Layered Contact Bridge Structure for Faster Switch Opening
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Solution Overview
Problem
Copper-based switching bridges in switching devices have low mechanical strength, leading to high mass, prolonged switch-off processes, and increased contact erosion, while existing solutions for improved rigidity are limited in application and increase manufacturing costs.
Innovation Solution
A switching bridge composed of multiple layers with a high-conductivity material like silver or copper for the contact area and a high-strength material like steel or fiber-reinforced plastic for structural support, allowing for customizable design and reduced mass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper-based switching bridges are used, then high electrical conductivity is achieved, but mechanical strength is low leading to high mass and prolonged switching
Solution Approach 1:
The patent applies composite materials by combining copper layers (for electrical conductivity) with reinforcing layers (such as steel or fiber-reinforced plastic) to create a switching bridge that achieves both high electrical conductivity and high mechanical strength. The copper layers maintain electrical performance while the reinforcing layers provide structural strength and reduce mass.
Solution Approach 2:
The switching bridge is segmented into multiple functional layers: copper layers for electrical conductivity, reinforcing layers for mechanical strength, and insulating layers for electrical isolation. This segmentation allows each layer to optimize its specific function while contributing to the overall performance of the switching bridge.
2Strength
If copper switching bridges are designed with increased volume to compensate for low strength, then mechanical strength improves, but mass increases leading to slower switching and increased contact erosion
Solution Approach 1:
The composite structure replaces solid copper with a multi-layer construction where lightweight reinforcing materials (steel or fiber-reinforced plastic) provide the necessary mechanical strength without the high density of copper. This reduces the overall mass while maintaining or improving mechanical strength.
Solution Approach 2:
The reinforcing layers are strategically positioned in areas where mechanical strength is most needed, such as near the contact points and support structures, while copper layers are positioned where electrical conductivity is critical. This local optimization ensures strength where required without unnecessarily increasing mass throughout the entire component.
3Stability of the object's composition
If special designs are used to improve rigidity of copper switching bridges, then rigidity increases, but the solution is limited to specific switch types and current strengths
Solution Approach 1:
The modular layered structure allows independent optimization of each layer's properties. Different copper layer configurations can be combined with different reinforcing layer types and thicknesses to create switching bridges tailored to specific switch types, current strengths, and rigidity requirements, greatly expanding application versatility.
Solution Approach 2:
The patent enables parameter changes by adjusting the number, thickness, and material composition of individual layers. This allows the switching bridge design to be adapted to different current ratings, voltage levels, and mechanical strength requirements without changing the fundamental structure, making it universally applicable across different switch types.
4Strength
If copper switching bridges with high volume are used, then mechanical strength is compensated, but manufacturing and storage costs increase
Solution Approach 1:
The switching bridge is manufactured as segmented layers that can be produced independently and then assembled. This modular approach allows for standardized production of copper layers and reinforcing layers, reducing manufacturing complexity and cost compared to producing large-volume solid copper components with complex geometries.
Solution Approach 2:
The composite construction uses thinner layers of materials that are more cost-effective than large volumes of copper. The reinforcing layers can be produced through cost-efficient processes such as laminating or bonding, reducing overall material and manufacturing costs while achieving the required mechanical strength.
Data Source
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AI summary
Disclosed is a connecting bridge (1) for a switching device (2), said connecting bridge (1) having an electrical switching contact (3) and a contact carrier (4) and the switching contact (3) being arranged on said contact carrier (4). According to the invention, the contact carrier (4) has at least one first sectional part (5) and at least one second sectional part (6), the first sectional part (5) comprises a first material, the second sectional part (6) comprises a second material, said second material differing from the first material, and the first sectional part (5) and the second sectional part (6) are interconnected.