REDCUBE The Impressive Press-Fit Technology and more

High amperage solution

Superior

mechanical retention

these are….

Terminals for Power!

Press-fit technology

What is it?

Advantages

Installation

Board considerations

Press-Fit Process

Introduction of all REDCUBE Terminals and configurations

Application examples

Questions?

AGENDA

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Powerful electrical connection

What is Press-Fit Technology?

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Solder-free

Gas-tight

High mechanical stability

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How is that achieved?

Quadratically designed pins

Laser cut from brass and then plated with tin

Massive Pin Style

Cold weld process: two metal surfaces are friction fit together to create a gas-tight connection

Plated Through Hole

PTH and pin will adapt as they are pressed

generating a homogenous cold-weld between

materials

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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

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

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Advantages

Space saving design

Double-sided mounting of circuit boards is possible

No solder bridges or issues with cold solder joints

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Advantages

TBL up to 57 A vs up to 300 A

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Overview of Press-Fit Process

Press in process should be made after all soldering processes because of high heat absorption of press-fit

PCB thickness 1.6-3.2mm

Hole should be at least 3 mm away from the edge

Other components should be spaced at least 4mm

away from press-fit hole

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Board (&) Layout Considerations

PCB > max PCB within range

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Plated Through Hole Specs

Drilled hole Deposited Copper

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 1.475 (±0.05) mm

Plating/Surfaces

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A little bit more on plating…

Chemical Tin (Sn) Hot-Air-Leveling (HAL)

Final Ø 1.475 (±0.05) mm Final Ø 1.45 (±0.05) mm

What’s the difference?

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Chemical Tin (Sn) Hot-Air-Leveling (HAL)

Tin Liquid solder

Nozzle

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Press-Fit Installation

+ Work pieces or Stamp

Cut-outs allow pins to portrude

BaseplatePress +

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 100-250 mm/min > REQUIRES CONSTANT PRESSURE

Process should be done after all soldering processes due to high heat absorption of REDCUBE Press-Fit

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Installation Must-Know’s

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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

Press-Fits are rated to support 10A per pin

Operating Current is defined by:

PCB

Cross section of cable & cable lug

Current Considerations

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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, M202015/16/09 [Name] [Version 1.0] 17

Current Considerations

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Current Considerations

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Meet the REDCUBE’s

Press-Fit Configurations

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Two-Row Pin Plate

Full Circumference Pin Plate

Full Plain Pin Plate

Two-Part Terminal + Plate Internal Thread

External Thread

Two-Part Terminal?

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Through-Hole <> External Thread <> Internal Thread

Ground Terminal (Base element)

+

Support Element

Double Secured

High current Board to Board connection

Flexible connection possibilities

Low load on PCB

Very low height

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How do you install?

Installed using basic press-fit process

Ground Terminal must be pressed to board first!!

Support Element can then be pressed into

base element

Time and space saving Wire-to-Board solution

Utilizes press-fit installation system

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New REDCUBE PLUG

High current and it’s reversible!

Mounting in tight spaces or areas with difficult access

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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

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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

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

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REDCUBE SMD

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)

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REDCUBE THR

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

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Applications

Applications

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Applications

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Questions??

Video: REDCube Terminals 4Power

Application Notes