High-Current Switch Structure With Shearable Conductor Sections
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Solution Overview
Problem
Existing switches for high current applications require large conductors, making it difficult to break the current conduction path efficiently, and previous pyrotechnic-based switches are bulky and costly due to the need for high forces to break thicker conductors.
Innovation Solution
A switch design featuring a conductor with insert conductors and shearable portions, where the insert conductors are retained by interference fit or solder, allowing a moveable member to displace and shear the conductor, reducing the force required to break the path and facilitating smaller, cheaper switches with improved arc resistance and suppression.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a large conductor is used to carry high current, then the current carrying capacity is improved, but the force required to break the conductor increases
Solution Approach 1:
The conductor is divided into multiple segments with weakened regions (notches) that create stress concentration points. These segmented sections allow the conductor to be broken into manageable pieces rather than requiring breaking of a single continuous large conductor, thereby reducing the force needed while maintaining high current carrying capacity through parallel paths.
Solution Approach 2:
The conductor has non-uniform cross-sectional area with specific weakened regions (notches) at predetermined break locations. These local variations in geometry create stress concentration points that facilitate breaking at specific locations while the rest of the conductor maintains its full cross-sectional area for high current carrying capacity.
2Speed
If a pyrotechnic actuator is used to break the conductor, then rapid opening is achieved, but the device size and cost increase
Solution Approach 1:
The conductor path is segmented into multiple sections with weakened regions, allowing the breaking process to occur in multiple locations simultaneously or sequentially. This segmentation reduces the force required from the actuator, enabling the use of smaller, less expensive actuators while maintaining rapid opening speed.
Solution Approach 2:
The conductor geometry is modified by introducing notches and weakened regions that change the stress distribution and reduce the force required for breaking. This parameter change in the conductor's physical structure allows smaller actuators to achieve the same breaking effect that would otherwise require large, expensive pyrotechnic actuators.
3Quantity of substance
If the conductor cross-sectional area is increased for high current, then the current capacity is improved, but the arc energy increases when breaking
Solution Approach 1:
The conductor is broken into multiple segments at different locations along its length. This segmentation creates multiple breaking points that interrupt the current path in a way that reduces arc energy, while the overall conductor cross-sectional area remains large enough to maintain high current carrying capacity during normal operation.
Solution Approach 2:
The conductor has varying cross-sectional characteristics along its length, with weakened regions (notches) at specific locations. These local variations allow the conductor to maintain large cross-sectional area for high current capacity in most regions, while the weakened regions facilitate controlled breaking that reduces arc energy generation.
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
Enables quick and reliable opening of high current conduction paths with smaller actuators, reducing the size and cost of switches while effectively managing electrical arcs by increasing arc resistance and reducing the severity of arc columns.
Implementation Method 1
the insert conductor may be at least partially retained in the respective hole by interference fit
Implementation Method 2
the insert conductor may be at least partially retained in the respective hole with solder
Implementation Method 3
the insert conductor may be at least partially retained in the respective hole with electrically conductive adhesive
Implementation Method 4
the moveable member is configured to at least partially displace the insert conductor from the hole with a first end portion of the moveable member and then shear the at least one shearable portion of the conductor
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
A switch for opening a current conduction path is provided. The switch comprises an actuator, a conductor, and a moveable member. The conductor has a length extending between two ends and a width extending between two sides. The conductor has a connection contact at either end, and at least one switching region disposed between the connection contacts. Each switching region extends between the two sides of the conductor and comprises a hole through the conductor, at least one shearable portion bounded by the hole and a nearest of the two sides of the conductor, and an insert conductor inserted into the hole and in electrical contact with the conductor, via the hole, such that a current conduction path is defined along the length of the conductor via the insert conductor and the at least one shearable portion of each switching region. The moveable member is aligned with the at least one switching region and arranged to move in a first direction toward the at least one switching region upon actuation by the actuator. When the moveable member moves in the first direction, the moveable member is configured to at least partially displace the insert conductor from the hole with a first end portion of the moveable member and then shear the at least one shearable portion of the conductor with a respective second end portion of the moveable member in order to break the current conduction path, wherein the first end portion extends further in the first direction than the respective second end portion.