Pyrotechnic circuit breaker for electric vehicle system

Abstract

A circuit breaker may include a plurality of mounting components comprised of an insulating material for receiving first and second bus bar components. The circuit breaker may include an arc chamber for providing a main arc path for current between the first and second busbar components. The circuit breaker includes a pyrotechnic charge and a pusher member between the first and second busbar members and the arc chamber. The pusher member may be composed of an insulating material and may be triggered to direct ionized particles or generated gas toward the arc chamber when a fault is detected.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to U.S. non-provisional application serial number 63 / 363,701, filed on April 27, 2022, and invention name “PYROTECHNIC CIRCUIT INTERRUPTER FOR ELECTRIC VEHICLE SYSTEMS,” the disclosure of which is incorporated by reference in its entirety into this application. Technical Field

[0002] The disclosed technology relates to electric vehicle power distribution. Background Art

[0003] Electric vehicles and associated infrastructure can utilize conductive cable systems for electrical conduction. These cable systems can provide high current carrying capabilities at the voltages required by electric vehicles and charging systems. These cables are typically flexible, contain conductive metals, and are encapsulated by single or multi-layer insulation and metal sleeves for touch safety and electromagnetic compatibility (EMC) shielding.

[0004] In some cases, the cable system or electrical system may encounter problems related to undesired currents or fault currents encountered in the cable system. For example, a failure of one or more components, such as a motor controller, may generate an undesired current or fault current. In another example, deformation of components caused by a vehicle collision may cause a sudden and dangerous fault current. In other examples, a failure of a charging component or system may also cause an undesired current.

[0005] In order to prevent damage to the electrical system, electrical components, or cabling system, the cabling system may incorporate some form of circuit interruption element or device that can be triggered in the event of a detected fault. For example, a circuit interruption type may include a fuse-based component that is primarily configured as a single-use device that is configured to interrupt the flow of electrical current. Fuse-based devices are generally inexpensive components that are primarily used for a single purpose. Another circuit interruption type corresponds to a circuit breaker-based component that is primarily configured as a multi-use device. Circuit breaker-based components are generally more expensive and complex devices. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] These and other features, aspects, and advantages of the present invention are described herein with reference to the accompanying drawings of preferred embodiments, which are intended to illustrate rather than to limit the present invention.

[0007] Figure 1 is a diagram of an embodiment of a pyrotechnic circuit breaker according to one or more aspects of the present application.

[0008] Figure 2Ais a cross-sectional side view of an embodiment of a pyrotechnic circuit breaker according to one or more aspects of the present application.

[0009] Figure 2B is a cross-sectional side view of an embodiment of a pyrotechnic circuit breaker according to one or more aspects of the present application.

[0010] Figure 2C is a cross-sectional side view of an embodiment of a pyrotechnic circuit breaker according to one or more aspects of the present application.

[0011] Figure 2D is a cross-sectional angle perspective of an embodiment of a pyrotechnic circuit breaker according to one or more aspects of the present application.

[0012] Figure 2E is a cross-sectional angle perspective of an embodiment of a pyrotechnic circuit breaker according to one or more aspects of the present application.

[0013] Figure 3A is a cross-sectional side view of a portion of a pyrotechnic circuit breaker according to one or more aspects of the present application.

[0014] Figure 3B is a top view of a portion of a pyrotechnic circuit breaker according to one or more aspects of the present application.

[0015] Figure 4 is a side view of a pyrotechnic circuit breaker according to one or more aspects of the present application. DETAILED DESCRIPTION

[0016] The following detailed description of certain embodiments presents various descriptions of specific embodiments. However, the innovations described herein may be embodied in a variety of different ways, for example, as defined and covered by the claims. This description refers to the accompanying drawings, in which reference numerals may represent identical or functionally similar elements. It should be understood that the elements shown in the figures are not necessarily drawn to scale. In addition, it will be understood that certain embodiments may include more elements and / or a subset of the elements shown than shown in the figures. In addition, some embodiments may incorporate any suitable combination of features from two or more of the drawings.

[0017] In general, one or more aspects of the present application correspond to a circuit breaker. For example, the circuit breaker may include a pyrotechnic charge that is triggered during a fault. The circuit breaker may include a plurality of mounting components for receiving a first busbar component and a second busbar component. The plurality of mounting components are formed of an insulating material. The circuit breaker may include an arc chamber for providing a main arc path for current between the first busbar component and the second busbar component. The circuit breaker may include a pyrotechnic charge and a push rod component located between the first busbar component and the second busbar component and the arc chamber. When a fault is detected, the push rod component may be triggered to direct ionized particles or generated gases toward the arc.

[0018] In some embodiments, such as those related to electric vehicles and electric vehicle charging systems, the electrical system may experience voltages in the range of 450 volts to 1000 volts, or possibly higher. Such voltages are generally considered "higher voltage" applications, and are generally required to implement authority requirements associated with high-speed electric vehicle charging. In the event of a fault or other detected event, the vehicle and / or charging cable system may include one or more circuit breaker components that can be triggered to avoid damage to the vehicle, external charging system, human participants, etc. As described above, the circuit breaker components can traditionally include fuse-based components or circuit breaker-based components.

[0019] Circuit breakers typically operate by forming an open circuit between the two ends of a cable system, such as a busbar, to prevent the flow of current between the two ends. The open circuit can be physically formed using some form of pyrotechnic charge that creates the open circuit in a relatively short period of time. However, at higher voltage levels, the creation of an open circuit may result in a situation where arcing occurs between the two ends of the cable system. In addition, depending on the configuration of the circuit breaker, the creation of an open circuit (e.g., the breaking of a busbar) may generate metallic gases within the physical proximity of the open circuit. In combination, the presence of metallic gases or other ionized particles and arcs can cause arc reignition or reverse connection. Generally speaking, arc reignition or reverse connection corresponds to an undesirable situation where an alternative current path may be formed inside the circuit breaker to reduce the efficiency of the circuit breaker. This reduction in effectiveness may cause direct or indirect damage to electrical components, charging components, or individuals.

[0020] To at least partially address the deficiencies described in circuit breakers, embodiments of the present disclosure relate to pyrotechnic circuit breaker components for electric vehicle charging systems. Exemplarily, aspects of the present application relate to pyrotechnic circuit breakers for electrical bus cable systems used in electric vehicle systems. The pyrotechnic circuit breaker includes an arc chamber for directing current between two ends of the cable system during an interruption event. When the device is activated while the current is flowing, the arc chamber contains or otherwise directs an arc plasma generated when the current flow between the two ends of the cable system (e.g., the two ends of the busbar) is interrupted. In addition, a combination of a pyrotechnic charge and a push rod element can be activated at the time of a fault to generate a shock wave that directs any formed gases away from the waypoint. This reduces the likelihood of a potential arc reignition.

[0021] In addition, other aspects of the pyrotechnic circuit breaker can be further constructed of insulating materials, such as plastic insulators, to prevent the formation of secondary arc paths. More specifically, in one embodiment, the components of the arc chamber portion of the pyrotechnic circuit breaker can be configured such that three sides of the arc chamber are primarily constructed of insulating materials, such as insulating plastic. By limiting the conductive material of the arc chamber along the desired arc path, the pyrotechnic circuit breaker of the present application avoids the arc reignition or reverse communication that may be formed with the arc chamber.

[0022] In other aspects, the arc chamber of the pyrotechnic circuit breaker can illustratively include interlocking or intersecting insulating plates or fins that separate the emissions of gas or other ionized particles. The resulting separation of gas or ionized particles further limits the size of secondary arcs or arc restrike along the rear of the pyrotechnic circuit breaker.

[0023] Additionally, in other aspects, separation of the generated gases can be directed away from the top surface of the arc chamber. In some cases, if the circuit breaker is triggered during installation, the generated gases or discharges will be directed away from people. This reduces the possibility of injury from hot gases.

[0024] The high technology disclosed herein can be applied to a variety of applications. Therefore, although the various benefits and combinations of various aspects of the pyrotechnic circuit breaker of the present application will be described, it will be understood by those skilled in the art that the various embodiments of the present application may include any single aspect or various combinations of various aspects. Therefore, reference to an embodiment or an alternative embodiment should not be interpreted as requiring any specific combination of various aspects or otherwise limiting combinations with other aspects unless explicitly stated in the specification.

[0025] Figure 1A side perspective of a pyrotechnic circuit breaker 100 according to an exemplary embodiment of the present application is described. The pyrotechnic circuit breaker 100 includes two parts of busbar components 102A and 102B. The first busbar component 102A and the second busbar component 102B can be a single integral busbar or separately connected busbar components. Illustratively, the busbar components can be made of a combination of materials including a conductive material for conducting electric current and one or more insulating materials. The specific shape and material of the busbar components can vary based on the location of the busbar within the electric vehicle, the operating range of the wiring system and the charging system, etc.

[0026] The busbar components 102A and 102B may include ends 120A and 120B. The ends 120A and 120B may include a plurality of mounting features for mounting the first busbar component 102A or the second busbar component 102B to additional components. The mounting features of the ends 120A or 120B may include holes, slots, grooves, clamps, or other features. The ends 120A or 120B may be connected to other busbar components. For example, the system may include a missing portion of the busbar, and a pyrotechnic circuit breaker may be integrated into the system.

[0027] The pyrotechnic circuit breaker 100 further includes an arc chamber 104 for providing a primary arc path for current between the two busbar components 102A and 102B. The pyrotechnic circuit breaker 100 further includes mounting components 106A and 106B for receiving the busbar components 102A and 102B, respectively. The mounting components 106A and 106B illustratively include insulating materials, such as insulating plastics (e.g., nylon plastics, thermoplastics, thermosetting materials, etc.). Arcing is prevented through the mounting components 106A and 106B. Figure 1 The mounting components 106A and 106B are illustrated positioned in a higher position after a failure where the busbar components 102A, 102B are no longer in direct contact.

[0028] The pyrotechnic circuit breaker 100 further includes a pyrotechnic charge and push rod assembly 108 located between the busbar assemblies 102A, 102B and the arc chamber 104. As described herein, illustratively, the pyrotechnic charge and push rod assembly 108 can be triggered when a fault is detected to direct ion particles or generated gases toward the arc chamber. Portions of the busbar assemblies 106A, 106B and the push rod assembly 108 are illustratively composed of an insulating material, such as an insulating plastic (e.g., nylon plastic, thermoplastic, thermosetting material, etc.), to prevent arcing in areas other than the arc chamber 104.

[0029] refer to Figure 2A-2E , will describe Figure 1 First refer to the operation of the illustrative components. Figure 2AIn the first operating state or nominal state, the busbar components 102A, 102B are physically connected and conduct current. In this regard, no current flows in the arc chamber 104 and the mounting components 106A, 106B, and the pyrotechnic charge and push rod component 108 do not mitigate any current flow. Figure 2A The pyrotechnic charge and pusher member 108 is illustrated to include a pyrotechnic charge 202 adjacent a pusher member 204 that forms a shaped shock wave as described herein. The specific shape of the pusher member 204 is illustrative in nature and should not be construed as limiting.

[0030] refer to Figure 2B Upon a triggering event associated with a detected fault or other criteria, the pyrotechnic charge 202 is activated and generates an upward force. This causes the busbar to break to separate the busbar components 102A and 102B at location 206. Location 206 may include a weakening feature. The weakening feature may include a notch, a hole, a slot, a bend, a pre-bent area, or other suitable feature. The weakening feature may be configured to guide the breakage or separation of the first busbar component 102A from the second busbar component 102B. In addition, the generated shock wave 208 guides any generated discharge (e.g., ionized material) to the arc chamber. The first busbar component 102A may further include a bend location 112A and the second busbar component 102B may further include a bend location 112B. The bend locations 112A and 112B may include bends, slots, holes, pre-stressed areas, pre-bent areas, notches, or other material weakening features. The bend locations 112A and 112B may include a single feature or multiple features. Bend locations 112A and 112B may each be located at first distances 114A and 114B from location 206. First distance 114A includes a portion of a first generatrix between location 206 and bend location 112A. Similarly, first distance 114B includes a portion of a second generatrix between location 206 and bend location 112B.

[0031] Go to Figure 2C After a triggering event, the pyrotechnic circuit breaker 100 is in a second operating state in which typical current flow in the busbar is blocked and in which any potential arcing is magnetically and physically directed to the arc chamber. Figure 2C As shown, busbar assemblies 102A, 102B are not in physical contact and include substantially vertical portions. In addition, components 106A and 106B made of insulating material and at least some portions of pyrotechnic push rod component 108 prevent current flow or arcing between the two busbar components. In addition, as shown Figure 2C As shown, the arc component 104 includes additional insulating material 212 such that gases generated by vaporization of portions of the insulating material force any generated arc into portions 214 of the arc component 104 . Figure 2D and2E Various views of the arc chamber 104 are shown, including cross-sections of the depicted portion 214 and the insulating material 212. Figure 2D and 2E As shown, the arc chamber may also have an outer surface 216 that is non-conductive.

[0032] The outer surface 216 may include an outer shell that contains at least a portion of the arc chamber. The outer surface 216 may be made of a single part, or may include multiple parts. The outer surface 216 may include mounting features or positioning features. For example, the outer surface 216 may include a first mounting seat 218A and a second mounting seat 218B. The first busbar component 102A may include a first busbar mounting seat 116A, which is connected to the first mounting seat 218A to position, hold, lock or otherwise engage the first busbar component 102A with the outer shell 216. Similarly, the second busbar component 102B may include a first busbar mounting seat 116A, which is connected to the first mounting seat 218A to position, hold, lock or otherwise engage the first busbar component 102A with the outer shell 216.

[0033] Now go to Figure 3A According to aspects of the present application, the arc chamber 104 of the pyrotechnic circuit breaker may illustratively include interlocking or intersecting insulating plates 302 or fins that separate the exhaust of gases or other ionized particles. The resulting separation of gases or ionized particles further reduces the likelihood of secondary arcing or arc reignition along the exhaust portion of the pyrotechnic circuit breaker. Figure 3A As shown, the plate 302 receives ionized material in response to the shock waves generated by the pyrotechnic charge and propulsion components 108 and directs the generated gases to a set of channels 304 to exhaust chambers 306. The exhaust chambers are formed so that a barrier 308 exists between each exhaust chamber 306. This allows the generated exhaust gases to cross each other and prevent or mitigate the formation of secondary arcs between any two chambers 306. Figure 3B A top view of the pyrotechnic circuit breaker 100 is shown having a plate 302 , a channel 304 , a chamber 306 , and a barrier 308 .

[0034] According to another aspect of the present application, the chamber 306 and the barrier 308 of the arc chamber can be further extended so that any generated gases are directed downward relative to the top surface of the pyrotechnic circuit breaker 100. More specifically, when the ion particles are directed upward, the chamber 306 forms a channel or path from the top surface and causes a set of digital paths to be released from the arc chamber 104 in a downward direction. The downward direction is Figure 4. The outer surface 216 may be constructed of an insulating material. In one embodiment, if the pyrotechnic charge 202 is activated during installation, any generated gaseous material (as described herein) is directed away from the user, including hands or tools that may be used during installation. This may prevent injuries, such as severe burns.

[0035] Unless the context clearly requires otherwise, throughout the specification and claims, the words "comprise," "comprising," "include," "including," and the like should be interpreted as inclusive and not exclusive or exhaustive; that is, as meaning "including but not limited to." The word "coupled," as generally used herein, refers to two or more elements that can be directly connected or connected through one or more intermediate elements. Similarly, the word "connected," as generally used herein, refers to two or more elements that can be directly connected or connected through one or more intermediate elements. Where the context permits, words in the above detailed description using the singular or plural may also include the plural or singular, respectively. The word "or" refers to a list of two or more items, and the word covers all of the following interpretations of the word: any item in the list, all items in the list, and any combination of items in the list.

[0036] Furthermore, unless expressly stated otherwise or understood in the context of use, conditional language used herein, such as "may," "might," "likely," "for example," "such as," etc., is generally intended to convey that some embodiments include but other embodiments do not include certain features, elements, and / or states. Thus, such conditional language is generally not intended to imply that one or more embodiments require a feature, element, and / or state in any way.

[0037] The foregoing description has been described with reference to specific embodiments. However, the above illustrative discussion is not intended to be exhaustive or to limit the invention to the precise forms described. In view of the above teachings, many modifications and variations are possible. Therefore, others skilled in the art will be able to best utilize the technology and various embodiments and make various modifications suitable for various uses.

[0038] Although the present disclosure and examples have been described with reference to the accompanying drawings, various changes and modifications will become apparent to those skilled in the art. These changes and modifications should be understood to be included within the scope of the present disclosure.

Claims

1. A circuit breaker comprising: a plurality of mounting members for receiving the first busbar member and the second busbar member, wherein the plurality of mounting members are comprised of an insulating material; an arc chamber for providing a main arc path for current between the first busbar member and the second busbar member; as well as A pyrotechnic charge and a push rod assembly located between the first busbar assembly and the second busbar assembly and the arc chamber, wherein the push rod assembly is capable of being triggered upon detection of a fault to direct ionized particles or generated gases toward the arc chamber, and wherein the push rod assembly is composed of an insulating material.

2. The circuit breaker of claim 1, wherein the circuit breaker is associated with a first operating state in which current flows between an integral busbar component including the first busbar component and the second busbar component.

3. The circuit breaker of claim 2, wherein the pyrotechnic charge is configured to rupture the monolithic busbar component to form the first busbar component and the second busbar component. 4 . The circuit breaker of claim 1 , wherein the push rod is configured to bend the first busbar member and the second busbar member.

5. The circuit breaker of claim 1, wherein the arc chamber includes interlocked or crossed insulating plates configured to separate discharges.

6. The circuit breaker of claim 1, wherein the circuit breaker is associated with a second operating state in which typical current flow in the busbar is prevented and in which any potential arcing is directed to the arc chamber.

7. A circuit breaker comprising: a pyrotechnic charge, wherein the pyrotechnic charge is configured to trigger upon detection of a fault, the triggering of the pyrotechnic charge generating a force; placing the circuit breaker into a second operating state; an arc chamber, wherein said force directs any discharge associated with said striking of said pyrotechnic charge into said arc chamber; as well as A push rod, wherein the force causes the push rod to move, and the push rod applies a contact force that causes the circuit breaker to transition from a first operating state to a second operating state.

8. The circuit breaker of claim 7, wherein the associated integral busbar component includes a weakening feature.

9. The circuit breaker of claim 7, wherein the arc chamber includes interlocked or crossed insulating plates configured to separate discharges.

10. The circuit breaker of claim 7, wherein the arc chamber further comprises a plurality of chambers configured to receive the discharge when the pyrotechnic charge is triggered.

11. The circuit breaker of claim 10, wherein the plurality of chambers are further configured to direct the discharge in a downward direction.

12. The circuit breaker of claim 10, wherein the plurality of chambers are isolated to prevent combination of exhaust gases.

13. The circuit breaker of claim 7, wherein the force comprises a shock wave.

14. The circuit breaker of claim 7, wherein in the second operating state, any potentially generated arc is directed to an arc chamber.

15. A circuit breaker comprising: a plurality of mounting components for receiving the busbar component, wherein the plurality of mounting components are composed of insulating material; an arc chamber for providing a main arc path for current between the first busbar member and the second busbar member; as well as Means for directing ionized particles or generated gases towards the arc chamber when a fault is detected.

16. The circuit breaker of claim 15, wherein said means for directing ionized particles or generated gases toward said arc chamber upon detection of a fault comprises a pyrotechnic charge and a push rod assembly located between said first and second busbar members and said arc chamber.

17. The circuit breaker of claim 15, wherein the arc chamber includes interlocked or crossed insulating plates configured to separate discharges.

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