Electronic Circuit Breaker Current Path Modulation

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Solution Overview

Problem

Electronic circuit breakers face challenges in efficiency and cost due to high current peaks and shorter lifetimes, especially for applications above 12 volts, where mechanical circuit breakers are less efficient and more costly than electronic ones.

Innovation Solution

Modulating current paths via a predefined pattern that selectively disables current flow in electronic circuit breakers using field-effect power switches, assessing power usage, and generating diagnostic signals for fault detection and safety mode activation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If mechanical circuit breakers are used for voltages over 12 volts, then reliability is improved, but cost increases and efficiency decreases

Engineering Contradiction:

Improvecircuit breaker reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces mechanical circuit breakers with electronic circuit breakers using semiconductor switches (MOSFETs, IGBTs, or BJT transistors) to achieve reliable fault protection while reducing cost and improving efficiency. The electronic switching elements eliminate mechanical wear and enable softer switching characteristics.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If electronic circuit breakers operate at high current, then productivity is improved, but current peaks reduce lifespan

Engineering Contradiction:

Improvecurrent handling capabilityVSAvoidcircuit breaker lifespan

Core Design Contradiction:

ProductivityVSDuration of action of stationary object

Solution Approach 1:

The patent implements periodic modulation of current paths through sequential activation and deactivation of parallel current paths. This periodic switching pattern prevents sustained high current peaks while maintaining overall current handling capability, thereby extending component lifespan.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The patent dynamically switches between multiple current paths using semiconductor devices, allowing the system to adapt current distribution in real-time. This dynamic control prevents any single path from承受ing excessive current stress, extending the operational life of electronic components.

Inventive Principle:

Principle #15Dynamics

3Object-affected harmful factors

If pre-charge circuits are added to electronic circuit breakers, then current peaks are reduced, but device complexity increases

Engineering Contradiction:

Improvecurrent peak mitigationVSAvoidcircuit breaker complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The patent introduces intermediate current paths that act as mediators between the power source and load. These intermediate paths provide alternative current routes during switching transitions, softening current peaks without requiring traditional pre-charge circuitry, thus avoiding additional complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent makes the semiconductor switches serve multiple functions: they act as both main switching elements and implicit pre-charge elements through their controlled activation sequences. This multi-functionality eliminates the need for separate pre-charge circuits, maintaining simplicity while mitigating current peaks.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Power

If multiple current paths are activated simultaneously, then power delivery is improved, but fault detection difficulty increases

Engineering Contradiction:

Improvepower delivery capabilityVSAvoidfault detection difficulty

Core Design Contradiction:

PowerVSDifficulty of detecting and measuring

Solution Approach 1:

The patent segments the current delivery function into multiple independent current paths that can be activated sequentially or selectively. This segmentation enables isolated monitoring and diagnostics of each path, making fault detection and measurement significantly easier while maintaining overall power delivery capability.

Inventive Principle:

Principle #1Segmentation

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

This approach improves efficiency, extends the lifespan of electronic circuit breakers, and reduces costs by mitigating current peaks and enabling soft turn-on without pre-charge circuits, while ensuring functional safety and electromagnetic compatibility.

Implementation Method 1

The electronic circuit breaker includes a plurality of field-effect power switches, each current path including a respective field-effect power switch

Methodology Applied

Scientific EffectField-effect transistor operation: Conduction (electrical)

Data Source

PatentUS11296493B2Apparatuses and methods involving modulation and assessment of current paths of an electronic circuit breaker

Publication Date: 2022.04.05 NXP USA INC

AI summary

An example apparatus is for use with an electronic circuit breaker having a plurality of current paths connected between a connection terminal to a power source and a load terminal. The apparatus includes power access circuitry and control circuitry. The power access circuitry monitors circuit access of power via the power source by modulating use of the plurality of current paths of the electronic circuit breaker while assessing actual usage of the power source via a power-related parameter relative to expected usage of the power source. The control circuitry responds to the assessment by generating a signal indicative of a diagnostic result associated with operation of the electronic circuit breaker.