Electrical Disconnecting Assembly for Power and Signal Isolation
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Solution Overview
Problem
Existing electrical isolating devices for 48 V vehicle systems are limited in functionality, primarily designed for disconnecting power lines but lack the ability to simultaneously disconnect signal paths and tap battery potential, which is essential for comprehensive system management during crashes or damage.
Innovation Solution
An electrical isolating device with a housing containing connection tabs that can be bimetallically coated, featuring a separation point and a drive mechanism to separate the tabs, along with a connecting element that accommodates multiple connections, including a battery contact, to enable both power and signal path disconnection while allowing access to battery potential.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If connectors from pyrotechnic airbag control units are used for disconnecting power lines, then the device can be manufactured with conventional components, but the functionality is severely limited to only 2-pin connection for igniting the igniter
Solution Approach 1:
The connecting element is designed as a multi-functional component that integrates multiple connection functions into a single structure. It provides at least two connections for the drive, two contact elements for a switching path, and a battery contact, all within one connector housing. This eliminates the need for multiple separate connectors and enables comprehensive system management including power disconnection, signal path disconnection, and battery potential access.
2Adaptability or versatility
If a single connecting element accommodates multiple connections including battery contact, then extended functionalities are achieved, but the device becomes more complex to manufacture
Solution Approach 1:
Multiple previously separate connection functions are merged into a single integrating connecting element. The element combines drive connections, switching path contact elements, and battery contact into one manufactured component. This consolidation simplifies the overall assembly process and reduces the number of separate manufacturing steps required, despite the increased functionality.
3Reliability
If the connecting tabs are separated under load using a drive mechanism, then the power line can be disconnected safely, but arc formation may occur between the separating tabs
Solution Approach 1:
An arc-quenching medium is introduced as an intermediary substance between the connecting tabs during the separation process. This medium (such as SF6 gas, nitrogen, or a liquid/gel substance) acts as a mediator that suppresses arc formation when the tabs are separated under load. The medium absorbs the arc energy and prevents harmful electrical discharges, enabling reliable disconnection even under loaded conditions.
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 device effectively disconnects both power and signal paths under load, extinguishes arcs with a medium, and allows accurate measurement of battery potential, enhancing safety and system management in vehicle electrical systems.
Implementation Method 1
an actuator, in particular a pyrotechnic drive, which influences the separation of the disconnection point
Implementation Method 2
The channel may contain a substantially incompressible medium, in particular a pasty or liquid medium, or a compressible medium such as a noble gas or an arc-quenching gas, such as SF6
Data Source
Figure 1a
Figure 1b
Figure 2~3
AI summary
The invention relates to an electrical disconnecting device comprising: a housing; a first connection tab (4a) inserted into the housing; a second connection tab (4b) inserted into the housing; a disconnection point (6) which, when closed, forms a current path between the first and the second connection tab (4a, 4b) and which is located physically between the connection tabs, wherein the disconnection point (6), when disconnected, disconnects the current path between the connection tabs (4a, 4b); a drive (8) which influences disconnection of the disconnection point (6); a channel formed in the housing, between the drive (8) and the disconnection point (6), wherein the drive closes the channel on a side facing away from the disconnection point; and a connection element which is located on the side of the drive facing away from the channel and which receives at least two electrical connections of the drive, characterised in that the connection element receives at least two contact elements of a switching path, in that the contact elements lead into the channel via respective connecting pieces and are short-circuited together in the channel at a connection point in such a way that, when the drive is triggered, the connection point is moved away from the contact elements such that the connecting pieces are mechanically separated.