Battery Junction Circuit Using Semiconductor Switching for Contactor Wear
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Solution Overview
Problem
Conventional electric battery pack systems face issues with the durability and space efficiency of mechanical contactors, which are prone to overheating and risk of permanent closure due to high currents, and require additional components like pull-up circuits for potential matching, leading to increased complexity and space usage.
Innovation Solution
The use of semiconductor apparatuses in a control circuit to manage current flow between the battery arrangement and electrical loads, including switching apparatuses and overload current breakers, which provide safer and more efficient switching with reduced space requirements compared to mechanical contactors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical contactors are used to disconnect battery arrangement from electrical loads, then complete disconnection is achieved, but durability is limited due to overheating and cooling requirements
Solution Approach 1:
The patent replaces mechanical contactors with semiconductor switches (MOSFETs or IGBTs) that provide electrical switching without mechanical moving parts. This substitution eliminates the overheating and wear issues inherent in mechanical contactors, thereby improving both reliability and working life while maintaining the ability to completely disconnect the battery arrangement from electrical loads
2Reliability
If mechanical contactors are used for complete disconnection, then safety is improved, but device size increases due to cooling requirements and bulky structure
Solution Approach 1:
The patent substitutes mechanical contactors with compact semiconductor switches that require minimal cooling infrastructure compared to bulky mechanical contactors. The semiconductor-based switching apparatus maintains complete disconnection capability and safety while occupying significantly less space, as semiconductors generate less heat and require smaller heat sinks or cooling systems
Solution Approach 2:
The patent changes the operating parameters by using semiconductor switches that operate at lower temperatures and with lower power losses compared to mechanical contactors. This parameter change allows for compact design without compromising safety or disconnection effectiveness
3Ease of operation
If mechanical contactors are used in high current situations, then switching is achieved, but welding between contact surfaces may occur causing permanent closing
Solution Approach 1:
The patent replaces mechanical contactors with semiconductor switches that control current flow through electronic field effects rather than mechanical contact. This eliminates the welding problem entirely, as there are no physical contact surfaces that can fuse together under high current, while maintaining full switching capability and improving reliability
4Reliability
If pull-up circuits are added to prevent permanent closing, then safety is improved, but device complexity increases
Solution Approach 1:
The patent replaces the complex mechanical contactor system with semiconductor switches that can be precisely controlled by electronic control circuits. The control circuit for semiconductor switches is simpler and more reliable than pull-up circuits for contactors, as it directly controls the switching element without requiring additional potential-matching components
Solution Approach 2:
The semiconductor switches and their control circuits perform multiple functions: they provide complete disconnection, control current flow, prevent welding, and manage potential differences all within a single integrated system, eliminating the need for separate pull-up circuits and reducing overall device complexity
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 semiconductor-based solution enhances the durability and performance of the battery junction by minimizing losses, ensuring safe switching, and reducing the risk of overheating, while also optimizing space usage and maintaining safety through controlled current management.
Implementation Method 1
a semiconductor apparatus provided between the battery arrangement and the loads and configured to control electric current between the battery arrangement and the loads
Implementation Method 2
a switching apparatus, which switching apparatus comprises at least one mechanical switch arranged in an electrical circuit connection between the first and the second control circuit branch for electrically connecting and disconnecting the first and the second control circuit branch
Data Source
AI summary
Provided is an electric battery junction arrangement for connecting an electric battery arrangement to one or more electrical loads. The electric battery arrangement comprising two or more electric battery cells and a control circuit comprising: (i) a first control circuit branch connectable to a positive side of the battery arrangement and a positive side of an electrical load; (ii) a second control circuit branch connectable to a negative side of the battery arrangement and a negative side of an electrical load; (iii) at least one semiconductor apparatus provided between and configured to control electric current between the battery arrangement and the loads; and (iv) a switching apparatus comprising at least one mechanical switch arranged in an electrical circuit connection between the first and the second control circuit branch for electrically connecting and disconnecting the first and the second control circuit branch to and from each other.