Integrated Fuse Module With Pyrotechnic Interrupter for Fast Disconnect
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing circuit protection systems lack a compact and efficient solution that combines both passive and active protection elements, particularly in applications where both overcurrent protection and immediate circuit disconnection are required.
Innovation Solution
An active/passive fuse module that integrates a fuse with an electrically insulating body, fusible elements, and arc-quenching material, coupled with a pyrotechnic interrupter (PI) that can be actuated to sever the fusible elements, ensuring both passive overcurrent protection and active circuit disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If both passive fuse and active pyrotechnic interrupter are implemented separately, then both overcurrent protection and immediate circuit disconnection are provided, but the device occupies more space and is more complex
Solution Approach 1:
The patent combines a passive fuse body containing fusible elements with an active pyrotechnic interrupter into a single integrated protection device. The fuse body and pyrotechnic interrupter are coupled together to form a unified module that provides both passive overcurrent protection and active circuit disconnection functions simultaneously, eliminating the need for separate protection devices.
Solution Approach 2:
The integrated protection device performs multiple functions: the passive fuse elements provide overcurrent protection by melting under excessive current, while the pyrotechnic interrupter provides active circuit disconnection through controlled detonation that drives a piston to separate contacts. This multi-functional design allows a single device to replace what would traditionally require multiple separate protection components.
2Reliability
If both passive fuse and active pyrotechnic interrupter are implemented separately, then both overcurrent protection and immediate circuit disconnection are provided, but the installation space is increased
Solution Approach 1:
The patent merges the passive fuse body and active pyrotechnic interrupter into a single compact integrated module. The fuse body contains the fusible elements and arc quenching material, while the pyrotechnic interrupter is coupled to this structure, sharing common components and space, thereby reducing the total volume compared to separate installations.
Solution Approach 2:
The design employs a nested structure where the pyrotechnic interrupter components (piston, drive pin, cutter) are arranged within and around the fuse body structure. The drive pin extends from the piston into the fuse body, and the cutter is positioned to engage the fusible element, creating a space-efficient nested arrangement that minimizes overall device volume.
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 active/passive fuse module effectively provides both passive overcurrent protection and active circuit disconnection, enabling efficient and reliable protection of electrical systems, especially in applications like automobiles where immediate disconnection is critical.
Implementation Method 1
a pyrotechnic ignitor disposed within the shaft above the piston configured to detonate upon receiving an initiation signal from a controller, whereby the piston and the drive pin are forcibly driven through the shaft
Implementation Method 2
If current flowing through a fuse element exceeds the fuse element's rated current, the fuse element will melt, disintegrate, or otherwise separate
Implementation Method 3
an arc quenching material disposed within the fuse body and surrounding the fusible element
Implementation Method 4
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
Data Source
AI summary
An active/passive fuse module including a fuse having an electrically insulating fuse body, first and second endcaps disposed on opposing ends of the fuse body, a fusible element extending through the fuse body between the first endcap and the second endcap, and an arc quenching material disposed within the fuse body and surrounding the fusible element. The fuse module further includes a pyrotechnic interrupter (PI) coupled to the fuse body, the PI having a housing defining a shaft, a piston disposed within the shaft, a drive pin extending from the piston into the fuse body, the drive pin terminating in a cutter disposed adjacent the fusible element, and a pyrotechnic ignitor disposed within the shaft above the piston configured to detonate upon receiving an initiation signal from a controller, whereby the piston and the drive pin are forcibly driven through the shaft causing the cutter to separate the fusible element.