Study of high-current press-fit connectors for electrical performance

Connectors for bringing high currents in and out of circuit boards are undergoing a significant evolution to meet the contemporary demand across various applications, including electric automotive, renewable energy, and automation. The development of high-current connectors has advanced considerably, moving away from traditional soldering methods to modern solderless press-fit connectors. This study subjects two high-current connector types, namely with solid press-fit and compliant press-fit pins, to a comprehensive evaluation based on both mechanical and electrical parameters. An experimental setup was meticulously prepared to measure the press-in force in relation to displacement. The choice of one connector over the other is determined mainly by application, but factors such as geometry, material and press-in forces can be equally important. Given the growing requirements for higher current and power capacities even in everyday applications, the impartial performance evaluation of these connectors becomes imperative for a deeper understanding and their effective use in various domains.