busbarconnectorpcbsoldering
I am going to use aluminum bus bars in a high-current PCB. What is the best technique to establish contact between the PCB and the bars?
I plan to make my own bars. The current is generally going to be around 100-150 A per single connection (a bar will be connected in several places).
Mill-max makes spring probe strips and buttons (See http://www.mill-max.com ) If you had two little PCBs you could put use the spring probes to hit large pads. You would need to apply constant pressure to insure the contacts stay mated.
There are conductive elastomer strips in a variety of sizes. The elastomer would connect two PCB pads.
Spring probes for in-circuit testing could work too.
I would look at the Mill-max contact strips first.
You might try searching for solderable bus bars. They come in various sizes and shapes. You can solder them down to the PCB, and they provide masses of current carrying capability.
Best Answer
If you want the bar to be flush against the PCB, consider broaching PCB PEM nuts.
If you want to raise the bus bar, consider pressfit threaded terminals.
https://www.digikey.com/short/2hm8p02f
If you want the bus bar to slip onto the PCB, consider busbar clips.
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