High voltage fault interrupt contactors with permanent open feature

Abstract

Contactors, devices, assemblies, and apparatuses having a permanent opening feature and methods of operating contactors having a permanent opening feature are disclosed. In particular embodiments, a contactor assembly having a permanent opening feature is disclosed that includes a movable contact configured to engage and disengage a stationary contact. The contactor assembly also includes an actuator assembly for driving the movable contact and a two-stage restrike prevention mechanism configured to prevent restrike at a first current level and provide a permanent opening at a second current level.

Description

Background Technology

[0001] Electromechanical switching devices, such as contactors and relays, are designed to carry a certain amount of current for a specific period of time. Such devices are particularly important in electric vehicles. Typically, electric vehicles include one or more high-voltage batteries connected to the vehicle's electrical distribution system via DC contactors to power the electric motor. A DC contactor is typically an electromechanical switch that disconnects or connects the high-current path between the battery pack and the vehicle's electrical distribution system.

[0002] As power levels continue to rise across industries, manufacturers are striving to design systems capable of safely handling accidents and emergencies that could lead to high-current short circuits. This difficulty often stems from the inability to find switching devices designed to withstand and / or interrupt high levels of fault current / voltage (i.e., short circuits). Furthermore, an ideal solution should reduce system complexity, weight, and cost. Summary of the Invention

[0003] Embodiments of this disclosure relate to a high-voltage fault-breaking contactor with permanent disconnection features, which achieves high power interruption performance with self-triggering capability and rapid arc suppression by utilizing levitation force and a two-stage reignition prevention mechanism. In a specific example, the fault-breaking contactor device is a single-pole single-throw, normally open contactor operating at a maximum voltage of at least 1,000 volts (V) and designed to continuously carry at least 750 A without active cooling. The fault-breaking contactor can interrupt high currents at high voltages without the need for an external short-circuit protection system or triggering device. The contactor includes an integrated two-stage electrode latching mechanism for permanent disconnection after a short-circuit event, preventing the switch from reigniting after opening.

[0004] Contactors, assemblies, devices, and apparatuses with permanent disconnection features are disclosed, as well as methods of operating contactors with permanent disconnection features. In a particular embodiment, a contactor assembly with permanent disconnection features is disclosed, comprising a moving contact configured to engage and disengage a stationary contact. The contactor assembly further includes an actuator assembly for driving the moving contact and a two-stage reignition prevention mechanism configured to prevent reignition at a first current level and provide permanent disconnection at a second current level.

[0005] In another embodiment, a method for operating a high-voltage fault-breaking contactor with a permanent disconnection feature is disclosed. The method includes: actuating a moving contact to separate the moving contact from a stationary contact. The method further includes: using a first holding mechanism to prevent reignition in response to a first holding force induced by a current in the contactor exceeding a first current threshold. Furthermore, the method includes: engaging a second holding mechanism to provide permanent disconnection between the moving and stationary contacts in response to a second holding force induced by a current exceeding a second current threshold, the second current threshold being greater than the first current threshold.

[0006] These and other features, aspects and advantages of this disclosure will be better understood when read in conjunction with the accompanying drawings, in which the same reference numerals denote the same parts. Attached Figure Description

[0007] Figure 1A A cross-sectional view of an exemplary contactor for a high-voltage fault-breaking contactor having a permanent disconnection feature, according to at least one embodiment of the present disclosure, is shown.

[0008] Figure 1B It shows Figure 1A An exploded view of the contactor shown.

[0009] Figure 2A At least one embodiment according to the present disclosure is shown. Figure 1A and Figure 1B A detailed view of the stationary contact assembly of the contactor shown.

[0010] Figure 2B At least one embodiment according to the present disclosure is shown. Figure 1A and Figure 1B A detailed view of an exemplary housing assembly of the contactor shown.

[0011] Figure 2C At least one embodiment according to the present disclosure is shown. Figure 1A and Figure 1B A detailed view of an exemplary arc chamber assembly of the contactor shown.

[0012] Figure 2D At least one embodiment according to the present disclosure is shown. Figure 1A and Figure 1B A detailed view of an exemplary moving contact assembly of the contactor shown.

[0013] Figure 2E At least one embodiment according to the present disclosure is shown. Figure 1A and Figure 1B A detailed view of an exemplary contact retaining component of the contactor shown.

[0014] Figure 3AAt least one embodiment according to the present disclosure is shown. Figure 1A and Figure 1B The default disconnect position of the contactor shown.

[0015] Figure 3B At least one embodiment according to the present disclosure is shown. Figure 1A and Figure 1B The contactor shown is activated.

[0016] Figure 3C At least one embodiment according to the present disclosure is shown. Figure 1A and Figure 1B The contactor is shown in the ON position.

[0017] Figure 3D At least one embodiment according to the present disclosure is shown. Figure 1A and Figure 1B The fault disconnect position of the contactor shown.

[0018] Figure 4 A flowchart illustrates an exemplary method for operating a contactor having a permanent disconnect feature according to at least one embodiment of the present disclosure.

[0019] Figure 5 A flowchart illustrates another exemplary method for operating a contactor having a permanent disconnect feature according to at least one embodiment of the present disclosure.

[0020] Figure 6 A flowchart illustrates another exemplary method for operating a contactor having a permanent disconnect feature according to at least one embodiment of the present disclosure. Detailed Implementation

[0021] The terminology used in this document to describe particular examples is not intended to limit further examples. Whenever a singular form such as “a,” “an,” and “the” is used, and the use of a single element is neither explicitly nor implicitly defined as mandatory, further examples may also use plural elements to achieve the same functionality. Similarly, when a function is subsequently described as being implemented using multiple elements, further examples may use a single element or processing entity to achieve the same functionality. It should be further understood that when the terms “comprise,” “comprising,” “includes,” and / or “including” are used, these terms specify the presence of the stated feature, integer, step, operation, process, action, element, and / or component, but do not preclude the presence or addition of one or more other features, integers, steps, operations, processes, actions, elements, components, and / or any combination thereof.

[0022] It should be understood that when one element is referred to as "connected" or "linked" to another element, these elements can be directly connected or linked, or connected or linked via one or more intermediate elements. If two elements A and B are combined using "or," this should be understood to disclose all possible combinations, i.e., only A, only B, and A and B. An alternative wording for the same combination is "at least one of A and B." This also applies to combinations of more than two elements.

[0023] Therefore, while the further examples are capable of various modifications and alternative forms, some specific examples are shown in the accompanying drawings and will be described in detail thereafter. However, this detailed description does not limit the further examples to the specific forms described. The further examples may cover all modifications, equivalents, and alternatives falling within the scope of this disclosure. Throughout the description of the accompanying drawings, the same reference numerals refer to the same or similar elements that may be implemented in the same or modified form while providing the same or similar function.

[0024] According to embodiments of this disclosure, a high-voltage fault-breaking contactor with permanent disconnection features is provided, which combines self-triggering capability and rapid arc suppression by utilizing levitation force and a two-stage reignition prevention mechanism. In a specific example, the fault-breaking contactor is a single-pole single-throw, normally open contactor that operates at a maximum of at least 1,000 volts (V) and is designed to continuously carry at least 750 A without active cooling. The fault-breaking contactor can interrupt high current at high voltage without requiring an external short-circuit protection system or triggering device. The contactor includes an integrated two-stage electrode latch for permanent disconnection after a short-circuit event, preventing the switch from reigniting after disconnection.

[0025] To further illustrate, Figure 1A and Figure 1B An example of a high-voltage fault-breaking contactor (hereinafter referred to as contactor 100) having a permanent disconnection mechanism according to at least one embodiment of the present disclosure is shown. Figure 1A It is a sectional view. Figure 1B It is a decomposed diagram.

[0026] Contactor 100 includes a lower coil yoke 196 surrounding a coil assembly 193, which includes a plunger tube 194 and a coil housing 195. A lower stationary magnetic core 190 is located between the plunger tube 194 and the coil housing 195. The coil housing 195 surrounds a coil (e.g., a solenoid) 115, and the plunger tube 194 surrounds a movable assembly having a plunger 108 coupled to a plunger shaft 110. Contactor 100 also includes an upper coil yoke 109 coupled to an upper flux tube 150, and a plunger spring 111 coupled between the upper coil yoke 109 and the plunger 108. Furthermore, contactor 100 includes stationary (fixed) contacts 102 and 104 and a moving contact 106. The moving contact 106 is configured to establish or disconnect the connection between the stationary contacts 102 and 104 in response to movement of the movable component. The stationary contacts 102 and 104 are coupled to an external connector 114 for connection to external components such as power supplies and electrical applications.

[0027] In the open state, the moving contact 106 is not in contact with the stationary contacts 102 and 104, so that no current flows between the stationary contacts 102 and 104. In this open state, the plunger spring 111 is configured to apply a preload force to the plunger 108 to prevent the movable component from moving to the closed state. In the closed state, the moving contact 106 is in contact with the stationary contacts 102 and 104, so that current flows through the moving contact 106 between the stationary contacts 102 and 104.

[0028] Controller ( Figure 1A and Figure 1B (Not shown) can be connected to contactor 100 and configured to control the current flowing to coil 115 of contactor 100. Coil 115 is made of windings of a conductive material (such as copper or aluminum). When coil 115 is connected to a power source and current flows through the windings, a strong magnetic field is generated, which flows through the magnetic circuit path of the contactor. This electromagnetic field is guided by the coil yoke and (multiple) static magnetic cores, which are made of ferromagnetic materials (such as low-carbon steel). This path of the magnetic field is called magnetic circuit 152, as shown in the image. Figure 1AAs indicated by the middle arrow, a magnetic field is guided to and magnetizes the plunger 108 located within the sealed plunger tube 194. The magnetized plunger 108 is then attracted to the upper flux tube 150 by magnetic force. This magnetic field forces the plunger 108 upward. When sufficient magnetic force is generated, the plunger 108 overcomes any holding spring force (preload force from the plunger spring 111) and begins to move. The plunger 108 and plunger shaft 110 drive the moving contact 106 toward the stationary contacts 102, 104 until the moving contact 106 is in the closed position, in which contact is established between the moving contact 106 and the stationary contacts 102, 104, thereby switching the contactor 100 from the open state to the closed state. When the moving contact 106 contacts the stationary contacts 102, 104, the high-voltage circuit is connected. When the plunger 108 contacts the upper flux tube 150, the magnetic circuit 152 is connected.

[0029] When coil 115 is disconnected from the low-voltage power supply, the ferromagnetic component loses its magnetism, and the magnetic force acting on plunger 108 decreases. This decrease in the magnetic field causes plunger 108 to separate from the upper flux tube 150, thereby opening the magnetic circuit 152. Plunger spring 111 returns plunger 108 to its original position. That is, when coil 115 is de-energized, plunger 108 is driven downward by the force of the energy stored in the compressed plunger spring 111 and contact spring 112, and the movable component pulls the moving contact 106 downward until the moving contact 106 is in the open position, thereby disconnecting the high-voltage circuit between the moving contact 106 and the stationary contacts 102 and 104.

[0030] Arc chamber 116 and arc shield 117 are disposed within housing 118. Arc shield 117 includes contact retaining spring 121 for preventing reignition during a circuit breaking event. Contactor 100 may be disposed within plastic housing 119. Various aspects of contactor 100 will be referenced... Figures 2A to 2E To provide a more detailed description.

[0031] To further illustrate, Figure 2A It shows including Figure 1A and Figure 1B A front view of an exemplary stationary contact assembly of stationary contacts 102, 104. Stationary contacts 102, 104 have optimized contact geometry for high-power disconnection. In this example, stationary contacts 102, 104 include a fusion tip 201. Fusion tips are specialized components of electrical contacts designed to melt under high current conditions, thereby forming a safety mechanism during fault events. Made of a low-melting-point material, the fusion tip efficiently handles normal current but heats up and vaporizes rapidly during current surges. This melting increases the contact gap, reduces the risk of arcing, and ensures current isolation for interrupting current. By protecting the main contact assembly and enabling rapid fault isolation, the fusion tip enhances system safety, reliability, and cost efficiency.

[0032] To further illustrate, Figure 2B It shows including Figure 1A and Figure 1B The image shows a front view of an exemplary housing assembly of housing 118 and stationary contacts 102, 104. The metal housing 118 includes eye rings 119 (e.g., ceramic eye rings) surrounding the stationary contacts 102, 104 and optional auxiliary terminals. The ceramic eye rings provide electrical insulation to the stationary contacts while allowing them to pass through the metal housing, thus ensuring safe and efficient operation. In certain embodiments, their material properties, such as high heat resistance and mechanical strength, enable them to withstand the intense heat and stress generated during high-power arcing. These eye rings contribute to the hermetic seal of the housing, preventing leaks and protecting internal components from external contaminants, thereby enabling the contactor to withstand prolonged high-power arcing without breaking.

[0033] Figure 2C A top view of the assembled arc chamber assembly is shown, the arc chamber assembly including... Figure 1A and Figure 1B The arc chamber 116 and arc shield 117 are included. In some examples, the arc chamber 116 is a plastic arc chamber with a shielding effect achieved through an internal labyrinth geometry. In this context, arc chamber shielding refers to a design strategy that uses barrier geometry, such as an internal labyrinth path, to control and limit the movement of the arc. These features “shield” certain areas, preventing the arc from propagating directly and forcing it to travel along a longer, more complex path. This reduces the strength and likelihood of arcing between critical components, improves insulation, and enhances the overall safety and performance of the system. The arc chamber provides longer terminal spacing and extended magnet dimensions. In electrical systems, spacing refers to the physical distance between two terminals or conductive elements, typically measured center-to-center. Longer spacing reduces the likelihood of arcing or breakdown by increasing the insulation distance between high-voltage components. This design feature is critical for enhancing safety and reliability in high-power and high-voltage applications. The longer spacing enhances high-voltage insulation strength compared to conventional implementations.

[0034] Figure 2D It shows including Figure 1A and Figure 1BA front view of an exemplary moving contact assembly of the moving contact 106. In some examples, the moving contact 106 has a shoulder geometry or offset height geometry as shown. Shoulder geometry allows for aggressive shielding by creating a baffle at the point of contact. In this context, shoulder geometry refers to a specific design feature of the moving contact where it has an offset or non-linear shape, thereby creating a physical barrier or baffle at the point of contact. These baffles interfere with the direct path of the arc, enhancing the shielding effect within the contact assembly. By forcing the arc to follow a more complex path, shoulder geometry improves arc containment and reduces the risk of electrical breakdown. This design is particularly effective in high-power applications, where controlling arc behavior is critical for safety and performance. The moving contact assembly also includes a longer plunger shaft 110 compared to conventional embodiments, which increases the maximum stroke clearance / contact clearance of the assembly to compensate for high-voltage interruptions. The longer plunger shaft increases the stroke clearance, i.e., the maximum distance the moving contact 106 can separate from the stationary contacts 102, 104 during operation. This extended clearance provides a greater physical barrier, making it more difficult for electric arcs to bridge the contacts 102, 104, and 106, especially during high-voltage interruptions. By more effectively suppressing arcs, it enhances the reliability and safety of the contactors in high-power applications. The increased travel clearance also allows the components to handle higher voltages without the risk of insulation breakdown or accidental current flow. This design is particularly advantageous in systems requiring rapid fault isolation, as it ensures complete disconnection even under extreme electrical conditions. Furthermore, the longer shaft improves overall performance and durability, accommodating the stresses of high-energy operation with minimal wear.

[0035] Figure 2E It shows Figure 1A and Figure 1B A perspective view of the arc shielding, which includes a two-stage engagement / retention mechanism designed to provide operational flexibility and enhanced safety under varying fault conditions. The mechanism adapts to different current levels to optimize performance. In the first stage, activated during lower current fault events, the retaining spring 121 holds the moving contact 106 after interruption, preventing reignition (i.e., the reformation of the arc between the stationary contacts). This ensures the system remains temporarily open and isolated, preventing accidental current flow, while allowing the contactor to be reset once the fault is cleared. This resettlement capability is particularly valuable for non-critical faults, enabling the system to quickly return to normal operation without the need for component replacement or prolonged downtime.

[0036] In the second phase, when the system experiences a severe fault with a current surge exceeding a threshold (e.g., 8kA), the plastic latch 203 engages to lock the moving contact 106 in a forced, permanent disconnect position. This prevents any possibility of reignition, ensuring the system remains completely isolated until inspection and maintenance can be performed. The use of the plastic latch provides precise activation under high current stress while maintaining a cost-effective and durable design. Together, these two phases ensure dual-mode functionality, combining resettlement for minor faults with robust safety measures for extreme conditions. This intelligent design enhances system reliability, minimizes downtime, and protects equipment and operators during high-power operation.

[0037] To further illustrate, Figures 3A-3D The diagram illustrates the various states of the contactor, demonstrating its operational phases and unique design features that enhance performance and safety in high-power systems. Figure 3A In this design, the contactor is depicted in its default normally open position, with the moving contact 106 separated from the stationary contacts 102 and 104. Notably, the nominal gap between the moving and stationary contacts is larger than that in conventional designs, thereby reducing the risk of accidental arcing and improving insulation strength. This increased default gap ensures greater safety and a baseline level of readiness for high-voltage conditions.

[0038] exist Figure 3B In the diagram, the contactor is shown in the closing process, with the moving contact 106 initially contacting the stationary contacts 102 and 104. This stage represents the transition to closing the circuit, allowing current to flow. Subsequently, as... Figure 3C As depicted, the plunger shaft 110 performs an overtravel motion, pressing the moving contact more firmly against the stationary contact. This overtravel action ensures reliable electrical contact, minimizes resistance, and reduces the possibility of contact bounce, which could otherwise lead to arcing or signal interruption.

[0039] The designed safety mechanism Figure 3D The middle is highlighted. Figure 3D The diagram illustrates the contactor's response to a high-current event, such as a surge exceeding 8 kA. In this scenario, a levitation force induced by the electromagnetic effect of the high current drives the moving contact 106 away from the stationary contacts 102 and 104. For safety, a plastic latch 203 engages the moving contact, locking it in place to provide a permanent disconnect and isolate the circuit from further current flow. This action prevents reignition and protects the system from damage. Furthermore, the travel gap at this stage is twice the nominal gap, further enhancing the isolation effect. This process is complemented by the melting of the fusion tip, which further increases the contact gap, accelerates arc extinction, and improves the overall robustness of the system under extreme conditions.

[0040] This series of states showcases the contactor's sophisticated design, balancing operational efficiency with advanced safety features. From the increased default clearance to the overtravel for safe connection and the advanced mechanism for fault isolation, this contactor is designed to handle demanding high-power applications with reliability and accuracy.

[0041] To further illustrate, Figure 4 A flowchart illustrating an exemplary method for operating a contactor having a permanent disconnect feature according to this disclosure is provided. Figure 4 The method includes: activating contactor 402, which includes one or more stationary contacts, a moving contact, and a two-stage contact holding mechanism. For example, this contactor can be used with... Figure 1A and Figure 1B The contactors shown are the same or similar. Turning on the contactor is achieved by energizing its coil, as shown below. Figure 3B and Figure 3C As shown.

[0042] Figure 4 The method further includes engaging the moving contact 404 by a first holding mechanism in response to a first holding force induced by a current exceeding a first current threshold. In some examples, engaging the moving contact 404 in response to a first holding force induced by a current exceeding a first current threshold is performed by the holding spring 121 engaging the moving contact 106, as described above.

[0043] Figure 4 The method further includes engaging the moving contact 406 by a second holding mechanism in response to a second holding force induced by a current exceeding a second current threshold. In some examples, engagement of the moving contact 406 in response to a current exceeding a second current threshold is performed by engaging the moving contact 106 by a contact latch 203, as described above.

[0044] To further illustrate, Figure 5 A flowchart illustrating another exemplary method for operating a contactor with a permanent disconnect feature according to this disclosure is provided. Figure 5 The method includes actuating the 502 moving contact to separate the moving contact from the stationary contact. For example, the contactor can be used with... Figure 1A and Figure 1B The contactor shown is the same or similar. Actuation 502 is performed by the controller removing the current supplied to the solenoid. This de-energization causes the solenoid plunger to retract, which in turn separates the moving contact from the stationary contact. The removal of current interrupts the magnetic field, allowing mechanical force or spring-loaded force to complete the separation process.

[0045] Figure 5The method further includes using a first holding mechanism to prevent reignition of 504 in response to a first holding force induced by the contactor current exceeding a first current threshold. Preventing reignition using the first holding mechanism in response to the first holding force induced by the contactor current exceeding the first current threshold can be performed by utilizing a holding spring (e.g., holding spring 121) within the arc shielding assembly. During a low-current fault event, the holding spring engages to hold the moving contact 106 after it has been pulled away from the fixed contacts 102 and 104, thereby ensuring that the circuit remains open and isolated without the risk of arc re-establishment. This mechanism temporarily isolates the system and allows for reset after the fault is cleared, providing an effective and safe way to prevent reignition under minor fault conditions.

[0046] also, Figure 5 The method includes engaging a second holding mechanism 506 to provide permanent disconnection between the moving contact and the stationary contact in response to a second holding force induced by a current exceeding a second current threshold, the second current threshold being greater than a first current threshold. Engaging the second holding mechanism 506 to provide permanent disconnection in response to the second holding force induced by a current exceeding the second current threshold can be performed by activating a plastic latch 203 designed for high-current fault scenarios. When the current exceeds this higher threshold, the latch is engaged to lock the moving contact 106 in a fully disconnected position, ensuring no possibility of reconnection or reignition. This mechanism enforces complete isolation until inspection and maintenance, providing a robust safety response to extreme electrical conditions while protecting the system and its components.

[0047] To further illustrate, Figure 6 A flowchart illustrating another exemplary method for operating a contactor with a permanent disconnect feature according to this disclosure is provided. Figure 6 The method increases the contact gap between the stationary and moving contacts by melting the fusion tip on the 602 stationary contact. Figure 5 The method can be extended. A fusion tip on the 602 stationary contact can be designed using a tip that responds to high current surges to increase the contact gap. When the current exceeds a critical threshold, the intense heat generated by the surge causes the fusion tip to rapidly melt and vaporize. This melting action effectively increases the physical separation between the stationary and moving contacts, reducing the likelihood of arcing or reignition. By incorporating this fail-safe mechanism, the fusion tip ensures enhanced system safety and isolation during severe failure events, protecting the contactor and connected equipment.

[0048] In view of the foregoing, this embodiment discloses a high-voltage fault-breaking contactor with a permanent disconnection mechanism, which achieves circuit-breaking requirements orders of magnitude higher than conventional methods. For short-circuit interruption, no external trigger is required. Therefore, this embodiment reduces the complexity and cost of the battery protection module.

[0049] In view of the foregoing, high-voltage fault-breaking contactors with permanent disconnection mechanisms offer several advantages, including: High current interruption without the need for an external short-circuit protection system; High-current interruption without the need for pyrotechnics; The shoulder geometry of the moving contact significantly improves the insulation resistance after circuit breaking; The hermetically sealed metal casing allows for very high maximum internal pressure; The fusion tip accelerates current isolation as the electrode melts; The two-stage latching mechanism allows for reset capability at low current levels, while preventing reignition through permanent disconnection at extreme current levels.

[0050] The flowcharts and schematic diagrams in the accompanying drawings illustrate the architecture, functionality, and operation of various embodiments of the apparatus and methods according to this disclosure. In some alternative embodiments, the functions marked in the blocks or steps may occur in a different order than shown in the drawings. For example, two blocks shown consecutively may actually be performed substantially simultaneously, or these blocks may sometimes be performed in reverse order, depending on the functions involved.

[0051] The advantages and features of this disclosure can be further described by the following statements:

[0052] 1. A contactor assembly having a permanent disconnect feature, the contactor assembly comprising: a moving contact configured to engage and disengage a stationary contact; an actuator assembly for driving the moving contact; and a two-stage reignition prevention mechanism configured to prevent reignition at a first current level and provide permanent disconnection at a second current level.

[0053] 2. The contactor assembly according to statement 1, wherein the two-stage holding mechanism includes a first holding mechanism and a second holding mechanism; wherein the first holding mechanism engages the moving contact above a first current threshold, and the second holding mechanism engages the moving contact above a second current threshold; and wherein the second current threshold is greater than the first current threshold.

[0054] 3. The contactor assembly according to statement 1 or 2, wherein the first retaining mechanism includes one or more retaining springs.

[0055] 4. The contactor assembly according to any one of statements 1-3, wherein one or more retaining springs allow the contactor assembly to reset after a low-current fault interruption without the need to replace parts.

[0056] 5. The contactor assembly according to any one of statements 1-4, wherein the second retaining mechanism comprises one or more permanent latches.

[0057] 6. The contactor assembly according to any one of statements 1-5, wherein the stationary contact includes a fusion tip that melts in the presence of a threshold current.

[0058] 7. The contactor assembly according to any one of statements 1-6, wherein the fusion tip is made of a material having a lower melting point than the rest of the stationary contact to ensure selective melting in the presence of a threshold current.

[0059] 8. The contactor assembly according to any one of statements 1-7 further includes an hermetically sealed metal housing having a ceramic eye ring that insulates the stationary contact.

[0060] 9. The contactor assembly according to any one of statements 1-8, wherein the moving contact has an offset height geometry that produces a baffle for arc suppression.

[0061] 10. The contactor assembly according to any one of statements 1-9 further includes an arc chamber having an internal labyrinth geometry for shielding the arc path.

[0062] 11. The contactor assembly according to any one of statements 1-10, wherein the two-stage holding mechanism is self-triggered.

[0063] 12. A method of operating a high-voltage fault-breaking contactor having a permanent disconnection feature, the method comprising: actuating a moving contact to separate the moving contact from a stationary contact; using a first holding mechanism to prevent reignition in response to a first holding force induced by a current in the contactor exceeding a first current threshold; and engaging a second holding mechanism to provide permanent disconnection between the moving contact and the stationary contact in response to a second holding force induced by a current exceeding a second current threshold, the second current threshold being greater than the first current threshold.

[0064] 13. The method according to statement 12 further includes melting the fusion tip on the stationary contact to increase the contact gap between the stationary contact and the moving contact.

[0065] 14. The method according to statement 12 or 13, wherein the fusion tip is made of a material having a lower melting point than the rest of the stationary contact to ensure selective melting in the presence of a threshold current.

[0066] 15. The method according to any one of statements 12-14, wherein the moving contact has an offset height geometry that produces a baffle for arc suppression.

[0067] 16. The method according to any one of statements 12-15, wherein the first retaining mechanism comprises one or more retaining springs.

[0068] 17. The method according to any one of statements 12-16, wherein one or more retaining springs allow the contactor to reset after a low-current fault interruption without the need to replace parts.

[0069] 18. The method according to any one of statements 12-17, wherein the second retaining mechanism comprises one or more permanent latches.

[0070] 19. The method according to any one of statements 12-18, wherein the contactor further comprises an hermetically sealed metal housing having a ceramic eye ring that insulates the stationary contact.

[0071] 20. The method according to any one of statements 12-19, wherein the contactor further includes an arc chamber having an internal labyrinth geometry for shielding the arc path.

[0072] One or more embodiments may be described herein by way of method steps illustrating the execution of specified functions and their relationships. For ease of description, the boundaries and order of these functional construction diagrams and method steps are arbitrarily defined herein. Alternative boundaries and orders may be defined provided that the specified functions and relationships are properly performed. Any such alternative boundaries or orders therefore fall within the scope and spirit of the claims. Furthermore, for ease of description, the boundaries of these functional construction diagrams are arbitrarily defined. Alternative boundaries may be defined provided that certain important functions are properly performed. Similarly, flowchart diagrams may be arbitrarily defined herein to illustrate certain important functions.

[0073] Within the scope of use, the boundaries and sequence of flowchart frames can be defined in other ways, but they still perform certain important functions. Therefore, these alternative definitions of functional building blocks and flowchart frames all fall within the scope and spirit of the claims.

[0074] As can be understood from the foregoing description, modifications and changes can be made to various embodiments of this disclosure without departing from the true spirit of this disclosure. The descriptions in this specification are for illustrative purposes only and should not be construed as limiting. The scope of this disclosure is defined only by the language of the appended claims.

Claims

1. A contactor assembly having a permanent disconnect feature, the contactor assembly comprising: A moving contact, configured to engage and disengage a stationary contact; An actuator assembly for driving the moving contact; as well as A two-stage reignition prevention mechanism is configured to prevent reignition at a first current level and provide permanent disconnection at a second current level.

2. The contactor assembly according to claim 1, wherein, The two-stage reignition prevention mechanism includes a first retaining mechanism and a second retaining mechanism; wherein the first retaining mechanism engages the moving contact above a first current threshold, and the second retaining mechanism engages the moving contact above a second current threshold; and wherein the second current threshold is greater than the first current threshold.

3. The contactor assembly according to claim 2, wherein, The first retaining mechanism includes one or more retaining springs.

4. The contactor assembly according to claim 3, wherein, The one or more retaining springs allow the contactor assembly to reset after a low-current fault interruption without requiring component replacement.

5. The contactor assembly according to claim 2, wherein, The second retaining mechanism includes one or more permanent latches.

6. The contactor assembly of claim 1, wherein, The stationary contact includes a fusion tip that melts in the presence of a threshold current.

7. The contactor assembly of claim 6, wherein, The fusion tip is made of a material having a lower melting point than the rest of the stationary contact to ensure selective melting in the presence of the threshold current.

8. The contactor assembly of claim 1 further includes an hermetically sealed metal housing having a ceramic eye ring that insulates the stationary contact.

9. The contactor assembly of claim 1, wherein, The moving contact has an offset height geometry that generates a baffle for arc suppression.

10. The contactor assembly of claim 1, further comprising an arc chamber having an internal labyrinth geometry that shields the arc path.

11. The contactor assembly of claim 1, wherein, The two-stage reignition prevention mechanism is self-triggered.

12. A method for operating a high-voltage fault-breaking contactor having a permanent disconnection feature, the method comprising: Actuate the moving contact to separate the moving contact from the stationary contact; In response to a first holding force induced by the current of the contactor exceeding a first current threshold, a first holding mechanism is used to prevent reignition. as well as In response to a second holding force induced by the current exceeding a second current threshold, a second holding mechanism is engaged to provide a permanent disconnection between the moving contact and the stationary contact, the second current threshold being greater than the first current threshold.

13. The method of claim 12 further includes melting the fusion tip on the stationary contact to increase the contact gap between the stationary contact and the moving contact.

14. The method according to claim 13, wherein, The fusion tip is made of a material with a lower melting point than the rest of the stationary contact to ensure selective melting in the presence of a threshold current.

15. The method according to claim 12, wherein, The moving contact has an offset height geometry that generates a baffle for arc suppression.

16. The method according to claim 12, wherein, The first retaining mechanism includes one or more retaining springs.

17. The method according to claim 16, wherein, The one or more retaining springs allow the contactor to reset after a low-current fault interruption without requiring component replacement.

18. The method according to claim 12, wherein, The second retaining mechanism includes one or more permanent latches.

19. The method according to claim 12, wherein, The contactor also includes an hermetically sealed metal housing having a ceramic eye ring that insulates the stationary contact.

20. The method according to claim 12, wherein, The contactor also includes an arc chamber with an internal labyrinth geometry that shields the arc path.

Images