DC Solid-State Switch Assembly for High Current Applications
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing high voltage, high current electromechanical relays are bulky, slow, prone to contact welding, and produce audible noise during switching, necessitating a lightweight, fast, and quiet switch solution.
Innovation Solution
A lightweight DC electronic solid-state switch assembly with a case, semiconductor dies, electrically conductive traces, and an insulating thermally conductive layer, capable of carrying at least 400 amperes with low voltage drop, scalable, and featuring fast fault interruptability and intelligent power control, without arc formation or audible noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
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 moving contact system with a solid-state electronic switching system using MOSFETs or IGBTs. This substitution eliminates the need for mechanical components such as armatures, springs, and moving contacts, thereby dramatically reducing device mass while maintaining high voltage and high current switching capability. The solid-state switch assembly weighs significantly less than 0.5 kg compared to traditional electromechanical relays.
Solution Approach 2:
The patent changes the fundamental operating parameters of the switching device by transitioning from electromagnetic actuation to electronic control. The solid-state switches operate with electronic gate signals instead of electromagnetic coils, enabling precise control with minimal power consumption and eliminating the mechanical movement that causes bulkiness in traditional relays.
2Ease of operation
If electromechanical relays are used for switching, then the switching function is achieved, but the switching speed becomes slow greater than 10 ms
Solution Approach 1:
The patent replaces the mechanical contact opening/closing mechanism with solid-state electronic switching. The MOSFETs or IGBTs can transition between on and off states in microsecond or nanosecond ranges, eliminating the mechanical inertia and contact bounce that limit electromechanical relay switching speed to greater than 10 ms.
Solution Approach 2:
The solid-state switching enables extremely rapid periodic switching operations with precise timing control. The electronic gates can be pulsed at high frequencies with precise duration control, allowing the switch to operate far beyond the 10 ms limitation of mechanical systems.
3Ease of operation
If electromechanical relays are used for high current switching, then the switching function is achieved, but contact welding occurs due to contact bounce
Solution Approach 1:
The patent eliminates mechanical contacts entirely by using solid-state MOSFETs or IGBTs for high current switching. This substitution removes the source of contact bounce and welding problems that plague electromechanical relays, significantly improving reliability for high current applications. The solid-state devices have no physical contacts that can weld or bounce.
Solution Approach 2:
The solid-state semiconductor devices can be replaced more easily and cheaply than repairing welded mechanical contacts, and their longer operational life without contact degradation provides better long-term reliability for high current switching applications.
4Ease of operation
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 replaces the mechanical switching action that produces audible clicks and buzzing with silent solid-state electronic switching. The MOSFETs or IGBTs transition between states without mechanical movement, eliminating the audible noise generated by armature movement, contact bounce, and electromagnetic coil operation in traditional relays.
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, reliable, and quiet switch with reduced power loss, high reliability, and fast switching times, addressing the limitations of traditional electromechanical relays.
Implementation Method 1
an electrically insulating and thermally conductive layer disposed on the base plate
Data Source
AI summary
A switch assembly includes a case and a direct current (DC) electronic solid-state switch coupled to the case. The case covers the DC electronic solid-state switch, and the DC electronic solid-state switch has an on-state and off-state. The DC electronic solid-state switch blocks between 650 volts and 1200 volts in a single direction in an off-state. The DC electronic solid-state switch continuously carries at least 400 amperes direct current with a voltage drop of less than one volt. The DC electronic solid-state switch also includes a plurality of semiconductor dies each forming a MOSFET. The DC electronic solid-state switch also includes a plurality of signal conductors.