Vacuum Interrupter Electrode Extension Assembly Welding

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Solution Overview

Problem

Vacuum interrupters face limitations in electrode stem design flexibility and modification post-assembly, leading to issues like oxidation and poor electrical and thermal conductivity, as well as damage to the sealed vacuum envelope.

Innovation Solution

The introduction of electrode extension assemblies with extension members welded to the electrode stems using electron beam or plasma welding, allowing for customization and the use of different materials, enabling modification and improvement of vacuum switching apparatus without compromising the vacuum seal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If electrode stems are modified after vacuum envelope assembly, then design flexibility and customization are improved, but oxidation and damage to the sealed vacuum envelope occur

Engineering Contradiction:

Improvedesign flexibilityVSAvoidvacuum seal integrity

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The electrode extension assembly is designed to be pre-assembled and pre-welded to the electrode stem before the vacuum envelope is sealed. This preliminary action allows the extension to be integrated into the vacuum interrupter without requiring post-assembly modification, thereby maintaining vacuum seal integrity while achieving design customization

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The electrode system is segmented into two parts: the original electrode stem and the separate extension assembly. This segmentation allows the extension to be designed and manufactured independently with specific geometries and materials, then integrated into the final product without compromising the vacuum envelope

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If electrode stems are modified after assembly, then design requirements can be met, but electrical and thermal conductivity deteriorate

Engineering Contradiction:

Improvedesign customizationVSAvoidelectrical and thermal conductivity

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The extension members are designed with optimized geometric parameters and material properties to match or enhance the electrical and thermal conductivity of the original electrode stem. By carefully selecting extension materials and dimensions, the assembly achieves both design customization and maintained conductivity performance

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The electrode extension assembly may use composite material structures or material combinations that provide both the desired geometric configuration and superior electrical/thermal conductivity properties, ensuring that customization does not compromise performance

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If traditional welding methods are used for extension members, then manufacturing is simpler, but oxidation and vacuum seal damage occur

Engineering Contradiction:

Improvewelding process simplicityVSAvoidvacuum envelope integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

Traditional arc welding or resistance welding methods are replaced with electron beam welding, which uses a focused beam of electrons to melt and join materials. This substitution eliminates the need for open flames or high-current arcs that could damage the vacuum envelope, while still achieving strong, oxidation-free welds

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The welding process is performed within a controlled inert or vacuum environment that prevents oxidation of the electrode stem and extension members during joining. This inert environment protects the vacuum seal integrity while enabling reliable welding of the extension assembly

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

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 enhances manufacturing efficiency, allows for complex geometries and material customization, reduces weight, and simplifies silver plating, while avoiding oxidation and maintaining the vacuum integrity, thus expanding the utility of vacuum switching apparatus in various applications.

Implementation Method 1

Each of the extension members may be joined to the electrode stem by a welded joint.

Methodology Applied

Scientific EffectWelding: Welding

Implementation Method 2

The welded joint may be formed by electron beam welding or plasma welding.

Methodology Applied

Scientific EffectElectron beam welding: Electron Beam

Implementation Method 3

The welded joint may be formed by electron beam welding or plasma welding.

Methodology Applied

Scientific EffectPlasma welding: Plasma

Data Source

PatentUS9330867B2Vacuum switching apparatus, and electrode extension assembly and associated assembly method therefor

Publication Date: 2016.05.03 EATON INTELLIGENT POWER LTD

AI summary

An electrode extension assembly is for a vacuum switching apparatus, such as a vacuum interrupter, including a vacuum envelope and separable contact assemblies. Each contact assembly includes a contact disposed in the interior of the vacuum envelope, and an electrode stem extending outwardly from the contact to the exterior of the vacuum envelope. The electrode extension assembly includes a number of extension members each being be joined to the electrode stem of a corresponding one of the contact assemblies on the exterior of the vacuum envelope by a welded joint formed by electron beam welding or plasma welding.