Active Passive Fuse Module with Pyrotechnic Piston
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Solution Overview
Problem
Existing circuit protection systems lack a compact, space-saving solution that integrates both passive and active protection elements to effectively manage overcurrent conditions and ensure safety in critical events like vehicle collisions, where immediate de-energization of electrical circuits is necessary to prevent damage and risk of fire or electrocution.
Innovation Solution
An active/passive fuse module that combines a passive fuse element with a pyrotechnic interrupter, featuring a piston and pyrotechnic ignitors, which can be actuated by a controller or current sensing module to physically open the circuit, providing both overcurrent protection and electrical isolation, and optionally includes a PTC element for additional current diversion and arc prevention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If both passive fuse element and pyrotechnic interrupter are integrated in a single module, then circuit protection reliability is improved, but device complexity increases
Solution Approach 1:
The patent combines a passive fuse element and a pyrotechnic interrupter into a single integrated fuse module. The passive fuse element provides overcurrent protection through melting, while the pyrotechnic interrupter provides active circuit opening capability. Both protection mechanisms are housed within the same module structure, allowing dual functionality in one device.
Solution Approach 2:
The fuse module is designed to perform multiple protection functions: passive overcurrent protection via the fuse element and active circuit interruption via the pyrotechnic interrupter. This multi-functional design allows a single device to address both gradual overcurrent conditions and immediate circuit opening requirements, replacing what would traditionally require separate protection devices.
2Volume of moving object
If passive fuse element and pyrotechnic interrupter are integrated in a single module, then space utilization is improved, but manufacturing complexity increases
Solution Approach 1:
The patent integrates the passive fuse element and pyrotechnic interrupter within a shared housing structure. The housing contains both components along with common elements such as terminals, insulation material, and the piston mechanism, reducing the overall space required compared to separate devices while consolidating manufacturing processes.
Solution Approach 2:
The fuse element is positioned within the housing structure that also contains the pyrotechnic interrupter components. The piston of the pyrotechnic interrupter is arranged to move through or alongside the fuse element, and both components share common structural elements like the housing and terminals, creating a nested arrangement that optimizes space utilization.
3Manufacturing precision
If fuse element has multiple weak points with specific geometry, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The fuse element is designed with specific local features including weak points, notches, or varied cross-sectional areas at predetermined locations. These localized geometric variations create controlled vulnerability points that ensure the fuse breaks at specific positions during overcurrent events, providing predictable and reliable operation while maintaining overall manufacturing simplicity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The module effectively interrupts electrical current and prevents arcing, allowing for safer de-energization of circuits in overcurrent conditions while maintaining a compact form factor suitable for various applications, enhancing safety and convenience in installation.
Implementation Method 1
a pyrotechnic ignitor configured to detonate and force the piston through the fuse element upon receiving an initiation signal
Implementation Method 2
the piston, which is formed of a dielectric material, provides an electrically insulating barrier between separated portions of the conductor to prevent electrical arcing therebetween
Implementation Method 3
If current flowing through a fuse element exceeds the fuse element's rated current, the fuse element will melt, disintegrate, or otherwise separate, thereby arresting the current
Data Source
AI summary
An active/passive fuse module including a base, a busbar disposed on the base and including a fuse element extending over a cavity in a top surface of the base and having a plurality of weak points formed therein, a pyrotechnic interrupter (PI) disposed atop the base and including a piston disposed within a shaft above the fuse element, the piston having an edge with a geometry that corresponds to a geometry of a pattern defined by the weak points in the fuse element, a first pyrotechnic ignitor coupled to a controller and configured to detonate and force the piston through the fuse element upon receiving an initiation signal from the controller, and a second pyrotechnic ignitor coupled to the busbar by a pair of leads and configured to detonate and force the piston through the fuse element upon an increase in voltage across the leads.