High current electrical switch and method

• US 20060261368A1
• Filed: 05/23/2005
• Published: 11/23/2006
• Est. Priority Date: 05/23/2005
• Status: Active Grant

• Current Assignee: Perfect Switch, LLC
• Original Assignee: Perfect Switch, LLC
• Inventors: Fogleman, H. Frank
• Granted Patent: US 7,522,405 B2
• Time in Patent Office: Days
• US Class Current: 257/107
• CPC Class Codes: H01L 25/115 the devices being arranged next to each other
• CPC Class Codes: H01L 2924/00 Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
• CPC Class Codes: H01L 2924/0002 Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
• CPC Class Codes: H03K 17/122 in field-effect transistor switches
• CPC Class Codes: H03K 17/6871 the output circuit comprising more than one controlled field-effect transistor

Abstract

A method and system are disclosed for a high current electrical switch. The switch may be suitable for switching, rectifying or blocking direct current in the range of one to a thousand amperes per module or assembly. It does so with such high efficiency that it produces relatively insignificant heat; such that it requires little or no cooling by convection or radiation. The relatively low heat that is generated in the process is conducted away quite effectively by the electric cables connected to the device.

Claims

1. A high current electrical switch, comprising:

a first primary conductor;

a second primary conductor; and

an array of one or more switching elements electrically connecting the first primary conductor to the second primary conductor and physically sandwiched between the first primary conductor and the second primary conductor;

wherein the array of switching elements has a resistance of less than about 500 micro-ohms.

2. The switch of claim 1, wherein each of the conductors has an effective resistance of less than 20 micro-ohms.

3. The switch of claim 1, further including a printed circuit board located substantially around the array of switching elements.

4. The switch of claim 3, wherein the printed circuit board includes a circuit to control the switching elements.

5. The switch of claim 1, wherein the switching elements are MOSFETs.

6. The switch of claim 5, wherein a drain lead of the MOSFET connects directly to the first primary conductor.

7. The switch of claim 5, wherein a source lead of the MOSFET connects directly to the second primary conductor.

8. The switch of claim 5, wherein a gate lead of the MOSFET connects directly to a printed circuit board.

9. The switch of claim 8, wherein a source lead of the MOSFET connects to the second primary conductor via a metal strip.

10. The switch of claim 9, wherein the metal strip includes tabs extending to the source leads of the MOSFET.

13. The switch of claim 11, further including a printed circuit board located substantially around the array of switching elements.

14. The switch of claim 13, wherein the printed circuit board includes a circuit to control the switching elements.

11. A high current electrical switch, comprising:

a first primary conductor;

a second primary conductor; and

an array of at least one switching element electrically connecting the first primary conductor to the second primary conductor and sandwiched between the first primary conductor and the second primary conductor;

wherein each of the conductors has an effective length to cross-sectional area ratio of less than about 40.

12. The switch of claim 11, wherein each of the conductors has an effective resistance of less than 20 micro-ohms.

15. The switch of claim 11, wherein the switching elements are MOSFETs.

16. The switch of claim 15, wherein a drain lead of the MOSFET connects directly to the first primary conductor.

17. The switch of claim 15, wherein a source lead of the MOSFET connects directly to the second primary conductor.

18. The switch of claim 15, wherein a gate lead of the MOSFET connects directly to a printed circuit board.

19. The switch of claim 18, wherein a source lead of the MOSFET connects to the second primary conductor via a metal strip.

20. The switch of claim 19, wherein the metal strip includes tabs extending to the source leads of the MOSFET.

21. A method of switching high electrical current, comprising:

providing an array of switching elements connected in parallel between a first conductor and a second conductor;

disposing the array of switching elements between the first conductor and the second conductor;

electrically connecting together each gate lead from each switching element; and

causing the switching elements to be controlled via the gate leads to close the switching elements to allow current to flow from the first conductor to the second conductor and to open the switching elements to not allow the current to flow from the first conductor to the second conductor.