Bi-material Pyrotechnic Housing with Metal Reinforcement
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Solution Overview
Problem
Existing pyrotechnic devices with plastic housings face limitations in geometry and mechanical strength, making it difficult to manufacture complex shapes and handle high forces, while metal housings pose challenges with injection molding and security clearance for pyrotechnic actuators.
Innovation Solution
A bi-material plastic housing with a metal reinforcement and two distinct plastic materials, where one material is overmolded onto the other, allowing for complex geometries and enhanced mechanical strength, and enabling flexible manufacturing and customization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a housing is made of plastic material, then it can be manufactured with injection molding process, but it is difficult to provide complex shapes and sufficient mechanical strength
Solution Approach 1:
The patent applies composite materials by combining a metal reinforcement core with a plastic body that has a bi-material structure. The metal reinforcement provides the necessary mechanical strength, while the plastic body offers ease of manufacture through injection molding. This composite structure resolves the contradiction between manufacturability and mechanical strength.
Solution Approach 2:
The patent implements local quality by using different materials in different regions of the housing. The metal reinforcement is positioned in areas requiring high mechanical strength, while the plastic body covers areas where ease of manufacture and complex geometry are prioritized. This localized material assignment resolves the contradiction between strength requirements and manufacturing ease.
2Strength
If a housing is made of metal material, then it provides sufficient mechanical strength, but it poses challenges with injection molding and security clearance for pyrotechnic actuators
Solution Approach 1:
The patent uses composite materials where a metal reinforcement provides mechanical strength while a plastic body enables injection molding manufacturing. This composite approach resolves the contradiction between needing metal strength and requiring plastic manufacturability.
Solution Approach 2:
The patent applies the nesting principle by placing the metal reinforcement inside the plastic body. The metal core is nested within the plastic housing, allowing the plastic to be injection molded over the metal structure. This nesting arrangement enables both metal strength and plastic manufacturability.
3Strength
If a strong plastic material is used to withstand internal pressure, then mechanical strength is improved, but it becomes difficult to inject into molds with complex shapes
Solution Approach 1:
The patent uses composite materials where a bi-material plastic body is injection molded over a metal reinforcement. The metal reinforcement provides pressure resistance, while the plastic body maintains injection molding flexibility for complex shapes. This composite structure resolves the contradiction between pressure resistance and manufacturing flexibility.
4Ease of manufacture
If a single plastic material is used for the housing, then manufacturing is simplified, but it cannot simultaneously provide good mechanical strength and complex precise geometries
Solution Approach 1:
The patent applies composite materials with a bi-material plastic body that combines materials with different properties. One material provides mechanical strength while the other enables complex precise geometries. This composite approach resolves the contradiction between manufacturing simplicity and geometry precision.
Solution Approach 2:
The patent implements local quality by using different plastic materials in different portions of the housing. Areas requiring high precision geometry use one material, while areas requiring mechanical strength use another material. This localized material assignment resolves the contradiction between precision and 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 solution provides a robust and customizable pyrotechnic switch with improved mechanical and electrical strength, enabling the production of complex shapes and secure handling of high forces, while simplifying manufacturing and ensuring secure handling of pyrotechnic actuators.
Implementation Method 1
a plastic body overmolded onto the metal reinforcement
Implementation Method 2
The plastic body is overmolded onto the metal reinforcement: this involves melting or molding a part (in this instance the plastic body) onto another already existing part (the metal reinforcement) positioned beforehand in the mold. Typically, the overmolding is carried out by pressurized injection.
Data Source
AI summary
The invention relates to a pyrotechnic switch, which comprises, a housing formed by a first housing part that is assembled with a second housing part, and at least one pyrotechnic actuator arranged in the housing, wherein at least one out of the first housing part or the second housing part comprises a metal reinforcement and a plastic body overmolded onto the metal reinforcement, wherein the plastic body comprises, a first portion made of a first plastic material, and a second portion made of a second plastic material.