PowerTwo Two-Piece Power Elements Original POWER ELEMENT Intelligent Systems configurable 500A reliable established mechanically usable /deployable individual dimensionsno stress on PCB high lifelong torque Two-piece Power Elements are a Würth Elektronik patented solution for through screw technologies on circuit boards. These high current terminal blocks and spacers enable a durable and reliable connection and mounting on the PCB without stressing it. Depending on the pin arrangement and the layout, currents of up to 500 ampere are possible. The assembly method allows individual adaptions regarding design and dimensions. That is the reason why Power Elements perfectly qualify as connecting elements for fuses, IGBTs, switches and cables and the circuit board or for board-to-board connections. Application Possibilities Technical Data Current carrying capacity per pin at 20 °C Current carrying capacity per pin at 85 °C Material Surfaces ~ 15 A ~ 10 A CuZn39Pb3 tin-plated (standard) further surfaces such as nickel, silver, nickel / gold and others on demand Dimensions Board-to-board stackable Wire-to-board screw connection of ring terminals Electro mechanics, through screw technology, spacers Retainers / fastenings of switches, fuses, IGBTs Any combination of all these and much more Length x width Height Height above PCB Pin length Pin diagonal from 9 x 9 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 Processing Würth Elektronik PowerTwo 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 Press Fit simultaneously. Basic element Press Fit part Circuit Board Base material PCB thickness Drilling diameter Final diameter HAL surface chemical surface Copper in hole thickness press-in FR4 (EP-GC-) from 1.5 mm 1.60 +/- 0.025 mm 1.45 +/- 0.05 mm 1.475 +/- 0.05 mm min. 25 µm, max. 80 µm Processing Parameters bolt/bush Push in part push-in 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 PowerTwo 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 PowerTwo Two-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 0.3 0.5 1.2 2.2 3.9 9.0 17.0 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 20 Pins, areal 250 16 Pins, areal 200 12 Pins, areal 150 100 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 188 96 60 35 192 construction form basic element pins circumferential basic element pins two-rowed bush through hole vertical bolt customer specific 9 10 12 13 16 18 20 22 Pins 4, 8, 12 4, 8, 12 8, 16 10, 16 12, 16, 20, 24 20, 25, 28, 40, 42 24, 32 28, 32, 56 M3-M4 M3-M4 M4-M5 M5-M6 M6-M8 M6-M8 M 8 - M 10 M 8 - M 10 · · · · · · · · Ø 3.1 - Ø 4.2 Ø 3.1 - Ø 4.2 Ø 4.1 - Ø 5.3 Ø 4.1 - Ø 6.4 Ø 6.1 - Ø 8.5 Ø 6.1 - Ø 8.5 Ø 8.1 - Ø 10.5 Ø 2.6 - Ø 10.5 All threads are also available in UNC. Supplies 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 For more information visit us at: www.we-online.com/pe or call our Hotline: +49 7941 9205-4444