Power Switching Module Isolation Removal for Fault Current Bypass
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Solution Overview
Problem
Conventional power electronic switching modules are not reliably electrically conductive in fault or shutdown situations and require excessive time for mechanical devices to establish secure contact, necessitating a faster and safer solution for handling error cases.
Innovation Solution
A power electronic switching module with switching contacts separated by insulation that is removable upon energization with a fault current, allowing the contacts to form an alternative fault current path through thermal insulation materials like thermoplastic or thermoset, which can melt or change state to facilitate rapid contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spring-loaded mechanical devices are used to ensure contact between emitter and collector in thermal failure, then reliable permanent contact is achieved, but considerable time is required for triggering
Solution Approach 1:
The patent replaces spring-loaded mechanical devices with a field-based approach where fault current directly removes insulation material to create conductive contact. This substitution eliminates mechanical moving parts and their associated response delays, achieving both reliability and speed.
Solution Approach 2:
The patent utilizes phase transition of insulation material (from solid to removed/condensed state) through thermal and electrical stress. The insulation material undergoes phase change when exposed to fault current, rapidly transforming from an insulating state to a removed state, enabling fast fault current path formation.
2Reliability
If external circuit breakers are used to switch electrically in fault situations, then electrical switching is achieved, but very high effort and permanent switching are required
Solution Approach 1:
The patent implements self-service by allowing the fault current itself to remove the insulation material and create the conductive path. The system uses the fault condition's own energy to establish the protective path, eliminating the need for external control mechanisms or complex switching devices.
Solution Approach 2:
The patent extracts the insulation material that separates the first and second switching contacts during fault conditions. By removing this insulating barrier through fault current action, the conductive path is automatically created without requiring external intervention or complex switching mechanisms.
3Reliability
If insulation is used to separate first and second switching contacts, then electrical insulation is provided, but the contacts cannot form conductive path in fault situations
Solution Approach 1:
The patent applies dynamics by making the insulation separation removable rather than fixed. The insulation material is positioned and designed to be removed by fault current, allowing the system to dynamically transition from an insulated state during normal operation to a conductive state during fault conditions.
Solution Approach 2:
The patent utilizes parameter changes by designing the insulation material to change its state or position when exposed to fault current parameters. The material's physical or electrical parameters change under fault conditions, enabling it to be removed and allowing conductive contact between switching contacts.
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 safe handling of faults by forming an alternative fault current path within milliseconds, ensuring reliable electrical conductivity and permanent resistance to residual currents.
Implementation Method 1
the insulation is transformed into a melt product (melt droplet), a gas, an aerosol, or a powder
Implementation Method 2
it is transformed into a melt product (melt droplet)
Implementation Method 3
as a result of the power semiconductor being energized with a fault current
Implementation Method 4
which is preferably carried away from the power semiconductor by the pressure exerted by it
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a power electronic switching module, comprising at least one power semiconductor (20), a first switching contact (30), which can be or is electrically connected to the power semiconductor (20), and a second switching contact (10), which can be or is electrically connected to the power semiconductor (20), wherein the first switching contact (30) and the second switching contact (10) are force-loaded towards each other, at least in one region, and are spaced apart from each other by means of an electrical insulation (40), wherein the insulation (40) is arranged and designed such that, in response to a fault current being supplied to the power semiconductor (20), the insulation (40) can be removed from where it spaces apart the first and second switching contacts (10, 30) from each other when there is no current supply. In the event of a fault, the first and second switching contacts (10, 30) are therefore no longer spaced apart by the insulation (40) and can make electrically conductive contact with each other because of being force-loaded towards each other and can form an alternative fault current path.