Electric Closing Element for Residual Capacitance Dissipation
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Solution Overview
Problem
Existing electric contactors in high-voltage applications, such as those in motor vehicles, face challenges with unreliable and slow dissipation of residual capacitance due to construction tolerances and surface contamination, leading to insufficient electrical isolation and potential safety issues during accidents.
Innovation Solution
The design features two copper or aluminum connection lugs with nickel-plated and tinned surfaces, a guide channel, and a contact element that is conductive only in the contact areas, allowing for a quick and reliable electrical connection through recesses and a displacement mechanism, ensuring fast and safe discharge of residual capacitance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional relay designs are used, then manufacturing complexity and cost increase, but electrical isolation and reliability are maintained through air dielectric strength
Solution Approach 1:
The patent introduces a closing element as an intermediary component that physically bridges the switch circuit and control circuit contact areas. This closing element with conductive surfaces establishes reliable electrical connection while the housing provides dielectric isolation, separating the functions of connection and insulation that were previously combined in relay designs
Solution Approach 2:
The patent replaces the traditional mechanical relay switching mechanism with an electrically actuated closing element system. The closing element is displaced by electrical forces (electromagnetic or electrostatic actuation) rather than mechanical arm movement, eliminating wear-prone mechanical contacts while maintaining electrical isolation through the housing structure
2Reliability
If conventional contactor designs are used, then manufacturing is simpler, but contact reliability deteriorates due to construction tolerances and surface contamination
Solution Approach 1:
The patent applies local quality by providing conductive surface coatings (such as silver, gold, or copper plating) on the closing element and contact areas. This localized conductive treatment ensures low contact resistance and high reliability at the critical contact interfaces, while the bulk material can be manufactured with standard tolerances
Solution Approach 2:
The patent incorporates preliminary protective actions through the housing design that pre-position s the closing element and maintains precise alignment between contact areas. The housing structure with guide channels and positioning features ensures reproducible contact geometry before actuation, compensating for manufacturing tolerances
3Speed
If standard dissipation paths are used, then residual capacitance dissipation is slow, but device complexity is reduced
Solution Approach 1:
The patent merges the dissipation path functionality into the existing closing element and contact structure. The same conductive closing element that establishes the switch circuit connection also provides the dissipation path to ground when activated, eliminating the need for separate dissipation components and reducing overall device complexity while achieving fast dissipation
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 configuration ensures a high-quality, low-impedance connection and rapid, reliable electrical contact, even under high-voltage conditions, enhancing safety by preventing electrical failures and ensuring continuous functionality throughout the vehicle's lifespan.
Implementation Method 1
the contact element must be electrically conductive at least in part, preferably at least along its surface, so that the contact element electrically connects the terminal lugs to one another
Implementation Method 2
The connection lugs can preferably also be nickel-plated and/or tinned, especially in an area where they are connected to energy conductors
Data Source
AI summary
An electric closer comprising a first connection lug, a second connection lug electrically insulated from the first connection lug, the first and second connection lugs each having at least one recess in a contact region disposed within a guide housing, an actuator for driving a contact element, the contact element being disposed in a guide housing between the actuator and the contact region of the connection lugs, and by the actuator from an open position, in which the connecting lugs are insulated from one another into a closed position, in which the connecting lugs are electrically connected to one another via the contact element, is displaceable, wherein in the closed position the contact element is accommodated in the recesses of the connecting lugs and wherein the contact element is guided in the displacement direction simultaneously in the respective recesses of the two connecting lugs during the displacement of the two connecting lugs.