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January 2013

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Subject:
From:
Steven Creswick <[log in to unmask]>
Reply To:
TechNet E-Mail Forum <[log in to unmask]>, Steven Creswick <[log in to unmask]>
Date:
Wed, 9 Jan 2013 18:15:55 -0500
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text/plain (121 lines)
Bob,

Glad to have made someone's day.  Always a pleasure.

Steve

-----Original Message-----
From: Robert Kondner [mailto:[log in to unmask]] 
Sent: Wednesday, January 09, 2013 6:13 PM
To: 'TechNet E-Mail Forum'; 'Steven Creswick'
Subject: RE: [TN] 200A Connections to PCB

Steve,

 Actually that is a great idea. Funny, I should have thought of that. The
company that developed that was just up the road from me in Hunt Valley MD.
I did a little work for them. I even have some of their material here
somewhere. They since closed down and sold out. Shame, really smart folks.

 The joints formed are amazingly strong. The Nano Foil sample kit had 2
pieces of 1 inch square 1/4 thick copper plates, solder plated. I did the
demo then put the fused pieces in a vise. Even with a big hammer I could not
shear apart the 1/4 inch think pieces of metal. And wow did I try.

Thanks again for the idea.

Bob K.

-----Original Message-----
From: TechNet [mailto:[log in to unmask]] On Behalf Of Steven Creswick
Sent: Wednesday, January 09, 2013 5:41 PM
To: [log in to unmask]
Subject: Re: [TN] 200A Connections to PCB

Robert,

This may be a bit too far out to be of use, but have you considered reactive
nanofoils?  Very much like Thermite in foil form instead of powder.  

Used to be made by NanoBond, but appear to have been absorbed into Indium -
http://www.indium.com/nanofoil/

Appear to still be limited to relatively low temps, but you might enquire.
You could prep the 'connector' off-line, then sandwich it to the board and
foil, and initiate the reaction.  Not sure how the resultant joint would
hold up to the mechanical stress of your structure, but thought I would
throw it out there and let you decide if it had merit.

My spark for the day


Steve Creswick
Sr Associate - Balanced Enterprise Solutions
http://www.linkedin.com/in/stevencreswick
                         616 834 1883



-----Original Message-----
From: TechNet [mailto:[log in to unmask]] On Behalf Of Robert Kondner
Sent: Thursday, January 03, 2013 10:32 AM
To: [log in to unmask]
Subject: [TN] 200A Connections to PCB

Hi,

 

I was wondering if anyone had suggestions about making high current
connections to a PCB.

 

I am working with a design for a 2KW DC to AC converter. Input current will
reach about 200 amps. The PCB will be a heavy copper single sided Aluminum
PCB much like that used for high power LED apps. Conductor temp rise is not
an issue as the thermal conduction to the Al base is very high and the base
is on a heat sing. The FETs will dump much more heat than the copper.

 

The problem is bringing wire terminations to the PCB. Any Ideas? The Al base
is applied against a heat sink so using through board type studs or bolt is
difficult. I am considering the use of a couple of Keystone screw terminals
with their legs cut off. The bodies could then be SMT reflowed to the copper
planes.

 

http://www.keyelco.com/products/specs/spec186.asp

 

Any other ideas out there?

 

Thanks,

Bob K. 



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