EP4659275A1

EP4659275A1 - Electrical device

Info

Publication number: EP4659275A1
Application number: EP23939962.9A
Authority: EP
Inventors: Peter Song; Alyssa Hatch; Nicholas Heeder; Thomas KOUWEN; Quan TA
Original assignee: Sensata Technologies Inc
Current assignee: Sensata Technologies Inc
Priority date: 2023-05-26
Filing date: 2023-09-08
Publication date: 2025-12-10
Also published as: KR20260017352A; CN120981875A; WO2024248832A1

Abstract

An improved electrical device includes a high voltage switch device and a fast disconnect device. The switch device is configured to selectively open/ close a high voltage circuit. The fast disconnect device can include a pyrotechnic actuator that forces a movable contact away from fixed contacts and optionally retains the movable contact in a detonated state.

Description

Electrical Device

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of priority of US Provisional Application No. 63/504,650, entitled “Electrical Device,” and filed on May 26, 2023, the entire disclosure of which is hereby incorporated by reference.

FIELD OF THE TECHNOLOGY

[0002] The subject disclosure relates to electrical switching devices, such as contactor devices and electrical fuse devices, and more particularly to improved contactor devices with high voltage switching and quick disconnect functioning.

BACKGROUND OF TECHNOLOGY

[0003] Many conventional devices are known to selectively power on or off electrical devices. For example, electrical contactors, e.g., high-voltage DC contactors, and fuses, e.g., electrical fuses and/or pyrotechnic fuses, are conventionally available and used in electrical systems. Contactors may be configured to interrupt or complete a circuit to control electrical power to and from a device. Fuses may be used for overcurrent protection. For example, fuses may be used to prevent short circuits, overloading, and/or permanent damage to an electrical system or a connected electrical device.

[0004] In many conventional systems, a contactor or other switching device is paired with one or more discrete fuses. In these arrangements, the contactor acts as a switch, e.g., to selectively allow/disallow current flow, and the fuse(s) is/are provided to break a circuit during a fault, short circuit, surge, or other event. The use of fuses separate from the switching device may result in difficulty in coordinating protection within a high voltage system. Moreover, some conventional fuses use thermal elements, which may be susceptible to fatigue and/or stress, which can lead to premature failure. Moreover, as electrical power levels continue to increase across industries, it may be more difficult to design and implement electrical systems that can safely handle accidents and emergencies resulting in high current short-circuits. For instance, it may be difficult to find switching devices designed to withstand and/or interrupt high levels of fault current/voltages (e.g., short circuits).

[0005] Accordingly, there is a need in the art for improved switching devices, interrupter devices, and methods of making such devices. There also is a need in the art for improved devices that may one or more of work at high voltage/current levels, are capable of quickly protecting against short circuits or similar events, and have one or more of reduced complexity, weight and/or cost.

SUMMARY OF THE TECHNOLOGY

[0006] The subject technology relates to improved electrical devices and methods of making and using those devices. In examples, aspects of this disclosure relate to improved switching devices with integrated short circuit disconnect capability. For example, aspects of this disclosure may relate to dual pole switching devices with integrated pyrotechnic actuated disconnects.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] So that those having ordinary skill in the art to which the disclosed systems and techniques pertain will more readily understand how to make and use the same, reference may be had to the following drawings. [0008] FIG. 1 A is an exploded perspective view of an electrical device, including a housing and a cover for the housing, in accordance with aspects of this disclosure.

[0009] FIG. IB is a perspective view of aspects of the electrical device of FIG. 1A, in accordance with aspects of this disclosure.

[0010] FIG. 1C is a perspective view of an example electrical device, in accordance with aspects of this disclosure.

[0011] FIG. 2 is a cross-sectional view of the electrical device of FIG. 1A, taken along section line 2-2 in FIG. 2, in accordance with aspects of this disclosure.

[0012] FIG. 3 A is the cross-section view of FIG. 2, with the electrical device in a first, open, configuration, in accordance with aspects of this disclosure.

[0013] FIG. 3B is the cross-section view of FIG. 2, with the electrical device in a second, closed, configuration, in accordance with aspects of this disclosure.

[0014] FIG. 3C is the cross-section view of FIG. 2, with the electrical device in a third, detonated, configuration, in accordance with aspects of this disclosure.

[0015] FIG. 4 includes a perspective view of a switch sub-assembly of an electrical device like the electrical device of FIG. 1, and an exploded perspective view of the switch sub-assembly, in accordance with aspects of this disclosure.

[0016] FIG. 5 is an exploded perspective view of a portion of the switch sub-assembly of FIG. 4, in accordance with aspects of this disclosure.

[0017] FIG. 6 is an exploded perspective view of additional aspects of the electrical device. DETAILED DESCRTPTTON

[0018] The subject technology overcomes many of the prior art problems associated with electrical devices. In brief summary, the subject technology provides improved electrical devices including a contactor design that combines the functionalities of a high voltage switching device and a fast disconnect device. Tn examples, the device may have three discrete operation states, including a first operating state in which a switch is open, e.g., in normal operation. The first operating state may be a default operating state. In the first operating state, no voltage or current flows through the device. A second operating state may be a state in which the switch is closed. For example, in the second operating state, a coil may be energized to cause one or more movable contacts to move into contact with one or more stationary contacts, thereby completing a circuit. In the second operating state, current, e.g., from a high voltage source, may flow through the device. A third operating state may be a triggered or disconnected state. For example, the third operating state may be a state in which the switch is fully opened to provide high voltage insulation, e.g., by preventing current flow through the device. For example, and a detailed herein, the third state may be a permanent disconnection of components within the device, e.g., to prevent current flow between those components.

[0019] In aspects of this disclosure, in the first and second operating states, the electrical device functions as a conventional switching device, (e.g., a contactor) providing a low resistance path, which may be optimized to carry high current and for thermal efficiency. In an over- current/fault condition, a pyrotechnic assembly integrated into the device, a current sensor, and/or an electronics module assembly facilitate measurement and detection of a fault. In response to the detection of the fault, a pyrotechnic device within the electrical device is initiated. The energy of the pyrotechnic is used to open the switch at a defined fault current, which may result in rapid arc suppression and a full disconnect between a high voltage power source and other downstream system components. The device may also be configured for an active trigger use case, e.g., such that the device can accept an external trigger signal.

[0020] Without limitation, the devices and techniques described herein may provide improved electrical devices, which may be less complex, may be cheaper to manufacture and/or use, and/or that may have improved safety and/or result in improved system protection, when compared to similar conventional systems. Moreover, while aspects of this disclosure may be particularly useful in certain application, like high voltage automotive systems, the systems and techniques described herein may be useful with many electrical systems.

[0021] Aspects of the disclosure will now be explained in more detail with reference to the

Figures.

[0022] FIGS. 1A, IB, and 1C are different views of an electrical device 100, which may be a contactor device, a fuse device, a pyrotechnic fuse, or the like. Tn FIGS 1 -1 C, the same reference numerals are used to reference the same components and features.

[0023] More specifically, FIG. 1 A is an exploded perspective view of the electrical device 100. The electrical device 100 generally includes a body or housing 102 and a cover 104 (shown removed in FIG. 1 A) configured to cooperate with the housing 102. For example, the cover 104 may be selectively coupled to the housing 102, e.g., to cover aspects of the device 100 contained in the housing. In the illustrated example, the housing 102 contains two switch assemblies 106, although in other implementations more or fewer switch assemblies 106 (and/ or other components) may be disposed in the housing 102. Among other features, discussed herein, each of the switch assemblies may include two fixed contacts 108. The fixed contacts 108 are configured to electrically connect internal components (detailed further herein) of the electrical device 100 to external circuitry, for example, to an electrical system or device. For example, the fixed contacts 108 may be terminals configured to facilitate connection of first electrical leads (not shown) from a voltage source to second electrical leads (also not shown) of a load to be powered by the voltage source.

[0024] The housing 102 can include any suitable material that can support the structure and function of the electrical device 100. For example, the housing 102 is illustrated as being a substantially rectangular receptacle sized to retain the two switch assemblies 106 in a side-by-side arrangement. Of course, the size, shape, and configuration of the housing 102 is for example only. In other contemplated examples, the housing 102 may be sized to retain only a single instance of the switch assembly 106 or to retain three or more instances of the switch assemblies 106.

[0025] As shown in FIG. 1C, the cover 104 includes a number of cutouts 110. When the cover 104 is coupled to the housing 102, the fixed contacts 108 are positioned in the cutouts 110, e.g., to access the fixed contacts 108 for connecting/ disconnecting the electrical device 100 to other components and/or systems. Thus, the housing 102, with the cutouts 110, will present the fixed contacts 108 in an array for selective attachment/detachment. As also shown in FIG. 1 A, the cover 104 may include indicia 112, e.g., Al, A2, Bl, B2. The indicia 112 may indicate, e.g., to a technician or the like, the arrangement of the fixed contacts 108 in the electrical device 100. For example, Al and A2 may correspond to terminals of a first of the switching assemblies 106, and Bl and B2 may correspond to terminals of a second of the switching assemblies 106. Of course, the indicia 112 may be other than the alphanumeric indicia and/or the indicia may not be included in some instances, for example, when only a single instance of the switching assemblies 106 is present. [0026] Visible in FIG. 1 A (and in FTG. 2, discussed further below) each of the switch assemblies 106 can also include a pyrotechnic actuator 114. As detailed herein, the pyrotechnic actuator 114 may be configured to detonate, e.g., in response to an event such as a surge, short- circuit, or the like. In examples, the electrical device 100 also includes electronics 116 in communication with the pyrotechnic actuators 114. The electronics 116 can include functionality to cause the pyrotechnic actuator(s) 114 to detonate, e.g. in response to detection of an overcurrent, short, a user-instruction, or other event. In additional aspects of this disclosure, the electronics 116 can include an integrated electronics assembly capable of measuring current (i.e. over-current detection), temperature, coil drive/economization, and/or the like. The electronics 116 can also optionally include a programmable trigger threshold, which may allow for bidirectional communication with external system(s), including but not limited to vehicle system(s) when the electrical device 100 is used in vehicles. The electronics 116 may also include an integrated closed loop current-based economization circuit for minimal power consumption and maximum efficiency.

[0027] In the illustrated example, e.g., of FIGS. 1A and IB, the electronics 116 include a printed circuit board assembly 118. The assembly 118 includes a flexible printed circuit board

120 and a number of electrical leads 121. The electrical leads 121 are configured to interconnect aspects of the electronics 116 and/or the electrical device 100. For example, the electrical leads

121 may provide an electrical connection between the pyrotechnic actuators 112 and additional electronic components 122, e.g., spaced elsewhere on the printed circuit board assembly 118. For instance, the additional electronic components can include logic and/or programming, which may be embodied as printed and/or other components on the printed circuit board 120. In the example of FIGS. 1 A and IB, the flexible printed circuit board 120 facilitates attachment of a first portion of the flexible printed circuit board 120 to the pyrotechnic actuators 1 12, e.g., proximate a top of the electrical device 100, and positioning of the additional electronic components 122 proximate a side of the electrical device 100. For example, the housing 102 may include a circuit board mounting section 124, which can include one or more mounting features 126, such as posts, clips of the like.

[0028] The housing 102 can also facilitate electrical connection of the printed circuit board assembly 118 (and thus the electronics 116) to one or more external components. As illustrated, the housing 102 includes an integrated port or receptacle 130. The receptacle 130 may facilitate selective connect! on/disconnecti on of the electrical device 100 to one or more external components, e.g., an external controller, system, or the like. Without limitation, the receptacle 130 may include one or more pin connectors, which may be configured to cooperatively couple with a plug or other component configured for receipt in the receptacle 130. In examples, the receptacle 130 may be connected to the printed circuit board assembly 118 via one or more leads, connectors, or the like.

[0029] In examples, and as shown in FIG. 1C, the printed circuit board assembly 118 can also be connected to one or more low voltage interconnects 132. The low voltage interconnects 132 may be leads that are coupled to the switching assemblies 106, e.g., to facilitate opening and/or closing of the switching assemblies.

[0030] The electronics 116 can also include components, logic and/or programming to sense an overcurrent event. For instance, the printed circuit board assembly 118 is illustrated as including a sensor 134. The sensor 134 may be configured to identify a current-related event. For example, the sensor 134 may be a hall-effect sensor arranged proximate the fixed contacts 108, to sense a change in a magnetic field that may be associated with an overcurrent event in a high voltage circuit facilitated by the fixed contacts 108. More specifically, the sensor 134 may generate a signal that is received by the additional electronics 128. As will be appreciated, sensing of an overcurrent event may be done other than via the sensor 134; the sensor 134 is for example only.

[0031] As illustrated in FIG. 1 A, the cover 104 includes atop portion 136 and a side portion 138. When the cover 104 is coupled to the housing 102, the top portion 136 covers a top of the housing 102 and the side portion 138 covers the circuit board mounting section 124, e.g., to cover the electronics 116 discussed above. In this manner, the housing 102 with attached cover 104 provides an integrated electrical device 100, best shown in FIG. 1C, with both switching capabilities and fault protection, as detailed further herein. The cutouts 110 provide access to the fixed terminals 108, to allow for connection of high voltage electrical equipment. The receptacle 130 provides for low voltage connection of the device 100, e.g., for control purposes, or the like. Of course, the illustrated examples of the cover 104 (and the housing 102) are only examples. Other configurations, orientations, and/or embodiments also are contemplated. For instance, the cover 104 may be formed of two (or more) separate section, e.g., one for placement on the top of the housing 102 and a second for placement on the side of the housing 102. In this manner, the assemblies 106 may be accessed separately from the electronics, e g., to facilitate repair, replacement, reconfiguration, or the like of the assemblies 106 without also exposing most of the electronics 116. This may be particularly useful when a number of the electronic devices 100 are provided next to each other, and it may be desirable to only access the top of the housing 102.

[0032] Modifications can also be made to the electronics 116. For instance, although use of the printed circuit board assembly 118 may be desirable to facilitate placement of the electronics 1 16 at different locations, in other examples aspects of the printed circuit board assembly 118 may be replaced by leads, interconnects, or the like, e.g., which are not formed on a circuit board. In still further examples, one or more rigid circuit boards may be used, e.g., disposed in a portion of the housing 102 that facilitates interconnection with the pyrotechnic actuators 114, the receptacle 130, the low voltage interconnects, and/or other aspects of the electrical device 100.

[0033] FIG. 2 is a cross-sectional view of the electrical device 100 taken along the section line 2-2 in FIG. 1A. In FIG. 2, the housing 102 and the cover 104 are removed for clarity. Accordingly, the cross-sectional view of the FIG. 2 generally corresponds to a cross-sectional view of one of the switch assemblies 106. Specifically, the view of FIG. 2 shows the fixed contacts 108, e.g., as fixed, or stationary contacts. The electrical device 100 also includes a movable contact 202. In the illustrated example, the movable contact 202 includes one or more optional isolation components 203. The isolation components 203 may be polymeric components that cover one or more surfaces of the movable contact 202, e.g., to electrically isolate the movable contact 202 from other metallic components, including but not limited to the shaft 205, a housing of the assembly 106, and/or the like. In some examples, the isolation components 203 may be components separate from the movable contact 202, although in further examples the isolation components 203 can be overmolded on the movable contact 202 or otherwise integrated into the movable contact 202.

[0034] The movable contact 202 is associated with an actuator subassembly 204 configured to, among other functions, facilitate selective opening and closing of the switch, e.g., by facilitating selective movement of the movable contact 202 into and out of contact with the fixed contacts 108. For example, the actuator subassembly 204 is illustrated as including a shaft 205 and a coil 206, e.g., a DC coil, which may be selectively energized, e.g., via the low voltage interconnects 134 discussed above, to cause a portion of the actuator assembly, e.g., the shaft 205 and an associated plunger, to move up and down, causing the movable contact 202 to accordingly move relative to the fixed contacts 108. Additional details of the actuator assembly 204 are shown in FIG. 6, and discussed in more detail below.

[0035] The movable contact 202 is configured to move relative to a distal (lower) end of the fixed contacts 108, e.g., in a volume 207 defined by a switch assembly housing 208 The switch assembly housing 208 includes a switch assembly housing base 210 and a switch assembly outer can 212 configured to cooperate with the switch assembly housing base 210. In examples, the switch assembly housing base 210 and the switch assembly outer can 212 are metal parts, e.g., steel parts, welded to each other and forming a hermetically-sealed volume in which aspects of the switch assembly 106 are housed. For instance, the housing base 210 and the outer can 212 can be configured such that the volume 207 defined thereby houses the various internal components of the electrical device 100 and is hermetically sealed. An electronegative gas may be contained in the volume. This hermetically sealed configuration can help mitigate or prevent electrical arcing between adjacent conductive elements, and in some embodiments, helps provide electrical isolation between spatially separated contacts, e.g., between the fixed contacts 108 and the movable contact 202. In some examples, the switch assembly housing 208 can be under vacuum conditions, and can be hermetically sealed using known means of generating hermetically sealed electrical devices.

[0036] FIG. 2 also shows additional details of the pyrotechnic actuators 114. Specifically, the pyrotechnic actuator 114 includes a pyrotechnic initiator 214 and a pyrotechnic piston 216. In normal operation, the pyrotechnic piston 216 (and the pyrotechnic initiator 214) is retained in a pyrotechnic housing 218. For instance, as shown, the pyrotechnic piston 216 may have an integrated seal, e.g., an O-ring or other resilient member, that creates an interference fit with an inner surface of the pyrotechnic housing 218. The integrated seal(s) may efficiently direct and transfer pyrotechnic energy to the actuator assembly 204. Specifically, in the event of an overcurrent event (or other event that requires circuit interrupt), the pyrotechnic initiator 214 is triggered to detonate. The detonation causes the pyrotechnic piston 216 to move downward, e.g., to contact a portion of the actuator assembly 204, such as a top of the shaft 205, and force the movable contact 202 away from the fixed contacts 108.

[0037] In more detail, and as illustrated in FIG. 2, the pyrotechnic actuator 114 includes one or more electrical leads 220 (one of which is shown). As shown in FIGS. 1A and IB above, the electrical leads 220 may be electrically coupled to the flexible circuit board assembly 118. Via the leads 220, the pyrotechnic actuator 114 may receive a signal corresponding to an overcurrent event. In response to the signal, the pyrotechnic initiator 214 detonates, forcing the pyrotechnic piston into the volume 207 to contact the actuator assembly 204. Additional details of the operation of the pyrotechnic actuator 114 are detailed further herein.

[0038] In the illustrated example, the pyrotechnic actuator 114, the movable contact 202, lower ends of the fixed contacts 108, and a portion of the actuator assembly 206 are disposed in the hermetically-sealed volume 207. FIG. 2 also shows permanent magnets 222 disposed in the switch assembly housing 208, e.g., proximate opposite ends of the movable contact 202. Other components may also be disposed in the volume 207.

[0039] FIG. 2 also illustrates a retention mechanism 224 disposed in the volume 207. The retention mechanism 224 generally includes a base plate 226 and a plurality of contact retention members 228. The base plate 226 may be disposed on the housing base plate 210. In the illustrated example, the base plate may include a flanged protrusion 230 configured for receipt in an opening (e.g., a central opening) in the housing base plate 210. The flanged protrusion 230 may position the retention mechanism 224 relative to the base plate and/or facilitate coupling of the two components, e.g., via a press-fit or the like. As also illustrated, the retention mechanism 224 can include a score 231 proximate the flanged protrusion 230. For example, the score 231 is a circular score formed in a top of the base plate 226, generally concentric with the flanged protrusion 230. As detailed further below, the score 231 may facilitate separation of the portion of the base plate 226 including the flanged protrusion 230 from the remainder of the base plate 226. The score 231 is shown for example only. Other methods of weakening a portion of the base plate 226, including perforations, non-circular thinned regions, and/or other frangible profiles may be used to facilitate separation of the portion of the base plate 226.

[0040] The contact retention members 228 are configured to facilitate retention of the movable contact 202 in a position spaced from the fixed contacts 108, e.g., in an open position. In the illustrated example, the contact retention members 228 comprise one or more tabs (three of which are illustrated) or protrusions having distal ends in a path of travel of the movable contact 202. The protrusions or tabs are angled, e.g. relative to a travel path (the vertical direction in the example) and resilient. For example, the retention members are configured to allow one-way travel of the movable contact 202, e.g., in a first (downward) direction, but to inhibit or prevent motion of the movable contact 202 in the opposite direction. In examples, the movement of the movable contact 202 resulting from contact by the pyrotechnic piston 216 is sufficient such that the movable contact 202 pushes the tabs out of the travel path until the movable contact 202 clears the distal ends of the retention members 228. Once the movable contact 202 clears the retention members 228, the retention members 228 are no longer contacted by the movable contact 202. Without the force applied by the movable contact 202, the retention members 228 “spring” back to their angled positions (the position illustrated in FIG. 2 and FIG. 3C, shown below), with the distal ends being disposed above (e.g., over) a top surface of the movable contact 202. With the distal ends of the retention members 228 over the movable contact 202, upward motion (in the orientation of FIG. 2 and 3C) is precluded by the retention members 228.

[0041] In non-limiting examples, the retention structure may be a molded part, e g., injection molded or the like from a rigid polymer. The retention members 228 are illustrated as being supported on the base plate 226, e.g., by one or more support legs 233. This is for example only. More specifically, the support legs 230 may be substantially vertical, and the retention members 228 extend from a position proximate a top of the support legs 230, in an angled manner to space the distal end of the retention member 228 from the support leg 233, e.g. in the horizontal direction and relatively lower. As noted above, the distal end is disposed in a path of travel of the movable contact 202. The support leg 233 is spaced from the travel path, e.g., so as to not impede travel of the movable contact 202. In examples, the support leg 233 is substantially rigid, with the retention member 228 being movable relative to the support leg 233. For example, the retention member 228 can pivot relative to the support leg 233 about a portion connecting the retention member 228 and the support leg 233. Such a portion may function as a pivot or hinge, e.g., a “living hinge.” During pivoting, the retention member 228 may pivot into a void 232 associated with the support leg 233.

[0042] Of course, the contact retention mechanism 224 is for example only. Modifications and alternative configurations also are contemplated. For example, other configurations that allow for movement of the movable contact 202 to a position spaced from the fixed contacts 108, and that can retain the movable contact 202 in this spaced position may be used. In one non-limiting example, the retention members 228 may be replaced with detents or spring-biased members that are biased into a position blocking upward movement of the movable contact when the movable contact travels a predetermined distance from the fixed contacts 108. In still further examples, one or more posts may extend upward from the base plate 226, e.g., in a footprint of the movable contact 202. In this example, a bottom of the movable contact 202 may have corresponding openings or bores that align with the posts, such that when the movable contact is forced into contact with the posts, the posts cooperate with the openings to retain the movable contact 202. For example, the posts may form an interference fit with the openings. In other examples, the posts may have a contour that expands or otherwise deforms to create a force that retains the movable contact 202 in a position spaced from the fixed contact 108.

[0043] The contact retention mechanism 224 can also include one or more additional features e.g., for facilitating alignment and/or connection of the components in the volume 207. For instance, the contact retention mechanism 224 is illustrated as including one or more flanges or protrusions 234 extending above the base 226. For example, the protrusions 234 may comprise alignment surfaces that facilitate placement of additional structure, including but not limited to arc suppression components 236, 238. For example, the arc suppression component 236 may act as a liner on an interior surface of the housing 208 to help mitigate damage should the electrical device 100 encounter an overcurrent event. Similarly, the arc suppression component 238 may act as a barrier between components of the electrical device 100. For example, the arc suppression component may separate the permanent magnets 222 from the contacts 108, 202. In some examples, the arc suppression components may be polymeric structures.

[0044] Other aspects of the electrical device 100 may be placed outside of the volume 207.

For instance, the coil 206 and portions of the actuator assembly 204 may be disposed in a lower, coil housing 240. The coil housing 240 is disposed below (in the orientation of FIG. 2) and separate from the switch assembly housing 208. Tn the illustrated example, the coil housing 240 includes a substantially U-shaped component, with exposed or open sides. In some examples, the coil 206 may be an over-molded coil, e.g., including a DC coil 206 encased in a polymer or other material(s). The over-molding and/or placement of the coil 206 outside of the hermetically-sealed volume 207 may mitigate issues, such as IR issues occurring during use of the electrical device 100. In the illustrated example, the coil 206 has a stepped profile, e g., including a first (radial) thickness 242 proximate a lower end of the coil 206 and a second (radial), thicker thickness 244 proximate an upper end of the coil 206. The varied thicknesses 242, 244 may facilitate placement of magnetic circuitry 246, e.g., disposed in the “stepped” region formed by the thicknesses 242, 244. For example, the circuitry 246 may be coupled to the electronics 116 discussed above, e.g., using the interconnects 134 discussed above.

[0045] FIGS. 3A-3C illustrate the cross-sectional view of FIG. 2, with each FIG. showing the electrical device 100 in a different operational state or configuration. Specifically, FIG. 3A shows a first, open state 302 in which the movable contact 202 is spaced from the fixed contacts 108 (e.g., the stationary contacts). In the first state 302, the fixed contacts 108 are electrically separated from the movable contact 202, and thus from each other, such that no current flows through the device 100.

[0046] FIG. 3B shows a second, closed state 304 in which the movable contact 202 is moved into contact with the fixed contacts 108. In this configuration, the device 100 is closed, such that current passes, via the movable contact 202, between the fixed contacts 108, and thus through the device. In examples, the DC coil 206 is energized to cause the actuator assembly 204 to move the movable contact 202 into contact with the fixed contacts 108 as shown in FIG. 3B. [0047] In the operating states 302, 304, the electrical device 100 functions as a conventional switching device (i.e. contactor). The device 100 may have a low resistance path optimized for high current carry and thermal efficiency, for example.

[0048] FIG. 3C shows a third, detonated state 306, which results from detonation of the pyrotechnic actuator 114. Specifically, in the detonated state 306, the pyrotechnic initiator 214 has received a signal, via the leads 220, to detonate, and the pyrotechnic initiator 214 has been detonated. As illustrated, the force caused by the detonation has caused the pyrotechnic piston 216 to eject from the pyrotechnic housing 218. Upon ejection, the pyrotechnic piston 216 contacts and drives a shaft associated with the actuator assembly 204 down (in the orientation of FIG. 3C), forcing the movable contact 202 away from the contact structures.

[0049] As also illustrated in FIG. 3C, the movable contact retention members 228 retain the movable contact 202 at a position proximate the bottom of the switch assembly housing 208. As discussed above, the movable contact retention members 228 may be protrusions or tabs having distal ends in a path of travel of the movable contact 202. The protrusions or tabs are angled, e g. relative to a travel path (the vertical direction in the example) and resilient. For example, the retention members are configured to allow one-way travel of the movable contact 202, e.g., in a first direction, but to inhibit or prevent motion of the movable contact 202 in the opposite direction. In examples, the movement of the movable contact 202 resulting from contact by the pyrotechnic piston 216 is sufficient such that the movable contact 202 pushes the tabs out of travel path until the movable contact 202 clears the distal ends of the retention members 228. Once the movable contact 202 clears the retention members 228, the retention members 228 are no longer contacted by the movable contact 202. The retention members 228 “spring” back to their angled positions, with the distal ends being disposed above (e.g., over) a top surface of the movable contact 202. With the distal ends of the retention members 228 over the movable contact 202, upward motion (in the orientation of FIG. 3C) is precluded by the retention members 228. The device 100 can be configured in the detonated state 306 in response to an overcurrent, e.g., resulting from a short, surge, or the like. In examples, the electronics 116 may include a fast-acting fault current detection circuit, e.g., including the sensor 134, which can trigger the pyrotechnic actuator (e.g., a squib) in <250pS at a preset current limit. In examples, combining the effect of strong magnetic fields (e.g., generated by the permanent magnets 222) and pressurized hydrogen, its arc suppression mechanism allows to safely switch beyond 10-MegaWatt load during a short circuit or overcurrent incident.

[0050] As also illustrated in FIG. 3C, the detonation of the pyrotechnic initiator 214 can also cause additional changes to the electrical device. For example, the downward force on the shaft 205, in addition to moving the movable contact 202, causes a breakaway portion 308 of the base plate 226 of the retention mechanism 224 to separate from a remainder of the base plate 226. In the illustrated example, the shaft 205 includes a standoff 310 that provides a wider diameter than a remainder of the shaft 205. During normal operation, the standoff may contact atop surface of the base plate 226, e.g., to establish a longitudinal position (e.g., a height) of the movable contact 202 in the open state 302 shown in FIG. 3A. Under the large force applied by the pyrotechnic plunger 216, however, the standoff 310 contacts the upper surface of the base plate 226 with a force sufficient to cause the breakaway portion 308 of the base plate 226 of the retention mechanism 224 to break away from the remainder of the base plate 226. The score 231 or other weakened portion facilitates breakage of the base plate 226. As shown in FIG. 3C, the breakaway portion 308 and the standoff 310 may pass through the base plate 210, at least partially out of the volume 207. [0051] As will be appreciated, the detonated state 306 may provide a permanent disconnection in which the switch is fully opened, providing high voltage insulation. In an overcurrent / fault condition, the integrated pyrotechnic assembly, current sensor, and electronics module assembly provides the capability for the device to measure, detect and initiate the pyrotechnic device within the device system. The energy of the pyrotechnic is utilized to open the switch at a defined fault current resulting in rapid arc suppression and full disconnect between HV power source and other system components downstream in the detonated state 306. The device can also be configured for an active trigger use case, where the device can accept an external trigger signal.

[0052] FIG. 4 includes a perspective view of an instance of the switch assembly 106. FIG. 4 also includes an exploded view of the switch assembly 106. As shown, the switch assembly 106 includes the base 210 and the outer can 212. When coupled, e.g., via welding or the like, the base 210 and the outer can 212 can form a hermetically-sealed volume (e.g., the volume 207 discussed above). As also illustrated, the fixed contacts 108 and the pyrotechnic actuator 114 are retained in the outer can 212.

[0053] FIG. 4 also shows the arc chamber components 236, 238, e.g., as part of an arc chamber subassembly. As noted above, the arc chamber component 236 may act as a sleeve or insert, e.g., disposed in the can 212. The arc chamber component 236 may mitigate effects of an overcurrent event, e.g., by controlling electrical arcing. Also in examples, the arc chamber component 236 can define first openings 402 and a second opening 404. The first openings 402 may be configured such that a portion of the fixed contacts 108 pass through the first openings 402. When the switch assembly 106 is assembled, the first openings 402 may circumscribe an outer surface of the fixed contacts 108. The second opening 404 may be configured to partially receive one or more portions of the pyrotechnic actuator 114. For example, the pyrotechnic housing 218 may be received in the second opening 404.

[0054] The arc chamber component 238 may be provided to further isolate components of the switch assembly 106. For example, the arc chamber component 238 may, along with the arc chamber component 236, define a volume for retaining the permanent magnets 222. Relative positions of the arc chamber components 236, 238 also are shown in FIG. 2.

[0055] FIG. 4 also shows that the switch assembly 106 includes a coil/magnetic circuit subassembly 406, e.g., which cooperates with the actuator assembly 204 to control the movable contact 202 as described herein. More specifically, the coil/magnetic circuit subassembly 406 includes a housing 408. The housing 408 is illustrated as a cylindrical housing, although other arrangements are possible. The housing 408 is configured to retain the coil 206, which as discussed above, may be an overmolded DC coil. The coil/magnetic circuit subassembly 406 also includes electrical connectors 410, shown as blade connectors. For example, the interconnects 134 discussed above may be coupled to the electrical connectors 410 to electrically couple the coil 206 to the electronics 116 discussed above. For example, the coil 206 may be selectively energized to move the shaft 205, thus resulting in movement of the movable contact 202. FIG. 4 also shows the coil housing 240.

[0056] FIG. 5 is an exploded perspective view of a portion of the switch assembly 106 including the outer can 212, the fixed contacts 108, and the pyrotechnic actuator 114. As illustrated, the outer can 212 defines three openings 502, 504, 506 in a top surface, configured to receive the two fixed contacts 108 and the pyrotechnic actuator 114. As will be appreciated, the openings 502, 504, 506 will align with the openings 402, 404 in the arc chamber isolation component 236. As also shown, the fixed contacts 108 generally include a cylindrical body with a flanged head. As shown, a sleeve 508, which may be a metal sleeve, is disposed around the cylindrical body of the fixed contact 108, below the flanged head. Moreover, an eyelet 510, e.g., a ring-shaped eyelet is positioned axially above the sleeve 508, between the sleeve 508 and a bottom of the flanged head of the fixed contact 108. This arrangement is also well illustrated in FIG. 2. The fixed contacts 108 are fixed to the outer can 212 via the one or more eyelets 510, e.g., by metal-to-glass welding techniques at the sleeve 508. For example, glass-to-metal-seals (GTMS) may maintain full hermeticity of the upper switch assembly, while maintaining isolation to external electronics.

[0057] FIG. 5 also shows a second sleeve 512 disposed around the cylindrical body of the fixed contacts 108. The second sleeve 512 is provided (radially) between the body of the fixed contact and the sleeve 508 and the eyelet 510 used for securing the fixed contact 108 to the outer can 212. The second sleeve 512 may be an optional ceramic sleeve. The ceramic sleeve may provide improved insulation and/or increase a creepage path associated with the assembly 106.

[0058] FIG. 5 also shows the pyrotechnic housing 218 in additional detail. The pyrotechnic housing 218 may be a cylindrical member, e.g., a barrel, containing the pyrotechnic initiator 214 and the pyrotechnic piston 216 as discussed above. In examples, the pyrotechnic housing 218 may be a metal material welded to the outer can 212 at the opening 506, e.g., to maintain a hermetic seal. In the illustrated example, the pyrotechnic housing 218 can include a flange 514 along its length. The flange 514 may have an outer diameter that is larger than a diameter of the opening 506. Accordingly, during assembly, the flange 514 may contact the outer can 212 proximate the opening 506 to enable welding or other attachment of the housing 218 to the can 212. As best shown in FIG. 2, the assembly 106 may be assembled such that the flange 514 is disposed inside the can 212, e.g., such that a top surface of the flange 514 is secured to an interior surface of the can 212. In other examples, however, the flange 514 may be outside the can, such that a bottom surface of the flange 514 is secured to an exterior surface of the can 212.

[0059] In some aspects of this disclosure, the pyrotechnic initiator / gas generator system assembly may be welded directly to the metal switch enclosure. This connection may allow for a fully hermetic switch assembly that includes the upper enclosure, the arc chamber, and aspects of the actuator assembly.

[0060] FIG. 6 is an exploded perspective view showing aspects of the actuator assembly 204. As shown, the actuator assembly 204 includes or is associated with the movable contact 202. In the example, the movable contact 202 is associated with the one or more isolation components 203. As discussed above, the isolation component(s) 203 may be one or more plastic components configured to electrically isolate the movable contact 202 from the remaining actuator components (e.g., the shaft 205) and the metal housing (e.g., the outer can 212). The isolation component(s) 203 may cover any or all surfaces of the movable contact 202 that do not contact the fixed contacts 108 during operation of the electrical device 100 in the closed state. Materials other than plastic may also be used for the isolation components. In some instances, the isolation component(s) 203 may be optional.

[0061] The movable contact 202 and the isolation component(s) 203 include an aperture or hole through which the shaft 205 can be inserted. As illustrated, the shaft 205 includes a flanged head 602. When the shaft 205 is inserted through the movable contact 202, the flanged head 602 contacts one of the isolation component(s) 203. Of course, when the isolation component(s) 203 are not used, the flanged head 602 may contact an upper surface of the movable contact 202. Other example arrangements also are contemplated. Any arrangement in which downward (in the orientation of FIG. 6) movement of the shaft causes corresponding movement of the movable contact 202 may be implemented.

[0062] As also shown in FIG. 6, the shaft 205 also extends through a contact spring 604, the standoff 310, the base plate 226 of the retention mechanism 224, the switch assembly housing base 210, a return spring 606, and a plunger 608. The plunger 608 is disposed in a plunger tube 610.

[0063] When assembled (as also shown in FIG. 2), the contact spring 604 is disposed axially between a bottom surface of the isolation component(s) 203 (or the movable contact 202) and a top surface of the standoff 310. The contact spring 604 may be a compression spring that biases the movable contact 202 away from the standoff 310. The standoff 310 may be fixed, e.g., welded to the shaft 205, to provide a region of the shaft with an increased diameter. In other examples, the standoff 310 may be integrated into the shaft 205, e.g., as a contoured or stepped outer surface of the shaft 205. As just noted, the increased diameter of the standoff 310 can be useful to provide a contact surface for the contact spring 604. Moreover, and as discussed above, the standoff 310 may be configured to contact an upper surface of the base plate 226 of the retention mechanism 224. In the open state 302 shown in FIG. 3A, the standoff 310 contacts the upper surface of the base plate 226 such that the height (e.g., the axial height) of the standoff 310 and the length of the contact spring 604 determine a position of the movable contact 202, i.e., a position relative to and spaced from the fixed contacts 108.

[0064] The plunger tube 610 is configured to be retained at a position in which the coil 206 (not shown in FIG. 6) circumscribes the plunger tube 610. When assembled, the plunger 608 is disposed in the plunger tube 610, and the plunger 608 is movable relative to the plunger tube 610. In examples, the plunger tube 610 may be fixed relative to the housing 408 retaining the coil 206 and the plunger 608 is free to move axially relative to the plunger tube 610 (and the coil 206) in response to activation/deactivation of the coil 206. The plunger 608 is coupled to a distal (lower end in the arrangement of FIG. 6) of the shaft 205. The return spring 606 is positioned on the shaft 205 between an upper surface of the plunger 608 and a lower surface of the switch assembly housing base 210. The return spring 606 biases the plunger 608 (and thus the shaft 205) away from the switch assembly housing base 210, e.g., in a downward direction in FIG. 6.

[0065] When assembled, the actuation assembly 204 includes the contact spring 604 that biases the shaft 205 and the movable contact 202 in a first direction (upward in the orientation of FIG. 6) and includes the return spring 606 that biases the shaft 205 and the movable contact 202 in a second, opposite direction (downward in the orientation of FIG. 6). The opposing forces result in an equilibrium position generally corresponding to the open state 302 shown in FIG. 3A. Activation of the coil 206 causes the plunger 608 to move (upward) against the biasing force of the return spring 606. The shaft 205 moves correspondingly, and the biasing force of the contact spring 604 maintains contact of the movable contact 202 with the head 602 of the shaft. With continued movement in this manner, the movable contact 202 contacts the fixed contacts 108, e.g., in the closed state 302 shown in FIG. 3B. Relative positioning of the components shown in FIG. 6 also are illustrated in FIG. 2 and FIGS. 3A-3C.

[0066] Some aspects of this disclosure can include a dual pole, bi-directional contactor which combines the functionalities of a high voltage switching device and a fast disconnect. The device may have three primary operating states, as discussed above. [0067] The unique arrangement of components of the electronic devices detailed herein can also provide a number of advantages, in addition to those already discussed, over conventional devices. For example, aspects of this disclosure can include positioning the coil and/or electronics outside of a hermetic assembly, which may improve post-interrupt insulation resistance. Additional aspects of this disclosure can include integrated overcurrent detection on the high voltage circuit, with autonomous shutdown capability.

[0068] Some additional aspects of this disclosure can include contactless auxiliary functionality with weld detection. Additional aspects of this disclosure may provide a modular architecture allowing for configurable performance. Additional aspects of this disclosure can include independently programmable trigger levels for individual switch disconnect (e.g., within a dual switch package). Additional aspects of this disclosure can include flexible mounting orientations and configurations. Additional aspects of this disclosure can include HV interface options include weldable, fastener, or the like. Additional aspects of this disclosure may be agnostic to air-cooled or liquid cooled systems.

[0069] While the subject technology has been described with respect to preferred embodiments, those skilled in the art will readily appreciate that various changes and/or modifications can be made to the subject technology without departing from the spirit or scope of the subject technology. For example, each claim may depend from any or all claims in a multiple dependent manner even though such has not been originally claimed.

Claims

WHAT TS CLAIMED TS:

1. A switching device comprising: a base; a can coupled to the base to define a volume defined at least in part by the base and the can; fixed contacts coupled to the can; a movable contact disposed in the volume; an actuator assembly configured to move the movable contact between a first position spaced from the fixed contacts and a second potion contacting the fixed contacts; a pyrotechnic actuator coupled to the can and configured to, in response to an overcurrent event, force the movable contact to a detonated position spaced from the fixed contacts; and a contact retention member configured to retain the movable contact in the detonated position.

2. The switching device of claim 1, wherein the pyrotechnic actuator comprises a pyrotechnic initiator and a pyrotechnic piston.

3. The switching device of claim 2, wherein detonation of the pyrotechnic initiator forces the pyrotechnic piston to contact a portion of the actuator assembly.

4. The switching device of claim 3, wherein: the actuator assembly comprises a shaft and a flared head at a top of the shaft, and the pyrotechnic piston is forced to contact the flared head of the shaft

5. The switching device of claim 1, wherein the actuator assembly comprises a standoff coupled to a shaft, the standoff being positioned to at least partially define a distance of the movable contact from the fixed contacts when the movable contact is disposed in the first position.

6. The switching device of claim 5, wherein, in the detonated position of the movable contact, the standoff passes through an opening in the base to a position at least partially outside of the volume.

7. The switching device of claim 6, further comprising a retention member base disposed on the base in the volume, wherein: the shaft passes through the retention member base; and when the pyrotechnic actuator is detonated, the standoff causes a portion of the retention member base to pass through the opening in the base.

8. The switching device of claim 7, wherein the retention member base comprises a weakened region that facilitates the portion of the retention member to disconnect from a remainder of the retention member base under a force applied by the pyrotechnic actuator on the shaft.

9. The switching device of claim 1 , wherein the contact retention member comprises a tab that extends into a travel path of movable contact.

10. The switching device of claim 9, wherein: the contact retention member extends from a support leg at an angle in a normal position, under a force applied to the movable contact by the pyrotechnic actuator, the contact retention member pivots relative to the support leg away from the normal position; further application of the force causes the movable contact to move to the detonated position at a position past the contact retention member; and with the movable contact in the detonated position, the retention member returns to the normal position with the support leg at least partially disposed above the movable contact, resisting movement of the movable contact toward the fixed contacts.

11. An electrical device comprising: a housing defining a volume; one or more switching devices disposed in the volume, a switching device of the one or more switching devices comprising: a base; a can coupled to the base to define a volume, fixed contacts secured to the can and extending into the volume, a movable contact disposed in the volume, an actuator assembly configured to move the movable contact between a first position spaced from the fixed contacts and a second potion contacting the fixed contacts, a pyrotechnic actuator coupled to the can and configured to, in response to an overcurrent event, force the movable contact to a detonated position spaced from the fixed contacts, and a contact retention member configured to retain the movable contact in the detonated position; and a cover coupled to the housing, the cover comprising one or more openings aligned with the fixed contacts to facilitate electrical connection to the fixed contacts.

12. The electrical device of claim 11, further comprising: a sensor in electrical communication with the pyrotechnic actuator, the sensor being configured to generate a signal in response to an overcurrent event, the signal causing the pyrotechnic actuator to detonate.

13. The electrical device of claim 12, wherein the sensor is a hall-effect sensor.

14. The electrical device of any one of claim 12 or claim 13, further comprising a flexible circuit board comprising the sensor and one or more leads, the flexible printed circuit board including a first portion configured to electrically connect to the pyrotechnic actuator and a second portion configured to electrically connect to a receptacle associated with the housing.

15. The electrical device of claim 14, wherein: the first portion of the flexible circuit board is disposed proximate a top of the housing of the electrical device; the second portion of the flexible printed circuit board is disposed on a side of the housing of the electrical device; and the cover comprises a top portion that, when the cover is coupled to the housing, covers the first portion of the flexible printed circuit board, and the cover comprises a side portion that, when the cover is coupled to the housing, covers the second portion of the flexible printed circuit board.