Compact Switching Device for Electric Vehicles Using Integrated Insulator
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Solution Overview
Problem
Existing high-power switching devices for electric vehicles are bulky and difficult to integrate into vehicle equipment, requiring significant space and separate insulation distances that complicate their integration.
Innovation Solution
A compact switching device with a cylindrical insulator and flexible conductive bar mechanism, where the conductive bar moves between individual and common terminals within a sealed, dielectric-filled cavity, reducing the distance between terminals and using integrated electromagnetic coils for actuation, allowing for efficient switching and reduced electromagnetic energy requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional switching devices are used with separate insulation distances, then electrical isolation is ensured, but the device occupies bulky space and is difficult to integrate into vehicle equipment
Solution Approach 1:
The patent merges the insulation function directly into the insulator body structure by forming recesses that receive individual terminals at different heights. This integration eliminates the need for separate insulation distances between terminals, as the insulator itself provides both mechanical support and electrical isolation. The common terminal and individual terminals are positioned within the same insulator structure, with the insulator material providing the necessary creepage and clearance distances, thereby reducing overall device volume while maintaining electrical isolation reliability.
Solution Approach 2:
The patent utilizes the vertical dimension by positioning individual terminals at different heights on the insulator surface. The insulator has a first individual terminal at a first height and a second individual terminal at a second height, creating a three-dimensional arrangement. This vertical stacking allows terminals to be electrically isolated through the insulator material in the vertical direction, eliminating the need for horizontal separation distances and reducing the device's footprint area.
2Ease of operation
If drive means extend beyond the space between terminals, then switching function is achieved, but the device becomes bulky and complex
Solution Approach 1:
The patent nests the drive means within the insulator structure. The drive means is positioned inside the insulator body, utilizing the internal space of the insulator rather than extending outward. This nesting approach allows the switching mechanism to be contained within the existing insulator boundaries, reducing overall device complexity and eliminating the need for external drive components that would increase device volume.
Solution Approach 2:
The patent segments the switching function into distinct components: contact means for making/breaking connections and drive means for actuating the contact means. The contact means includes movable contacts that can be actuated by the drive means positioned within the insulator. This segmentation allows the drive means to be compact and integrated, rather than requiring a large external mechanism, thereby reducing device complexity while maintaining full switching functionality.
3Volume of moving object
If terminals are positioned close together, then device volume is reduced, but electrical isolation between terminals is compromised
Solution Approach 1:
The patent uses the insulator material as a composite structure that provides both mechanical support and electrical isolation properties. The insulator is designed with specific material properties that ensure adequate creepage and clearance distances between terminals positioned in close proximity. By selecting appropriate insulator materials with high dielectric strength and suitable surface properties, the patent achieves effective electrical isolation between the common terminal and individual terminals even when they are positioned close together in three-dimensional space.
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 enables a compact, efficient switching device with reduced switching time and minimized electromagnetic energy use, facilitating easier integration into vehicle systems while maintaining effective electrical isolation and connectivity.
Implementation Method 1
The internal cavity is sealed and filled with a dielectric fluid, for example of the dielectric gas type such as sulfur hexafluoride, dry air or else vacuum.
Implementation Method 2
The drive means is integrated within the insulator and comprises two electromagnetic coils which surround the internal cavity.
Data Source
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AI summary
Switching device (D) arranged on an electrically powered vehicle, capable of switching, by rectilinear movement of a contact means (52) by means of a drive means (60), indifferently in both directions, between a first state in which said contact means (52) establishes an electrical connection between a first individual terminal (I1) and a common terminal (Co) and a second state in which said contact means (52) establishes an electrical connection between a second individual terminal (I2) and said common terminal (Co), said switching device (D) characterized in that said individual terminals (I1, I2), said common terminal (Co), said contact means (52) are arranged within a single insulator (14).