Integrated Pyrotechnic Actuator Assembly for Vehicle Safety
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Solution Overview
Problem
Conventional pyrotechnic actuator units for vehicle safety systems, such as airbag modules, are over-dimensioned and expensive, requiring high manufacturing and testing efforts due to the use of prefabricated and separately tested igniter components.
Innovation Solution
A compact pyrotechnic actuator assembly with a single housing that directly encases the pyrotechnic charge and includes an electric ignition unit, eliminating the need for a prefabricated igniter, and featuring a housing design with a recess for retaining means that allows for easy fixation and controlled activation, reducing manufacturing and testing efforts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a prefabricated pyrotechnic igniter is used as a separate component, then the igniter can be independently tested and qualified, but the device complexity and manufacturing cost increase due to multiple components and assembly steps
Solution Approach 1:
The patent combines the pyrotechnic charge, ignition unit, and housing into a single integrated actuator assembly. The housing (16) directly receives the pyrotechnic charge (24) without requiring a separate igniter component, eliminating the need for separate igniter qualification and reducing assembly complexity while maintaining reliability through direct integration of all functional elements into one tested unit
2Strength
If conventional explosive studs are used, then high forces can be absorbed and components can be displaced or broken, but the activating energy required is extremely high and the components are over-dimensioned and expensive
Solution Approach 1:
The patent changes the pyrotechnic charge formulation and configuration to achieve effective tether release at lower activating energy levels. The charge (24) is specifically designed to generate sufficient gas pressure for tether release without requiring the extremely high energy levels of conventional explosive studs, thereby reducing the overall energy input requirement while maintaining the necessary force generation capability
3Ease of manufacture
If a single housing design is used to directly receive the pyrotechnic charge, then manufacturing and testing effort is reduced, but the housing must simultaneously provide tight sealing and retaining means fixation functionality
Solution Approach 1:
The housing (16) is designed as a multi-functional component that simultaneously provides: (1) a substantially tight housing chamber to contain the pyrotechnic charge, (2) a contact portion (30) for fixing the retaining means (12), and (3) structural support for the electric ignition unit. This universal design consolidates multiple functions into one component, reducing the number of parts and assembly steps while maintaining the necessary sealing and fixation capabilities
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 results in a cost-effective, easily manufacturable, and reliable pyrotechnic actuator assembly that reduces the complexity and cost of production while ensuring safe and controlled release of retaining means in vehicle safety systems.
Implementation Method 1
a pyrotechnic charge 24 being directly received in the housing chamber 22
Implementation Method 2
the two housing parts 18, 20 forming a substantially tight housing chamber 22
Implementation Method 3
an electric ignition unit 26 for triggering the pyrotechnic charge 24
Data Source
AI summary
The invention relates to a pyrotechnic actuator assembly (10) for release of a retaining means (12) in a vehicle safety system (14) comprising a housing (16) composed of a first housing part (18) and a second housing part (20) fixedly connected to the first housing part (18), the two housing parts (18, 20) forming a substantially tight housing chamber (22), a pyrotechnic charge (24) received in the housing chamber (22) as well as an electric ignition unit (26) for triggering of the pyrotechnic charge (24), wherein the electric ignition unit (26) extends from outside of the housing chamber (22) through the first housing part (18) into the housing chamber (22), and wherein the housing (16) includes a housing chamber portion (28) to which the pyrotechnic charge (24) is directly adjacent and includes a contact portion (30) for fastening the retaining means (12). Moreover the invention also comprises an airbag module of a vehicle safety system including such actuator assembly (10).