Linear puffer switch

A method of manufacturing an electrical switch assembly, the method comprising:

• providing a piston tube;
• embedding a first voltage screen into a first electrically-insulating epoxy overmold;
• coupling the first electrically-insulating epoxy overmold to a movable conductor;
• inserting the movable conductor within the piston tube;
• embedding a second voltage screen into a second electrically-insulating epoxy overmold;
• coupling the second electrically-insulating epoxy overmold to a stationary conductor;
• and
• coupling the piston tube to the second electrically-insulating epoxy overmold.

An electrical switch assembly comprising:

• a stationary conductor having a stationary electrode;
• and
• a movable conductor movable relative to the stationary conductor between a closed position, in which the movable conductor and the stationary conductor are electrically connected, and an open position, in which the movable conductor and the stationary conductor are separated to interrupt the electrical connection between the movable conductor and the stationary conductor;
• a piston tube configured to slidably receive the movable conductor;
• a nozzle coupled to the movable conductor, the nozzle configured to compress a dielectric gas and direct a pulse of the gas around the stationary conductor in response to movement of the movable conductor from the closed position toward the open position;
• a first electrically insulating overmold surrounding a tip portion of the movable conductor;
• a second electrically insulating overmold surrounding the stationary electrode;
• a first voltage screen embedded within the first electrically insulating overmold and electrically connected to the movable conductor;
• and
• a second voltage screen embedded within the second electrically insulating overmold and electrically connected to the stationary conductor.