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High current transistor connections

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IconicPCB:
Looking for comments on how to connect to high current transistors supplied in TO-3 packages.

What to avoid and how to obtain reliable connections at say 50 A continuous.

T3sl4co1l:
Like, new bought TO-3s?  Who does that?

Just regular old soldered connections is all I've seen.  No, you can't practically make a joint with wire that's rated for 50A in a conduit.  Fortunately, 14AWG will handle that just fine, for a little while at least.  The same can be said for TO-3s, so it seems fine to me. :-)

Tim

nsrmagazin:
The transistor goes to a connector with very short PCB traces and very wide. The connector goes to where ever you want.

IconicPCB:
The transistor is rated to dissipate 300W.
To be used in a linear power supply.

25Amps continuous, 50Amp peak at 28V output.

Problem is to make reliable connections.
The regulator driver will ensure the transistor SOA is maintained.

Fan cooled heatsink will be employed but never the less the connection needs to be reliable and since the unit may under some circumstances get sufficiently hot the soldered joint is potentially the weak spot.

MagicSmoker:
Probably best to use a socket rather than attempt to solder directly to the pins. Also, you are almost certainly going to need to use multiple devices, anyway, since total R_theta from junction to ambient is unlikely to be under the 0.25C/W necessary to allow 300W Pd at 25C ambient.

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