Pyrotechnic circuit breakers for electric vehicle systems

Abstract

The circuit breaker may include a plurality of mounting components for receiving the first and second busbar components, the mounting components being made of an insulating material. The circuit breaker may include an arc chamber forming a primary arc path for current between the first and second busbar components. The circuit breaker may include a pyrotechnic charge pusher component located between the first and second busbar components and the arc chamber. The pusher component may be made of an insulating material and may be operated upon detection of a fault to direct ionized particles or derived gases toward the arc chamber.

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] This application claims the benefit of U.S. Provisional Application No. 63 / 363,701, filed April 27, 2022, entitled "PYROTECHNIC CIRCUIT INTERRUPTER FOR ELECTRIC VEHICLE SYSTEMS," which is incorporated herein by reference in its entirety.

[0002] The disclosed technology relates to power distribution for electric vehicles. [Background technology]

[0003] Electric vehicles and their associated infrastructure can use conductive cable systems to conduct electricity. These cable systems can provide high current-carrying capacity at the voltages required for electric vehicles and charging systems. These cables are typically flexible and contain conductive metal encapsulated by one or more layers of insulation and metal sleeves for touch safety and electromagnetic compatibility (EMC) shielding.

[0004] In some scenarios, a cable system or electrical system may have problems with unwanted current or fault current being caused in the cable system. For example, a malfunction of one or more components, such as a motor controller, may cause unwanted current or fault current. In other examples, deformation of a component caused by a vehicle collision may cause a sudden and dangerous fault current. In still other examples, a malfunction of a charging component or system may also cause unwanted current.

[0005] To prevent damage to electrical systems, electrical components, or cable systems, cable systems may incorporate some form of circuit breaker component or device that is operable when a fault is detected. Illustratively, circuit breaker types may include fuse-based components that are primarily configured as single-use devices configured to interrupt the flow of electrical current. Fuse-based devices are generally inexpensive components intended primarily for single-use use. Another circuit breaker type includes circuit breaker-based components that are primarily configured as multi-use devices. Circuit breaker-based components are typically more expensive and complex devices. [Brief explanation of the drawings]

[0006] These and other features, aspects, and advantages of the present invention are described herein with reference to drawings of preferred embodiments, which are intended to be illustrative, not limiting, of the invention.

[0007] [Figure 1] FIG. 1 illustrates an embodiment of a pyrotechnic circuit breaker in accordance with one or more aspects of the present application.

[0008] [Figure 2A] FIG. 1 is a side cross-sectional view of an embodiment of a pyrotechnic circuit breaker in accordance with one or more aspects of the present application.

[0009] [Figure 2B] FIG. 1 is a side cross-sectional view of an embodiment of a pyrotechnic circuit breaker in accordance with one or more aspects of the present application.

[0010] [Figure 2C] FIG. 1 is a side cross-sectional view of an embodiment of a pyrotechnic circuit breaker in accordance with one or more aspects of the present application.

[0011] [Figure 2D] FIG. 1 is a cross-sectional perspective view of an embodiment of a pyrotechnic circuit breaker in accordance with one or more aspects of the present application.

[0012] [Figure 2E] FIG. 1 is a cross-sectional perspective view of an embodiment of a pyrotechnic circuit breaker in accordance with one or more aspects of the present application.

[0013] [Figure 3A] FIG. 1 is a side cross-sectional view of a portion of a pyrotechnic circuit breaker in accordance with one or more aspects of the present application.

[0014] [Figure 3B] FIG. 1 is a top view of a portion of a pyrotechnic circuit breaker in accordance with one or more aspects of the present application.

[0015] [Figure 4] FIG. 1 is a side view of a pyrotechnic circuit breaker in accordance with one or more aspects of the present application. DETAILED DESCRIPTION OF THE INVENTION

[0016] In the following detailed description of certain embodiments, various illustrations of specific embodiments are provided. However, the innovations described herein can be embodied in many different ways, for example, as defined and encompassed by the claims. This description refers to the drawings, in which reference numbers may indicate identical or functionally similar elements. It should be noted that the elements shown are not necessarily drawn to scale. It should also be understood that certain embodiments may include more elements and / or a subset of the elements shown. Furthermore, some embodiments may incorporate any suitable combination of features from two or more drawings.

[0017] Generally described, one or more aspects of the present application correspond to a circuit breaker. Illustratively, the circuit breaker may include a pyrotechnic charge that can be triggered during a fault. The circuit breaker may include a plurality of mounting components for receiving the first and second busbar components. The mounting components are made of an insulating material. The circuit breaker may include an arc chamber that forms a primary arc path for current between the first and second busbar components. The circuit breaker may include a pyrotechnic charge pusher component positioned between the first and second busbar components and the arc chamber. The pusher component can be operated upon detection of a fault to direct ionized particles or derived gas toward the arc.

[0018] In some embodiments, such as those relating to electric vehicles and electric vehicle charging systems, the electrical system may experience voltages ranging from 450V to 1000V, or even higher. Such voltages are generally considered to be for "high voltage" applications and are often required to achieve the power demands associated with fast electric vehicle charging. In the event of a fault or other detected event, the vehicle and / or charging cable system may incorporate one or more circuit breaker components operable to prevent damage to the vehicle, the external charging system, personnel, etc. As discussed above, circuit breaker components may traditionally include fuse-based or circuit breaker-based components.

[0019] Circuit breakers generally operate by creating an open circuit between two ends of a cable system, such as a bus bar, to prevent current flow between the ends. An open circuit may be physically created using some form of pyrotechnic charge that creates an open circuit in a relatively short period of time. However, at higher voltage levels, the creation of an open circuit may result in arcing between the two ends of the cable system. Additionally, depending on the circuit breaker configuration, the creation of an open circuit (e.g., a shattered bus bar) may create metallic gases in the physical proximity of the open circuit. The combined presence of metallic gases or other ionized particles and arcs can result in arc restrike or back commutation. Generally described, arc restrike or back commutation corresponds to an undesirable condition in which an alternate current path is created within the circuit breaker, reducing the effectiveness of the circuit breaker. Such reduced effectiveness may cause direct or indirect damage to electrical components, live parts, or individuals.

[0020] To address, at least in part, the described deficiencies of circuit breakers, embodiments of the present disclosure relate to a pyrotechnic circuit breaker component for use in an electric vehicle charging system. Illustratively, aspects of the present disclosure relate to a pyrotechnic circuit breaker for use in an electric busbar-cable system used in an electric vehicle system. The pyrotechnic circuit breaker includes an arc chamber intended to induce current between ends of the cable system during a break event. When the device is activated while current is flowing, the arc chamber contains or induces an arc plasma that is generated when the current flow is interrupted between two ends of the cable system (e.g., two ends of a busbar). Additionally, activation of a combination of a pyrotechnic charge and a pusher element during a fault can generate a resulting shock wave that pushes forming gas away from the open circuit, mitigating the possibility of a potential arc restrike.

[0021] Additionally, other aspects of the pyrotechnic circuit breaker may further be constructed with insulating material, such as plastic insulators, to prevent the formation of secondary arc paths. More specifically, in one embodiment, components of the arc chamber portion of the pyrotechnic circuit breaker may be constructed such that three sides of the arc chamber are primarily constructed of insulating material, such as insulating plastic. By confining the conductive material of the arc chamber along the desired arc path, the pyrotechnic circuit breaker of the present application avoids arc restriking or backcommunication that could otherwise occur in the arc chamber.

[0022] In yet another aspect, the arc chamber of the pyrotechnic circuit breaker may include, for example, interlocks or interdigitated insulating plates or fins that isolate the emission of gases or other ionized particles. Isolation of the resulting gases or ionized particles further limits the size of the secondary arc or arc restrike along the rear of the pyrotechnic circuit breaker.

[0023] Additionally, in other aspects, the separation of resulting gases may be directed away from the top surface of the arc chamber. In some scenarios, if the circuit breaker operates during the installation process, resulting gases or emissions are directed away from the vicinity of personnel, thereby reducing the possibility of injury or harm caused by hot gases.

[0024] The technology disclosed herein is applicable to a variety of applications. Thus, while various advantages and combinations of aspects of the pyrotechnic circuit breaker of the present application are described, those skilled in the art will understand that various embodiments of the present application may include any individual aspect or various combinations thereof. Thus, reference to embodiments or alternative embodiments should not be construed as requiring any particular combination of aspects, or exclusive combinations with other aspects, unless specifically identified in the description.

[0025] FIG. 1 illustrates a side perspective view of a pyrotechnic circuit breaker 100 according to an exemplary embodiment of the present application. The pyrotechnic circuit breaker 100 includes two busbar components 102A and 102B. The first busbar component 102A and the second busbar component 102B may be a single, integral busbar or may be separate, connected busbar components. Illustratively, the busbar components may be constructed from a combination of materials including a conductive material for conducting electrical current and one or more insulating materials. The specific shape and materials of the busbar components may vary depending on the location of the busbar within the electric vehicle, the operating range of the cabling system and charging system, etc.

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

[0027] The pyrotechnic circuit breaker 100 further includes an arc chamber 104 that forms 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 are constructed of an insulating material, such as an insulating plastic (e.g., nylon plastic, a thermoplastic material, a thermoset material, etc.), that prevents the formation of an arc through the mounting components 106A and 106B. FIG. 1 shows the mounting components 106A and 106B oriented in an upward position after a fault, with the busbar components 102A and 102B not in direct contact.

[0028] Pyrotechnic circuit breaker 100 further includes a pyrotechnic charge pusher component 108 positioned between busbar components 102A, 102B and arc chamber 104. As described herein, pyrotechnic charge pusher component 108 can be activated, for example, upon detection of a fault, to direct ionized particles or derived gases toward the arc chamber. 106A, 106B and portions of pusher component 108 are constructed of an insulating material, such as, for example, an insulating plastic (e.g., a nylon plastic, a thermoplastic material, a thermoset material, etc.), that prevents the formation of an arc in areas other than arc chamber 104.

[0029] 1 will now be described with reference to FIGS. 2A-2E. Referring initially to FIG. 2A, in a first operational or normal state, the busbar components 102A, 102B are physically connected and conduct electrical current. In this regard, no current flows through the arc chamber 104 and mounting components 106A, 106B, and the pyrotechnic charge pusher component 108 does not mitigate the flow of current. FIG. 2A illustrates that the pyrotechnic charge pusher component 108 includes a pyrotechnic charge 202 adjacent to a pusher component 204 that forms a shock wave as described herein. The particular shape of the pusher component 204 is exemplary in nature and should not be construed as limiting.

[0030] Referring to FIG. 2B , upon a trigger event related to a detected fault or other criteria, the pyrotechnic charge 202 is activated, generating an upward force. This causes the busbar to fracture, separating the busbar components 102A and 102B at location 206. A weakening feature may be provided at location 206. The weakening feature may include a notch, hole, slot, bend, pre-bend region, or another suitable feature. The weakening feature may be configured to guide the fracture or separation of the first busbar component 102A from the second busbar component 102B. Additionally, a resulting shock wave 208 induces a resulting discharge (e.g., ionized material) into the arc chamber. The first busbar component 102A may further include a bent portion 112A, and the second busbar component 102B may further include a bent portion 112B. Bend locations 112A and 112B may include bends, slots, holes, prestressed areas, pre-bend areas, notches, or other material weakening features. Bend locations 112A and 112B may include one or more features. Bend locations 112A and 112B may be located at first distances 114A and 114B, respectively, from location 206. First distance 114A includes a portion of the first bus bar between location 206 and bend location 112A. Similarly, first distance 114B includes a portion of the second bus bar between location 206 and bend location 112B.

[0031] Referring to FIG. 2C, after a triggering event, the pyrotechnic circuit breaker 100 is in a second operating state in which normal current flow within the busbar is prevented and any resulting arc is magnetically and physically guided toward the arc chamber. As shown in FIG. 2C, the busbar components 102A, 102B include substantially perpendicular portions that do not physically contact each other. Additionally, components 106A, 106B and at least a portion of the pyrotechnic pusher component 108, constructed of insulating material, prevent current flow or arcing between the two busbar components. Additionally, as shown in FIG. 2C, the arc component 104 includes additional insulating material 212 such that a resulting arc is pushed into portion 214 of the arc component 104 by gases generated by evaporation of a portion of the insulating material. FIGS. 2D and 2E show different perspectives of the arc chamber 104, including cross-sections to show portion 214 and insulating material 212. As shown in FIGS. 2D and 2E, the arc chamber may have a non-conductive outer surface 216.

[0032] The exterior surface 216 may comprise a housing that surrounds at least a portion of the arc chamber. The exterior surface 216 may be comprised of a single piece or may have multiple pieces. The exterior surface 216 may have a mounting or positioning feature. For example, the exterior surface 216 may have a first mounting portion 218A and a second mounting portion 218B. The first busbar component 102A may have a first busbar mounting portion 116A that connects with the first mounting portion 218A to position, retain, lock, or engage the first busbar component 102A relative to the housing 216. Similarly, the second busbar component 102B may have a first busbar mounting portion 116A that connects with the first mounting portion 218A to position, retain, lock, or engage the first busbar component 102A relative to the housing 216.

[0033] Referring now to FIG. 3A , according to an embodiment of the present disclosure, the arc chamber 104 of the pyrotechnic circuit breaker may include, for example, interlocking or interdigitated insulating plates 302 or fins that separate the exhaust of gases or other ionized particles. Separating the resulting gases or ionized particles further reduces the likelihood of secondary arcing or arc restrike along the exhaust section of the pyrotechnic circuit breaker. As shown in FIG. 3A , the plates 302 receive ionized material in response to the shock wave generated by the pyrotechnic charge pusher component 108 and direct the resulting gases into a set of channels 304 in the exhaust chambers 306. The exhaust chambers are configured such that a barrier 308 exists between each exhaust chamber 306, thereby combining the resulting exhaust and preventing or mitigating secondary arcing between any two chambers 306. FIG. 3B illustrates a top perspective view of the pyrotechnic circuit breaker 100 with the plates 302, channels 304, chambers 306, and barrier 308.

[0034] According to yet another aspect of the present application, the chamber 306 and barrier 308 of the arc chamber may be further extended to direct any resulting gases downward relative to the top surface of the pyrotechnic circuit breaker 100. More specifically, the chamber 306 forms a channel or path from the top surface as the ionized particles are directed upward, releasing a set of digitized paths downward from the arc chamber 104. The downward direction is indicated by the arrows in FIG. 4 . The exterior surface 216 may be constructed of an insulating material. In one embodiment, when the pyrotechnic charge 202 is activated during installation, any resulting gaseous material (as described herein) is directed away from the user, including any hands or tools that may be used during installation. This can prevent injuries, such as significant burns.

[0035] Unless the context clearly dictates otherwise, throughout the specification and claims, words such as "comprise," "comprising," "include," "including," and the like, are to be construed in an inclusive sense, as opposed to an exclusive or exhaustive sense; i.e., "including but not limited to." The term "coupled," as generally used herein, refers to two or more elements that are directly connected or may be connected by one or more intermediate elements. Similarly, the term "connected," as generally used herein, refers to two or more elements that are directly connected or may be connected by 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" in reference to a list of two or more items encompasses all of the following interpretations of that word: any of the items in the list, all of the items in the list, and any combination of the items in the list.

[0036] Additionally, conditional language used herein, particularly "can," "could," "may," "for example," "such as," and the like, unless expressly stated otherwise or understood otherwise within the context in which it is used, is generally intended to convey that certain embodiments include certain features, elements, and / or conditions, while other embodiments do not. Thus, such conditional language is generally not intended to imply that features, elements, and / or conditions are in any way required for one or more embodiments.

[0037] The above description has been given with reference to specific embodiments. However, the above illustrative description is not intended to be exhaustive or to limit the invention to the precise form described. Many modifications and variations are possible in light of the above teachings. This will enable those skilled in the art to best utilize the techniques and various embodiments with various modifications suitable for various applications.

[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, and such changes and modifications should be understood to be included within the scope of the present disclosure.

Claims

1. A plurality of mounting components for receiving a first busbar component and a second busbar component, wherein the plurality of mounting components are made of an insulating material, An arc chamber for forming a primary arc path for current between the first busbar component and the second busbar component, A pyrotechnic charge pusher component located between the first busbar component and the second busbar component, and below the arc chamber, wherein the pusher component is configured to be activated when a fault is detected to guide ionized particles or derived gases toward the arc chamber, and the pusher component is made of an insulating material, Equipped with, A circuit breaker in which, upon detection of the aforementioned fault, the pyrotechnic charge generates an upward force, pushing the pusher component and thereby generating a derived shock wave that induces a discharge into the arc chamber.

2. The circuit breaker according to claim 1, wherein the circuit breaker is associated with a first operating state in which the flow of current occurs between integrated busbar components, and the integrated busbar components include the first busbar component and the second busbar component.

3. The circuit breaker according to claim 2, wherein the pyrotechnic charge is configured to break the integrated busbar component to form the first busbar component and the second busbar component.

4. The circuit breaker according to claim 1, wherein the pusher is configured to bend the first busbar component and the second busbar component.

5. The circuit breaker according to claim 1, wherein the arc chamber comprises an insulating plate configured to separate the discharge.

6. The circuit breaker according to claim 1, wherein the circuit breaker is associated with a second operating state in which current in the busbar is prevented and any resulting arc is directed toward the arc chamber.

7. The circuit breaker according to claim 6, wherein any resulting arc is guided magnetically and physically toward the arc chamber.

8. The circuit breaker according to claim 5, wherein the exhaust chambers are formed such that a barrier exists between each exhaust chamber.

9. The circuit breaker according to claim 8, wherein the exhaust chamber and the barrier are configured to guide the discharge downward relative to the upper surface of the circuit breaker.

10. The circuit breaker according to claim 9, wherein the exhaust chamber is configured to form a channel from the top surface when the ionized particles are guided upward, and to guide the discharge emitted from the arc chamber downward into a set of digitized channels.

11. The circuit breaker according to claim 3, wherein the integrated busbar component comprises a weakening mechanism configured to guide fracture, the weakening mechanism comprising a notch, a hole, a slot, a bend, and a pre-bend region.

12. The circuit breaker according to claim 1, wherein the first busbar component has a first bending position, and the second busbar component has a second bending position, and the first bending position and the second bending position include a notch, a bend, a slot, a hole, a pre-bending region, and a pre-stressed region.

13. The circuit breaker according to claim 1, wherein the three sides of the arc chamber are made of an insulating material to restrict the conductive material of the arc chamber along a desired arc path.

14. The circuit breaker according to claim 13, wherein the derived gas comprises a gas produced through the evaporation of a portion of the insulating material, and the derived gas is configured to push the ionized particles into the induction portion.

15. The circuit breaker according to claim 1, wherein the pusher component is configured to form a shaped derived shock wave.

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