High-Current Power Switch Segmented Busbar Design
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Solution Overview
Problem
Existing circuit breakers face limitations in current-carrying capacity and thermal conductivity while maintaining a cost-effective design.
Innovation Solution
The circuit breaker features a modular design with separate components for connection means, heat sinks, and fastening elements, allowing for the selection of materials with optimal conductivity and mechanical strength, and includes heat sinks with cooling ribs for enhanced convection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If connection means are made of aluminum in one piece with busbars, then manufacturing is simpler, but current-carrying capacity is limited due to higher resistance
Solution Approach 1:
The connection means is divided into separate components: copper busbars for current conduction and aluminum connection means for mechanical fastening. This segmentation allows each component to be optimized for its specific function - copper for low resistance and high current capacity, aluminum for lightweight mechanical support.
Solution Approach 2:
Different materials are used in different locations based on functional requirements. Copper is used where current conduction is critical (busbars and connection means contact areas), while aluminum is used where mechanical strength and weight are more important (fastening elements and structural components).
2Device complexity
If heat sinks are integrated into current paths, then structure is simplified, but current-carrying capacity decreases due to higher resistance materials
Solution Approach 1:
The heat sinks are separated from the current paths, allowing copper busbars to maintain pure electrical conduction functions while aluminum heat sinks handle thermal management. This prevents the degradation of current-carrying capacity that would occur if heat sinks made of higher resistance materials were integrated into the electrical path.
Solution Approach 2:
The thermal management function is extracted from the electrical conduction path. Heat sinks are positioned adjacent to busbars to conduct heat away without being part of the electrical circuit, thus maintaining optimal electrical performance while providing effective cooling.
3Ease of manufacture
If pole head and pole carrier are made of single material, then manufacturing is easier, but both current-carrying capacity and thermal conductivity cannot be optimized simultaneously
Solution Approach 1:
The pole head and pole carrier utilize composite construction with different materials optimized for specific functions. Copper components provide superior electrical and thermal conductivity for current paths, while aluminum components provide lightweight structural support and heat dissipation. This composite approach allows simultaneous optimization of both current-carrying capacity and thermal conductivity.
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 approach improves current-carrying capacity and heat dissipation properties while maintaining a cost-effective design by selecting materials with low resistance for connections, high conductivity for heat sinks, and sufficient mechanical strength for fastening elements.
Implementation Method 1
at least one heat sink is attached in a thermally conductive manner outside the current paths on the first and the second busbar
Implementation Method 2
The heat sinks advantageously have cooling ribs, which are aligned depending on the installation position of the circuit breaker according to the invention to enable good convection
Data Source
AI summary
The invention relates to a power switch, especially a high-current switch, comprising at least one pole unit with a pole head and a pole base and a contact system interposed therebetween, for switching a current that is guided via at least one first conductor rail of the pole base and at least one second conductor rail of the pole head, the pole head and the pole base having respective connecting elements. The aim of the invention is to provide a power switch of the aforementioned type which has a cost-effective design and improved current carrying capacity and thermal conductivity. For this purpose, the connecting elements are configured only to connect the at least one first conductor rail and the at least one second conductor rail to the contact system while forming current paths. At least one cooling body is attached outside the conducting paths to the first and the second conductor rail, respectively. The fastening elements of the pole unit are attached outside the conducting paths to the conductor rails.