Bidirectional AC Solid-State Switch with Common Drain Conductor
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Solution Overview
Problem
Existing high voltage, high current electromechanical relays are bulky, have slow switching speeds, and produce noise due to contact welding and bounce, necessitating a lightweight, fast, and reliable solid-state switch capable of bidirectional control with low voltage drops.
Innovation Solution
The AC electronic solid-state switch employs a base plate with an insulating and thermally conductive layer, semiconductor dies forming MOSFETs or IGBTs, and a common drain/source conductor configuration, allowing bidirectional blocking of 650-1700 volts and continuous 500 A current with a voltage drop of less than 2V, while minimizing size and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electromechanical relays are used for high voltage and high current switching, then the switching capability is achieved, but the device becomes bulky with mass greater than 0.5 kg
Solution Approach 1:
The patent replaces the mechanical relay system with a solid-state electronic switch using MOSFETs or IGBTs. The mechanically operated contacts are substituted with semiconductor devices that can handle high voltage and current without moving parts, thereby achieving the required switching capability while dramatically reducing the mass to 300 grams or less.
Solution Approach 2:
The patent changes the fundamental operating parameters of the switch from mechanical to solid-state. By using semiconductor devices with specific voltage ratings (650V-1700V) and arranging them in series/parallel configurations, the system achieves high voltage and current handling capabilities with significantly reduced mass compared to electromechanical relays.
2Reliability
If electromechanical relays are used for high current switching, then the switching function is achieved, but the switching speed becomes slow greater than 10 ms
Solution Approach 1:
The patent eliminates the mechanical moving parts in relays by using solid-state semiconductor switches (MOSFETs/IGBTs). These electronic devices switch through electrical field effects rather than mechanical motion, achieving switching speeds in the microsecond range compared to the millisecond speeds of mechanical relays, thus dramatically improving the switching speed while maintaining the switching function.
3Reliability
If electromechanical relays are used for high current switching, then the switching capability is achieved, but contact welding occurs due to contact bounce
Solution Approach 1:
The patent replaces mechanical contacts with solid-state semiconductor devices that have no physical contacts to weld or bounce. The MOSFETs or IGBTs control current flow through electrical fields and semiconductor junctions, completely eliminating the phenomenon of contact welding and bounce that plagues electromechanical relays during high current switching.
4Reliability
If electromechanical relays are used for switching, then the switching function is achieved, but audible noise is produced during switching
Solution Approach 1:
The patent substitutes the noisy mechanical switching operation with silent solid-state electronic switching. The MOSFETs or IGBTs transition between on and off states through electrical field control without mechanical movement, eliminating the audible clicking and buzzing noises characteristic of electromechanical relays during switching operations.
5Adaptability or versatility
If solid-state switches are used for bidirectional control, then the control versatility is improved, but the voltage drop increases
Solution Approach 1:
The patent divides the bidirectional switching function into multiple unidirectional semiconductor switches (MOSFETs or IGBTs) arranged in series and parallel configurations. By segmenting the total voltage and current handling across multiple devices, each operating within its optimal range, the system achieves bidirectional control capability while maintaining low voltage drops through efficient parallel current sharing.
Solution Approach 2:
The patent creates a universal solid-state switch design that can handle bidirectional voltage blocking and current conduction. The symmetric arrangement of semiconductor devices allows the same structure to efficiently control power flow in both directions, achieving multi-functionality without significant voltage drop through proper device selection and parallel configuration.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a compact, high-performance AC electronic solid-state switch that effectively addresses the limitations of electromechanical relays by offering fast switching, low noise, and efficient bidirectional control with minimal voltage drop and reduced mass.
Implementation Method 1
an electrically insulating and thermally conductive layer disposed on the base plate
Data Source
AI summary
An AC electronic solid-state switch includes an electrically insulating and thermally conductive layer, a first electrically conductive trace, a second electrically conductive trace, and a plurality of semiconductor dies each electrically connected to the first electrically conductive trace and the second electrically conductive trace. Each of the plurality of semiconductor dies forms a MOSFET, IGBT or other types of electronically controllable switch. The AC electronic solid-state switch further includes a common drain conductor that is electrically connected to each drain terminal of the plurality of semiconductor dies. The AC electronic solid-state switch is configured to block between 650 volts and 1700 volts in the off-state in a first direction and a second direction, the second direction being opposite the first direction, and the AC electronic solid-state switch is configured to carry at least 500 A continuously in the on-state with a voltage drop of less than 2V.