. This merging of functions achieves reliable connections without requiring complex multi-component assemblies, maintaining manufacturing simplicity.
Solution Approach 2:
The multi-functional terminal element design achieves reliable connections through a single universal component rather than multiple specialized parts. This approach maintains manufacturing simplicity by reducing the number of different component types and assembly steps required, while still providing robust electrical and mechanical connections.
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 approach enables the easy and cost-effective formation of terminal elements that can be efficiently integrated into power semiconductor modules, simplifying the connection with external connector elements and reducing manufacturing complexity.
Implementation Method 1
stamping a blank from a metal sheet
Implementation Method 2
forming a thread on a surface of the first section
Implementation Method 3
bending the first section to form a sleeve
Data Source
AI summary
A method includes: stamping a blank from a metal sheet, the blank including a first section and a second section, the second section being an elongated section having a length in a vertical direction that is at least twice its width in a first horizontal direction, the first section being 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, the sleeve including an opening facing in the vertical direction towards the second section.