Vacuum Interrupter Disk Insulator Compact Design
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Solution Overview
Problem
Existing vacuum interrupters face challenges in achieving a compact and cost-effective design due to the reliance on the length of insulating material for insulation strength, which increases material costs and complexity.
Innovation Solution
The use of a disk-like insulator with a radial wall thickness at least 1.5 times its axial length provides insulation strength through diameter or wall thickness, allowing for a compact construction and reduced material usage, with the insulator also serving as a housing flange and incorporating undercuts to maintain insulation during metal vapor deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an annular hollow-cylindrical ceramic insulator is used with radial wall thickness similar to axial length, then insulation strength is achieved, but the vacuum interrupter has increased length and requires more conductor material
Solution Approach 1:
The patent transitions from a cylindrical insulator geometry to a disk-like insulator geometry, changing the primary dimension for insulation from axial length to radial wall thickness. This dimensional change allows the insulation strength to be achieved through the thickness of the disk rather than its length, thereby reducing the overall length of the vacuum interrupter while maintaining the required insulation performance.
2Strength
If an annular hollow-cylindrical ceramic insulator is used, then insulation is provided, but manufacturing cost increases due to more conductor material
Solution Approach 1:
By changing the insulator geometry from cylindrical to disk-like, the patent reduces the amount of conductor material needed for connection pins and other components, since the compact dimensions reduce the required conductor length. This dimensional change directly lowers manufacturing costs while maintaining insulation strength through optimized radial wall thickness.
Solution Approach 2:
The disk-like insulator serves multiple functions: it provides insulation strength, acts as a housing flange (eliminating the need for separate metallic housing flanges in some embodiments), and supports connection pins. This multi-functionality reduces the total number of components and simplifies manufacturing, contributing to cost reduction.
3Reliability
If metal vapor deposits on the inner surface of the insulator during switching, then insulation strength is reduced, but with undercuts the insulation strength is maintained
Solution Approach 1:
The patent converts the harmful effect of metal vapor deposition into a beneficial outcome by designing undercuts in the disk-like insulator. These undercuts create geometric features that prevent metal vapor from forming continuous conductive layers on the insulator surface. The harmful deposition is thus transformed into a non-harmful situation where insulation strength is maintained despite the presence of metal vapor.
Solution Approach 2:
The undercuts create local geometric variations on the insulator surface that specifically address the problem of metal vapor deposition. By modifying the local geometry at critical areas where vapor deposition occurs, the patent ensures that these local features prevent the formation of conductive paths, thereby maintaining overall insulation strength during switching operations.
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 results in a cost-effective, compact vacuum interrupter capable of maintaining insulation strength even during switching processes, suitable for various voltage levels and applications, including higher measurement voltages.
Implementation Method 1
the at least one insulating material housing region being formed by a disk-like insulator
Implementation Method 2
a vacuum interrupter having a housing comprising at least a first metallic housing flange, through which a first connection pin extends into the vacuum interrupter in a vacuum-tight manner
Implementation Method 3
the disk-like insulator has undercuts such that metal vapor occurring during the switching process does not completely cover an inner surface of the disk-like insulator
Data Source
AI summary
A vacuum interrupter has a housing with at least a first metal flange through which a first connection pin extends into the vacuum interrupter in a vacuum-tight manner to a first contact. The housing has at least one insulating-material housing region formed by a disc-like insulator. A second connection pin extends into the vacuum interrupter in a vacuum-tight manner to a second contact. The vacuum interrupter can be produced in a cost-effective manner with a compact construction. There is also described a switch pole for a switching device having a vacuum interrupter.