Switching Device Integrated Housing Contact Bridge
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Solution Overview
Problem
Existing switching devices for electrical consumers face challenges in achieving a compact design with minimal external dimensions and low manufacturing costs, particularly due to complex wiring and high heat loss when the bridging unit and power module are in separate housings.
Innovation Solution
The switching device integrates the power module and bridging unit in a common housing with controllable semiconductor and electromechanical switching elements, where the first and second connection parts are arranged on one side, reducing wiring complexity and using a contact bridge for electrical connection, and includes a fan element for efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the bridging unit and power module are housed in separate enclosures, then the switching device can be provided as prefabricated components, but the wiring effort is complex and results in high production costs and increased heat loss
Solution Approach 1:
The patent merges the bridging unit and power module into a single integrated housing, eliminating the need for complex external wiring between separate components. The electromechanical switching elements of the bridging unit are directly connected to the semiconductor switching elements of the power module within the same enclosure, significantly reducing wiring complexity and production costs while maintaining the benefits of prefabricated modular components
2Ease of manufacture
If the bridging unit and power module are housed in separate enclosures, then the components can be manufactured independently, but the electrical connection requires considerable effort and negatively impacts heat loss during operation
Solution Approach 1:
By housing both the bridging unit and power module in a single enclosure with direct internal connections, the patent minimizes the length and number of electrical connections between components. This reduces resistive losses and heat generation in the connecting conductors, while still allowing the components to be manufactured and tested independently before final assembly
3Ease of operation
If the first and second terminals are arranged on opposite sides of the power module, then the electrical connection is straightforward, but the external dimensions of the switching device are larger
Solution Approach 1:
The patent arranges the first and second terminals on the same side of the power module rather than opposite sides, and uses contact bridges that extend in a lateral direction to connect corresponding terminals of the bridging unit and power module. This dimensional reconfiguration reduces the external length of the switching device while maintaining straightforward electrical connectivity through the contact bridges
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 enables a compact, cost-effective design with reduced heat loss and improved robustness by minimizing current paths and contact points, allowing for easy installation and efficient heat dissipation.
Implementation Method 1
The controllable electromechanical switching element is designed with a low contact resistance and is closable to form a bypass
Implementation Method 2
A fan element, which conveys air along a heat sink for cooling, is attached to a housing cover
Data Source
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AI summary
The invention relates to a switching device for a single-phase or multi-phase electrical load. The switching device comprises a number of conductor strands (LS1, LS2, LS3) corresponding to the number of phases (P1, P2, P3), each conductor strand (LS1, LS2, LS3) comprising a first terminal (8) serving as an input for connection to a mains phase (L1, L2, L3) and a second terminal (9) serving as an output for connection to a terminal phase (T1, T2, T3) of the electrical load. At least one controllable semiconductor switching element (11, 12) is provided for each phase (P1, P2, P3), wherein the at least one controllable semiconductor switching element (11, 12) is connected between the first and the second terminal (8, 9).Furthermore, a bridging unit (20) comprises a controllable electromechanical switching element (21) with low on-resistance for each phase (P1, P2, P3), wherein the controllable electromechanical switching element (21) is connected in parallel to the at least one controllable semiconductor switching element (11, 12) of that phase (P1, P2, P3) between the first and second terminal parts (8, 9). The first and second terminal parts (8, 9) of each phase (P1, P2, P3) are arranged adjacent to each other in close proximity along one direction of extension (ER) on one side of the power module (10). A contact bridge (25) of the electromechanical switching element (21) of the bridging unit (20) assigned to each phase (P1, P2, P3) extends along the direction of extension (ER) to electrically connect the first and second terminal parts (8, 9) when switched on.