Waterproof Circuit Breaker with Integrated Safety Sensor
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Solution Overview
Problem
Conventional circuit breakers for high power systems are complex, costly to manufacture, and lack waterproof design, posing safety risks due to potential short-circuiting from water seepage and increased electrical resistance from contamination, especially in outdoor applications like electric vehicles.
Innovation Solution
A circuit breaker with a simplified structure featuring a switch device and connecting device with a flexible seal and snap-fit engagement, providing a waterproof rating of IP69K, and an integrated safety sensor unit for automatic power cutoff in case of environmental hazards or accidents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional circuit breaker design with multiple components (lever, guide slot, positioning pin, safety latch) is used to ensure reliable connection and power cutoff, then the reliability of power transmission is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple functions (connection, positioning, locking, and power cutoff control) into a single integrated connector component. The connector includes conductive blades that directly establish electrical connection with terminals while incorporating a latch mechanism and positioning features in one unified structure, eliminating the need for separate lever, guide slot, positioning pin, and safety latch components.
Solution Approach 2:
The connector is designed as a multi-functional component that simultaneously performs electrical connection, mechanical positioning, secure locking, and power cutoff control. The conductive blades provide electrical connection, while integrated features enable positioning and locking functions, allowing one component to replace multiple specialized parts.
2Ease of manufacture
If conventional circuit breaker design is used without waterproof features, then the manufacturing cost is reduced, but the reliability deteriorates due to potential short-circuiting from water seepage and contamination
Solution Approach 1:
The patent incorporates a waterproof seal (thin film barrier) within the connector structure to prevent water and contaminants from reaching the conductive elements. This seal creates a protective barrier that maintains reliability in outdoor environments while being integrated into the connector design to avoid significant manufacturing complexity.
3Ease of repair
If the switch device is frequently detached for maintenance, then the ease of repair is improved, but the electrical resistance increases due to contamination and rust at contact points
Solution Approach 1:
The waterproof seal creates a protective environment for the conductive elements during storage and maintenance, preventing contamination and rust when the connector is detached. This ensures that when reconnected, the contact points remain clean and maintain low electrical resistance.
Solution Approach 2:
The connector is designed as a consumable component that can be easily replaced as a complete unit. Rather than attempting to clean and maintain contact points after detachment, the entire connector can be swapped out, ensuring reliable electrical connection without the complexity of cleaning procedures.
Data Source
AI summary
A high power system provided with a circuit breaker is disclosed, in which the circuit breaker controls the electrical connection in the system. The circuit breaker has a switch device and a connecting device. Two conductive terminals provided in the connecting device are spaced apart from each other and connected to a power source. The connecting device is equipped with a safety latch for transmitting a signal demanding the establishment of electrical connection to an interrupting control circuit. A conductive element provided in the switch device is electrically connected to the conductive terminals of the connecting device, and then a latch releasing element provided in the switch device drives the safety latch to activate the interrupting control circuit, so as to permit power transmission in the high power system.