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Conductive connection of sheet metal

Based on the trends of e-mobility and autonomous driving, the number of electrical connections are ever increasing in automotive applications. To meet the high reliability requirements over the vehicle lifetime, low-resistance, reliable electrical connections are required.
Not only do automotive applications require this: Applications in the other areas such as photovoltaic power, energy storage systems, building technology and more also require long-life, reliable electrical connections – therefore there are many applications in electrical power distribution.

The term TOX®-eClinching summarizes our many years of know-how, our in-depth process competences, our global Service line-up and the high quality technical systems which are required for the production of reliable, electrically conductive connections.

TOX®-eClinching is based on the long-proven and conventional clinching process with process-related advantages like:

  • Very high retaining forces
  • Easy and efficient quality monitoring
  • Excellent electrical conductivity

The process is ideally suited to the production and joining of electronic components. Possible applications are found in the automotive arena such as contacts of battery cells, bus bars, fuse elements, etc. Also applications in the non-automotive area such as power distribution and lighting are common. Compared to conventional soldered, welded or screwed connections, TOX®-eClinching provides substantial advantages:

  • no pre-treatment required of the surface
  • no heat input required at the process

Creation of conductivity

TOX®-eClinching creates electrically excellent conductive connections due to metallic microcontacts.

The most reliable electrical connection is based on a combination of material, force & form bonds to avoid relaxation in the contact area.

Connection with optimized material bond

During TOX®-eClinching a punch presses the to-be-joined metal sheets into a die. The undercut created by the plastic forming (form bond) ensures high retention forces in the neck area (force bond). At the same time a material connection (material bond) with many micro-contacts is created providing excellent electrical conductivity.

Enlarged contact zone

The clinch forming process, almost doubles the effective contact area.  This increases considerably when joining thick sheet metal. This additional area increases the conductivity of the connection and is an important “plus” for the electrical conductivity.


Soft plating, such as tin layers on copper, is reshaped without being pulled off, retaining conductivity.

Numerous micro-contacts ensure the conductive connection of the materials.

How to achieve highly conductive joints with a long term stability?

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Permanently low contact resistance

TOX®-eClinching is a proven technology to join electrically conductive components mechanically and electrically. It joins the components reliably as well as permanently.

Constant conductivity ensured by high retaining forces

Since clinched joints can withstand mechanical loads (e.g. torques) and temperature changes more reliably in the long term compared to other connection methods, the relaxation processes - or the relaxation of the connection – have little effect. With little relaxation, the contact resistance remains consistently low and the high conductivity is maintained. Consequently the eClinching process fits perfectly to meet the high requirements of power distribution in both automotive and non-automotive applications.

Relaxation in the contact area

A TOX®-eClinch Point remains safely in the stable range as the principally unavoidable relaxation is insignificant and practically not quantifiable. The relaxation can be classified as negligible. If the process-specific characteristics are not observed, there is a risk of entering the unstable range.

Application examples/Customer parts

  • Pre-fuse box for residual currents up to 250A
  • Electrical auxilary heater
  • Busbar with fuses and capacitor
  • Control box for Li-Ion battery
  • Busbar for building automation
  • Pre-fuse box for fuses up to 150A
  • U busbar with fuses


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