Active / Passive Automotive Fuse Module

Abstract

To provide an active / passive automotive fuse module including both a passive circuit protection element and an active circuit protection element in the field of a circuit protection device.SOLUTION: An active / passive automotive fuse module 10 according to an embodiment of the present disclosure may include an electrically insulating base 12, and a fuse plate 14 including a busbar portion located on the upper surface of the base and above a projectile cavity formed in the base, the fuse plate includes a flexible portion that is electrically connected to the busbar portion and is adapted to open when the amount of current flowing through the fuse plate exceeds the current rating of the active / passive automotive fuse module, the active / passive automotive fuse module further includes an ignition breaker (PI) containing a projectile located above the busbar portion, and located above the base, and the PI is configured to drive the projectile through the busbar portion when the PI is activated.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] (Cross - Reference to Related Applications) This application claims the benefit of U.S. Provisional Patent Application No. 62 / 844,358, filed May 7, 2019, which is incorporated herein by reference in its entirety.

[0002] (Field of the Invention) The present disclosure generally relates to the field of circuit protection devices, and more specifically to an active / passive automotive fuse module that includes both passive and active circuit protection elements.

Background Art

[0003] Fuses are typically implemented within automotive electrical systems to provide over - current protection. Most automotive fuses are "passive" devices that include a fuse element configured to carry a rated amount of current during normal operation. When the current flowing through the fuse element exceeds the rated current of the fuse element, the fuse element melts, decomposes, or separates in another way, thereby stopping the current and preventing or reducing damage to the connected electrical components.

[0004] In some cases, it may be desirable to "actively" generate a physical opening within an electrical circuit, regardless of the amount of current flowing through the circuit. For example, when an automobile is involved in a collision, it may be desirable to physically open the electrical circuit within the automobile to reduce the risk of fire and / or electrocution immediately after the collision, such that the electrical supply to the connected electrical components is reliably stopped. For that purpose, so-called pyrotechnic interruptors (PIs) have been developed that can be selectively actuated upon the occurrence of a specific event to interrupt the flow of current within the circuit. For example, in the case of an automobile collision, a controller (e.g., an airbag control unit, a battery management system, etc.) can send a start signal to the PI to detonate an explosive within the PI. The resulting increase in pressure within the PI rapidly and forcibly drives a projectile through a conductor extending through the PI. Thereby, the current flowing through the PI is interrupted, and the projectile formed of a dielectric material provides an electrical insulation barrier between the separated portions of the conductor to prevent electrical arcing therebetween.

[0005] In certain automotive applications, it may be desirable to implement both passive circuit protection elements and active circuit protection elements. Further, it may be more desirable to implement such elements in a small space-saving form factor that facilitates convenient installation and is well-suited for high-voltage applications.

[0006] With respect to these and other considerations, the improvements of the present invention can be useful. SUMMARY OF THE INVENTION MEANS FOR SOLVING THE PROBLEM

[0007] This "Summary of the Invention" is provided to introduce in a simplified form a selection of concepts further described below in the "Detailed Description of the Invention". This "Summary of the Invention" is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0008] Exemplary embodiments of an active / passive automotive fuse module according to the present disclosure may include an electrically insulating base and a fuse plate including a busbar portion disposed on an upper surface of the base and above a projectile cavity formed within the base, the fuse plate being electrically connected to the busbar portion and further including a fusible portion adapted to open when the amount of current flowing through the fuse plate exceeds the current rating of the active / passive automotive fuse module, the active / passive automotive fuse module further including a pyrotechnic interruptor (PI) disposed on the base and positioned above the busbar portion, the PI being configured to drive a projectile through the busbar portion upon actuation of the PI.

[0009] Another exemplary embodiment of an active / passive automotive fuse module according to the present disclosure includes an electrically insulating base, a fuse plate including a busbar portion disposed on an upper surface of the base and above a projectile cavity formed within the base, and first and second fusible portions extending vertically into respective first and second fuse cavities formed in the base on an opposite side of the projectile cavity from first and second ends of the busbar portion, the first and second fusible portions being adapted to open when the amount of current flowing through the fuse plate exceeds the current rating of the active / passive automotive fuse module, and first and second end portions extending from lower ends of the first and second fusible portions, respectively, for connecting the active / passive automotive fuse module within a circuit. The active / passive automotive fuse module may further include a pyrotechnic interruptor (PI) disposed on the base, the PI including an initiator and a projectile positioned above the busbar portion, the initiator being configured to detonate and press the projectile through the busbar portion upon receipt of a start signal by the PI.

Brief Description of the Drawings

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Figure 1

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Figure 2

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Figure 3

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Figure 4

Mode for Carrying Out the Invention

[0014] The active / passive automotive fuse module according to the present disclosure will now be described more fully with reference to the accompanying drawings, in which preferred embodiments of the active / passive automotive fuse module are presented. However, it will be understood that the active / passive automotive fuse module may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will convey to those skilled in the art a particular exemplary aspect of the active / passive automotive fuse module.

[0015] Referring to FIGS. 1 - 3, perspective and cross-sectional views are shown illustrating an active / passive automotive fuse module 10 (hereinafter, "fuse module 10") according to an exemplary, non-limiting embodiment of the present disclosure. For convenience and clarity, terms such as "front", "rear", "top", "bottom", "above", "below", "vertical", and "horizontal" may be used herein to describe the relative placement and orientation of the various components of fuse module 10, each of which relates to the shape and orientation of fuse module 10 as shown in FIGS. 1 - 3. The terms include the specifically recited words, their derivatives, and words of similar meaning.

[0016] The fuse module 10 can generally include a base 12, a fuse plate 14, a spacer cap 16, and a pyrotechnic interruptor (PI) 18. The base 12 may be a substantially rectangular member formed of an electrically insulating material (e.g., plastic, polymer, ceramic, etc.). As illustrated in the cross-sectional view of the fuse module 10 shown in FIG. 2, the base 12 may include vertically elongated first and second fuse cavities 18a, 18b formed on its upper surface. The first and second fuse cavities 18a, 18b may be substantially identical and may have a lower end (e.g., a floor) located above the bottom surface of the base 12. The base 12 may further include a projectile cavity 20 formed horizontally intermediate the fuse cavities 18a, 18b on its upper surface. The projectile cavity 20 may be shorter than the fuse cavities 18a, 18b. The present disclosure is not limited in this regard.

[0017] The fuse plate 14 may be formed from a single piece of conductive material (e.g., pressed from a single copper sheet) and may include a busbar portion 22, first and second fusible portions 24a, 24b, and first and second end portions 26a, 26b. The busbar portion 22 may be disposed horizontally on the upper surface of the base 12 and may extend from a first end disposed above the first fuse cavity 18a, over the projectile cavity 20, to a second end disposed above the second fuse cavity 18b. The first and second fusible portions 24a, 24b may each extend vertically downward from the first and second ends of the busbar portion 22 into their respective first and second fuse cavities 18a, 18b. The lower ends of the first and second fusible portions 24a, 24b may extend through respective slots formed in the floors of the first and second fuse cavities 18a, 18b and may terminate below the bottom surface of the base 12. The first and second end portions 26a, 26b may extend vertically outward (i.e., away from the projectile cavity 20) from the lower ends of the first and second fusible portions 24a, 24b and may include respective mounting openings 30a, 30b formed therethrough for connecting the fuse module 10 in a circuit (e.g., between a battery and one or more electrical loads of a vehicle).

[0018] The first and second fusible portions 24a, 24b may be configured to melt, decompose, or otherwise open when the current flowing through the fuse plate 14 exceeds a predetermined threshold or "current rating" of the fuse module 10. In various embodiments, the first and second fusible portions 24a, 24b may include perforations, slots, thinning or narrowing segments, and / or various other features to make the first and second fusible portions 24a, 24b more likely to melt or open than other portions of the fuse plate 14. In non-limiting embodiments, the first and second fusible portions 24a, 24b may be configured to have a current rating in the range of 30 amperes to 1000 amperes. In various embodiments, an arc quenching, fuse filling material (not shown), such as sand, silica, etc., may partially or completely fill the first and second fuse cavities 18a, 18b and substantially surround the first and second fusible portions 24a, 24b to quench an electric arc that can propagate in other ways when the first and second fusible portions 24a, 24b open during an overcurrent condition. Thus, the fuse module 10 may be particularly suitable for high voltage applications. The fuse module 10 is described and illustrated as having two fusible portions 24a, 24b, but various alternative embodiments of the fuse module 10 that may include only one fusible portion or more than two fusible portions are contemplated.

[0019] The spacer cap 16 may be formed of an electrically insulating material that is the same as or similar to the conductive material from which the base 12 is formed and may be disposed on the base 12 and the bus bar portion 22 of the fuse plate 14. The spacer cap 16 may define a projectile channel 32 that extends vertically therethrough. The projectile channel 32 may be disposed directly above the projectile cavity 20 of the bus bar portion 22 and the base 12. Although the spacer cap 16 is shown as being separate from the base 12, in various alternative embodiments, it is contemplated that the base 12 and the spacer cap 16 may be formed as a single continuous body. The present disclosure is not limited in this regard.

[0020] PI18, which may be various commercially available ones (for example, sold under the product name "PYROSWITCH" by AUTOLIV), may include a housing 36 having a mounting flange 38. The housing 36 may be disposed on top of the spacer cap 16, and the mechanical fasteners 40a, 40b extend through these components to fasten the mounting flange 38, spacer cap 16, and base 12 together in a vertically stacked relationship as shown. The housing 36 may have a vertically oriented hollow shaft 41 extending therethrough, and the shaft 41 has a first open end located directly above the projectile channel 32 of the spacer cap 16. The shaft 41 may extend into the projectile channel 32 and include a projectile 42 that rests on the busbar portion 22 of the fuse plate 14. In various embodiments, the projectile 42 may have a pointed or wedge-shaped tip that is disposed in a facing relationship with the busbar portion 22. The present disclosure is not limited in this regard.

[0021] The housing 36 may further accommodate a primer 44 that is disposed adjacent to the second upper end of the shaft 41 and configured to discharge an explosive output to the second upper end of the shaft 41. In various embodiments, the primer 44 may be operably connected to a controller 45 (such as an airbag control unit, a battery management system, etc.) located within the vehicle. Upon the occurrence of a specific event such as a vehicle collision, the controller 45 may send a start signal to the PI18 to detonate the primer 44. The explosive output of the detonation may result in increasing the pressure within the shaft 41 and rapidly pressing the projectile 42 downward through the busbar portion 22 of the fuse plate 14 as shown in FIG. 3. Thereby, the busbar portion 22 is cut, and the current flowing through the fuse plate 14 is interrupted. The projectile 42, which may be formed of a dielectric material, can provide an electrical insulation barrier between the separated ends of the busbar portion 22 to prevent electrical arcing therebetween.

[0022] Referring to FIG. 4, a perspective view is shown illustrating another active / passive automotive fuse module 100 (hereinafter, "fuse module 100") according to an exemplary, non-limiting embodiment of the present disclosure. Fuse module 100 may be substantially identical to fuse module 10 described above, except for first and second end portions 26a, 26b of fuse plate 14 of fuse module 10 that have been replaced by first and second end protrusions 126a, 126b that extend vertically. First and second end protrusions 126a, 126b may be adapted for "plug-in" use of fuse module 100, and first and second end protrusions 126a, 126b may be fitted into complementary receptacles for connecting fuse module 100 within a circuit.

[0023] In view of the foregoing description, it will be appreciated that the active / passive automotive fuse module of the present disclosure is in a single compact space-saving form factor that facilitates convenient installation within an automobile and facilitates the implementation of both passive circuit protection elements and active circuit protection elements (e.g., conventional fuse elements and ignition interrupters). It will be further appreciated that the active / passive automotive fuse module of the present disclosure may be particularly suitable for high voltage applications.

[0024] As used herein, an element or step recited in the singular and proceeded by the word "a" or "an" should be understood as not excluding a plurality of elements or steps, unless such exclusion is explicitly recited. Further, reference to "one embodiment" of the present disclosure is not intended to be construed as excluding the existence of additional embodiments that incorporate the recited features.

[0025] This disclosure refers to specific embodiments, but numerous modifications, alterations, and changes to the described embodiments are possible without departing from the sphere and scope of this disclosure as defined in the appended "Claims." Accordingly, this disclosure is not intended to be limited to the described embodiments, but rather is intended to have the full scope defined by the language of the following claims and their equivalents.

Claims

1. An active / passive automotive fuse module, comprising: An electrically insulating base; A fuse plate, comprising: A bus bar portion disposed on the upper surface of the base and above a projectile cavity formed within the base; A fusible portion electrically connected to the bus bar portion and adapted to open when the amount of current flowing through the fuse plate exceeds the current rating of the active / passive automotive fuse module. The fusible portion has a first fusible portion extending vertically from a first end of the bus bar portion and a second fusible portion extending vertically from a second end of the bus bar portion. The first fusible portion is disposed within a first fuse cavity within the base, and the second fusible portion is disposed within a second fuse cavity within the base. The first fuse cavity is formed on a first side of the projectile cavity, and the second fuse cavity is formed on a second side of the projectile cavity. The first side is opposite the second side with respect to the direction of extension of the bus bar portion in the base. The fusible portion; A pyrotechnic interrupt (PI) disposed on the base and including a projectile and an initiator. The projectile is disposed within a shaft and positioned above the bus bar portion, and the initiator is disposed adjacent to the shaft. The PI is configured to drive the projectile through the bus bar portion in response to an increase in pressure within the shaft caused by the initiator that detonates in response to an actuation signal from an operably connected controller; The PI functions as an active circuit protection element independently of the fusible portion that functions as a passive circuit protection element. An active / passive automotive fuse module.

2. The active / passive automotive fuse module according to claim 1, wherein at least one of the first fuse cavity and the second fuse cavity is at least partially filled with an arc quenching material surrounding the fusible portion.

3. Further comprising a spacer cap disposed between the base and the PI, having a projectile channel extending therethrough, and a portion of the projectile extending into the projectile channel, the active / passive automotive fuse module according to claim 1 or 2.

4. The PI receives an activation signal from the controller in response to the occurrence of a predetermined event, the predetermined event including an automotive collision, the active / passive automotive fuse module according to any one of claims 1 to 3.

5. The fuse plate further comprises a terminal portion extending from the fusible portion through the base and having a mounting opening formed through the base to facilitate electrical connection within the circuit, the active / passive automotive fuse module according to any one of claims 1 to 4.

6. The fuse plate further comprises a terminal portion extending from the fusible portion through the base and terminating in a flat protrusion adapted to be inserted into a receptacle to facilitate electrical connection within the circuit, the active / passive automotive fuse module according to any one of claims 1 to 5.

7. An active / passive automotive fuse module, comprising: An electrically insulating base; A fuse plate, A bus bar portion disposed above the upper surface of the base and above a projectile cavity formed within the base; A first fusible portion and a second fusible portion extending perpendicularly from a first end and a second end of the bus bar portion into a first fuse cavity and a second fuse cavity, respectively, wherein the first fuse cavity and the second fuse cavity are formed in the base on one side and the other side of the projectile cavity with respect to the extending direction of the bus bar portion, and the first fusible portion and the second fusible portion are adapted to open when the amount of current flowing through the fuse plate exceeds the current rating of the active / passive automotive fuse module, the first fusible portion and the second fusible portion; A fuse plate including a first terminal portion and a second terminal portion extending from lower ends of the first fusible portion and the second fusible portion, respectively, for connecting the active / passive automotive fuse module in a circuit; An ignition interrupter (PI) including an initiator and a projectile disposed on the base and positioned above the bus bar portion, wherein the initiator is configured to explode and press the projectile through the bus bar portion upon receiving a start signal from the PI; The PI is an active / passive automotive fuse module that functions as an active circuit protection element independently of the first and second fusible portions that function as passive circuit protection elements. Claims 8 The active / passive automotive fuse module according to claim 7, wherein the first fuse cavity and the second fuse cavity are at least partially filled with an arc quenching material surrounding the first fusible portion and the second fusible portion. Claims 9 The active / passive automotive fuse module according to claim 7 or 8, further comprising a spacer cap disposed between the base and the PI, having a projectile channel extending therethrough, and a portion of the projectile extending into the projectile channel. Claims 10 A controller that is operably connected to the detonator of the PI outside the active / passive vehicle fuse module and is adapted to transmit an activation signal to the detonator upon the occurrence of a predetermined event, the active / passive vehicle fuse module according to any one of claims 7 to 9.

11. The active / passive vehicle fuse module according to any one of claims 7 to 10, wherein each of the first end portion and the second end portion has a mounting opening formed therethrough the base to facilitate electrical connection within the circuit.

12. The active / passive vehicle fuse module according to any one of claims 7 to 11, wherein each of the first end portion and the second end portion terminates in a flat protrusion adapted to be inserted into a receptacle to facilitate electrical connection within the circuit.

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