Levitation fuse device

Abstract

Disclosed are fuse devices and electrical systems using the fuse devices, the fuse devices having internal components for causing a fuse blow event when a predetermined current level is reached through the contacts. The internal components may include a levitation actuator that causes separation between one or more of the contacts when the current level approaches the predetermined level. This causes contact levitation and arcing, which increases resistance at the separated contacts. This in turn causes current through the contacts to seek another path, which in embodiments herein is a path to a pyroelectric feature. The current activates the pyroelectric feature, which causes the contacts to separate, placing the fuse device in a "blown fuse" condition where current can no longer flow through the contacts.

Description

Technical Field

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 055,172, filed Jul. 22, 2021.

[0002] Devices related to triggering mechanisms and configurations for use by electrical switching devices such as electrical fuse devices are described herein.

Background Art

[0003] Connecting and disconnecting electrical circuits is as old as the electrical circuits themselves and is often used as a way to switch the power to connected electrical devices between an “on” state and an “off” state. An example of one device commonly used to connect and disconnect a circuit is a contactor that is electrically connected to one or more devices or power sources, and the contactor is configured such that the contactor can interrupt or complete the circuit in order to control the power to and from the device. One type of conventional contactor is a hermetically sealed contactor.

[0004] In addition to contactors that serve the purpose of connecting and disconnecting electrical circuits during normal operation of a device, various additional devices can be used to provide overcurrent protection. These devices can prevent short circuits, overloads, and permanent damage to the electrical system or the connected electrical devices. These devices include a disconnecting device that can quickly disconnect the circuit in a permanent manner such that the circuit remains open until the disconnecting device is repaired, replaced, or reset. One such type of disconnecting device is a fuse device. Conventional fuses are a type of low-resistance conductor that serves as a sacrificial device. A typical fuse includes a metal wire or strip that melts when too much current flows through it, interrupting the circuit to which it is connected.

[0005] As society progresses, various innovations in electrical systems and electronic devices are becoming increasingly commonplace. Examples of such innovations include recent advances in electric vehicles, which could one day become the standard for energy efficiency and replace traditional petroleum-powered vehicles. In such expensive and commonly used electrical devices, overcurrent protection is particularly applicable to prevent device malfunction and permanent damage to the device. Furthermore, overcurrent protection can prevent safety hazards such as electrical fires. These modern improvements to electrical systems and devices require modern solutions to increase the simplicity and efficiency of the mechanism for triggering fuse devices. [Overview of the project] [Means for solving the problem]

[0006] The present invention relates to a fuse device and an electrical system using the fuse device, the device having an internal component for causing a fuse blown event when a predetermined current level is reached through the contacts. The internal component may include a levitation actuator that causes separation between one or more of the contacts as the current level approaches the predetermined level. This causes contact levitation and arcing, which increases the resistance at the separated contacts. This, in turn, causes the current through the contacts to seek another path, which in the embodiments herein is a path to a pyro-feature. The current activates the pyro-feature, which causes the contacts to separate, placing the fuse device in a "fuse blown" state where current can no longer flow through the contacts.

[0007] One embodiment of an electrical switching device according to the present invention comprises at least two fixed contacts. A movable contact is configured to operate in a first position in which the movable contact is electrically in contact with the fixed contacts. The movable contact is further configured to operate in a second position in which the movable contact is not electrically in contact with the fixed contacts. A levitation actuator is included on the movable contact or on one of the fixed contacts. The levitation actuator causes separation between the movable contact and at least one of the fixed contacts when the movable contact is in the first position and a threshold current passes through the fixed and movable contacts.

[0008] Another embodiment of the electrical switching device according to the present invention comprises a housing and fixed contacts configured to be electrically coupled to external components of the housing and to conduct electrical signals from the external components to internal components of the housing. A movable contact is included, which is movable from a first position that allows current to flow through the movable contact between the fixed contacts to a second position that does not allow current to flow through the movable contact from the fixed contacts. A levitation actuator is included to cause the movable contact to move from the first position to the second position.

[0009] One embodiment of an electrical system according to the present invention comprises, internally, an electrical circuit and an electrical device electrically connected to the electrical circuit for opening or closing the circuit. The switching device comprises at least two fixed contacts. A movable contact is movable from a first position in which the movable contact electrically contacts the fixed contacts to a second position in which the movable contact does not electrically contact the fixed contacts. A levitation actuator is included on the movable contact or one of the fixed contacts. The levitation actuator causes separation between the movable contact and at least one of the fixed contacts when the movable contact is in the first position and a threshold current passes through the fixed contacts and the movable contact.

[0010] These and other further features and advantages of the present invention will be apparent to those skilled in the art from the following detailed description, along with the accompanying drawings, where similar numbers designate corresponding parts in the figures. [Brief explanation of the drawing]

[0011] [Figure 1] This is a perspective view of one embodiment of a fuse device according to the present invention. [Figure 2] This is an exploded view of one embodiment of the fuse device according to the present invention. [Figure 3] This is a cross-sectional view of one embodiment of the fuse device according to the present invention. [Figure 4] This is a partial cross-sectional view of one embodiment of the fuse device according to the present invention. [Figure 5] This is a partial perspective view of one embodiment of the fuse device according to the present invention. [Figure 6] This is another partial perspective view of one embodiment of a fuse device according to the present invention. [Figure 7] This is a perspective view of another embodiment of the fuse device according to the present invention. [Figure 8] This is a perspective cross-sectional view of another embodiment of the fuse device according to the present invention. [Figure 9] This is another perspective cross-sectional view of another embodiment of the fuse device according to the present invention. [Figure 10] This is a partial perspective view of another embodiment of the fuse device according to the present invention. [Figure 11] This is a partial perspective cross-sectional view of another embodiment of the fuse device according to the present invention. [Figure 12] This is a schematic diagram of one embodiment of the squib activation circuit according to the present invention. [Figure 13] This is a partial perspective view of another embodiment of the contacts in the fuse device according to the present invention. [Figure 14] This is a partial side view of another embodiment of the contacts in the fuse device according to the present invention. [Figure 15]Perspective view of one embodiment of a fuse device according to the present invention. [Figure 16] Front view of the fuse device shown in FIG. 17. [Figure 17] Side view of the fuse device shown in FIG. 15. [Figure 18] Exploded view of the fuse device shown in FIG. 15. [Figure 19] Cross-sectional view of the fuse device shown in FIG. 15 taken along section line 19-19. [Figure 20] Cross-sectional view of the fuse device shown in FIG. 15 taken along section line 20-20. [Figure 21] Perspective view of one embodiment of a floating actuator according to the present invention. [Figure 22] Side view of the floating actuator shown in FIG. 21. [Figure 23] Perspective view of another embodiment of a floating actuator according to the present invention. [Figure 24] Side view of the floating actuator shown in FIG. 23. [Figure 25] Perspective view of another embodiment of a floating actuator according to the present invention. [Figure 26] Partial cross-sectional view of the floating actuator shown in FIG. 25 taken along section line 26-26. [Figure 27] Partial cross-sectional view of the floating actuator shown in FIG. 25 taken along section line 27-27. [Figure 28] Cross-sectional view of yet another floating actuator according to the present invention. [Figure 29] Side view of the floating actuator shown in FIG. 28. [Figure 30] Cross-sectional view of the floating actuator shown in FIG. 28 showing the magnetic field generated during operation. [Figure 31] View showing another embodiment of a fuse device according to the present invention. [Figure 32]This figure shows yet another embodiment of the fuse device according to the present invention. [Modes for carrying out the invention]

[0012] This disclosure will now provide a detailed description of various embodiments. These embodiments describe devices with switching features and disconnection configurations for use with switching devices, such as fuse devices, that integrate pyrotechnic circuit disconnection features. These switching devices may be electrically connected to an electrical device or system and switch power to the connected device or system on or off. Exemplary devices disclosed herein may utilize different passive and / or active triggering configurations in addition to, or instead of, the disclosed switching features. Passive triggering features offer the advantage of automatically triggering pyrotechnic circuit disconnection in response to a threshold current level.

[0013] In some embodiments, the switching device according to the present invention comprises an internal pyrotechnic charge coupled to a pyrotechnic activation or triggering mechanism. The pyrotechnic triggering mechanism may be directly coupled to the high-voltage (fixed) contacts of the switching device using a known electrical coupling mechanism. The pyrotechnic charge is configured to activate or blow a fuse device, permanently disconnecting the circuit by, for example, moving a movable contact to a state where it is not in contact with the fixed contact. This is referred to herein as a “fuse blow event.” This typically occurs when the current passing through the fuse device exceeds a threshold level.

[0014] The fuse device according to the present invention may have features for causing a small or slight separation between a movable contact and a fixed contact at an elevated current level exceeding a threshold level. In some embodiments, these features include a levitation actuator that utilizes the elevated current through the contacts to cause the separation. This separation may consequently cause increased resistance through the contacts, such as causing arcing at the contacts. This causes the electrical signal flowing through the contacts to seek a path of lower resistance. Embodiments of the present invention may have a pyrotechnic device coupled to the contacts through a path of lower resistance. Instead of passing through the contacts, the electrical signal on the contacts passes through the pyrotechnic device, which causes activation that generates a force to separate the contacts. This causes a fuse-blowing event that breaks the conductive path through the contacts.

[0015] The levitation actuator according to the present invention may have many different feature parts configured in many different ways. In some embodiments, the levitation actuator may comprise one or more ferromagnetic components configured on or around movable and / or fixed contacts, such that current at the contacts flows into these ferromagnetic components. In some of these embodiments, one of the components may be fixed to more than one, and one or more may be mounted on the movable contact. When the current through the contacts reaches a threshold level, the current from the contacts passing through the ferromagnetic feature part generates a magnetic field that produces an attractive force between the two. This attractive force can overcome the closing force that holds the movable contact relative to the fixed contact, causing separation of the movable contact from at least one of the fixed contacts. This results in increased resistance as described above, and activation of the pyrotechnic device.

[0016] This ferromagnetic attraction allows the fuse device according to the present invention to be designed to automatically trip or blow at a desired threshold current level. This current level can be varied and adjusted based on several factors, such as the size of the ferromagnetic feature and the holding force of the movable contact relative to the fixed contact.

[0017] Fuses, and their internal contacts, may also experience rotational forces on their internal contacts that can affect their operation. While the inventors do not wish to limit themselves to any single theory of operation, it is understood that these rotational forces may be at least partially generated by a Lorentz force that can induce currents to move through the fuse's persistent magnetic field. In this regard, the rotational forces may cause slight rotation of the contacts within the fuse, resulting in portions of the contacts sticking to or rubbing against the support structure. In some fuses made from certain materials (AgSnO on Ag), the contacts may also experience frictional sticking. Both of these can result in the fuse having unpredictable levitation currents. Embodiments of the present invention, as described in more detail below, may also feature elements to minimize or prevent this contact rotation, thereby resulting in a device with more predictable levitation characteristics.

[0018] Throughout this description, preferred embodiments and examples described should be considered as examples rather than limitations of the invention. As used herein, the terms “invention,” “device,” “invention,” or “this device” refer to any one of the embodiments of the invention and any equivalent described herein. Furthermore, references to various features of “invention,” “device,” “invention,” or “this device” throughout this document do not imply that all claimed embodiments or methods must include the features referred to.

[0019] When an element or feature is described as being "on top of" or "in close proximity to" another element or feature, it is understood that the element or feature may be directly on top of or in close proximity to that other element or feature, or that there may be an intervening element or feature. When an element is described as being "attached," "connected," or "joined" to another element, it is understood that the element may be directly attached, connected, or joined to that other element, or that there may be an intervening element. In contrast, when an element is described as being "directly attached," "directly connected," or "directly joined" to another element, there is no intervening element.

[0020] Terms expressing relationships, such as “outward,” “upward,” “downward,” “below,” “horizontal,” “vertical,” and similar terms, may be used herein to describe the relationship of one feature to another. It is understood that these terms are intended to encompass different orientations in addition to the orientation depicted in the figures.

[0021] The terms, first, second, and others may be used herein to describe various elements or components, but these elements or components should not be limited by these terms. These terms are simply used to distinguish one element or component from another. Thus, the first element or component discussed below may be referred to as the second element or component without departing from the teachings of the present invention.

[0022] The technical terms used herein are for the sole purpose of describing individual embodiments and are not intended to be limiting to the present invention. Where used herein, the singular forms “a,” “an,” and “the” are intended to also include the plural form unless otherwise explicitly indicated in the context. It will be further understood that, where used herein, the terms “equipped with” and “equipped with” specify the presence of a described feature, integer, step, operation, element, and / or component, but do not exclude the presence or addition of one or more other feature, integer, step, operation, element, component, and / or groups thereof.

[0023] Embodiments of the present invention are described herein with reference to schematic and illustrative drawings, which are schematic illustrations of idealized embodiments of the present invention. Therefore, variations from the shapes shown in the illustrative drawings are to be expected, for example, as a result of manufacturing techniques and / or tolerances. Embodiments of the present invention should not be construed as being limited to the individual shapes of the regions illustrated herein, but rather to include deviations in shape resulting from, for example, manufacturing.

[0024] Figure 1-5 shows one embodiment of the fuse device 10 according to the present invention, with the internal components best shown in Figure 2-5. The envelope containing the internal components of the fuse device generally includes a cover 12 and a housing 14. The housing 14 may provide mounting features that can be specified for individual customer installations, including most of the components. The cover 12 may provide a barrier to protect the fuse device features below the cover 12 and to provide mechanical strength to help the fuse device 10 withstand pyrofuse events (i.e., fuse blow events). The fuse device includes fixed contacts 18, which are configured so that various internal components of the fuse device 10 can be electrically connected to an external electrical system or device through their fixed contacts. This allows the fuse device 10 to complete an electrical circuit or to break an electrical circuit, as described herein.

[0025] The fixed contacts are electrically isolated from each other and do not interact with any other components inside the housing 14, so that electricity cannot flow freely between them. The fixed contacts 18 may include any suitable conductive material for providing an electrical connection to the internal components of the fuse device, e.g., various metals and metallic materials, or any electrical contact material or structure known in the art. Each of the fixed contacts 18 may include a single continuous contact structure (as shown) or may include a plurality of electrically connected structures. For example, in some embodiments, the fixed contacts 18 may include two parts. The first part extends from the cover 12 and is electrically connected to a second part inside the fuse device 10, which is configured to interact with other components inside the housing, as described herein.

[0026] In the embodiment shown, the fixed contacts are accessible through the cover 12. The cover 12 may also include vertical walls 16 to provide an external barrier between the contacts 18 to help maintain insulation between the contacts 18 during operation and during fuse blow events.

[0027] The fuse device 10 also includes a cap assembly 20 that can be fitted onto the cup 22 to form a fuse device body which may have any shape, including any regular or irregular polygons, suitable for holding various internal components of the fuse device. In some embodiments, a hermetic seal may be present between the cap assembly 20 and the cup 22. The hermetic seal may be maintained by including an adhesive such as epoxy between the two or by welding the two together. The fixed contact 18 protrudes through the cap assembly 20 and proceeds from the internal chamber of the fuse device formed by the cup 22 and the cap assembly 20, so that the fixed contact can be accessed for use. The cap assembly 20 forms an airtight or hermetic seal around the contact 18. The cap assembly 20 may be made from many different materials such as plastic, and the cup 22 may be made from a material such as plastic or metal.

[0028] In some embodiments, the cap assembly 20 and cup 22 may be at least partially filled with an electronegative gas, such as sulfur hexafluoride, or a mixture of nitrogen and sulfur hexafluoride. In some embodiments, the cap assembly and cup may contain a material that has low permeability to the gas injected into the housing, or is substantially permeable. In yet other embodiments, the cap assembly and cup may contain various gases, liquids, or solids configured to enhance the performance of the device. In different embodiments, the fuse device body may be a continuous structure or may consist of more, such as two component parts joined together. Some exemplary body configurations include those described in U.S. Patents 7,321,281, 7,944,333, 8,446,240, and 9,013,254, all of which are assigned to Gigavac, Inc., the assignee of this application, and all of which are incorporated herein by reference in their entirety.

[0029] In the embodiment shown, the cap assembly 20 seals against the top of the cup 22 to hold the internal components of the fuse device and to form an arc chamber as described below. The lower side of the cap assembly also includes a dielectric maze 24 (or labyrinth), as best shown in Figure 3. The maze 24 provides a series of fluctuating surfaces and channels that help maintain the insulation and dielectric strength between the fixed contacts 18. Contact arcing and material discharge during operation can create contact deposits on the inner surface of the fuse device 10. The accumulation of these materials can result in the formation of electrical paths on the inner surface of the cap assembly 20, which can consequently create short-circuit paths between the fixed contacts 18. The fluctuating surfaces of the maze 24 can prevent the accumulation of these deposits in a way that would allow the formation of electrical paths, thereby helping to maintain the dielectric withstand voltage required between the fixed contacts after a fuse-opening event. The cap assembly 20 and cup 22 also provide mechanical strength to resist the arc pressure generated during an arcing event, which helps prevent the device 10 from flying off during the arcing event.

[0030] The fuse device 10 also includes a movable contact 26 that is mounted on the guide portion 28 by a spring support portion 30 and a leaf spring 32. During normal operation, the movable contact 26 is held in contact with the fixed contacts 18 to form an electrical path between the fixed contacts 18 that passes through the movable contact 26. During a fuse blow event, the movable contact 26 is moved to a state where it is not in contact with the fixed contacts 18, thereby breaking the electrical path between the fixed contacts 18 that normally passes through the movable contact 26.

[0031] The spring support 30 holds the leaf spring 32 in a desired position such that the leaf spring 26 presses against the movable contact 26 to hold the movable contact 26 in contact with the fixed contact 18. The leaf spring is flexible as a retaining force is applied to press against the movable contact 26, such that the retaining force holds the movable contact 26 against the fixed contact 18 for low and stable contact resistance during normal operation. Many different retaining forces can be applied, and some embodiments have a retaining force of approximately 3 pounds overall, i.e., 1.5 pounds for each of the fixed contacts.

[0032] The leaf spring 32 may be mechanically connected to the movable contact 26 to prevent rotation of the movable contact 26 due to the Lorentz-induced rotational force as described above. This can eliminate or reduce frictional locking with respect to the movable contact, which can vary the levitation triggering level (fuse-blowing event). In some embodiments of the present invention, it is noted that the leaf spring 32 is simply required to stop the rotation of the movable contact 26 and maintain contact force with the fixed contact 18. In these embodiments, complete attachment of the leaf spring 26 to the movable contact 26 may not be required. The spring support 30 and the leaf spring 32 should be made from a robust material such as metal or plastic, some of which include metal, allowing for reliable operation in over-temperature ranges that would cause less robust materials (such as plastic) to fail.

[0033] The guide section 28 holds the spring support section 30, the leaf spring 32, and the movable contact 26 assembly, and may also include a capture section 34 that traps the movable contact 26 in a lower position following a fuse blow event. This prevents the movable contact 26 from bouncing back in a closed state following a fuse blow event, or from floating within the fuse device 10, which could cause potential dielectric problems. The guide section 28 also covers the lower part of the fuse arc chamber, as described below.

[0034] The fuse device 10 also comprises an internal envelope 36 and a magnet 38. The internal envelope 36 holds the magnet 38 at a desired location, and the movable contact 26, spring support 30, leaf spring 32, and pyro plunger 40 are held within the envelope. The inner surface of the envelope 36 also includes a primary arc chamber and may include a labyrinth to prevent the formation of conductive paths by deposits that could consequently cause failure after a fuse blow event. The magnet 38 is configured to create a high-density magnetic flux across the contacts during an opening (or blow) event to reduce or eliminate high-power electrical arcing. The magnet may be configured to eliminate different levels of arcing, with some embodiments eliminating approximately 10 MW of arcing.

[0035] The fuse device 10 further includes a squib and a printed circuit board (PCB) assembly 42, which is mounted on a cap assembly 20 and configured to operate on a pyro-plunger 40 during a fuse blow event. The squib serves as a pyro-device and can be configured in many different ways; different squibs with rounded corners may be used. In some embodiments, different types of conventional automotive airbag initiators may be used. The squib provides the explosive energy in a fuse blow event, causing the plunger 40 to move downward and separate the movable contact 26 from the fixed contact 18 against the retaining force of the leaf spring 32. As the plunger 40 moves the movable contact 26 downward, the leaf spring 32 bends until it disengages from the spring support 30. The movable contact 26 is then pushed further down by the plunger until it is held in the capture portion 34 on the guide portion 28. This keeps the fuse device 10 in the open (open) state.

[0036] The fuse device 10 further comprises a levitation actuator 44, which is configured to actuate a squib / PCB assembly 42 at a desired threshold current level through the contacts, thereby blowing the fuse device 10. The levitation actuator 44 includes a lower fixed bar 46 and an inverted U-shaped bar 48 mounted on the movable contact 26 above the fixed bar 46. The fixed bar 46 can be mounted in many different locations and in many different ways, and the embodiment shown has a fixed bar 46 mounted on the envelope 36 just below the movable contact 26 (best shown in Figure 3). A space / gap 50 is provided between the fixed bar 46 and the lowest surfaces of the movable contact 26 and the U-shaped bar 48 to allow the movable contact 28 to move toward the fixed bar 46.

[0037] The stationary and U-shaped bars 46, 48 may be made of a ferromagnetic material that amplifies and focuses the magnetic field generated by the current flow through the movable contact 26. The fuse device 10 may be configured to trip or break at a specific current level passing through the contact. When this current level is reached, the U-shaped bar 48 generates a tensile force toward the stationary bar 46. This closes the space 50, which simultaneously isolates the side of the movable contact 26, with the levitation actuator 44, from one of the fixed contacts 18 on that side. This creates increased resistance (such as by arcing) in this isolation between the movable contact 26 and one of the fixed contacts 18. This increased resistance causes the current in the fixed contact 18 to seek a path of lower resistance. In the fuse device 10, this path of lower resistance passes through the connection, squib conductor 52 (best shown in Figure 5). The current then acts on the squib assembly 42, causing the plunger 40 to move the movable contact 26 so that it is not in contact with the fixed contact 18 and is held in the capture portion 34. This keeps the movable contact 26 and the fuse device 10 in the open or closed position.

[0038] In the embodiments described above, the fuse device is tripped by an internal feature configuration that automatically signals the squib to activate when a predetermined (trip) current level is reached through the contacts. This automatic tripping occurs without the need for an external signal and is referred to as "passive" activation. However, it is understood that the fuse device according to the present invention can also be activated by many other internal passive signals and by external "active" signals.

[0039] Next, referring to Figure 6 in conjunction with Figure 7, a configuration is shown that enables passive internal activation as described above, along with active external activation. Figure 6 shows a fuse device 100 with fixed contacts 102 and a squib / PCB assembly 104 mounted on a cap assembly 106. In this embodiment, a first squib conductor 108 is shown that carries the activation signal from the internal components of the fuse device 100 as described above.

[0040] The squib / PCB assembly 104 also includes a low-voltage power control wire 110 used to connect to an external source for the active activation of the squib. This activation can be controlled by any one or more different external features or systems, which may be customized for individual fuse device applications. The squib / PCB assembly 104 also includes a coil 112 and a reed switch 113. The coil 112 generates a magnetic field that can close the reed switch 113, causing the squib to be activated by a current flowing between the contacts or terminals 102.

[0041] This embodiment of the present invention may comprise many different electronic elements configured in many different ways to provide an active activation signal. Figure 7 shows one embodiment of a circuit 120 configured to provide an active activation signal to a fuse device according to the present invention. The activation signal applied to the coil 126 is supplied from a low-voltage power supply 124. The coil 126 generates a magnetic field that causes the reed switch 128 to close. This results in a low-resistance path for the signal applied to the fixed contact 130, which in turn causes the squib 132 to activate. It should be understood that this circuit is merely one of many active signal activation circuits that may be used by the present invention, and that these circuits may be used in conjunction with the passive activation configurations described herein.

[0042] Figure 8-12 shows another embodiment of the fuse device 150 according to the present invention, which can also be activated by an internal passive signal or an external active signal. The fuse device 150 comprises first and second squibs 152, 154 mounted on PCB 156. The first squib 152 is configured to be activated based on the reception of an external active signal, and the second squib 154 is configured to be activated from an internal passive signal as described above. The fuse device is configured similarly to the fuse device 10 described above. However, in this embodiment, an active trigger connection pin 158 is included for connection to an external device that provides an active activation signal. The external device may provide different types of activation signals in different embodiments, and the embodiment shown is configured for activation by a low-voltage signal.

[0043] The fuse device 150 also comprises a squib funnel 160 and a plunger 162 formed in the lower opening, the squib funnel 160 having first and second squibs 152, 154 formed in the larger upper opening of the funnel 160. The force from the activation of either the first squib 152 or the second squib 154 is directed by the funnel 160 toward the plunger 162. This results in the plunger being moved downward, pushing the movable contact toward a state where it is not in contact with the fixed contact, as described above.

[0044] As described above, the fuse device according to the present invention may have a leaf spring and spring support for preventing contact rotation under Lorentz force. Other embodiments may have other features to reduce or eliminate this problem. Figures 13 and 14 show another embodiment of a fixed contact 200 and a movable contact 202 for reducing or eliminating this rotation. In the shown embodiment, the contact area between the fixed contact 200 and the movable contact 202 has opposing V-shaped notches 204 that form a square-shaped space 206. A pin or roller 208 is held to resist lateral movement of the fixed and movable contacts in relation to each other. The roller 208 may include many different materials, and some embodiments include a non-conductive material.

[0045] It is understood that embodiments of the fuse device according to the present invention may have many other features to provide reliable operation under different operating conditions. Referring again to Figures 2, 3, and 5, the fixed contact 18 and the movable contact 26 may be made from many conductive materials, or combinations of conductive materials, such as metals. In some embodiments, the contacts may be made from copper (Au) as a whole or primarily as copper. In some embodiments, the surfaces on which the fixed contact 18 contacts the surface of the movable contact 26 may experience small point melting or micro-welding at currents below the desired trip (or fuse blow) current. This can result in adhesion between the surfaces, which may consequently create a need for a greater force to separate them. This may consequently create an unpredictable (or higher) trip current to separate the contacts.

[0046] To mitigate or eliminate this problem, the surfaces that the fixed contact 18 and movable contact 26 make contact may contain or be coated with a material that resists melting and micro-welding between the contacts. This material may be silver tin oxide (AgSnO) or silver carbide (AgC or Ag2C). s Many different materials, including but not limited to silver alloys such as ), can be used on the opposing surfaces of the fixed contact 18 and the movable contact 26. The addition of this material may reduce or eliminate sticking between the contacts. It is understood that the same or different materials may be included on the opposing surfaces.

[0047] The use of this material at contacts may offer the additional advantage of enabling the use of contacts in open (or non-hermetic) configurations where there is a risk of oxidation at the contacts. This material may reduce or eliminate oxidation formation on the contact surfaces.

[0048] Figure 15-20 shows another embodiment of the fuse device 300 according to the present invention, having many features similar to those of the fuse device 10 shown in Figure 1-5 and described above. As described above, the envelope containing the internal components of the fuse device 300 generally comprises a cover 302 and a housing 304. The housing 304 contains most of the internal components and may provide mounting features that specify the installation. The cover 302 may provide a barrier to protect the lower fuse device features and components, as well as to provide mechanical strength.

[0049] The fuse device comprises fixed contacts 308 configured such that various internal components of the fuse device 300 can be electrically connected to an external electrical system or device. This allows the fuse device 300 to function to either disconnect or complete an electrical circuit, as described herein.

[0050] The fixed contacts 308 are electrically isolated from each other when they are not interacting with any other components inside the housing 304. The fixed contacts 308 may include the materials described above and may include a single or multi-part structure as described above. The fixed contacts 308 extend from the cover 302 and are available for connection to an electrical system. The lower portion of the contacts 308 passes through the cover 302 to interact with the internal components of the housing. The cover 12 may also include vertical walls 306 that act as external barriers between the contacts 308 to help maintain insulation between the contacts 308 during operation and during interruption events.

[0051] The fuse device 300 also includes a cap assembly 310 that can be fitted onto the cup 312 to form a fuse device body which may have any shape. In some embodiments, a hermetic seal may exist between the cap assembly 310 and the cup 312 using the method described above. The fixed contacts 308 protrude through the cap assembly 310 and advance from the internal chamber of the fuse device formed by the cup 312 and the cap assembly 310, so that their fixed contacts can be accessed for use. The cap assembly 310 forms an airtight or hermetic seal around the contacts 308, and the cap assembly 310 may be made from one of the many different materials described above. The cap assembly 310 and the cup 312 may also be at least partially filled with an electronegative gas and other materials, also described above.

[0052] In the embodiment shown, the cap assembly 310 seals against the top of the cup 312 to hold the internal components of the fuse device and to form an arc. The lower side of the cap assembly 310 also includes a dielectric labyrinth 314, as best shown in Figure 20. The labyrinth 314 provides a series of varying surfaces and channels that help maintain the insulation and dielectric strength between the fixed contacts 308. The cap assembly 310 and the cup 312 also add mechanical strength to resist the arc pressure that occurs during an arcing event.

[0053] The fuse device 300 also comprises a movable contact 316 mounted on a guide 318 by a spring support 320 and a leaf spring 322, configured to operate in the same or similar manner as described above. The leaf spring 322 may be mechanically connected to the movable contact 316 to prevent rotation of the movable contact 316 due to the Lorentz induced rotational force as described above. The spring support 320 and the leaf spring 322 should be made of a robust material such as metal to enable reliable operation in the over-temperature range. The guide 318 may include a capture bar, as described below, which holds the spring support 320, the leaf spring 322, and the movable contact 316, and also traps the movable contact 316 in a lower position following a fuse blow event.

[0054] The fuse device 300 also comprises an internal envelope 326 and an arc magnet 328, the internal envelope 326 holding the magnet 338 at a desired location. A movable contact 316, a spring support 320, a leaf spring 322, and a pyro-plunger 330 are also held within the envelope 326. As described above, the inner surface of the envelope 326 also comprises a primary arc chamber and may also comprise a labyrinth to prevent the formation of conductive paths by deposits that could consequently cause failure after a fuse blow event.

[0055] The fuse device 300 further comprises a squib and printed circuit board (PCB) assembly 332, which is mounted on a cap assembly 310 and configured to operate on a pyro plunger 330 during a fuse blow event. First and second squibs 334, 336 are mounted on the PCB 338. As described above, the first squib 334 may be configured to be activated based on the reception of an external active signal, and the second squib 336 may be configured to be activated from an internal passive signal, as described above. An active trigger connection pin 340 is included for connection to an external device that provides an active activation signal. In different embodiments, the external device may provide different types of activation signals, and in some embodiments, it is configured for activation by a low-voltage signal.

[0056] It is noted that the plunger 330 can be configured in many different ways and with different features to provide consistent and reliable operation. In some embodiments, one or more sealing rings 331 may be included on the plunger 330 between the plunger 330 and its plunger opening 333. This provides a good seal between the two, and the rings 331 compensate for manufacturing variations. The result is that the plunger opens under consistent and predictable force. The rings 331 can be made from many materials and can be located in many places, and at least one of the rings is made from silicone and is located on the top of the plunger 330.

[0057] It is noted that the fuse device 300 may be configured to operate with two squibs or with a single squib. In a single squib configuration, the plug may be included in an unused squib opening. For example, in a configuration where only passive activation is desired, only the second squib 336 may be included, and the plug may be fitted in the opening of the first squib. In a configuration where only external active signal activation is desired, the first squib 334 may be included, and the plug may be fitted in the opening of the second squib. This provides flexibility in the use of the fuse device 300.

[0058] The active trigger connection pin 340 can be accessed through a cover 302 with a standard squib connector. The cover also includes a test access window 341, allowing direct electrical access to the first and second squibs 334, 336 for final testing during manufacturing. In other embodiments, it is understood that the first and second squibs may also be accessed for other purposes, such as troubleshooting.

[0059] The fuse device 300 further comprises a levitation actuator 344 (shown in Figure 20), configured similarly to the levitation actuator 44 described above with reference to Figure 1-5. The levitation actuator 344 operates to cause a second squib 336 on the squib and the PCB assembly 332 to blow the fuse device 300 with a desired current passing through the contacts, as described above. The levitation actuator comprises a lower stationary bar 346 and an inverted U-shaped bar 348, which is mounted on the movable contact 316 above the stationary bar 346 with a space between the two.

[0060] The stationary and U-shaped bars 346, 348 may be made of a ferromagnetic material that amplifies and focuses the magnetic field caused by the current flow through the movable contact 316. When this current level is reached, the U-shaped bar 348 generates a tensile force toward the stationary bar 346. This causes separation of the movable contact 316 and one of the fixed contacts 308. This creates increased resistance between the fixed and movable contacts, which in turn causes the current to proceed to the second squib 336 and activate the second squib 336, causing the plunger 330 to move the movable contact 336 to an open or disconnected position, such that it is not in contact with the fixed contact 308.

[0061] The fuse device 300 also further comprises a slanted section 350 and a capture bar 352, which are mounted on the guide section 318. The slanted section 350 works with a stationary bar 346 (and a U-shaped bar in some embodiments) to move the stationary bar to the side during a fuse blow event, resulting in an increased gap between the fixed contact 308 and the movable contact 336. As the movable contact 336 moves downward towards the guide section 318 and the slanted section 350 during a fuse blow event, the stationary bar 346 rests on the curved surface 354 of the slanted section 350 and moves in the direction of that curved surface 354. This moves the stationary bar 346 toward the vertical leg of the movable contact 336 and away from the lower surface of the movable contact 336. In this position, the fixed bar 346 does not prevent the movable contact 336 from moving the maximum distance to the guide 318, resulting in maximum separation between the fixed contact 308 and the movable contact 336. The capture bar 352 can capture its fixed bar 346 in the guide 318 in order to hold the movable contact 336 in the guide 318 following a fuse blow event.

[0062] The fuse device 300 further comprises a gas diverter cap 356 fitted to the cover 302 above the gas pressure tube 358. During a fuse blow event, excess gas may build up inside the fuse device 300. The gas pressure tube 358 provides a path from inside the fuse device 300 to below the gas diverter cap 356. This provides a path for the gas from inside the fuse device to diffuse below the cap 356, reducing the possibility that the fuse device 300 may blow apart during a fuse blow event.

[0063] It is understood that the levitation actuator according to the present invention can be configured in many different ways and with different features. Figures 21 and 22 show another embodiment of the levitation actuator 400 according to the present invention, which may comprise a lower stationary bar 402 and an inverted U-shaped bar 404 mounted on a movable contact 406 above the stationary bar 402. A space / gap 407 is left between the lower bar 402 and the U-shaped bar 404, and space is also between the lower surface of the movable contact 406 and the lower bar 402.

[0064] In this embodiment, a mounting bracket (or retainer) 408 is included, which is fixed at its upper end to a fixed contact 410 and at its lower end to a fixed bar 402. This results in the fixed bar 402 being mounted to the fixed contact 410 by the bracket (backet) 408. Many different mechanisms can be used to secure the bracket in place, and the embodiment shown uses a tab 412 which can be attached to the surface at the bottom using known mounting methods.

[0065] Bracket 408 also includes a guide portion 414 around the U-shaped bar 404, which guides the movement of the U-shaped bar 404 rather than fixing it to the U-shaped bar 404. When the current rises, the magnetic force generated in the stationary bar 402 and the U-shaped bar 404 pulls the U-shaped bar 404 toward the stationary bar 402. The U-shaped bar 404 moves along the guide portion 414 to close the gap 407, which causes the movable contact 406 to move toward the stationary bar 402, separating the movable contact 406 from the fixed contact 410. This, in turn, causes an electrical signal to be sent to the squib to cause a fuse blow event. The force generated during this fuse blow event may cause the bracket 408 to separate from the stationary bar 402 or the fixed contact, or may cause the bracket 408 to break. When this occurs, the movable contact 406 can move freely in response to the fuse trip position while not in contact with the fixed contact 410.

[0066] Figures 23 and 24 show another embodiment of the levitation actuator 450 according to the present invention. In this embodiment, a U-shaped bar 452 is mounted on the movable contact 454 and the fixed contact 458, the U-shaped bar 452 being constructed in the same manner as described above and made from the same material. An L-shaped pry bar 456 is included, extending from the gap between the movable contact 454 and the fixed contact 458 and below the lower surface of the movable contact 454. A gap 460 is included between the lower surface of the movable contact 454 and the lower portion of the pry bar 452. The pry bar 456 further comprises a pry bar tip 462, which is formed in the gap between the fixed contact 458 and the movable contact 454.

[0067] The pry bar 456 includes at least a movable iron portion 461 below the U-shaped bar 452, which is made from one of the materials described above that generates a magnetic field in the presence of current passing through contacts 454, 458. The U-shaped bar 452 is also made from a material that similarly generates a magnetic field. This magnetic field attracts the movable iron portion 460 toward the U-shaped bar 452, and in the presence of a desired increased current passing through contacts 454, 458, the movement of portion 460 toward the U-shaped bar 452 causes the gap 460 to close. The closing of the gap, in turn, causes a "pry bar" motion at the tip of the pry bar 462 that results in the separation of the movable contact 454 from the fixed contact 458. This results in increased resistance between the movable contact 454 and the fixed contact, and an electrical signal is sent to the squib to cause a fuse blow event.

[0068] Figures 25-27 show another embodiment of the levitation actuator 500 according to the present invention, wherein the movable contact 504 comprises two opposing movable yokes 502a, 502b mounted on one of the vertical legs of the movable contact. Each of the movable yokes has opposing tabs 506 (shown in Figures 26 and 27), each positioned in one of the movable contact grooves 508 on the upper surface of the movable contact. This results in the tabs being located on the surface between the movable contact 504 and one of the fixed contacts 510.

[0069] The yokes 502a and 502b can be made from the materials discussed above, and as current passes through contacts 504 and 510, magnetic fields are generated by the yokes 502a and 502b. These magnetic fields attract the yokes 502a and 502b toward each other and rotate slightly around the ledge 512, so as to close the gap 514. This rotation causes the tabs 506 to rotate in their respective grooves 508 to generate an isolation force between the movable contact 504 and the fixed contact 510. With increased current, this isolation force is sufficient to separate the movable contact 504 from the fixed contact 510. This, in turn, leads to the activation of the squib, causing a fuse blow event.

[0070] Figure 28-30 shows another embodiment of the levitation actuator 550 according to the present invention, comprising a trigger 552, the trigger 552 being primarily mounted on the vertical leg (or portion) of the movable contact 554, with a portion covering the surface of the horizontal portion of the movable contact 554 near the transition to the vertical leg. The trigger 552 may be made from the materials discussed above and generates a magnetic field B parallel to the current flow in the movable contact. This, in turn, generates a Lorentz force L (i.e., an electromagnetic trigger field) that produces an opening Lorentz force. In the rising current through the movable contact 554 and the fixed contact 556, this Lorentz force may be sufficient to cause separation between the movable contact 554 and the fixed contact 556, thereby causing a fuse blow event.

[0071] The levitation actuator 550 provides a simple method without moving parts. The levitation actuator 550 offers a further advantage in that the trigger configuration in this embodiment creates the same Lorentz field by currents flowing through contacts in different directions. This provides flexibility in using this levitation actuator in fuse devices where currents may flow through contacts in both directions.

[0072] It has been noted that the energy released in high-energy fuse blow events (e.g., 10 MW) can damage the fuse package. Even with good contact clearance and strong arc magnetic blowout strength, a weak package may not interrupt more than 10 MW of interruption. This is a problem when fuse package size is reduced. A common failure in these fuse devices may occur along the edge of the cup at the interface with the cap assembly.

[0073] Different embodiments of the present invention may also include different features for improving the strength of the fuse device against damage related to fuse blow events. It is understood that these features may be applied to each of the embodiments described above.

[0074] Figure 31 shows one embodiment of a fuse device 600 according to the present invention, having a cap assembly 602, a squib 604, and a cup 606. In this embodiment, a strap 608 may be included, fitted over the top of the cup 606. The strap 608 may be included in many different locations, and the shown strap may extend across the center of the cup and have a squib opening 607 to allow access to the squib 604. The strap 608 may be made from many different heavy materials, such as different metals or plastics, and may be fitted to the cup using known fitting methods and materials.

[0075] Figure 32 shows another embodiment of the fuse device 650 according to the present invention, having a cap assembly 652, a squib 654, and a cup 656. The cap assembly 652 is provided with a reinforcing lip 658 that extends over the upper edge of the cup 656 and down the upper portion of the outer surface of the cup 656. This reinforcing lip not only provides and improves the seal between the cap assembly 652 and the cup 656, but also reduces the outward bending of the upper cup during a fuse blow event.

[0076] It is understood that other features may be included to improve the strength of the fuse package, such as an increased potting thickness around the top of cup 656. This is simply one additional feature that may be included to add strength, and the present invention should not be limited to these individual embodiments.

[0077] Although the present invention has been described in detail with reference to certain preferred configurations of the invention, other versions are possible. Embodiments of the invention may include any combination of coexisting features shown in various figures, and these embodiments should not be limited to those expressly illustrated and discussed. Therefore, the spirit and scope of the invention should not be limited to the versions described above.

[0078] The foregoing is intended to encompass all modifications and alternative constructs that fall within the spirit and scope of the present invention, and no part of this disclosure is intended to be made publicly available, expressly or implicitly, unless otherwise described in any claim.

Claims

1. An electrical switching device, At least two fixed contacts, A movable contact configured to operate in a first position and a second position, wherein the movable contact is electrically in contact with at least two fixed contacts in the first position and is spaced apart from at least two fixed contacts in the second position. A levitation actuator mounted on the movable contact or on one of the at least two fixed contacts, for causing separation between the movable contact and at least one of the at least two fixed contacts when the movable contact is in a first position and a threshold current passes through at least two fixed contacts and the movable contact, A capturing part for holding the movable contact in the second position, When activated based on separation, a pyrotechnic device is used to move the movable contact from a first position to a second position. Equipped with, An electrical switching device in which a movable contact has a vertical portion, and a levitation actuator has opposing yokes mounted on the vertical portion.

2. The electrical switching device according to claim 1, wherein a threshold current passing through at least two fixed contacts and movable contacts is used to activate a pyrotechnic device.

3. The electric switching device according to claim 1, wherein the levitation actuator is at least partially made from a ferromagnetic material.

4. The electric switching device according to claim 1, wherein the levitation actuator further comprises a first bar below the movable contact and a second bar attached to the movable contact.

5. The electrical switching device according to claim 4, wherein the second bar is U-shaped.

6. The electric switching device according to claim 4, wherein the levitation actuator is mounted on at least two fixed contacts and further includes a guide for guiding the movement of a second bar.

7. The electric switching device according to claim 1, wherein the levitation actuator comprises an L-shaped pry bar.

8. The electric switching device according to claim 1, wherein the levitation actuator further comprises a trigger mounted on a vertical portion.

9. An electrical switching device, Housing and Fixed contacts configured to be electrically coupled to an external component on the outside of the housing, and to conduct electrical signals from the external component to an internal component of the housing, A movable contact within a housing, wherein the movable contact is movable from a first position to a second position, the first position allows current to flow between the fixed contact and the movable contact, and the second position prevents current from flowing between the fixed contact and the movable contact. A levitation actuator for causing movement of a movable contact from a first position that creates separation between a movable contact and one of a fixed contact, wherein the levitation actuator comprises a first bar below the movable contact and a second bar attached to the movable contact, A capturing part for holding the movable contact in the second position, When activated based on separation, a pyrotechnic device is used to move the movable contact from a first position to a second position. Equipped with, An electrical switching device in which a movable contact has a vertical portion, and a levitation actuator has opposing yokes mounted on the vertical portion.

10. The electric switching device according to claim 9, wherein the levitation actuator is mounted on a movable contact or on one of the fixed contacts.

11. The electrical switching device according to claim 9, wherein the movable contact is in contact with a fixed contact in a first position, and when the movable contact is in the first position and a threshold current passes through the fixed contact and the movable contact, the levitation actuator causes separation between the movable contact and one of the fixed contacts.

12. The electrical switching device according to claim 11, wherein a threshold current passing through a fixed contact and a movable contact is used to activate a pyrotechnic device.

13. The electric switching device according to claim 9, wherein the levitation actuator is at least partially made from a ferromagnetic material.

14. It is an electrical system, Electrical circuits and, An electrical switching device that is electrically connected to an electrical circuit for opening or closing the electrical circuit, At least two fixed contacts, A movable contact configured to operate in a first position and a second position, wherein the movable contact is electrically in contact with at least two fixed contacts in the first position and is spaced apart from at least two fixed contacts in the second position. A levitation actuator mounted on the movable contact or on one of the at least two fixed contacts, for causing separation between the movable contact and at least one of the at least two fixed contacts when the movable contact is in a first position and a threshold current passes through at least two fixed contacts and the movable contact, A capturing part for holding the movable contact in the second position, An electrical switching device comprising a pyrotechnic device for moving a movable contact from a first position to a second position when activated based on separation. Equipped with, An electrical system in which a movable contact has a vertical portion, and a levitation actuator has opposing yokes mounted on the vertical portion.

15. The electric switching device according to claim 10, wherein the levitation actuator comprises one of an L-shaped pry bar, opposing yokes, or a trigger.

16. The electrical system according to claim 14, wherein the levitation actuator is at least partially made from a ferromagnetic material.

17. The electrical system according to claim 14, wherein the levitation actuator further comprises a first bar below a movable contact and a second bar mounted on the movable contact.

18. The electrical system according to claim 14, wherein a threshold current passing through at least two fixed and movable contacts causes isolation for activating a pyrotechnic device.

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