Exploding Foil Initiator Assembly with Segmented Header
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Solution Overview
Problem
Modern initiator assemblies, particularly those with exploding foil initiators, are labor-intensive and costly to fabricate, making them unsuitable for applications involving high shock loads or requiring a strong and durable hermetic seal.
Innovation Solution
The initiator assembly design includes a header body, seal members, an insulating spacer, a frame member, and an initiator chip with terminal-to-initiator contacts, which are electrically coupled to provide a robust and cost-effective solution for initiating energetic materials through combustion, deflagration, or detonation events, while ensuring a strong seal and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If modern initiator assemblies with exploding foil initiators are used, then the initiator can effectively initiate energetic materials, but the fabrication becomes labor-intensive and costly
Solution Approach 1:
The initiator assembly is divided into distinct functional components: a header body containing the exploding foil initiator, a separate insulating spacer, a frame member, and a plastic encapsulation. This segmentation allows each component to be manufactured independently using optimized processes, reducing overall fabrication complexity while maintaining initiator effectiveness.
Solution Approach 2:
The patent introduces a header body as an intermediary component that houses the exploding foil initiator and provides structured interfaces for electrical connections and sealing. This intermediary structure simplifies the assembly process by organizing complex elements into a manageable module that can be integrated with other components.
2Reliability
If modern initiator assemblies with exploding foil initiators are used, then the initiator can effectively initiate energetic materials, but the fabrication becomes labor-intensive and costly
Solution Approach 1:
By segmenting the initiator assembly into independently manufacturable components, each part can be produced through automated processes rather than complex manual assembly. The header body, insulating spacer, and frame member can be manufactured separately and assembled systematically, improving production efficiency.
Solution Approach 2:
The header body serves multiple functions: it houses the exploding foil initiator, provides electrical connection interfaces through terminal apertures, ensures sealing through seal member receptacles, and offers structural support. This multi-functionality reduces the number of separate components needed, simplifying fabrication.
3Strength
If a strong and durable hermetic seal is required, then the initiator assembly can withstand high shock loads, but the fabrication complexity increases
Solution Approach 1:
The sealing function is segmented into dedicated seal members that are integrated into specific receptacles within the header body and frame member. This segmentation allows the sealing system to be optimized independently from other functions, achieving high durability without unnecessarily increasing overall assembly complexity.
Solution Approach 2:
The patent employs composite construction combining metal components (header body, frame member) with polymer materials (plastic encapsulation, seal members). This composite approach enables the assembly to withstand high shock loads while maintaining hermetic sealing, as each material contributes its superior properties.
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 design enhances the fabrication efficiency and reduces costs, providing a reliable and durable initiator assembly suitable for applications with high shock loads and stringent sealing requirements.
Implementation Method 1
The initiator is configured to initiate an energetic material such that the energetic material is at least partly consumed in an event involving one or more of combustion, deflagration and detonation
Implementation Method 2
The initiator is configured to initiate an energetic material such that the energetic material is at least partly consumed in an event involving one or more of combustion, deflagration and detonation
Implementation Method 3
The initiator is configured to initiate an energetic material such that the energetic material is at least partly consumed in an event involving one or more of combustion, deflagration and detonation
Implementation Method 4
Each seal member is received in an associated one of the first terminal apertures
Implementation Method 5
Each terminal-to-initiator contact is electrically coupled to an associated one of the terminals and an associated one of the initiator contacts
Data Source
AI summary
An initiator that includes a header body, an insulating spacer, an initiator, a plurality of terminals and a plurality of contacts. The insulating spacer is coupled to the header body. The initiator forms at least a portion of an exploding foil initiator and includes a plurality of electric interfaces. The initiator is secured to a side of the insulating spacer opposite the header body. The terminals extend through the header body. The contacts electrically couple the electric interfaces to the terminals.