Description:TECHNICAL FIELD
[0001] The present disclosure relates, in general, to effective heat dissipation, and more specifically, relates to an arrangement for effective heat dissipation in direct current (DC) air circuit breakers (ACBs).

BACKGROUND
[0002] Increasing emphasis on renewable energy sources, data centers, electric vehicle charging stations, telecom and communication networks has led to a growing demand for direct current (DC) switchgears and particularly in solar power applications. DC switchgears are extensively used in renewable energy systems, such as solar photovoltaic (PV) installations and wind farms. They facilitate the switching, control, and protection of DC power generated by solar panels or wind turbines before it is converted into AC power for grid integration or local consumption. DC air circuit breaker is a protective device used in electrical systems to interrupt the flow of DC in the event of an overload, short circuit, or other fault condition. Unlike AC circuit breakers, they must handle the unique challenges posed by DC, such as the absence of zero-crossing points and the presence of arc voltage.
[0003] DC air circuit breakers (ACBs) play a critical role in safeguarding electric circuits. However, their operation can generate internal heat, leading to elevated temperatures along the current path. Heat exchange occurs through conduction, convection, and radiation processes among various components within the system. These heat generation and transfer phenomena create a complex temperature distribution within the circuit breaker. To ensure safe and efficient operation, it is crucial to accurately understand and manage the thermal behavior of DC ACBs. Additionally, as conductors are often in contact with insulators, which can be a part of the breaker or a customer-made support structure, it is essential to prevent conductor temperatures from surpassing the deformation, melting, or ignition points of the surrounding materials. Failure to maintain the temperature within specified limits can result in hazardous situations such as fires, leading to property damage or even loss of life.
[0004] Therefore, it is desired to overcome the drawbacks, shortcomings, and limitations associated with existing solutions, and develop an improved thermal design and heat dissipation system that are necessary to prevent overheating and ensure optimal performance of ACBs, particularly in demanding applications like solar power.

OBJECTS OF THE PRESENT DISCLOSURE
[0005] An object of the present disclosure relates, in general, to effective heat dissipation, and more specifically, relates to an arrangement for effective heat dissipation in a direct current (DC) air circuit breaker.
[0006] Another object of the present disclosure is to provide a switchgear device with enhanced convection area through the integration of c-shaped links between the poles and cooling fins, promoting increased airflow for more effective heat dissipation.
[0007] Another object of the present disclosure is to provide a switchgear device with improved thermal performance as a result of introduced modifications, leading to superior convection and conduction losses.
[0008] Another object of the present disclosure is to provide a switchgear device with an extended lifespan and increased reliability due to a significant reduction in temperatures at heat-generating sources, adaptors, and terminals.
[0009] Another object of the present disclosure is to provide a switchgear device with increased current rating capacity, allowing the switchgear device to efficiently handle higher electrical loads.
[0010] Yet another object of the present disclosure is to provide a switchgear device with assurance of compliance with IEC and UL standards, ensuring the switchgear device meets internationally recognized safety and performance requirements, thereby providing a robust and reliable solution for electrical applications.
 
SUMMARY
[0011] The present disclosure relates in general, to effective heat dissipation, and more specifically, relates to an arrangement for effective heat dissipation in direct current (DC) air circuit breaker. The main objective of the present disclosure is to overcome the drawbacks, limitations, and shortcomings of the existing system and solution, by providing the switchgear device with a heat dissipation arrangement for a circuit breaker that ensures compliance with international standards, addresses challenges in DC systems, and optimizes heat transfer for enhanced thermal performance.
[0012] The disclosed switchgear device includes a fixed contact configured to provide electrical contact and stability during the operation of the circuit breaker. A moving contact is coupled to the fixed contact, forming a dynamic linkage that facilitates engagement and disengagement, allowing the flow and interruption of electrical current. An adapter, coupled to the fixed contact, serves as connectors for the connection and integration of components within the circuit breaker. A series connector, coupled to the adapter, establishes a serial connection between multiple poles of the circuit breaker, thereby increasing the length of the arc. A customer connection terminal, accommodated at the bottom portion, facilitates optimal heat dissipation. A cooling fin defines C-shaped links strategically positioned between the series connector and multiple poles, enhancing both conduction and convection near heat-generating sources and increasing air flow circulation at the terminals of the circuit breaker.
[0013] Further, the series connection is established by configuring source and load connections at the bottom portion, utilizing C-shaped links on the adapter at the top portion to create the series connection. Adapters at the bottom portion mechanically connect load and source connections with busbars, which serve as heatsinks strategically located at the bottom portion, minimizing temperatures at customer connection terminals for enhanced thermal performance. Busbars can be made from copper, aluminum, or any combination thereof. The optimized C-shaped links and cooling fins, achieved through a simulation process, increase conduction and convection near heat-generating sources, improving air flow circulation at the terminals. The cooling fins result in an optimized heat transfer from the heat-generating sources to the surrounding air, contributing to a substantial reduction in terminal temperatures and compliance with desired limits. The series connector effectively increases the length of the arc, addressing challenges associated with extinguishing arcs in DC systems. The circuit breaker demonstrates compliance with both international electrotechnical commission (IEC) and underwriters laboratories (UL) standards, affirming adherence to internationally recognized safety and performance requirements.
[0014] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The following drawings form part of the present specification and are included to further illustrate aspects of the present disclosure. The disclosure may be better understood by reference to the drawings in combination with the detailed description of the specific embodiments presented herein.
[0016] FIG. 1A illustrates an exemplary view of the connection of the circuit breaker, in accordance with an embodiment of the present disclosure.
[0017] FIG. 1B illustrates an exemplary view of circuit breaker contacts and heat dissipation arrangement, in accordance with an embodiment of the present disclosure.
[0018] FIG. 1C illustrates an exemplary view of DC ACB and link arrangements, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION
[0019] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. If the specification states a component or feature “may”, “can”, “could”, or “might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.
[0020] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0021] The present disclosure relates, in general, to effective heat dissipation, and more specifically, relates to an arrangement for effective heat dissipation in a direct current (DC) air circuit breaker. The present disclosure provides a switchgear device with a heat dissipation arrangement for a circuit breaker. The device includes a fixed contact ensuring stability, a moving contact forming a dynamic linkage for controlled current flow interruption, adapters for connection and integration, a series connector increasing the arc length, customer connection terminals for optimized heat dissipation, and cooling fins with C-shaped links enhancing conduction and convection near heat sources. The series connection configuration, use of adapters for mechanical connections, and strategic placement of busbars as heatsinks at the bottom are disclosed. The present disclosure ensures compliance with international standards, addresses challenges in DC systems, and optimizes heat transfer for enhanced thermal performance. The present disclosure can be described in enabling detail in the following examples, which may represent more than one embodiment of the present disclosure.
[0022] The advantages achieved by the switchgear device of the present disclosure can be clear from the embodiments provided herein. The present disclosure encompasses effective heat dissipation in a direct current (DC) air circuit breaker. It aims to enhance the convection area by integrating c-shaped links between the poles and cooling fins, fostering increased airflow for more efficient heat dissipation. Additionally, the disclosed arrangement introduces modifications for improved thermal performance, leading to superior convection and conduction losses in the switchgear device. This results in an extended lifespan and increased reliability, achieved through a substantial reduction in temperatures at heat-generating sources, adaptors, and terminals. Furthermore, the disclosure enhances the current rating capacity of the switchgear device, enabling efficient handling of higher electrical loads. Moreover, it ensures compliance with international standards such as IEC and UL, guaranteeing safety and performance requirements and providing a robust and reliable solution for various electrical applications. The description of terms and features related to the present disclosure shall be clear from the embodiments that are illustrated and described; however, the invention is not limited to these embodiments only. Numerous modifications, changes, variations, substitutions, and equivalents of the embodiments are possible within the scope of the present disclosure. Additionally, the invention can include other embodiments that are within the scope of the claims but are not described in detail with respect to the following description.
[0023] FIG. 1A illustrates an exemplary view of the connection of circuit breaker, in accordance with an embodiment of the present disclosure.
[0024] Referring to FIG. 1A, switch gear device 100 for effective heat dissipation in direct current (DC) air circuit breaker (ACB) 102 (also referred to as a circuit breaker 102, herein) is disclosed. The circuit breaker 102 is an electromagnetic safety device designed to protect electrical equipment by allowing the flow of current and interrupting the flow of current during abnormal conditions. In an embodiment, the circuit breaker 102 shown in FIG 1A, is an electromagnetic safety device, configured for safeguarding electrical equipment from abnormal conditions. The circuit breaker 102 is configured to effectively manage elevated temperatures arising from its operation to ensure reliable functionality. The arrangement 100 is introduced to enhance thermal performance, specifically addressing concerns related to potential safety issues associated with excessive heat, particularly in customer-accessible links. The arrangement 100 can include a fixed contact 104, a moving contact 106, adapters 108, series connectors 110, cooling fins 112, and customer connections 114.
[0025] In an embodiment, the fixed contact 104 is a stationary component, providing a point of electrical contact and stability during the operation of the circuit breaker 102. The moving contact 106 is coupled to the fixed contact 104, forming a dynamic linkage that facilitates an engagement and disengagement of the moving contact 106 with the fixed contact 104, thereby enabling controlled initiation and interruption of the flow of electrical current. For instance, during normal operation, the contacts may be engaged to permit the flow of electrical current, and under certain conditions such as overloads or faults, the contacts can be deliberately disengaged to interrupt the current flow, providing a protective function.
[0026] The adapters 108 serve as connectors facilitating the connection and integration of the components within the circuit breaker 102, contributing to the overall functionality of the device. The series connectors 110 are elements employed to establish a serial connection between multiple poles of the circuit breaker, effectively increasing the length of the arc and addressing challenges associated with extinguishing arcs in DC systems.
[0027] The present disclosure relates to a unique configuration of links equipped with cooling fins 112, specifically configured to enhance the thermal performance of circuit breaker terminals. This proposed arrangement effectively dissipates heat, ensuring that temperatures are maintained comfortably within the specified limits. Consequently, a substantial reduction in the maximum temperature along the mating contacts and the conductor path is achieved, contributing to an enhancement in the overall thermal efficiency of the DC circuit breaker.
[0028] The cooling fins 112 are specialized structures integrated into the circuit breaker's configuration, designed to enhance thermal performance by efficiently dissipating heat, thereby maintaining temperatures within specified limits. The cooling fins 112 defining C-shaped links strategically positioned between the series connector and the multiple poles of the circuit breaker, enhancing both conduction and convection near heat-generating sources and increasing air flow circulation at the terminals of the circuit breaker. The utilization of the cooling fins 112 results in an optimized heat transfer from the heat-generating sources of the circuit breaker to surrounding air, contributing to a substantial reduction in terminal temperatures and compliance with desired limits.
[0029] In DC applications, the circuit breakers 102 is used by connecting the multiple poles of the circuit breaker 102 in series. This practice is commonly adopted due to the higher operating voltages in DC systems compared to the nominal voltage for which circuit breakers are designed for AC operations. Additionally, the absence of a current zero in DC further complicates the task of extinguishing arcs. By connecting poles in series, the number of current breaks is increased, effectively increasing the length of the arc.
[0030] Various methods can be employed to establish a series connection in circuit breakers. In the current approach, as depicted in FIG. 1A, the source and load are connected in the following manner, where the source and load connections are made from the bottom, while C-shaped links are utilized to create series connections on the top adapters. The bottom adapters are employed to connect the load and source connections with the busbars.
[0031] The customer connection terminals 114 refers to the points within the circuit breaker where external connections are made, typically designed to ensure optimal heat dissipation and maintain temperatures within acceptable limits for customer-accessible terminals. The customer connection terminals 114 is accommodated at bottom portion of the arrangement for optimal heat dissipation.
[0032] In a natural convection system, the lower parts offer better heat dissipation due to the presence of cooler air. The temperature of the air rises, as it is moved upward leading to a decrease in the effectiveness of heat dissipation. To achieve maximum heat dissipation, the customer and source connections are connected at the bottom. The busbars, made of copper or aluminum, serve as a substantial heatsink. Placing this large heatsink at the bottom helps to reduce the temperature at the customer connection terminals 114.
[0033] The present disclosure involves the DC circuit breaker that incorporates a modified heat dissipation element. The element can include modified C-shaped links and cooling fins, optimized with the help of a simulation process to improve conduction and convection near the heat-generating parts. By utilizing cooling fins, heat transfer from the components of the breaker to the surrounding air is enhanced. This, in turn, helps to reduce the temperature at the terminals, keeping it within the desired limits.
[0034] The C-shaped links and cooling fins, optimized with the simulation process to increase conduction and convection near the heat-generating components and increase the air flow circulation at the terminals of the circuit breaker.
[0035] The integration of computer-aided engineering (CAE) simulation has streamlined and expedited the analysis of the thermal behavior of the product. A simulation methodology, encompassing Finite Element Method (FEM) and Computational Fluid Dynamics (CFD) analyses, has been established for the validation and optimization of the heat dissipation system design concept. Through simulations conducted on the existing breaker design, areas characterized by high heat concentration and fluid flow patterns were identified. These insights were leveraged to develop and optimize an innovative heat dissipation system design, aiming to enhance conduction and convection losses while improving air flow circulation at the terminals. This modified design innovation has yielded a substantial 20% improvement in heat dissipation, effectively reducing temperatures at both moving and fixed contacts, as well as at the terminals.
[0036] FIG. 1B illustrates an exemplary view of circuit breaker contacts and heat dissipation element, in accordance with an embodiment of the present disclosure. The visual representation highlights the arrangement and interaction of the circuit breaker components, emphasizing the incorporation of a heat dissipation element for efficient thermal management.
[0037] FIG. 1C illustrates an exemplary view of DC ACB and link arrangements, in accordance with an embodiment of the present disclosure. In this configuration, the DC ACB is strategically arranged with precision in link connections. The source and load connections are established from the bottom, while C-shaped links are ingeniously employed on the top adapters. This arrangement not only defines the structural organization of the DC ACB but also demonstrates the specific positioning of links, emphasizing their role in creating series connections. The bottom adapters play a crucial role in connecting the load and source connections to the busbars, ensuring a reduction in the temperature at the customer's terminals. The proposed arrangement contributes to the efficient operation of the DC ACB.
[0038] In an implementation, the circuit breaker 102 within an industrial power distribution system is equipped with the heat dissipation arrangement to ensure optimal functionality during both normal and abnormal operating conditions. During normal operations, the fixed contact 104 and moving contact 106 are engaged, facilitating the uninterrupted flow of electrical current through the circuit breaker, thereby supporting the smooth operation of machinery and equipment within the industrial plant. Upon detection of abnormal conditions, such as overloads or faults, the moving contact 106, mechanically coupled to the fixed contact 104, dynamically responds to the situation. The dynamic linkage facilitates the swift disengagement of contacts, promptly interrupting the electrical current flow to protect the equipment and the overall system. The disclosed arrangement 100 encompasses cooling fins 112 and C-shaped links strategically positioned between the series connector and multiple poles of the circuit breaker. These components synergistically dissipate heat generated in critical areas, including the mating contacts and conductor path, ensuring efficient heat management during both normal and abnormal operational scenarios.
[0039] For effective heat dissipation, customer connection terminal 114 is strategically accommodated at the bottom portion of the arrangement. This placement ensures that external connections are made in a manner that optimally supports cooling processes, contributing to temperature reduction. The arrangement strategically connects customer and source connections at the bottom, capitalizing on the cooler air present in lower regions. Furthermore, the incorporation of busbars constructed from materials such as copper or aluminum serves as substantial heatsinks, efficiently dissipating heat and reducing temperatures at the customer connection terminals.
[0040] Thus, the present invention overcomes the drawbacks, shortcomings, and limitations associated with existing solutions, and provides an effective heat dissipation in a direct current (DC) air circuit breaker. It aims to enhance the convection area by integrating c-shaped links between the poles and cooling fins, fostering increased airflow for more efficient heat dissipation. Additionally, the disclosed arrangement introduces modifications for improved thermal performance, leading to superior convection and conduction losses in the switchgear device. This results in an extended lifespan and increased reliability, achieved through a substantial reduction in temperatures at heat-generating sources, adaptors, and terminals. Furthermore, the disclosure enhances the current rating capacity of the switchgear device, enabling efficient handling of higher electrical loads. Moreover, it ensures compliance with international standards such as IEC and UL, guaranteeing safety and performance requirements and providing a robust and reliable solution for various electrical applications.
[0041] It will be apparent to those skilled in the art that the switchgear device 100 of the disclosure may be provided using some or all of the mentioned features and components without departing from the scope of the present disclosure. While various embodiments of the present disclosure have been illustrated and described herein, it will be clear that the disclosure is not limited to these embodiments only. Numerous modifications, changes, variations, substitutions, and equivalents will be apparent to those skilled in the art, without departing from the spirit and scope of the disclosure, as described in the claims.

ADVANTAGES OF THE PRESENT INVENTION
[0042] The present invention provides a switchgear device with enhanced convection area through the integration of C-shaped links between the poles and cooling fins, promoting increased airflow for more effective heat dissipation.
[0043] The present invention provides a switchgear device with improved thermal performance as a result of introduced modifications, leading to superior convection and conduction losses.
[0044] The present invention provides a switchgear device with an extended lifespan and increased reliability due to a significant reduction in temperatures at heat-generating sources, adaptors, and terminals.
[0045] The present invention provides a switchgear device with increased current rating capacity, allowing the switchgear device to efficiently handle higher electrical loads.
[0046] The present invention provides a switchgear device with assurance of compliance with IEC and UL standards, ensuring the switchgear device meets internationally recognized safety and performance requirements, thereby providing a robust and reliable solution for electrical applications.

, Claims:1. A switchgear device (100) with heat dissipation arrangement, the switchgear device comprising:
a fixed contact (104) configured to provide electrical contact and stability during operation of a circuit breaker (102);
a moving contact (106) is coupled to the fixed contact (104), forming a dynamic linkage that facilitates an engagement and disengagement of the moving contact (106) with the fixed contact (104), permitting and interrupting flow of electrical current;
an adapter (108) coupled to the fixed contact (104) serves as a connector for connection of components within the circuit breaker;
a series connector (110) coupled to the adapter, facilitates establishment of a serial connection between multiple poles of the circuit breaker, thereby increasing length of the arc;
a customer connection terminal (114) accommodated at bottom portion for optimal heat dissipation; and
a cooling fin (112) defining a C-shaped links strategically positioned between the series connector and the multiple poles of the circuit breaker, enhancing both conduction and convection near heat-generating sources and increasing air flow circulation at the terminals of the circuit breaker.
2. The switchgear device as claimed in claim 1, wherein the series connection is established by configuring a source and load connections at the bottom portion, utilizing the C-shaped links on the adapter at top portion to create the series connection.
3. The switchgear device as claimed in claim 1, wherein the adapter (108) at the bottom portion is employed to mechanically connect the load and source connections with busbars.
4. The switchgear device as claimed in claim 1, wherein the busbars serve as heatsinks strategically located at the bottom portion, minimizing temperatures at the customer connection terminal (114) for enhanced thermal performance.
5. The switchgear device as claimed in claim 1, wherein the busbars are made from copper, aluminum and any combination thereof.
6. The switchgear device as claimed in claim 1, wherein the C-shaped links and cooling fin, (112) are optimized with simulation process to increase conduction and convection near the heat-generating sources and increase the air flow circulation at the terminals of the circuit breaker.
7. The switchgear device as claimed in claim 1, wherein the cooling fin (112) results in an optimized heat transfer from the heat-generating sources of the circuit breaker to surrounding air, contributing to a substantial reduction in terminal temperatures and compliance with desired limits.
8. The switchgear device as claimed in claim 1, wherein the series connector (110) increases the length of the arc, addressing challenges associated with extinguishing arcs in DC systems.
9. The switchgear device as claimed in claim 1, wherein the circuit breaker demonstrates compliance with both international electrotechnical commission (IEC) and underwriters laboratories (UL) standards, affirming adherence to internationally recognized safety and performance requirements.