PCB Solid-State Relay Layout for Fast High-Current Switching
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Solution Overview
Problem
Existing electromechanical relays used in vehicle systems are large, have slow switching speeds, suffer from contact welding, and require manual replacement, making them inefficient for high current and voltage applications.
Innovation Solution
A PCB-based bi-directional solid state relay is developed, utilizing field effect transistors or insulated gate bipolar transistors, which are scalable, have low on-resistance, and fast response times, eliminating the need for mechanical components and allowing for voltage, temperature, and current sensing, with a control module for switch protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electromechanical relays are used in vehicle systems, then high current and voltage control is achieved, but the device size is large, switching speed is slow, and mechanical contact welding occurs
Solution Approach 1:
The patent replaces electromechanical relays with solid-state switches (MOSFETs or IGBTs) implemented on PCBs, eliminating mechanical moving parts and contacts. This substitution resolves the contradiction by maintaining high current/voltage control capability while removing mechanical complexity and contact welding issues, achieving faster switching speeds and improved reliability.
Solution Approach 2:
The patent changes the fundamental operating parameters from mechanical to solid-state by using semiconductor devices with different physical characteristics. The solid-state switches operate without mechanical movement, enabling faster switching speeds (microseconds vs. milliseconds) and eliminating contact wear, thereby improving reliability while reducing device complexity.
2Power
If electromechanical relays are used, then high current control is achieved, but contact welding occurs and manual replacement is required
Solution Approach 1:
The patent replaces mechanical relay contacts with solid-state semiconductor switches that have no moving parts. This eliminates contact welding entirely while maintaining the ability to handle high currents through parallel-connected MOSFETs or IGBTs. The solid-state nature also enables automated replacement and reduces maintenance requirements.
Solution Approach 2:
The solid-state relay design incorporates protection circuits and control logic that automatically manage switching operations and fault detection. This self-service capability reduces the need for manual intervention and repair, as the system can detect and respond to abnormal conditions without human assistance.
3Ease of manufacture
If solid state switches are implemented on separate PCBs, then scalability and low on-resistance are achieved, but device assembly complexity increases
Solution Approach 1:
The patent merges multiple separate PCBs into a single integrated PCB assembly containing all solid-state switches (first and second solid state switches). This consolidation maintains the scalability and low on-resistance benefits of multiple parallel switches while simplifying the overall device assembly by eliminating the need to assemble and connect separate PCBs, thereby reducing assembly complexity.
Solution Approach 2:
The integrated PCB design serves multiple functions simultaneously: it provides the switching elements, the interconnections between switches, the mounting structure, and the electrical pathways. This multi-functionality achieves scalability and low on-resistance while avoiding the additional complexity of assembling separate PCBs, as the single PCB performs all necessary roles.
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 PCB-based solid state relay effectively blocks high voltage and current, offers fast switching, and is scalable, reducing size and cost while eliminating the need for manual replacement and mechanical parts, enhancing efficiency and reliability in vehicle systems.
Implementation Method 1
A PCB-based solid state relay may be implemented using field effect transistors or insulated gate bipolar transistors
Implementation Method 2
A PCB-based solid state relay may be implemented using field effect transistors or insulated gate bipolar transistors
Data Source
AI summary
A bi-directional solid state switch includes: a first bus bar; a second bus bar; a first solid state switch implemented on a first printed circuit board (PCB), the first solid state switch including: a first control terminal; a first terminal electrically connected to the first bus bar; and a second terminal; and a second solid state switch implemented on a second PCB, the second solid state switch including: a second control terminal; a third terminal electrically connected to the second terminal of the first solid state switch; and a fourth terminal electrically connected to the second bus bar.