Patent Description:
This background description is set forth below for the purpose of providing context only. Therefore, any aspect of this background description, to the extent that it does not otherwise qualify as prior art, is neither expressly nor impliedly admitted as prior art against the instant disclosure.

In <CIT> there is disclosed a solid state circuit breaker module, comprising a transistor, a transient voltage suppression device, and a circuit board, wherein the transistor and the transient voltage suppression device are electrically connected to the circuit board; the solid state circuit breaker module is configured to be connected to one or more first non-scalable modules to regulate current; and the solid state circuit breaker module is configured to receive one or more scalable modules.

A further solid state circuit breaker module is disclosed in <CIT> which utilizes solid state relays which are made up of individual switching circuit modules.

Some solid state circuit breaker assemblies may not be sufficiently robust, may not be designed for a wide variety of applications, and/or may involve complex assembly processes.

There is a desire for solutions/options that minimize or eliminate one or more challenges or shortcomings of solid state circuit breaker assemblies. The foregoing discussion is intended only to illustrate examples of the present field and should not be taken as a disavowal of scope.

The present invention is a solid state circuit breaker assembly as it is defined in claim <NUM>.

The present invention further is a method of assembling a solid state circuit breaker assembly as it is defined in claim <NUM>.

The foregoing and other aspects, features, details, utilities, and/or advantages of embodiments of the present disclosure will be apparent from reading the following description, and from reviewing the accompanying drawings.

Reference will now be made in detail to embodiments of the present disclosure, examples of which are described herein and illustrated in the accompanying drawings. While the present disclosure will be described in conjunction with embodiments and/or examples, it will be understood that they are not intended to limit the present disclosure to these embodiments and/or examples. On the contrary, the present disclosure is intended to cover alternatives, modifications, and equivalents.

In embodiments, such as generally illustrated in <FIG>, a solid state circuit breaker assembly <NUM> may include one or more first modules <NUM> (which may also be referred to as a "non-scalable module(s)") and/or one or more second modules <NUM> (which may also referred to as a "scalable module(s)"). The first/non-scalable modules <NUM> and/or the second/scalable modules <NUM> may be connected (e.g., electrically and/or mechanically) to form the solid state circuit breaker assembly <NUM>. The solid state circuit breaker assembly <NUM> may be configured to receive high current and/or high voltage. The solid state circuit breaker assembly <NUM> may be configured to disconnect a source <NUM> (e.g., a high-power source) from one or more electronic components if the voltage and/or current exceed a threshold current of the solid state circuit breaker assembly <NUM>. One or more scalable modules <NUM> may be added to the solid state circuit breaker assembly <NUM> to increase current and/or voltage capacity of the solid state circuit breaker assembly <NUM>.

In embodiments, such as generally illustrated in <FIG>, a solid state circuit breaker assembly <NUM> may include two non-scalable modules <NUM> and/or one or more scalable modules <NUM>. For example and without limitation, the one or more scalable modules <NUM> may be substantially positioned or disposed between the non-scalable modules <NUM>. The solid state circuit breaker assembly <NUM> may be modular, such that one or more scalable modules <NUM> may be added and/or removed from the assembly <NUM> (e.g., the modules <NUM>, <NUM> may be removed and/or added with minimal tools and/or effort). The solid state circuit breaker assembly <NUM> may comprise various numbers of scalable modules <NUM>. An increase in the number of scalable modules <NUM> connected to the first modules <NUM> may increase (scale up) the voltage and/or current capability of the solid state circuit breaker assembly <NUM>. For example and without limitation, connecting additional scalable modules <NUM> to the solid state circuit breaker assembly <NUM> may increase (e.g., as a function of the number of scalable modules <NUM>) the voltage capacity of the solid state circuit breaker assembly <NUM>.

With embodiments, a first non-scalable module <NUM> may be configured to receive high currents and/or high voltages. In embodiments, a first non-scalable module may be uniquely structured (e.g., sized) to provide for worst-case requirements, such as current/voltage carrying capability, as well as structural/mechanical requirements (e.g., vibration and shock). The first non-scalable module <NUM> may receive high currents and/or high voltages, and/or the first non-scalable module <NUM> may route the high current to the one or more scalable modules <NUM>. The first non-scalable module <NUM> may connect the solid state circuit breaker assembly <NUM> to a source <NUM> (e.g., a voltage and/or a current source). The one or more first modules <NUM> may include one or more of a variety of electronic components. For example and without limitation, the one or more first modules <NUM> may include a controller <NUM>, a current sensor <NUM>, a gate driver <NUM>, and/or one or more low voltage auxiliary power supplies <NUM> (see, e.g., <FIG>).

In embodiments, a first non-scalable module <NUM> may be configured as a first portion <NUM> and/or a second portion <NUM> of a housing <NUM> of the solid state circuit breaker assembly <NUM>. The first module <NUM> may protect components of the solid state circuit breaker assembly <NUM> from external interference (e.g., electrical and/or mechanical interference). The housing <NUM> may include one or more of a variety of materials, such as a polymer. The housing <NUM> may include one or more of a variety of shapes, sizes, and/or configurations. For example and without limitation, the first portion <NUM> of the housing <NUM> may be substantially cylindrical and/or box-shaped. The non-scalable module <NUM> may include one or more mounting portions <NUM> that may connect the solid state circuit breaker assembly <NUM> to a mounting surface <NUM> (e.g., a portion of an aircraft and/or an electrical component frame, such as illustrated in <FIG>). The one or more mounting portions <NUM> may include one or more fasteners, connectors, and/or apertures to sufficiently secure (e.g., limit movement in at least one direction) the solid state circuit breaker assembly <NUM> to the mounting surface <NUM>. The mounting portions <NUM> may be disposed at or about a periphery of the housing <NUM>.

With embodiments, at least one of the non-scalable modules <NUM> may be configured as a cover (e.g., a second portion of the housing <NUM> may serve as a cover) and/or a connector assembly. A non-scalable module <NUM> may be connected to another non-scalable module <NUM> to form the housing <NUM> of the solid state circuit breaker assembly <NUM>. For example and without limitation, a first non-scalable module <NUM> may include a first portion <NUM> of the housing <NUM> and/or another second non-scalable module <NUM> may include a second portion <NUM> (e.g., a cover) of the housing <NUM>. One or more scalable modules <NUM> may be disposed between the non-scalable modules <NUM>. The non-scalable modules <NUM> (e.g., the first housing portion <NUM> and/or the second hosing portion <NUM>) may be configured to protect and/or isolate the scalable modules <NUM> from electrical and/or mechanical interference.

In embodiments, such as generally illustrated in <FIG>, the non-scalable module <NUM> may include one or more terminals <NUM> for receiving high voltage and/or high current (e.g., the non-scalable module <NUM> may be connected to a power source <NUM> to be managed by the solid state circuit breaker assembly <NUM>). The non-scalable module <NUM> may include a connector <NUM> that may be configured to connect with the low voltage power supply <NUM> of another first module <NUM>. One or more auxiliary components may be connected to the non-scalable module <NUM> to facilitate monitoring of the solid state circuit breaker assembly <NUM>. For example and without limitation, in embodiments, a single non-scalable module <NUM> may be connected with one or more scalable modules <NUM>. A single non-scalable module <NUM> may include a controller <NUM>, a current sensor <NUM>, a gate driver <NUM>, a power supply <NUM>, a housing <NUM>, and/or a connector <NUM> (e.g., a single non-scalable module <NUM> may be used instead of a first non-scalable module <NUM> and a second non scalable <NUM> module). The scalable modules <NUM> may be connected and/or assembled with (e.g., connected on top) of the non-scalable module <NUM> (e.g., stacked).

In embodiments, the solid state circuit breaker assembly <NUM> may include one or more scalable modules <NUM>. The scalable modules <NUM> may be configured to operate in conjunction with the non-scalable modules <NUM> as the circuit breakers of the solid state circuit breaker assembly <NUM>. Any number of scalable modules <NUM> may be added to the solid state circuit breaker assembly <NUM> to increase the voltage capacity of the assembly <NUM> (such as electrical design constraints may permit). Similarly, one or more scalable modules <NUM> may be electrically disconnected and/or removed from the solid state circuit breaker assembly <NUM> to reduce the voltage capacity of the assembly <NUM>. The scalable modules <NUM> may be configured to incrementally increase the voltage rating of the solid state circuit breaker assembly <NUM>. For example and without limitation, the one or more scalable modules <NUM> may be substantially identical. Each scalable module <NUM> may include a voltage carrying capacity X and/or a current carrying capacity Y. Such as generally illustrated in <FIG>, if two scalable modules <NUM> are connected to the solid state circuit breaker assembly <NUM>, the voltage capacity of the assembly <NUM> may be 2X (e.g., twice the capacity of a single scalable module <NUM>). Similarly, if three scalable modules <NUM> are connected to the solid state circuit breaker assembly <NUM>, the voltage capacity of the assembly <NUM> may be 3X (see, e.g., <FIG>). The voltage capacity of the assembly <NUM> may be equal to the voltage rating of a single scalable module <NUM> multiplied by the number of scalable modules <NUM> electrically connected to the non-scalable modules <NUM>. In embodiments, the scalable modules <NUM> may be configured to manage an alternating current supply of <NUM> volts and/or a direct current supply of about <NUM>,<NUM> volts or more or less.

With embodiments, such as generally illustrated in <FIG>, one or more scalable modules <NUM> may include a transistor <NUM> (e.g., a MOSFET, JFET, bipolar junction transistor, etc.), a transient voltage suppression device <NUM>, a circuit board <NUM>, and/or a heat sink <NUM>. The transistors <NUM>, transient voltage suppression devices <NUM>, and/or heat sinks <NUM> may be connected to the circuit board <NUM> of the scalable module <NUM>. The heat sink <NUM> may be a function of the structure of the scalable module <NUM>. For example and without limitation, the structure of the scalable module <NUM> may be configured such as to sufficiently dissipate heat from the scalable module <NUM> during operation of the solid state circuit breaker assembly <NUM>. Additionally or alternatively, the circuit board <NUM> may include heat sinks <NUM> connected to a surface of the circuit board <NUM>. Each scalable module <NUM> may include any number of transistors <NUM>, transient voltage suppression devices <NUM>, and/or heat sinks <NUM>. For example and without limitation, increasing the number of the transistors <NUM> and/or the transient voltage suppression devices <NUM> may increase the current carrying capability of each scalable module <NUM>.

In embodiments, each scalable module <NUM> may include a current carrying capacity Y. The current carrying capacity Y of each scalable module <NUM> may be dependent on the number of transistors <NUM> and/or transient voltage suppression devices <NUM> connected to the circuit board <NUM> of the scalable module <NUM>. For example and without limitation, a scalable module <NUM> with twice the number of transistors <NUM> and/or voltage suppression devices <NUM> may be configured such that the scalable module <NUM> may include a current capacity of 2Y (e.g., twice the current capacity). To increase the current carrying capacity of the one or more scalable modules <NUM>, the quantity of transistors <NUM> and transient voltage suppression devices <NUM> connected to the circuit board <NUM> may be increased.

With embodiments, each scalable module <NUM> may be configured to include the same quantity of transistors <NUM> and/or transient voltage suppression devices <NUM> to facilitate modular scaling of the assembly <NUM>. Including the same quantity of transistors <NUM> and/or transient voltage suppression devices <NUM> may facilitate modular scaling such that adding sequential scalable modules <NUM> incrementally increases the current capacity by a constant magnitude. In embodiments, transistors <NUM> and/or the transient voltage suppression devices <NUM> may be disposed symmetrically on the circuit board <NUM> such as to limit differences in connection length to each transistor <NUM> and/or each transient voltage suppression device <NUM> (e.g., see <FIG>). For example and without limitation, a first side <NUM> of the circuit board <NUM> may include the same number of transistors <NUM> and/or transient voltage suppression devices <NUM> as a second side <NUM> of the circuit board <NUM>. The transistors <NUM> and/or the transient voltage suppression devices <NUM> may be disposed on the circuit board <NUM> in a substantially circular pattern (see, e.g., <FIG>).

In embodiments, one or more non-scalable modules <NUM> and/or one or more scalable modules <NUM> may be removed and/or added to the solid state circuit breaker assembly <NUM> while the assembly may be active (e.g., while the non-scalable module <NUM> may be connected to the source <NUM>). The controller <NUM> in the non-scalable module <NUM> may be configured to sense when a non-scalable module <NUM> and/or a scalable module <NUM> may be removed from the solid state circuit breaker assembly <NUM>. The controller <NUM> may be configured to automatically deactivate (e.g., momentarily disconnect) the solid state circuit breaker assembly <NUM> upon sensing the removal of a non-scalable module <NUM> and/or a scalable module <NUM>. The controller <NUM> may disconnect the non-scalable modules <NUM> from the source (e.g., the power supply <NUM>). The controller <NUM> may sense whether the solid state circuit breaker assembly <NUM> is sufficiently connected before activating/re-activating the assembly <NUM>.

With embodiments, the controller <NUM> of the non-scalable module <NUM> may be configured to sense the number of scalable modules <NUM> connected to the solid state circuit breaker assembly <NUM>. If the controller <NUM> determines that the number of scalable modules <NUM> connected to the assembly <NUM> exceeds a maximum design threshold, the controller <NUM> may not permit operation of the solid state circuit breaker assembly <NUM>. Once the proper number of scalable modules <NUM> are connected in the assembly <NUM>, the controller <NUM> may permit operation of the solid state circuit breaker assembly <NUM>.

In embodiments, the one or more non-scalable modules <NUM> and/or the one or more scalable modules <NUM> may be electrically and/or physically connected to one another. In embodiments, modules <NUM>, <NUM> may be electrically connected via contacts <NUM> on an outer portion of the modules <NUM>, <NUM> (see, e.g., <FIG>). For example and without limitation, each module <NUM>, <NUM> may include one or more contacts <NUM> to facilitate electrical connection between modules <NUM>, <NUM>. The one or more contacts <NUM> may be configured as a threaded connection. The modules <NUM>, <NUM> may be connected to other modules <NUM>, <NUM> via a snap connection (e.g., the contacts <NUM> between the modules <NUM>, <NUM> may be configured to snap together and/or compress to provide an electrical connection between modules <NUM>, <NUM>). When connecting and/or disconnecting modules <NUM>, <NUM> from the solid state circuit breaker assembly <NUM>, the modules <NUM>, <NUM> may be separated and/or pushed together until the contacts <NUM> disengage and/or engage (e.g., via a snap fit connection). For example and without limitation, if one or more of the scalable modules <NUM> are not functioning properly, the one or more scalable modules <NUM> may be easily replaced without disconnecting the solid state circuit breaker assembly <NUM> from the power source <NUM> (e.g., modules <NUM>, <NUM> may be swapped while the circuit is active/hot).

With embodiments, such as generally illustrated in <FIG>, a method <NUM> of assembling a solid state circuit breaker assembly <NUM> may include providing a first non-scalable module <NUM> (e.g., a housing/controller module) that may include a controller <NUM> and/or a current sensor <NUM> (step <NUM>). The method may include providing a second non-scalable module <NUM> (e.g., a cover/connector module) that may include at least one contact <NUM> to connect to a power supply <NUM> (step <NUM>). The method may include providing at least one scalable module <NUM> (step <NUM>). The scalable module <NUM> may include a transistor <NUM>, a transient voltage suppression device <NUM>, a circuit board <NUM>, and/or a heat sink <NUM>. The method may include connecting the at least one scalable module <NUM> to the first non-scalable module <NUM> (step <NUM>). The method may include connecting one or more additional scalable modules <NUM> to the scalable module <NUM> (step <NUM>), and/or connecting the second non-scalable module <NUM> to the at least one or more scalable modules <NUM> (step <NUM>). Connecting the non-scalable modules <NUM> and the scalable modules <NUM> may include stacking the modules <NUM>, <NUM>. Connecting additional scalable modules <NUM> to the non-scalable modules <NUM> may increase a voltage capacity of the solid state circuit breaker assembly <NUM>. The method may include removing one or more modules <NUM>, <NUM> from the assembly <NUM> without deactivating (e.g., manually) the assembly <NUM> (step <NUM>). The method may include sensing the removal of one or more modules and automatically deactivating the assembly <NUM> (step <NUM>). The method may include replacing and/or adding modules <NUM>, <NUM> to the assembly <NUM> and/or the assembly <NUM> may automatically activate when a sufficient number of modules <NUM>, <NUM> are connected (step <NUM> and <NUM>).

In embodiments, an advantage to utilizing scalable modules <NUM> may be cost reduction. Core components of a product family may be shared while the scalable modules <NUM> may be utilized in different quantities and/or sizes to increase and/or decrease the voltage and/or current rating. The reduction in distinctive components may reduce development expenses and/or reduce procurement costs due to higher quantities. Among other things, cost savings may be gained over the life of the protection device in cases of repairs and/or management since the failed modules <NUM>, <NUM> may be replaced independently. An additional benefit of scalable modules <NUM> may be shared and/or reduced certification cost and/or documentation and procedures.

Various embodiments are described herein for various apparatuses, systems, and/or methods. Numerous specific details are set forth to provide a thorough understanding of the overall structure, function, manufacture, and use of the embodiments as described in the specification and illustrated in the accompanying drawings. It will be understood by those skilled in the art, however, that the embodiments may be practiced without such specific details. In other instances, well-known operations, components, and elements have not been described in detail so as not to obscure the embodiments described in the specification. Those of ordinary skill in the art will understand that the embodiments described and illustrated herein are non-limiting examples, and thus it can be appreciated that the specific structural and functional details disclosed herein may be representative and do not necessarily limit the scope of the embodiments.

Reference throughout the specification to "various embodiments," "with embodiments," "in embodiments," or "an embodiment," or the like, means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. Thus, appearances of the phrases "in various embodiments," "with embodiments," "in embodiments," or "an embodiment," or the like, in places throughout the specification are not necessarily all referring to the same embodiment. Thus, the particular features, structures, or characteristics illustrated or described in connection with one embodiment/example may be combined, in whole or in part, with the features, structures, functions, and/or characteristics of one or more other embodiments/examples without limitation given that such combination is not illogical or non-functional.

It should be understood that references to a single element are not necessarily so limited and may include one or more of such element. Any directional references (e.g., plus, minus, upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are only used for identification purposes to aid the reader's understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of embodiments.

Joinder references (e.g., attached, coupled, connected, and the like) are to be construed broadly and may include intermediate members between a connection of elements and relative movement between elements. As such, joinder references do not necessarily imply that two elements are directly connected/coupled and in fixed relation to each other. The use of "e.g." in the specification is to be construed broadly and is used to provide non-limiting examples of embodiments of the disclosure, and the disclosure is not limited to such examples. Uses of "and" and "or" are to be construed broadly (e.g., to be treated as "and/or"). For example and without limitation, uses of "and" do not necessarily require all elements or features listed, and uses of "or" are intended to be inclusive unless such a construction would be illogical.

Claim 1:
A solid state circuit breaker assembly (<NUM>), comprising:
a first non-scalable module (<NUM>) including:
a controller (<NUM>); and
a current sensor (<NUM>) electrically connected to the controller;
a second non-scalable module (<NUM>) including at least one contact (<NUM>) configured to be connected to a power supply (<NUM>); and
at least one scalable module (<NUM>) including:
a transistor (<NUM>);
a transient voltage suppression device (<NUM>); and
a circuit board (<NUM>) electrically connected to the transistor (<NUM>) and the transient voltage suppression device (<NUM>);
wherein the scalable module (<NUM>) is configured to be electrically and mechanically connected between the first non-scalable module (<NUM>) and the second non-scalable module (<NUM>),
wherein the first non-scalable module (<NUM>), the second non-scalable module (<NUM>), and the at least one scalable module (<NUM>) are configured to be modular such that additional scalable modules (<NUM>) are configured to be connected to the solid state circuit breaker assembly (<NUM>) between the first non-scalable module and the second non-scalable module to scale up the voltage and/or current capability of the solid state circuit breaker assembly (<NUM>).