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Connection of high current bus-bar with PCB

IP.com Disclosure Number: IPCOM000031511D
Publication Date: 2004-Sep-28
Document File: 5 page(s) / 534K

Publishing Venue

The IP.com Prior Art Database

Abstract

This paper presents a method for connecting high current bus-bar with printed circuit board (PCB). Bus-bar leads are soldered around a mounted screw in PCB mounting. Leads stands around mounted screw perform a good current balancing flow between PCB and bus-bar which is essential to achieve high current load. Connecting bus-bar with PCB by this method (mounted screw with lead soldering) can also provide a stronger mechanical force than either using soldered leads or using mounted screw alone.

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CONNECTION OF HIGH CURRENT BUS-BAR WITH PCB

Bernard Yau; Ricky Wong; Man Ho, Chiang; Francois Lai

October 2003

ABSTRACT

This paper presents a method for connecting high current bus-bar with printed circuit board (PCB). Bus-bar leads are soldered around a mounted screw in PCB mounting. Leads stands around mounted screw perform a good current balancing flow between PCB and bus-bar which is essential to achieve high current load. Connecting bus-bar with PCB by this method (mounted screw with lead soldering) can also provide a stronger mechanical force than either using soldered leads or using mounted screw alone.

REVIEW OF CURRENT PRACTISES

Connecting metal bus-bar with PCB can be done by screw mounting or soldering alone, however, neither of these two methods alone can provide good connection between power supply and system when high current flow, low resistance and secured joint is needed for durability.

Connection with mounted screw alone may not provide a low DC resistance consistently, as it depends on the surface finishing quality and mounting force. Different coefficient of thermal expansion between PCB and metal bus-bar (such as copper bus-bar) will also affect the quality of connection since the screw may be loosen during thermal cycling on power supply applications.

Soldered leads can only ensure the low DC resistance between bus-bar and PCB. However, if any force was applied on solder joints through the bus-bar, the solder joints may be cracked due to the stress.

NEW INVENTION DESCRIPTION

The objective of the invention presented in this paper is to use soldered leads placed around a mounting screw to connect PCB with bus-bar to achieve high current load.

Figure 1: Assembly of Bus-bar with Power supply PCB

When an assembly of the power supply on other system, a force will be applied onto the bus-bar and power supply’s PCB during actual application. Prolonged cycling stress on the solder joint will affect the reliability of the solder joints, and it may cause solder crack.

Figure 2. Assembly of power supply with system

If this happens, the DC resistance between PCB and bus-bar increases and it will affect the current flow through the bus-bar and increase power loss.

Addition...