Passive triggering mechanism for switching devices incorporating pyrotechnic features

Abstract

The present invention relates to a passive trigger mechanism for a switching device including a pyrotechnic feature. A passive trigger mechanism for activating a pyrotechnic feature within an electrical switching device, such as a contactor device and a fuse device, is disclosed herein. The activation of the pyrotechnic feature is configured to change the configuration of the internal components of the switching device and prevent current from flowing through the device. In some embodiments, the trigger mechanism includes a feature that responds to a magnetic field, such as a reed switch. In some embodiments, the reed switch responds to an increased current and a signal with the increased current can then be used to activate the pyrotechnic feature. In other embodiments, the reed switch uses a power signal from an auxiliary power supply to activate the pyrotechnic feature.

Description

Technical Field

[0001] Devices are described herein that relate to triggering mechanisms and configurations for electrical switching devices, such as contactor devices and electrical fuse devices. Background Art

[0002] Connecting and disconnecting circuits is as old as electrical circuits themselves and is commonly used as a method of switching power to connected electrical devices between "on" and "off" states. An example of a device commonly used to connect and disconnect circuits is a contactor, which is electrically connected to one or more devices or power sources. A contactor is configured so that it can open or complete an electrical circuit to control power to and from a device. One conventional contactor is a hermetically sealed contactor.

[0003] In addition to the contactors used to connect and disconnect the circuit during normal operation of the device, various additional devices can be employed to provide overcurrent protection. These devices can prevent short circuits, overloads, and permanent damage to the electrical system or connected electrical devices. These devices include disconnect devices that can quickly disconnect the circuit in a permanent manner so that the circuit will remain disconnected until the disconnect device is repaired, replaced, or reset. One such disconnect device is a fuse. A traditional fuse is a low-resistance resistor that serves as a sacrificial device. A typical fuse includes a metal wire or strip that melts when too much current flows through it, thereby disconnecting the circuit it is connected to.

[0004] As society progresses, various innovations to electrical systems and electronic devices are becoming more common. Examples of such innovations include recent advances in electric vehicles, which could one day become the energy-efficient standard and replace traditional petroleum-powered vehicles. In such expensive and routinely used electrical devices, overcurrent protection is particularly useful in preventing device failures and preventing permanent damage to the device. Additionally, overcurrent protection can prevent safety hazards, such as electrical fires. These modern improvements to electrical systems and devices require modern solutions to increase the convenience and efficiency of the mechanism that triggers the fuse device. Summary of the invention

[0005] Passive triggering components and configurations for activating pyrotechnic features for use as a fusing mechanism within a switching device (e.g., a contactor or a fuse device) are described herein. These passive triggering configurations can be configured to trigger in response to a threshold magnetic field strength corresponding to a threshold level of current flowing through the device corresponding to a hazardous overcurrent. The current threshold level required to trigger these passive triggering configurations can be related to the distance between the passive triggering mechanism (e.g., a reed switch) and a portion of the device (e.g., a power terminal or a feature connected to a power terminal).

[0006] One embodiment of an electrical switching device according to the present invention includes a housing having an internal component configured to change the state of the switching device from a closed state that allows current to flow through the switching device to an open state that disconnects current flowing through the switching device. A pyrotechnic feature is included, which is configured to interact with the internal component to convert the switching device from the closed state to the open state when the pyrotechnic feature is activated. A passive trigger switch structure is also included, which is configured to activate the pyrotechnic feature when the passive trigger switch structure is triggered, and the passive trigger switch structure is configured to trigger in response to an elevated current signal flowing through the switching device. The passive trigger switch is also arranged to activate the pyrotechnic feature using the elevated current signal.

[0007] One embodiment of an electrical system according to the present invention includes a working power circuit, the working power circuit including a working power source coupled to a working load through a current path, with a contactor between the power source and the load, and a pyrotechnic activation circuit, the pyrotechnic activation circuit including a trigger, the trigger being configured to sense an increased current in the working power circuit, the activation circuit also including a pyrotechnic actuator, the trigger activating the pyrotechnic actuator to operate on the contactor to open the current path in the working power circuit.

[0008] One embodiment of a pyrotechnic activation circuit according to the present invention includes a trigger configured to sense a magnetic field in response to an elevated current in a circuit, including a pyrotechnic actuator, wherein the trigger activates the pyrotechnic actuator in response to an elevated current level to open the circuit carrying the elevated current, wherein the trigger activates the pyrotechnic actuator using the elevated current.

[0009] These and other further features and advantages of the present invention will become apparent to those skilled in the art from the following detailed description taken in conjunction with the accompanying drawings, in which like numerals represent corresponding parts throughout the drawings, and in which: BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Figure 1 is a front cross-sectional view of an embodiment of a contactor capable of incorporating features of the present invention, shown in a "closed" orientation allowing current to flow through the device;

[0011] Figure 2 yes Figure 1 A front cross-sectional view of an embodiment of a contactor device, shown in an "open" or "off" orientation preventing current from flowing through the device;

[0012] Figure 3 yes Figure 1 A front cross-sectional view of an embodiment of a contactor device of , shown in different orientations, wherein the disconnecting element has been "triggered";

[0013] Figure 4is a front cross-sectional view of a fuse device capable of incorporating features of the present invention, shown in a resting, "untriggered" state;

[0014] Figure 5 is a front cross-sectional view of a fuse device capable of incorporating features of the present invention, shown in an activated "triggered" state;

[0015] Figure 6 is a front, top perspective view of a pyrotechnic triggering arrangement incorporating features of the present invention;

[0016] Figure 7 yes Figure 6 Rear view and top view of the pyrotechnic trigger configuration;

[0017] Figure 8 is a front, top perspective view of another pyrotechnic triggering configuration incorporating features of the present invention;

[0018] Fig. 9 yes Figure 8 Rear view and top view of the pyrotechnic trigger configuration;

[0019] Fig.10 is a front, top perspective view of yet another pyrotechnic triggering arrangement incorporating features of the present invention;

[0020] Fig.11 yes Fig.10 A front cross-sectional view of a portion of a pyrotechnic trigger configuration;

[0021] Fig.12 is a schematic diagram of an embodiment of a pyrotechnic power switching circuit according to the present invention;

[0022] as well as

[0023] Fig.13 is a schematic diagram of another embodiment of a pyrotechnic power switching circuit according to the present invention. DETAILED DESCRIPTION

[0024] The present disclosure will now set forth a detailed description of various embodiments. These embodiments set forth passive switching features and configurations for use with switching devices such as contactors or fuse devices that integrate pyrotechnic disconnect features. These switching devices can be electrically connected to an electrical device or system to "turn on" or "turn off" power to the connected device or system. Although the example devices disclosed herein can utilize active triggering configurations to supplement or replace the disclosed passive features, the passive features provide the advantage of automatically triggering the pyrotechnic circuit disconnection in response to a threshold current level.

[0025] In some embodiments, a printed circuit board (PCB) or external trigger mechanism is configured to direct a signal to a pyrotechnic pin in communication with a pyrotechnic charge. Power for the signal to trigger the pyrotechnic feature of the switching device may be provided by a separate power source (i.e., a power source other than the power source of the device or electrical system to which the switching device is connected). Alternatively, power for the signal may be provided or diverted from the power source of the device or electrical system to which the switching device is connected. The pyrotechnic charge is configured to act as a fuse to permanently open the circuit through the contactor or fuse device, such as by causing the movable contact to move without contacting the fixed contact.

[0026] The PCB or external trigger mechanism includes a passive trigger switch, such as a reed switch, which opens in its resting state, preventing a trigger signal from being sent to the pyrotechnic pin and thereby allowing current to flow through the device. The passive trigger switch can be configured to trigger in response to a magnetic field of sufficient strength that can be calculated to correspond to a desired threshold current level through the device, e.g., a dangerous overcurrent. Because the required threshold strength of the magnetic field required to trigger the passive trigger switch depends on the proximity of the passive trigger switch to the source of the magnetic field, the passive trigger switch can be configured as a "proximity switch." This allows the desired trip current to be set based on the distance between the passive trigger switch and an area of ​​the device, such as one of the power terminals.

[0027] In other embodiments, additional features may be included. For example, an iron core structure may be positioned at least partially around one power terminal of the switching device, and the trip current may be determined by the distance between the core structure and the passive trigger switch. In some embodiments, an external trigger mechanism may be utilized that may include a conductive bus portion and a passive trigger switch separated from the conductive bus portion by a non-magnetic spacer portion. In these embodiments, the trip current may be determined by the thickness of the non-magnetic spacer portion.

[0028] Throughout the specification, the preferred embodiments and examples shown should be considered as examples, rather than limitations of the present invention. As used herein, the terms "invention", "device", "the present invention" or "existing device" refer to any one embodiment of the present invention described herein, as well as any equivalents. In addition, the various features of "invention", "device", "the present invention" or "existing device" cited throughout this document do not mean that all claimed embodiments or methods must include the cited features.

[0029] It should also be understood that when an element or feature is referred to as being "on" or "adjacent" another element or feature, it can be directly on or adjacent to the other element or feature, or there can be intermediate elements or features. It should also be understood that when an element is referred to as being "attached," "connected," or "coupled" to another element, it can be directly attached, connected, or coupled to the other element, or there can be intermediate elements. Conversely, when an element is referred to as being "directly attached," "directly connected," or "directly coupled" to another element, there are no intermediate elements.

[0030] Relative terms such as "outer", "above", "below", "below", "horizontal", "vertical" and similar terms may be used herein to describe the relationship of one feature to another. It should be understood that these terms are intended to encompass different orientations in addition to the orientation shown in the Figures.

[0031] Although the terms first, second, etc. may be used herein to describe various elements or components, these elements or components should not be limited by these terms. These terms are only used to distinguish one element or component from another element or component. Therefore, without departing from the teachings of the present invention, the first element or component discussed below may be referred to as the second element or component.

[0032] The terms used herein are only used to describe specific embodiments and are not intended to limit the present invention. As used herein, the singular forms "a", "an" and "the" are also intended to include the plural forms, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises", "comprising", when used herein, specify the presence of the features, wholes, steps, operations, elements and / or parts, but do not exclude the presence or addition of one or more other features, wholes, steps, operations, elements, parts and / or combinations thereof.

[0033] Embodiments of the present invention are described herein with reference to various views and illustrations that are schematic diagrams of idealized embodiments of the present invention. Therefore, variations in the shapes of the illustrations due to, for example, manufacturing techniques and / or tolerances are expected. Embodiments of the present invention should not be construed as limited to the specific shapes of the regions shown herein, but rather include deviations in shapes due to, for example, manufacturing.

[0034] It should be understood that when a first element is referred to as being "between," "sandwiched" or "sandwiched" between two or more other elements, the first element may be directly between the two or more other elements or intermediate elements may also be present between the two or more other elements. For example, if a first element is "between" or "sandwiched" between a second element and a third element, the first element may be directly between the second element and the third element without intermediate elements, or the first element may be adjacent to one or more additional elements, with the first element and these additional elements both being between the second and third elements.

[0035] Before describing in detail a specific pyrotechnic triggering configuration incorporating features of the present invention, an example switching device incorporating pyrotechnic features and providing an example environment for a passive triggering configuration in accordance with the present invention will first be described. These switching devices may include any switching device incorporating pyrotechnic features, such as a contactor configured to allow the device to switch between an "on" and "off" state.

[0036] In some contactor devices, the pyrotechnic feature is used as a fuse element incorporated into the contactor device. An example of such a contactor device is set forth in U.S. Application No. 16 / 101,143, entitled "Contactor Device Integrating Pyrotechnic Disconnect Features," assigned to Gigavac, Inc., the assignee of the present application, and incorporated herein by reference. In addition to a contactor configured to freely switch between "on" and "off" states, a pyrotechnic trigger configuration according to the present disclosure may also be used with a sacrificial fuse device that is configured to allow current to pass through an electrical system or device when not triggered and to prevent current from passing through an electrical system or device when triggered. An example of such a fuse device is set forth in U.S. Application No. 15 / 889,516, entitled "MECHANICAL FUSE DEVICE," assigned to Gigavac, Inc., the assignee of the present application, and incorporated herein by reference.

[0037] Referring to an exemplary contactor device including a pyrotechnic feature, Figure 1 A cross-sectional view of an exemplary embodiment of a contactor device 100 is shown that includes an integrated pyrotechnic disconnect feature that may function as a sacrificial disconnect in the event of an overcurrent. Figure 1 The contactor device 100 is shown in a "closed" circuit position, wherein current flow through the contactor device is initiated. Figure 1 The pyrotechnic disconnect portion of the contactor device 100 is also shown in its non-triggered or "set" mechanical orientation, allowing the contactor device to operate normally between its "closed" and "open" positions. The disconnect portion of the contactor device 100 also has a "triggered" orientation, in which the circuit is disconnected and current through the contactor device is permanently disabled until the device is replaced or repaired and reset. The "closed" and "open" contactor modes, as well as the "set" and "triggered" disconnect modes, are all described in further detail herein.

[0038] Figure 1The contactor device 100 includes a body 102 (also referred to as a housing 102), and two or more fixed contact structures 104, 106 (two are shown), which are configured to electrically connect the internal components of the contactor device to an external circuit, such as an electrical system or device. The body 102 may include any suitable material capable of supporting the structure and features of the contactor device 100 as disclosed herein, and the preferred material is a strong material that can provide structural support for the contactor device 100 without interfering with the current passing through the fixed contacts 104, 106 and the internal components of the device. In some embodiments, the body 102 includes a durable plastic or polymer. The body 102 at least partially surrounds the various internal components of the contactor device 100, which will be described in further detail herein.

[0039] The body 102 may include any shape suitable for accommodating various internal components, including any regular or irregular polygons. The body 102 may be a continuous structure, or may include multiple components connected together, for example, including a base "cup" and a top "head" portion sealed with an epoxy material. Some exemplary body configurations include those described in U.S. Patent Nos. 7,321,281, 7,944,333, 8,446,240, and 9,013,254, all of which are assigned to Gigavac, Inc., the assignee of the present application, and all of which are incorporated herein by reference in their entirety.

[0040] The fixed contacts 104, 106 are configured so that various internal components of the contactor device 100 housed in the body 102 can be electrically connected to an external electrical system or device, so that the contactor device 100 can be used as a switch to disconnect or complete a circuit as described herein. The fixed contacts 104, 106 may include any suitable conductive material for providing electrical contact with the internal components of the contactor device, for example, various metals and metallic materials or any electrical contact material or structure known in the art. The fixed contacts 104, 106 may include a single continuous contact structure (as shown) or may include multiple electrical connection structures. For example, in some embodiments, the fixed contacts 104, 106 may include two parts, a first part extending from the body 102, which is electrically connected to a second part inside the body 102, and the second part is configured to interact with other components inside the body as described herein.

[0041] The body 102 can be configured so that the interior space of the body 102 that houses the various internal components of the contactor device 100 is hermetically sealed. When coupled with the use of an electronegative gas, this hermetic sealing configuration can help mitigate or prevent arcing between adjacent conductive elements, and in some embodiments, help provide electrical isolation between spatially separated contacts. In some embodiments, the body 102 may be under vacuum conditions. The body 102 can be sealed using any known tool for producing a hermetic sealed electrical device. Some examples of hermetic sealing devices include those described in U.S. Patents Nos. 7,321,281, 7,944,333, 8,446,240, and 9,013,254, all of which are assigned to Gigavac Co., Ltd., the assignee of the present application, and all of which are incorporated by reference into the present application in their entirety.

[0042] In some embodiments, the body 102 can be at least partially filled with an electronegative gas, such as sulfur hexafluoride or a mixture of nitrogen and sulfur hexafluoride. In some embodiments, the body 102 comprises a material having low permeability or substantially no permeability to the gas injected into the housing. In some embodiments, the body can include various gases, liquids, or solids configured to increase the performance of the device.

[0043] Before describing the pyrotechnic disconnect feature of the contactor device 100 for overcurrent protection, the contactor components used during ordinary switching use of the contactor device 100 will first be described. When not interacting with any other components inside the body 102, the fixed contacts 104, 106 are oppositely electrically isolated from each other so that electricity cannot flow freely between them. The fixed contacts 104, 106 can be electrically isolated from each other by any known electrical isolation structure or method.

[0044] When the contactor device 100 is in its "closed" position, as shown in FIG. Figure 1 As shown, both electrically isolated fixed contacts 104, 106 are in contact with a movable contact 108. The movable contact 108 acts as a bridge to allow electrical signals to flow through the device, for example, from the first fixed contact 104 to the movable contact 108 to the second contact 106, and vice versa. Therefore, the contactor device 100 can be connected to a circuit, system, or device and complete the circuit while the movable contact is in electrical contact with the fixed contact.

[0045] The movable contact 108 may include any suitable conductive material, including any of the materials discussed herein with respect to the stationary contacts 104, 106. Like the stationary contacts 104, 106, the movable contact 108 may include a single continuous structure (as shown), or may include multiple components that are electrically connected to each other to act as a contact bridge between the electrically isolated stationary contacts 104, 106 so that electricity can flow through the contactor device 100.

[0046] The movable contact 108 can be configured so that it can move in and out of electrical contact with the fixed contacts 104, 106. This allows the circuit to be "closed" or completed when the movable contact is in electrical contact with the fixed contacts 104, 106, and "opened" or disconnected when the movable contact 108 is not in electrical contact with the fixed contacts 104, 106. The fixed contacts 104, 106 are electrically isolated from each other when not in contact with the movable contact. In some embodiments, including Figure 1 In the illustrated embodiment, the movable contact 108 is physically connected to a shaft structure 110, which is configured to move along a predetermined distance within the contactor device 100. The shaft 110 may include any material or shape suitable for its characteristics as an internal movable component that is physically connected to the movable contact 108 so that the movable contact 108 can move with the shaft 110.

[0047] As described herein, the movement of the shaft 110 controls the movement of the movable contact 108, which in turn controls the position of the movable contact 108 relative to the fixed contacts 104, 106, which in turn controls the flow of current through the contactor device 100. The movement of the shaft can be controlled by various configurations, including but not limited to electrical and electronic, magnetic and solenoid, and manual. Exemplary manual configurations for controlling the shaft connected to the movable contact are set forth in U.S. Patent No. 9,013,254 to Gigavac, Inc., the assignee of the present application, and all of which are incorporated by reference in their entirety into the present application. Some example configurations of the manual control feature include magnetic configurations, diaphragm configurations, and corrugated configurations.

[0048] exist Figure 1In the illustrated embodiment, the movement of the shaft 110 is controlled by using a solenoid configuration. A plunger structure 111 is connected to a portion of the shaft 110 or at least partially surrounds a portion of the shaft 110. The body 102 also houses a solenoid 112. Many different solenoids can be used, and an example of a suitable solenoid is a solenoid that operates at a low voltage and relatively high force. An example of a suitable solenoid is a commercially available solenoid model SD1564 N1200 from Bicron Co., Ltd., although many other solenoids can be used. In the illustrated embodiment, the plunger structure 111 may include a metal material that can be moved and controlled by the solenoid 112. The movement of the plunger structure 111 controls the movement of the connecting shaft 110, which in turn controls the movement of the connected movable contact 108.

[0049] The travel distance of the shaft 110 can be controlled using various features, such as a spring to control the trip / overtrip distance or various portions of the body 102 that can block or limit the travel distance of the shaft 110. Figure 1 In the illustrated embodiment, the travel distance of the shaft 110 is controlled in part by a hard stop 113 that is configured to abut against a wing portion 114 of the shaft 110 to limit the distance of the shaft 110 when the shaft 110 has traveled a sufficient distance from the fixed contacts 104, 106. The hard stop 113 may include any material or shape suitable for providing a surface that interacts with the shaft 110 to limit the movement or travel distance of the shaft 110. Figure 1 In the illustrated embodiment, the hard stop 113 comprises a plastic material. In some embodiments, the hard stop 113 is configured to break or shear off when a pyrotechnic disconnect element is triggered, which will be discussed in further detail below.

[0050] Now that the basic switching features of the contactor device 110 have been described, the pyrotechnic disconnect element will now be described. The contactor device 100 may include several elements that may be used as overcurrent protection, including a pyrotechnic charge 202 and a piston structure 204. The piston structure 204 may be positioned adjacent to or at least partially around one or more internal components, for example, the shaft 110 as shown. Movement of the piston from a rest position may change the configuration of the internal components to disconnect the current flowing through the device, for example, by pushing or otherwise moving the shaft 100 as described herein. The pyrotechnic charge 202 may be configured such that it is activated when the current exceeds a predetermined threshold level to prevent permanent damage to the connected electrical device or a safety hazard such as an electrical fire.

[0051] The contactor device 100 may include various sensor features that may detect when the current through the device has reached a dangerous level and may trigger the pyrotechnic charge when the threshold level is detected. In some embodiments, the contactor device 100 may include a dedicated current sensor that is configured to detect the level of current flowing through the device. The current sensor may be configured to directly or indirectly activate the pyrotechnic charge when the current reaches a threshold level. In some embodiments, when the threshold current level is detected, the current sensor may send a signal proportional to the detected current to activate the pyrotechnic charge. In some embodiments, the current sensor may include a Hall effect sensor, a transformer or current clamp meter, a resistor, a fiber optic current sensor, or an interferometer.

[0052] In some embodiments, the pyrotechnic charge 202 is configured to be activated by an electrical pulse and driven by an airbag system that is configured to detect multiple factors, similar to those used in modern vehicles. In some embodiments, the contactor device 100 may include one or more pyrotechnic pins 203, which may be configured to trigger the pyrotechnic charge 202 when the pyrotechnic pins 203 receive an activation signal. In some embodiments, the pyrotechnic charge may be connected to another component that already monitors the flowing current. The other component, such as a battery management component, may then be configured to send a signal to activate the pyrotechnic charge when a threshold current level is detected.

[0053] The pyrotechnic charge 202 can be a single charge structure or a multi-charge structure. In some embodiments, the pyrotechnic charge 202 includes a dual charge structure, which first includes an initiator charge and then includes a second gas generator charge. As described herein, many different types of pyrotechnic charges can be used if the pyrotechnic charge used is sufficient to provide sufficient force to move the piston structure 204 to permanently destroy the circuit of the contactor device 100. In some embodiments, the pyrotechnic charge 202 includes zirconium perchlorate, which has the advantage of being suitable for use as an initiator charge and a gas generator charge. In some embodiments, the initiator charge includes a fast-burning material, such as zirconium perchlorate, zirconium tungsten perchlorate, potassium titanium perchlorate, potassium hydrogen perchlorate, or potassium hydrogen perchlorate. In some embodiments, the gas generator charge includes a slow-burning material, such as potassium boron nitrate or black powder.

[0054] When the pyrotechnic charge 202 is activated, the force generated causes the piston structure 204 to be driven away from its resting position near or around the pyrotechnic charge 202, which in turn causes the piston structure 204 to push against the shaft 110 and causes the shaft to be driven away from the fixed contacts 104, 106. The force generated is also sufficient to cause the hard stop 113 to break or shear off, resulting in the shaft 110 being forced further away from the fixed contacts 104, 106, for example, being pushed into a separate internal compartment 206 of the body 102. The piston structure 204 may include sufficient dimensions (e.g., shape, size, spatial orientation, or other configuration) so that the piston structure 204 can hold the internal components in a certain position or configuration in which current cannot flow through the contactor device. This is accomplished, for example, by holding the shaft 110 in a position away from the fixed contacts 104, 106, for example, by holding the shaft 110 so that it is substantially located within the separate internal compartment 206 of the body 102. This in turn causes the movable contact 108 connected to the shaft 110 to be separated from the fixed contacts 104, 106 by an even larger spatial gap, placing the device in a "triggered" or permanently "on" configuration in which electricity cannot flow through the device. In some embodiments, the piston structure 204 includes sufficient dimensions so that once it is displaced by activating the pyrotechnic feature 202, the piston structure 204 is forced into a position that interacts with a portion of the body 102 so that it cannot be easily displaced.

[0055] In addition to the large spatial gaps that are rapidly created between the stationary contacts 104, 106 and the movable contact 108, other structures may be used. For example, in some embodiments, one or more arc ejection magnets 208 (two are shown) may be utilized to further control the arc. While the primary method for breaking the current is to rapidly open the contacts to a larger air gap as described herein, additional performance may be obtained through a secondary gas blast to the arc, such as by using a gas generator charge.

[0056] In some embodiments, comprising Figure 1 The illustrated embodiments may include other optional design features that may help prevent hazards caused by rapid accumulation of gases due to activation of the pyrotechnic charge 202. In these embodiments, the body 102 may be configured such that when the pyrotechnic charge 202 is activated, the piston structure 204 drives the shaft 110 with sufficient force to pierce a portion of the body 102. This will allow the rapid accumulation of gases to escape. In some embodiments, this is achieved by a portion of the body 102 that includes a diaphragm that can be pierced during the pyrotechnic disconnect cycle, for example, by a sharp portion 210 of the shaft 110, allowing gases to escape from a connected vent portion 212 of the body 102, which may be a high temperature filter membrane. The high temperature gases may then be exhausted from the body 102. The pressure relief may cool the arc and improve performance and prevent contactor housing rupture.

[0057] The difference between breaking the circuit of current through the contactor device 100 during normal switching operation and the permanent breaking of the circuit of current through the contactor device 100 when the device is in its "triggered" state is Figures 2 to 3 is better shown in . Figures 2 to 3 Shows Figure 1 The contactor device 100 is similar to the contactor device 100 of FIG. 1 , but in a different orientation. The contactor device 100 includes a body 102, fixed contacts 104, 106, a movable contact 108, a shaft 110, a plunger structure 111, a solenoid 112, a hard stop 113, a wing portion 114 of the shaft 110, a pyrotechnic charge 202, a hot pin 203, a piston structure 204, a separate compartment 206 of the body 102, an arc blow-out magnet 208, a sharp portion 210 of the shaft 110, and a vent portion 212 of the body 102.

[0058] The contactor device 100 is Figure 2 , which is shown in its “open” state, showing that the shaft 110 moves so that the connected movable contact 108 is separated from the fixed contacts 104, 106 by the disconnection space gap 302. Figure 2 As shown, the contactor device 100 is still in the "set" position without activating the pyrotechnic feature. The disconnection space gap 302 separates the movable contact 108 from the fixed contacts 104, 106 by a sufficient distance, which are otherwise electrically isolated from each other, to disconnect the current through the device. Figure 3 The contactor device 100 is shown in its triggered state when the pyrotechnic charge 202 is activated, causing the piston structure 204 to force the shaft 110 and the movable contact 108 in a direction away from the fixed contact 104. This quickly creates a large breaking space gap 350 between the fixed contacts 104, 106 and the movable contact 108.

[0059] like Figure 3 As shown, the force generated by the activation of the pyrotechnic charge 202 and the resulting sudden movement of the piston structure 204 and the shaft 110 can be sufficient to cause the hard stop 113 to break or shear away from its original position connected to the body 113. The hard stop 113 may include a solid material connected to or integrated with the body 102 so that it acts as a stop for the shaft 110 during normal device operation between the "closed" and "open" circuit states. However, during operation of the pyrotechnic disconnect feature, the hard stop 113 can be intentionally designed to "fail" as a stop structure and break or shear away to allow the shaft 110 to enter the separate body compartment 206.

[0060] In some embodiments, the piston structure 204 can be configured so that it can interact with the piston stop portion 352 of the body 102 after the pyrotechnic charge 202 is activated. This can be done, for example, by interacting with a position of the piston structure 204, for example, a portion of the piston stop portion 352 is configured to interact or cooperate with another portion on the piston structure 204.

[0061] In some embodiments, the piston structure 204 will not be in contact with the piston stop portion 352 until the piston structure 204 has been displaced by activation of the pyrotechnic charge 202. This results in the piston structure 204 being held between the piston stop portion 352 and the movable contact 108 when the pyrotechnic charge 202 has been activated and the piston structure 204 is forced from its rest position. Figure 3 As shown, this configuration places the piston structure 204 in a position to hold or lock the piston structure 204 on the movable contact 108. The piston structure 204 holds the movable contact 108 in place and helps maintain the circuit breaking space gap 350 so that the fixed contacts 104, 106 and the movable contact 108 do not slide back into contact with each other, making the contactor device 100 inoperable.

[0062] In some embodiments, as an alternative to or in addition to the piston stop portion 352 of the body 102, the separate compartment 206 of the body 102 may include sufficient dimensions, including, for example, a size and shape, such that the separate compartment 206 can interact with a portion of the shaft 110 that has moved into the separate compartment 206 due to activation of the pyrotechnic charge 202.

[0063] In some embodiments, the separate compartment can be configured to interact with a sheared hard stop 113 or another structure connected to the shaft 110, which has been moved into the separate compartment 206 due to the activation of the pyrotechnic charge 202. During normal device operation, these portions of the shaft 110 or the connecting structure were not previously within the separate compartment 206, but are forced into the separate compartment 206 during the pyrotechnic cycle during the overcurrent protection operation. The separate compartment 206 includes sufficient size, shape, or additional features, such as features configured to interact or cooperate with corresponding features on the shaft 110 or the connecting structure to hold the shaft 110 in place so that the movable contact 108 connected to the shaft 110 cannot slide back into contact with the fixed contacts 104, 106.

[0064] In addition to the above features, Figures 1 to 3The contactor device 100 may also include a PCB 400. As will be discussed further herein, the PCB allows for efficient and convenient connection of the internal components of the contactor device 100 to a pyrotechnic activation arrangement incorporating features of the present invention. The PCB 400 may be a PCB designed to accommodate a pyrotechnic activation arrangement incorporating features of the present invention. Figures 1 to 3 In the illustrated embodiment, the PCB 400 is shown as being located near the top of the contactor device 100; however, it should be understood that the PCB 400 can be located in or on any portion of the contactor device 100 and can be inside the contactor device 100 or outside the contactor device 100.

[0065] In addition to contactor devices that can operate during normal operation to limit or allow current flow through the device, another type of switching device that can be used as an example environment for use with a passive pyrotechnic trigger configuration is a fuse device. A fuse device only allows current to flow through the device during normal operation and acts as a sacrificial circuit break when a threshold current level passes through the device. Figures 4 to 5 Such an exemplary fuse device 430 is shown, which includes similar features and is similar to Figures 1 to 3 The contactor device 100 in FIG. 1 operates similarly, however, does not include some of these features, such as a solenoid or other mechanism for opening and closing the fixed and movable contacts. During normal operation, the fuse device 430 is always in a "closed" state, allowing current to flow through the device, until the pyrotechnic feature is activated, causing the device to thereafter be in an "open" state, preventing current from flowing through the device. Figures 4 to 5 Shown is a body 432 (similar to the above Figures 1 to 3 The main body 102 in the embodiment of the present invention), the fixed contacts 434, 436 (similar to the above Figures 1 to 3 However, in this embodiment, the fixed contacts 434, 436 are formed separately from the power terminals 438, 440, and the power terminals 438, 440 are electrically connected to the fixed contacts 434, 436 for connection to an external circuit, and the power terminals and the fixed contacts are connected to each other. Figures 1 to 3 The implementation method is the same. Figures 4 to 5 Further shown is a movable contact 442 (similar to the above Figures 1 to 3 The movable contact 108 in the embodiment of the present invention), the shaft structure 444 (similar to the above Figures 1 to 3 The shaft structure 110 in FIG. 1 , except for a different shape).

[0066] The shaft structure 444 is connected to the movable contact 442 and the piston structure 446 (which is similar to the above Figures 1 to 34, 436). The piston structure 446 can at least partially surround the pyrotechnic charge 448 so that when the pyrotechnic charge 448 is activated, the movable contact 442 and the piston structure 446 are forced in a direction away from the fixed contacts 434, 436, thereby breaking the circuit. In some embodiments, the fuse device 430 may include a support structure 450, which is configured to help hold the fixed contacts 434, 436 and the movable contact 442 in place. In some embodiments, triggering the pyrotechnic charge 448 causes the piston structure 446 to be driven away from the pyrotechnic charge in a manner that the support structure 450 is destroyed or displaced. In some embodiments, the fuse device 430 can be triggered by an active signal. In some embodiments, the fuse device 430 can be triggered by a passive triggering configuration, such as those discussed herein. Figure 4 The fuse device 430 is shown in a "closed" state, wherein the fixed contacts 434, 436 and the movable contact 442 are together and allow current to flow through the device 430. Conversely, Figure 5 The fuse device 430 is shown in its “open” state after activation of the pyrotechnic charge 448 , wherein the fixed contacts 434 , 436 and the movable contact 444 are separated and current flow through the device 430 is prevented.

[0067] Now that two types of switching devices, contactors and fuse devices, have been described as example environments in which pyrotechnic triggering mechanisms according to the present disclosure may be utilized, embodiments of pyrotechnic triggering mechanisms may now be more fully described. Figures 6 to 11 In the following embodiments described, reference will be made to Figures 1 to 3 However, it should be understood that the pyrotechnic triggering configuration is described with reference to the contactor device. Figures 6 to 11 The described pyrotechnic triggering arrangement may be applied as a triggering device in any switching mechanism that includes a pyrotechnic feature, including for example Figures 4 to 5 A fuse device is described.

[0068] Figure 6 A pyrotechnic triggering arrangement 500 is shown, which includes a PCB 502 (traces not shown) (similar to Figures 1 to 3 PCB 400 in), power terminal 504 (similar to Figures 1 to 3 The fixed contact structures 104, 106 in the embodiment of the present invention, and the passive trigger switch 506. Figure 6 Also shown is a pyrotechnic activation arrangement 500 integrated with an electrical device 503 , which includes a body 508 , which may be similar to body 102 , containing internal components. Figure 6The pyrotechnic trigger configuration 500 is shown without the top "cap" portion of the body, leaving the PCB 502 visible and exposed, however, it should be understood that in normal device operation, components such as an enclosed body including a cap and epoxy material may be included. Figure 6 Also shown is a pyrotechnic pin 510, which is similar to Figures 1 to 3 The pyrotechnic pin 203 in the embodiment of the present invention includes a coil pin 512 which allows electrical connection to an internal coil or solenoid, for example, similar to Figures 1 to 3 The solenoid 112 in the embodiment of the present invention also includes a tubular structure 514, which can help to form an internal airtight seal or management of electronegative gases within the electrical device 503.

[0069] exist Figure 6 In operation of the pyrotechnic trigger arrangement 500, when a predetermined level of current is passed through the device 503, for example, a level of current representing a dangerous level of current that may cause permanent damage to the device or create a hazard such as a fire, the passive trigger switch 506 will be activated. This in turn completes the circuit which transmits a signal to the pyrotechnic pin 510, thereby activating an internal pyrotechnic element, such as Figures 1 to 3 502. In these embodiments, PCB 502 can be configured so that it directs the trigger signal to pyrotechnic pins 510, which are in electrical communication with pyrotechnic features inside device 503. The electrical path of the trigger signal can be dependent on closing or activating passive trigger switch 506, such that when passive trigger switch 506 is open or untriggered (in a quiescent state), the electrical path of the trigger signal to pyrotechnic pins 510 is blocked. Likewise, when passive trigger switch 506 is closed or activated, the trigger signal can be directed to pyrotechnic pins 510 and trigger the internal pyrotechnic features.

[0070] The passive trigger switch 506 can be connected to a sensor that is configured to detect when a predetermined level of current passes through the device 503, and the sensor signals the passive trigger switch 506 to trigger. In some embodiments, the passive trigger switch 506 itself is configured to detect or passively respond and trigger when the current flowing through the device 503 reaches a predetermined level. For example, in some embodiments, the passive trigger switch 506 includes a switch that is configured to react to a magnetic field generated by current flowing through the power terminal 504 of the device 503 or current passing through an area of ​​the device 503.

[0071] In some embodiments, the passive trigger switch 506 is a reed switch or other switching mechanism that is configured to activate in response to generating a magnetic field of sufficient strength. The reed switch can use different configurations. For example, the reed switch can be configured so that the contacts are open when stationary and closed when there is a sufficient magnetic field, or closed when stationary and open when there is a sufficient magnetic field. In addition, in some embodiments, the reed switch can be organized into a reed relay and actuated by a magnetic coil. In most embodiments in which a reed switch is incorporated herein, the reed switch is configured so that the contacts are open when stationary, preventing the electrical signal from traveling to the pyrotechnic pin 510 and activating the pyrotechnic feature until a sufficient magnetic field corresponding to a dangerous current level closes the reed switch.

[0072] In some embodiments, the PCB 502 includes a plurality of passive trigger switch mounting features 516 that allow the pyrotechnic trigger configuration 500 to be adjusted according to the desired trip current. Figure 7 Shown is a pyrotechnic trigger arrangement 500, a PCB 502, an electrical device 503, a power terminal 504, a passive trigger switch 506, a body 508, a pyrotechnic pin 510, a coil pin 512, a tubular structure 514, and a trigger switch mounting feature 516. Figure 7 As shown, by mounting the passive trigger switch 506 to a different one of the trigger switch mounting features 516 , the desired trip current may be adjusted, which in turn adjusts the trip distance 518 between the passive trigger switch 506 and one or more power terminals 504 .

[0073] By adjusting the trip distance 518 between the passive trigger switch 506 and one or more power terminals 504, the amount of current flowing through the device 503 that is required to activate the passive trigger switch 506, thereby triggering the internal pyrotechnic features of the device, can be adjusted. For example, the passive trigger switch 506 may include a reed switch that is configured to activate when a predetermined magnetic field is generated due to a predetermined current level flowing through the power terminals 504. The strength of the magnetic field required to trigger the passive trigger switch 506, and therefore the level of the corresponding current flowing through the device required to trigger the passive trigger switch 506, can be adjusted by simply changing the trip distance 518 between the passive trigger switch 506 and the power terminals 504. In the illustrated embodiment, this can be achieved by mounting the passive trigger switch 506 to different passive trigger switch mounting features 516.

[0074] By moving the passive trigger switch 506 away from the power terminal 504, a larger magnetic field and therefore a larger current will be required to trigger the passive trigger switch 506 and thus the pyrotechnic feature of the device 503. This can provide a pre-designed switching device with a pre-designed PCB so that the device can be mass-manufactured while allowing different trip currents based on the placement of the passive trigger switch 506 at different ones of the passive trigger switch mounting features 516. For example, the passive trigger switch mounting feature 516 can be at a location on the PCB 502 that corresponds to different levels of magnetic field strength, which in turn can correspond to different levels of desired trip currents. A company can manufacture one PCB configuration and can place the passive trigger switch 506 on different passive trigger switch mounting features 516 to produce a device that will trip at different currents. In embodiments utilizing a coil or solenoid, for example, like a contactor, the passive trigger switch 506 can be configured to shut off the power to the coil. In these embodiments, this configuration can reduce the time it takes for the pyrotechnic feature to open the contacts because it does not have to work against the coil.

[0075] In other embodiments, additional features may be included in place of or in addition to the trigger switch mounting features 516 to further interact with the passive trigger switch 506. For example, Figure 8 shows a similar Figure 6 and Figure 7 The device 602 of the pyrotechnic triggering arrangement 600 of the pyrotechnic triggering arrangement 500 in FIG. The device 603 includes a PCB 602 (similar to Figure 7 PCB 502 in), electrical device 603 (similar to Figure 7 The electrical device 503 in the embodiment of the present invention) and the power terminal 604 (similar to Figure 7 The device 603 also includes a passive trigger switch 606 (similar to Figure 7 Passive trigger switch 506 in), body 608 (similar to Figure 7 The main body 508 in the figure), the pyrotechnic pin 610 (similar to Figure 7 Firework pin 510), coil pin 612 (similar to Figure 7 The coil pin 512 in FIG. 1 and the tubular structure 614 (similar to Figure 7 Although similar embodiments may include trigger switch mounting features, Figure 8 The embodiment shown in does not include a trigger switch mounting feature. Instead, the pyrotechnic trigger arrangement 600 includes a core structure 630 that facilitates determining a target trip current for the pyrotechnic trigger arrangement 600.

[0076] The core structure 630 can include any known material capable of directing, directing, or controlling a magnetic field generated by an electric current flowing through the device 603. For example, in some embodiments, the core structure 630 includes a metal. In some embodiments, the core structure 630 includes iron, an iron alloy, or other iron-containing material. In some embodiments, the core structure 630 is magnetic. The core structure 630 can include any suitable shape or configuration that produces the desired magnetic field characteristics, including any regular or irregular polygonal or custom shape. Figure 8 In the illustrated embodiment, the core structure 630 comprises a curved strip. The core structure 630 can be configured in any spatial position relative to the device 603 and the PCB 602 to facilitate the interaction between the generated magnetic field and the passive trigger switch 606. Figure 8 In the illustrated embodiment, the core structure 630 at least partially surrounds one of the power terminals 604 and is adjacent to the passive trigger switch 606 .

[0077] The magnetic field generated from the core structure 630 may be more important than the magnetic field generated by the power terminals themselves, and the desired trigger current may be controlled by adjusting the distance between a portion of the core structure 630 and the passive trigger switch 606, rather than from a magnetic field generated by the power terminals themselves. Figure 6 to Figure 7 The power supply terminal 604 and the passive trigger switch 606 in the embodiment of FIG. Fig. 9 A pyrotechnic trigger arrangement 600 , a PCB 602 , an electrical device 603 , power terminals 604 , a passive trigger switch 606 , a body 608 , a pyrotechnic pin 610 , a coil pin 612 , a tubular structure 614 , and a core structure 630 are shown. Fig. 9 Also shown is a trip distance 636 between the passive trigger switch 606 and the core structure 630. Figures 7 and 8 Similar to the embodiments of , the passive trigger switch 606 may include a reed switch or other passive mechanism that is configured to activate when a predetermined magnetic field is generated due to a predetermined current level flowing through the power terminal 604 and / or the core structure 630.

[0078] The strength of the magnetic field required to trigger the passive trigger switch 606, and therefore the level of the corresponding current flowing through the device required to trigger the passive trigger switch 606, can be adjusted by simply changing the trip distance 636 between the passive trigger switch 606 and a portion of the core structure 630. By moving the passive trigger switch 606 away from the core structure 630, a larger magnetic field, and therefore a larger current, will be required to trigger the passive trigger switch 606, and therefore trigger the pyrotechnic feature of the device 603.

[0079] In some embodiments, an external trigger mechanism may be used instead of or in addition to the trigger switch mounting feature 606 or the core structure 630. In some embodiments, this external trigger mechanism may replace the need for a PCB, but in other embodiments, the external trigger mechanism may be used in addition to a PCB. Fig.10 An example implementation is shown in where an external trigger mechanism replaces the need for a PCB. Fig.10 A pyrotechnic trigger configuration 700 (similar to Figure 8 Configuration 700 includes an electrical device 703 (similar to Figure 8 Electrical device 603 in), power supply terminal 704 (similar to Figure 8 power supply terminal 604 in), passive trigger switch 706 (similar to Figure 8 Passive trigger switch in), body 708 (similar to Figure 8 The main body 608 in the figure), the pyrotechnic pin 710 (similar to Figure 8 pyrotechnic pin 610 in FIG. 1 ), access point 712 (which may provide line access to the internal solenoid or coil), and tubular structure 714 (similar to Figure 8 The tubular structure 614 in FIG. Fig.10 Also shown is a body 708 including a top or cap portion 716 through which the power terminals 704 protrude.

[0080] It should be understood that Fig.10 Similar top or cap portions of the cap portion 716 of the body 708 shown in FIG. 7 can be applied to all other embodiments incorporating features of the present invention. For example, it should be understood that Figure 6 and Figure 8 The device embodiment is shown without the cap portion to better illustrate the underlying PCB configuration. However, during final assembly, Figure 6 and Figure 8 Embodiments may have all internal components completely enclosed within the body and include a cap portion of the body.

[0081] Fig.10 The embodiment of FIG. 7 also shows an external trigger mechanism 730, which includes a passive trigger switch 706, a conductive bus bar 732, and a spacing portion 734. Fig.10 As shown, the conductive bus bar 732 may include multiple connection parts, wherein the conductive bus bar 732 in the illustrated embodiment includes a first connection point 736 and a second connection point 738, the first connection point 736 is configured to be connected to the device 708 at one of the power terminals 704, and the second connection point 738 is configured to be connected to an external power source.

[0082] Conductive bus bar 732 may include any conductive material, such as a metallic material. In some embodiments, conductive bus bar 732 includes copper. Spacer portion 734 may include a non-magnetic material. Conductive bus bar 732 may be configured to allow current to flow to pyrotechnic pin 710 and thereby trigger an internal pyrotechnic feature of device 703. Similar to Figure 6 and Figure 8 The passive trigger switch in the illustrated embodiment, passive trigger switch 706 is configured in an open state which does not allow current to flow through the conductive bus bar 732 and thus allows the pyrotechnic feature to be triggered.

[0083] When the current from device 703 reaches a threshold level, sufficient magnetic field is generated to trigger passive trigger switch 706. This allows current from an external power source connected to second connection 738 of conductive bus bar 732 to flow through conductive bus bar 732 to pyrotechnic pin 710 and thereby trigger the pyrotechnic feature of the device.

[0084] The threshold magnetic field required to activate the passive trigger switch 706, and therefore determine the current level required to be sufficiently dangerous to warrant activation of the pyrotechnic circuit breaking feature, can be adjusted by adjusting the distance between the passive trigger switch 706 and the conductive bus bar 732. This can be achieved, for example, by adjusting the thickness of the non-magnetic spacer portion 734. For example, Fig.11 Show Fig.10 A close-up cross-sectional view of the external trigger mechanism 730 of FIG. 1 , including the passive trigger switch 706 , the conductive bus bar 732 and the spacer portion 734 , the first connection point 736 and the second connection point 738 . Fig.11 Also shown is a trip distance 750 , which corresponds to the thickness of the non-magnetic spacer portion 734 .

[0085] Similar to the embodiments discussed above, the passive trigger switch 706 may include a reed switch or other passive mechanism. The switch may be configured to activate when a predetermined magnetic field is generated due to a predetermined current level flowing through the power terminal 604, in which case the power terminal 604 is electrically connected to an external trigger mechanism. The magnetic field strength required to trigger the passive trigger switch 706, and therefore the level of the corresponding current flowing through the device 703 required to trigger the passive trigger switch 706, can be adjusted by simply changing the trip distance 750 between the passive trigger switch 706 and the conductive bus bar 732. By increasing the thickness of the non-magnetic spacer portion 734, and therefore moving the passive trigger switch 706 away from the conductive bus bar 732, a larger magnetic field, and therefore a larger current, will be required to trigger the passive trigger switch 706 and therefore trigger the pyrotechnic feature of the device 703. Similarly, by moving the passive trigger switch 706 closer to the conductive bus bar 732, a smaller magnetic field will be required, and therefore a smaller current will be required to trigger the passive trigger switch 706 and therefore trigger the pyrotechnic feature of the device 703.

[0086] It will be appreciated that different pyrotechnic passive switching circuits may be arranged in many different ways in accordance with the present invention. Fig.12 A simplified schematic diagram of one embodiment of a pyrotechnic passive switching circuit 800 according to the present invention is shown. The circuit 800 generally includes an operating power supply circuit 802, which includes a standard operating power supply 804 coupled to an operating load 806, which is energized and powered by the power supply 802. A contactor or fuse 808 is arranged in the circuit 800 to disconnect the electrical connection between the power supply 804 and the load when a hazardous current flows in the circuit 802. It should be understood that the fuse 808 can also include a feature of acting as a contactor to disconnect the power supply 804 from the load during normal operating conditions. It should also be understood that the fuse 808 can include a contactor, wherein the passive switching circuit 800 operates to change the state of the contactor to disconnect the circuit path as described above.

[0087] A pyrotechnic activation circuit 810 may be included that is arranged to work with the operating power supply circuit 802 to prevent overcurrent conditions. The circuit 810 includes a pyrotechnic actuator / activator 812 as described above, which is arranged to change the state of the fuse 808 when activated. The circuit also includes an overcurrent-activated pyrotechnic fuse trigger 814 that is arranged adjacent to the circuit 802 in a position that allows it to sense an overcurrent condition in the circuit 802. In the illustrated embodiment, the trigger 814 may include a reed switch, but it should be understood that many different alternative devices may be used. The trigger 814 may be placed in many different locations relative to the circuit 802, such as adjacent to the power supply terminals as described above, or adjacent to other conductors in the circuit that carry the operating current. The circuit 810 may also include an auxiliary power supply 816 that may be coupled to the pyrotechnic actuator 812 when the fuse trigger is closed in response to an elevated current level.

[0088] During operation, fuse 808 is closed, allowing the operating power supply 804 to power the load 806. When normal current levels flow through the circuit 802, the trigger 814 remains open and the auxiliary power supply 816 is disconnected from the pyrotechnic actuator 812. When current above a certain level (a dangerously high level) flows through the circuit 802, the trigger 814 closes in response to the elevated magnetic field. This connects the auxiliary power supply to the pyrotechnic actuator 812, causing it to actuate and open fuse 808. This in turn disconnects the operating power supply 804 from the load 806 to break the conductive path for the elevated current in the circuit 802.

[0089] It should be understood that other circuits according to the present invention can be arranged in many different ways with many different devices and components. Many different auxiliary power sources can be used, with some embodiments using an integrated battery or capacitor circuit to store a charge sufficient to activate the pyrotechnic actuator 812. In other embodiments, the auxiliary power source can include an on-board low voltage power source that is still sufficient to activate the pyrotechnic actuator 812.

[0090] Fig.13 Another embodiment of a pyrotechnic passive switching circuit 900 according to the present invention is shown, which includes a plurality of Fig.12 900 includes an operating power circuit 902 that includes a standard operating power source 904 coupled to an operating load 906. A contactor or fuse 908 is disposed in the circuit 900 to disconnect the electrical connection between the power source 904 and the load 906 when a hazardous current flows in the circuit 902.

[0091] Circuit 900 includes a pyrotechnic actuator / activator 912 and an overcurrent-actuated pyrotechnic fuse trigger 914 similar to those described above. However, in circuit 900, these elements are not arranged in a separate pyrotechnic activation circuit that works with an auxiliary power supply to activate pyrotechnic actuator 912. Instead, these elements are integrated with the operating power supply circuit 902, and trigger 914 is arranged to sense an elevated current in circuit 902 and also coupled to circuit 902 at the conductor carrying the elevated current. In the illustrated embodiment, trigger 914 is coupled to the circuit conductor in parallel with fuse 908, but it should be understood that it can be arranged in other ways.

[0092] During normal operation, trigger 914 is open and power from power source 904 is conducted through fuse 908 to load 906. When trigger 914 senses an elevated current, it closes and the elevated current passes through trigger 914 to pyrotechnic actuator 912, activating the actuator and opening fuse 908. This disrupts the normal conduction path between power source 904 and load 908.

[0093] The trigger 914 is also arranged so that the elevated current from the power supply 904 quickly ruptures or otherwise destroys the trigger 914, thereby breaking the current path through the trigger 914. The trigger 914 carries the current long enough to activate the actuator, but is destroyed shortly thereafter. This results in the power supply 904 being electrically isolated from the load 906, and any elevated current path being broken. It should be understood that the trigger 914 and the actuator 912 can have elements that contain them during rupture or activation, such as an encapsulation material such as epoxy.

[0094] It will also be appreciated that the elements of the circuit according to the present invention may be coupled together using many different electrical conductors. This may include conductive paths or wires on a printed circuit board. It will also be appreciated that the above circuit may be arranged on and integrated with a contactor or fuse to provide an easy to use and compact device. The circuit 900 may provide certain advantages, such as not requiring a separate auxiliary power supply to activate the pyrotechnic actuator 912. This may result in a simplified and less expensive device.

[0095] Although the present invention has been described in detail with reference to certain preferred configurations of the present invention, other versions are possible. Embodiments of the present invention may include any combination of compatible features shown in the various drawings, and these embodiments should not be limited to those explicitly shown and discussed. Therefore, the spirit and scope of the present invention should not be limited to the above versions.

[0096] The foregoing is intended to cover all modifications and alternative constructions that fall within the spirit and scope of the invention, wherein no part of this disclosure is intended, either expressly or implicitly, to be dedicated to the public domain unless recited in any of the claims.

Claims

1. An electrical switching device, comprising: case; an internal component within the housing, the internal component configured to change the state of the switching device from a closed state that allows current to flow through the switching device to an open state that blocks current from flowing through the switching device; a pyrotechnic feature configured to interact with the internal component to transition the switching device from the closed state to the open state when the pyrotechnic feature is activated; a passive trigger switch structure configured to activate the pyrotechnic feature when triggered, the passive trigger switch structure configured to trigger in response to a magnetic field reaching a threshold strength when a threshold current level flows through the switching device; a power terminal electrically connected to the internal component to connect to an external circuit; as well as At least one core structure at least partially surrounds at least one of the power terminals, wherein the threshold strength of the magnetic field is determined by a distance of a passive trigger switch from a portion of the at least one core structure.

2. The electrical switching device according to claim 1, wherein: The passive trigger switch comprises a reed switch.

3. The electrical switching device according to claim 1, wherein: The passive trigger switch is connected to the PCB.

4. The electrical switching device according to claim 3, wherein: The threshold strength of the magnetic field is determined at least in part by a distance of the passive trigger switch from at least one of the power terminals.

5. The electrical switching device according to claim 4, wherein: The PCB includes a plurality of passive trigger switch mounting features.

6. The electrical switching device according to claim 5, wherein: The plurality of passive trigger switch mounting features are configured at locations at different distances from at least one of the power terminals such that the locations correspond to different desired trigger thresholds based on different magnetic field threshold strengths.

7. An electrical switching device, comprising: case; an internal component within the housing, the internal component configured to change the state of the switching device from a closed state that allows current to flow through the switching device to an open state that blocks current from flowing through the switching device; a pyrotechnic feature configured to interact with the internal component to transition the switching device from the closed state to the open state when the pyrotechnic feature is activated; a passive trigger switch configured to activate the pyrotechnic feature when triggered, the passive trigger switch configured to trigger in response to an elevated current signal flowing through the switching device, the passive trigger switch being arranged to use the elevated current signal to activate the pyrotechnic feature; as well as PCB, wherein the passive trigger switch is connected to the PCB, wherein the PCB includes a plurality of passive trigger switch mounting features.

8. The electrical switching device according to claim 7, wherein: The passive trigger switch comprises a reed switch.

9. The electrical switching device according to claim 8, wherein: The plurality of passive trigger switch mounting features are configured at locations at different distances from at least one of the power terminals such that the locations correspond to different desired trigger thresholds based on different magnetic field threshold strengths.

10. The electrical switching device according to claim 7, further comprising a power terminal, wherein: The passive trigger switch is arranged to trigger in response to an increased current in the power supply terminal.

11. An electrical system comprising: A working power circuit, comprising a working power source coupled to a working load through a current path, a contactor being located between the power source and the load; a pyrotechnic trigger circuit, including a trigger / switch, configured to sense an elevated current in said operating power circuit; as well as a pyrotechnic actuator, the trigger / switch closing in response to the elevated current in the operating power circuit and conducting the elevated current for a sufficient time to activate the pyrotechnic actuator to operate on the contactor to open the current path in the operating power circuit, wherein upon actuation of the pyrotechnic actuator, the trigger / switch is destroyed by the elevated current.

12. The system according to claim 11, wherein: The contactor includes internal components within a housing configured to change a state of a switching device from a closed state that allows current to flow through the contactor to an open state that interrupts current flow through the contactor.

13. The system according to claim 12, wherein: When the pyrotechnic actuator is activated, the pyrotechnic actuator interacts with the internal component to transition the contactor from the closed state to the open state.

14. The system according to claim 12, wherein: The trigger circuit uses the elevated current to activate the pyrotechnic actuator.

15. The system of claim 12, wherein: The trigger circuit uses an auxiliary power source to activate the pyrotechnic actuator.

16. The system of claim 15, wherein: The auxiliary power source includes a battery, a capacitor circuit or a low voltage power source.

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