Circuit Breaker Conductive Loop Layout for Compact Cascaded Contacts
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Solution Overview
Problem
The increase in rated voltage of photovoltaic systems necessitates higher rated voltage circuit breakers, which are achieved through cascade-connected contacts, leading to increased product volume, cumbersome wiring, and complex integration with other electrical equipment.
Innovation Solution
A circuit breaker design with coaxially mounted moving contacts and insulating spacers that ensure insulation between static and moving contacts, allowing for compact structure and simplified terminal arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional separate connection methods are used for trip unit and closure mechanism, then manufacturing and assembly are simple, but contact resistance is high and connection reliability is poor
Solution Approach 1:
The patent merges the trip unit and closure mechanism into a single integrated structure where the trip unit is directly mounted on the closure mechanism. The conductive loop is formed by integrally connecting the trip unit base, closure mechanism, and linkage components, eliminating separate connection points and reducing contact resistance while improving connection reliability.
Solution Approach 2:
The conductive loop components are pre-configured and positioned during the design and manufacturing phase to ensure optimal electrical connection paths. The trip unit base, closure mechanism, and linkage are designed with built-in conductive pathways that are established before final assembly, ensuring low contact resistance from the outset.
2Reliability
If conductive materials are added to improve electrical connection, then electrical conductivity improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent utilizes composite construction where the closure mechanism and linkage components are formed from materials that inherently possess both mechanical strength and electrical conductivity. This eliminates the need for separate conductive material additions, as the structural components themselves provide the necessary electrical pathways.
Solution Approach 2:
The structural and electrical functions are merged into single components. The closure mechanism serves both mechanical operation and electrical conduction purposes, while the linkage components simultaneously provide mechanical connection and electrical pathway, eliminating the need for additional conductive materials.
3Ease of manufacture
If multiple separate components are used for the conductive path, then manufacturing is easier, but contact resistance increases and reliability decreases
Solution Approach 1:
While maintaining segmentable components for manufacturing purposes, the patent designs the conductive loop with continuous, overlapping contact surfaces between segments. The trip unit base, closure mechanism, and linkage are divided into manufacturable sections but feature integrated conductive pathways that ensure continuous electrical connection without high-resistance joints.
Solution Approach 2:
The conductive pathways are pre-established within each component during manufacturing, with contact surfaces designed and positioned to ensure optimal electrical connection when assembled. The components are pre-configured with built-in conductive features that align automatically during assembly, minimizing contact resistance.
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 design reduces product volume and simplifies wiring, facilitating integration with other electrical equipment while maintaining insulation and operational efficiency.
Implementation Method 1
a conductive loop formed by the hot line terminal, the trip unit, the closure mechanism, and the load line terminal
Data Source
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AI summary
An electrical path for a circuit breaker, comprising: a first contact group and a second contact group. The first contact group comprises a first static contact (121) and a first moving contact (122), and the first static contact (121) is connected to an inlet terminal (101). The second contact group comprises a second static contact (131) and a second moving contact (132), wherein the first moving contact (122) and the second moving contact (132) are electrically connected, the second static contact (131) is connected to a trip unit (104), and the trip unit (104) is connected to an outlet terminal (105). The electrical path for a circuit breaker according to one or more embodiments of the present invention electrically connects a plurality of moving contacts (122, 132, 222). The plurality of moving contacts (122, 132, 222) are coaxially mounted, and the second static contact (131) is connected, across the second moving contact (132), to the outlet terminal (105) while ensuring insulation. Under the premise of making the overall structure of the circuit breaker compact and occupy a small space, the inlet terminal and the outlet terminal are arranged on the two sides, thereby facilitating the wiring of the circuit breaker and other electrical equipment.