REDCUBE The Impressive Press-Fit Technology and more

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1 REDCUBE The Impressive Press-Fit Technology and more High amperage solution Superior mechanical retention these are. Terminals for Power!

2 AGENDA Press-fit technology What is it? Advantages Installation Board considerations Press-Fit Process Introduction of all REDCUBE Terminals and configurations Application examples Questions? 2015/16/09 [Name] [Version 1.0] 2

3 What is Press-Fit Technology? Powerful electrical connection High mechanical stability Solder-free Gas-tight 2015/16/09 [Name] [Version 1.0] 3

4 How is that achieved? Cold weld process: two metal surfaces are friction fit together to create a gas-tight connection Quadratically designed pins Laser cut from brass and then plated with tin PTH and pin will adapt as they are pressed generating a homogenous cold-weld between materials Plated Through Hole Massive Pin Style 2015/16/09 [Name] [Version 1.0] 4

brass to copper resulting in a strong mechanical

5 And a closer look. As pin is inserted into via cold weld process and gas-tight connection are happening at each corner Absolutely homogenous connection from brass to copper resulting in a strong mechanical connection with contact resistance less than 200μOhm 2015/16/09 [Name] [Version 1.0] 5

6 Advantages Low resistance connection (100μOhm - 200μOhm) -- less heat must be dissipated through the system No heat development on sensitive components No thermal stress of the circuit board Very high ampacity (up to 500A) High mechanical holding forces Mechanically more stable than solder components RELIABLE with a Failure in Time value up to 30 times better than soldered elements Suitable for rough environmental conditions extremely high environmental stability 2015/16/09 [Name] [Version 1.0] 6

7 Advantages Space saving design Double-sided mounting of circuit boards is possible No solder bridges or issues with cold solder joints TBL up to 57 A vs up to 300 A 2015/16/09 [Name] [Version 1.0] 7

8 Overview of Press-Fit Process 2015/16/09 [Name] [Version 1.0] 8

Board (&) Layout Considerations Press in process should be made after all soldering processes because of high heat absorption of press-fit PCB thickness 1.6-3.

9 Board (&) Layout Considerations Press in process should be made after all soldering processes because of high heat absorption of press-fit PCB thickness mm PCB > max PCB within range Hole should be at least 3 mm away from the edge Other components should be spaced at least 4mm away from press-fit hole 2015/16/09 [Name] [Version 1.0] 9

Min/max: 25-60µm Optimal: 30-40µm Tin (Sn)

10 Plated Through Hole Specs Drilled hole Deposited Copper Plating/Surfaces Ø1.6 mm 0.03mm Copper (Cu) needed in sleeve: Min/max: 25-60µm Optimal: 30-40µm Tin (Sn) coating: Max: 15µm Optimal: 2-6µm Final Ø (±0.05) mm 2015/16/09 [Name] [Version 1.0] 10

11 A little bit more on plating Chemical Tin (Sn) Hot-Air-Leveling (HAL) Final Ø (±0.05) mm Final Ø 1.45 (±0.05) mm 2015/16/09 [Name] [Version 1.0] 11

12 What s the difference? Chemical Tin (Sn) Hot-Air-Leveling (HAL) Nozzle Tin Liquid solder 2015/16/09 [Name] [Version 1.0] 12

13 Press-Fit Installation Press + Baseplate + Work pieces or Stamp Cut-outs allow pins to portrude 2015/16/09 [Name] [Version 1.0] 13

14 Installation Must-Know s Insertion force per pin should be at least 40 N (typically 100N) max 250 N Extraction force per pin should be at least 30 N, or up to the insertion force Press stroke should be 90 degrees to the circuit board pins should protrude slightly!! Press connection area must be supported during pressing process Force-fitting speed mm/min > REQUIRES CONSTANT PRESSURE Process should be done after all soldering processes due to high heat absorption of REDCUBE Press-Fit 2015/16/09 [Name] [Version 1.0] 14

Solder need not apply Heavy thick parts difficult

achieve a good solder joint Heating the press-fit

15 Solder need not apply Heavy thick parts difficult to bring to overall temperature required to achieve a good solder joint Heating the press-fit can lead to thermal expansion weakening the connection! Becomes unusable if tin melts and cumulates in the thread Air Gaps 2015/16/09 [Name] [Version 1.0] 15

16 Current Considerations Press-Fits are rated to support 10A per pin Operating Current is defined by: PCB Cross section of cable & cable lug 2015/16/09 [Name] [Version 1.0] 16

17 Current Considerations Current I (50 C) Current I (20 C) Cross-Section Cable lug thread size 23A 32A 2.5mm² M3, M4, M5 30A 42A 4mm² (M3), M4, M5, M6 38A 54A 6mm² M4, M5, M6, M8, M10 52A 73A 10mm² M4, M5, M6, M8, M10 70A 98A 16mm² M5, M6, M8, M10, M12 92A 129A 25mm² M5, M6, M8, M10, M12 112A 158A 35mm² M6, M8, M10, M12, M16 140A 198A 50mm² M6, M8, M10, M12, M16 174A 245A 70mm² M8, M10, M12, M16 207A 292A 95mm² M8, M10, M12, M16 244A 344A 120mm² M8, M10, M12, M16, M20 391A 150mm² M10, M12, M16, M /16/09 [Name] [Version 1.0] 17

18 Current Considerations 2015/16/09 [Name] [Version 1.0] 18

19 Meet the REDCUBE s 2015/16/09 [Name] [Version 1.0] 19

20 Press-Fit Configurations Full Circumference Pin Plate Two-Part Terminal + Plate Internal Thread Two-Row Pin Plate External Thread Full Plain Pin Plate 2015/16/09 [Name] [Version 1.0] 20

21 Two-Part Terminal? Double Secured High current Board to Board connection Ground Terminal (Base element) + Support Element Flexible connection possibilities Low load on PCB Very low height Through-Hole <> External Thread <> Internal Thread 2015/16/09 [Name] [Version 1.0] 21

22 How do you install? Installed using basic press-fit process Support Element can then be pressed into base element Ground Terminal must be pressed to board first!! 2015/16/09 [Name] [Version 1.0] 22

23 New REDCUBE PLUG Time and space saving Wire-to-Board solution High current and it s reversible! Utilizes press-fit installation system Mounting in tight spaces or areas with difficult access 2015/16/09 [Name] [Version 1.0] 23

of housing After actuating spring returns to initial

24 REDCUBE Direct Plug Terminal Simple, tool-free connection: Allow connector into plug by pushing on top of housing After actuating spring returns to initial position, locking connector in place 2015/16/09 [Name] [Version 1.0] 24

25 Now, Throw in the Connector Standard hexagonal crimping tools is used to secure contact to the wire Gas-tight crimp connection Precise connector design ends for simple cable insertion Current capacity is determined by cross sections 2015/16/09 [Name] [Version 1.0] 25

26 REDCUBE SMD Combines high-current technology with timesaving ease of automated assembly Combination of component s small size and large-area connection to the pad achieves a low contact resistance and low self heating 2015/16/09 [Name] [Version 1.0] 26

material, which guarantees better torque

27 REDCUBE THR Combines Through Hole Technology with pick and place mounting and reflow soldering High mechanical stability Special design - Milled from solid material, which guarantees better torque and higher ampacity (up to 85 A) 2015/16/09 [Name] [Version 1.0] 27

28 Applications Market Areas Wind and Solar Energy Medical Industrial Agricultural Power Supplies and Battery Systems Power Converters Frequency Converters Drive Systems Inverter Modules DC/AC Inverters AC Mains Filtering Stepping Motor Control 2015/16/09 [Name] [Version 1.0] 28

29 Applications 2015/16/09 [Name] [Version 1.0] 29

30 Applications 2015/16/09 [Name] [Version 1.0] 30

31 Questions?? Video: REDCube Terminals 4Power Application Notes 2015/16/09 [Name] [Version 1.0] 31

TN1250 Technical note

TN1250 Technical note Technical note Press-fit ACEPACK power modules mounting instructions Introduction ST introduces the ACEPACK Power Module family, designed for easy mounting and reliable performance in rugged applications.