Integrated Fuse Module With Pyrotechnic Interruption and Arc Quenching
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Solution Overview
Problem
Existing circuit protection systems lack a compact, efficient solution that combines both passive and active elements to provide overcurrent protection and ensure rapid circuit disconnection regardless of current levels, particularly in applications like automobile collisions.
Innovation Solution
An active/passive fuse module integrating a pyrotechnic interrupter and a fusible element, where the pyrotechnic interrupter can be actuated by a controller to rapidly disconnect the circuit, and the fusible element melts passively when current exceeds a threshold, with an arc-quenching material to manage electrical arcs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If both passive and active circuit protection elements are implemented, then circuit protection reliability is improved, but device complexity increases
Solution Approach 1:
The patent combines a passive fuse element and an active pyrotechnic interrupter into a single integrated fuse module housing. The passive fuse element provides overcurrent protection through melting, while the active pyrotechnic interrupter provides rapid circuit opening upon collision detection. Both protection mechanisms are merged into one compact device that occupies a single fuse slot, achieving improved reliability without proportionally increasing complexity.
Solution Approach 2:
The fuse module is designed to perform multiple functions: passive overcurrent protection via the fusible element, active circuit interruption via the pyrotechnic interrupter, and arc quenching via the quenching material. This multi-functional design allows a single device to replace what would traditionally require multiple separate protection components, improving reliability while managing complexity through functional integration.
2Ease of operation
If a compact form factor is implemented, then ease of installation is improved, but device complexity increases
Solution Approach 1:
The patent employs a nested structure where the passive fuse element, active pyrotechnic interrupter, and arc quenching material are all contained within a single fuse module housing. This nesting arrangement allows multiple functional components to be packed into a compact form factor that fits standard fuse slots, improving ease of installation while containing the inherent complexity within an integrated structure.
Solution Approach 2:
Multiple protection functions (passive fusing, active interruption, arc quenching) are merged into a single integrated module that maintains external dimensions compatible with standard fuse replacements. This merging enables compact installation in existing fuse slots while incorporating sophisticated multi-functional protection mechanisms within the unified housing.
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 fuse module provides rapid and complete circuit disconnection, handling high currents without damage, ensuring safety by preventing electrical arcs and facilitating installation in a compact form factor.
Implementation Method 1
a pyrotechnic ignitor within the PI to be detonated. A resultant increase in pressure within the PI rapidly forces a piston or blade through a conductor
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
If current flowing through a fuse element exceeds the fuse element's rated current, the fuse element will melt
Implementation Method 4
an arc-quenching material to manage electrical arcs
Data Source
Figure 1A~1B
Figure 2
Figure 3A~3B
AI summary
An active/passive fuse module 10 including a fuse 12 having an electrically insulating fuse body 14, first and second endcaps 18, 20 disposed on opposing ends of the fuse body, a fusible element 24 extending through the fuse body between the first endcap and the second endcap, and an arc quenching material 26 disposed within the fuse body and surrounding the fusible element. The fuse module further includes a pyrotechnic interrupter (PI) 13 coupled to the fuse body 14, the PI having a housing 30 defining a shaft 44, a piston 42 disposed within the shaft, a drive pin 48 extending from the piston into the fuse body, the drive pin terminating in a cutter 50 disposed adjacent the fusible element, and a pyrotechnic ignitor 46 disposed within the shaft above the piston configured to detonate upon receiving an initiation signal from a controller 52, whereby the piston and the drive pin are forcibly driven through the shaft causing the cutter 50 to separate the fusible element 24.