PowerOne Single-Piece Power Elements Original POWER ELEMENT Intelligent Systems configurable 1000A reliable established mechanically usable /deployable individual design individual dimensions Single-piece Power Elements are used for the supply and distribution of high currents in connection with circuit board based systems. Depending on the pin arrangement and the layout, currents of up to 1,000 ampere are possible. PowerOne high current terminal blocks and spacers were developed by Würth Elektronik in 1987. Meanwhile this product group has been successfully used in the field in thousands of various designs. The manufacturing method allows individual adaptions regarding design and dimensions. That is the reason why Power Elements perfectly qualify as connecting element for fuses, IGBTs, switches and cables to the circuit board or as contact element for board-to-board respectively board-to-case. Application Possibilities Board-to-board over 90° or packaging Wire-to-board screw connection of ring terminals Electro mechanics such as hinges and case mounting Spacers Retainers / fastenings of switches, fuses, IGBTs Any combination of all these and much more Processing Würth Elektronik PowerOne Power Elements are pressed in into the circuit board. Soldering is not necessary. Therefore, the PCBs are not exposed to temperature stress. This processing step easily blends in to the processing chain and is highly cost efficient. With the aid of the corresponding Press Fit tools, several Power Elements can be pressed in simultaneously. Technical Data Current carrying capacity per pin at 20 °C Current carrying capacity per pin at 85 °C Material Surfaces ~ 10 /15 A (areal /circumferential pins) ~ 6 /10 A (areal /circumferential pins) CuZn39Pb3 tin-plated (standard) further surfaces such as nickel, silver, nickel / gold and others on demand Dimensions Length x width Height Height above PCB Pin length Pin diagonal from 5 x 5 to 22 x 22 mm from 3 mm individually from 3 mm individually up to 7.5 mm (standard of 3.5 mm) 1.6 mm standard others on demand Circuit Board Base material PCB thickness Drilling diameter Final diameter HAL surface chemical surface Copper in hole thickness FR4 (EP-GC-) from 1.5 mm 1.6 +/- 0.025 mm 1.45 +/- 0.05 mm 1.475 +/- 0.05 mm min. 25 µm, max. 80 µm Processing Parameters For assembling prototypes, no special equipment is needed for pressing in, a simple toggle press is sufficient The circuit board needs support during the pressing procedure The pressing force must be executed in a 90° angle to the circuit board After the pressing process the pins should stand out of the drilled hole (ca. 0.2 - 0.5 mm) Plated through holes of the circuit board must be executed according to our indications PowerOne high current terminal blocks and spacers are manufactured for pressing, soldering is not intended www.we-online.com/pe Press-in force min. 40 N per Pin max. 250 N per Pin Retention force Press-in speed 60 - 80 % of the press-in force 100 - 250 mm /min Compliant PowerOne Single-Piece Power Elements Circuit Board Design For the massive Press Fit Technology the PCBs are to be finished according to the Würth Elektronik ICS Press Fit specifications (see table on the side). Particular attention should be paid to the drill diameter and the copper thickness. Due to the different layer thicknesses of Hot Air Levelling compared to chemical surfaces, the final diameters vary. Würth Elektronik ICS – Press Fit Specification 5.1 Drill Ø 1.6 +/- 0.025 mm Cu-H Cu A End Ø Torques The torques indicated in the table are based on DIN 267 part 25. Different material combinations or different thread lengths of the connectors are not regarded here. Thread Reference values for a pre-dimensioning can be found under Technical Data on page 1. depends on surface HAL chem. surfaces 1.45 +/- 0.05 mm 1.475 +/- 0.05 mm M 2.5 M3 M4 M5 M6 M8 M 10 M 12 0.3 0.5 1.2 2.2 3.9 9.0 17.0 35.0 Derating Curve electricity A The current carrying capacity of a Press Fit connection needs to be seen in the context of the overall system. The Press Fit zone has a very low electrical contact resistance of 100 - 200 µOhm. The limiting factor therefore usually lies in the circuit board layout or in the connection of a feed line. min. 25 µm, max. 80 µm min. 125 µm Torques for Brass (Nm) Current Carrying Capacity Cu - in Hole Annular Ring 300 36 Pins, areal 250 25 Pins, areal 200 9 Pins, areal 150 20 Pins, areal 100 16 Pins, areal 12 Pins, areal 50 0 20 30 40 50 60 70 80 90 100 ambient temperature °C 110 120 130 example 2-layer 70 µm final copper Overview of Standard Products available products 138 85 22 93 32 2176 construction form bush blind hole vertical bush through hole vertical bush through hole horizontal bolt bracket through hole horizontal customer specific 5 7 9 10 12 13 16 18 20 22 Pins 4, 6, 9 4, 6, 9 4, 8, 12, 16 4, 8, 12, 16 4, 10, 16, 25 4, 10, 16, 25 12, 20, 36 14, 24, 40, 49 16, 28, 48, 64 18, 32, 56, 81 Supplies Under the product category PowerCover, we offer a large choice of twist and contact protection elements. Press Fit tools and die plates for the prototype assembling with small Press Fit systems and also for serial production with automats, are available on demand. www.we-online.com/pe M 2.5 - M 3 M 2.5 - M 5 M3-M6 M3-M6 M4-M6 M4-M8 M 5 - M 10 M 5 - M 10 M 5 - M 10 M 5 - M 10 · Ø 2.6 - Ø 3.4 · Ø 2.6 - Ø 5.5 · Ø 3.2 - Ø 6.6 · Ø 3.2 - Ø 6.6 · Ø 4.2 - Ø 6.6 · Ø 4.2 - Ø 9.0 · Ø 5.2 - Ø 10.5 · Ø 5.2 - Ø 10.5 · Ø 5.2 - Ø 10.5 · Ø 5.2 - Ø 10.5 All threads are also available in UNC. For more information visit us at: www.we-online.com/pe or call our Hotline: +49 7941 9205-4444