Projectile Assembly With Molded Igniter for Easier Breaker Integration
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Solution Overview
Problem
Existing electric circuit breaker devices face challenges in achieving easy assembly and effective operation due to the need for thickened polymer housings or increased mass with stainless steel casings, which complicate the structure and assembly, and do not efficiently utilize the kinetic energy generated by the igniter for cutting or deforming components.
Innovation Solution
A projectile assembly where a synthetic resin projectile and igniter are accommodated in a cylinder with through holes and crimped portions, allowing the projectile to jump out and collide with other members upon igniter operation, utilizing the combustion product pressure to cut or deform components, and an electric circuit breaker device with a housing made of synthetic resin, where the igniter and projectile are integrated via injection-molding, eliminating the need for press-fitting and O-rings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a polymeric material (resin material) is used as a material of a housing, then the housing can provide electrical insulation, but the housing needs to be thickened to impart required strength
Solution Approach 1:
The patent employs a composite structure combining a resin housing with a metal reinforcement member (cylinder) to achieve both electrical insulation and mechanical strength. The resin material provides insulation properties while the metal cylinder reinforces the housing, allowing it to maintain required strength without excessive thickening.
Solution Approach 2:
The metal cylinder is disposed inside the resin housing, creating a nested structure where the reinforcement member is contained within the insulating housing. This nested arrangement allows the metal cylinder to strengthen the housing from the interior without adding external bulk.
2Strength
If a casing of stainless steel is used, then the housing can provide high strength, but increase in mass becomes greater and an insulating case needs to be disposed in combination
Solution Approach 1:
The metal cylinder is disposed inside the resin housing, creating a nested structure where the reinforcement member is contained within the insulating housing. This nested arrangement allows the metal cylinder to strengthen the housing from the interior without adding external bulk.
Solution Approach 2:
The patent employs a composite structure combining a resin housing with a metal reinforcement member (cylinder) to achieve both electrical insulation and mechanical strength. The resin material provides insulation properties while the metal cylinder reinforces the housing, allowing it to maintain required strength without excessive thickening.
3Strength
If a metal cylinder is used to reinforce a housing made of a resin, then the housing strength is improved, but the structure becomes more complex and assembly is more difficult
Solution Approach 1:
The igniter and projectile are pre-assembled within the cylinder as an integrated unit before being installed in the housing. This preliminary assembly simplifies the final installation process, as the pre-assembled unit is inserted as a single component rather than requiring separate assembly of multiple parts during final installation.
Solution Approach 2:
The metal cylinder is disposed inside the resin housing, creating a nested structure where the reinforcement member is contained within the insulating housing. This nested arrangement allows the metal cylinder to strengthen the housing from the interior without adding external bulk.
4Ease of manufacture
If the igniter and projectile are separately assembled in the housing, then the components can be independently manufactured, but the assembly process becomes more complex
Solution Approach 1:
The igniter and projectile are pre-assembled within the cylinder as an integrated unit before being installed in the housing. This preliminary assembly simplifies the final installation process, as the pre-assembled unit is inserted as a single component rather than requiring separate assembly of multiple parts during final installation.
Solution Approach 2:
The igniter and projectile are combined within the cylinder as an integrated assembly unit. This merging of components into a single pre-assembled unit reduces the number of separate assembly steps required during final installation, thereby reducing overall assembly complexity.
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 enables easy assembly, efficient use of kinetic energy for cutting or deforming components, and ensures reliable operation by integrating the igniter and projectile within the housing, reducing assembly complexity and enhancing performance in electric circuit interruption.
Implementation Method 1
an igniter, a projectile (piston), a conductor, and the like are accommodated in a housing
Data Source
AI summary
[Problem]Provided is a method for manufacturing an assembly including an igniter, a projectile, and a cylinder that is easy to assemble.[Solution]A method for manufacturing an assembly included in an electric circuit breaker device, the assembly including an igniter, a projectile, and a cylinder, is a method for disposing a projectile and an igniter in a cylinder of an electric circuit breaker device, the method including: a first step of preparing a cylinder having a first opening, a plurality of through holes formed at intervals in a circumferential direction in a peripheral wall portion on a first opening side, and a second opening, and disposing a projectile in the cylinder; a second step of disposing an igniter main body portion in the cylinder and then disposing the cylinder in a mold; a third step of injection-molding a resin from the first opening side of the cylinder to form a resin portion; a fourth step of removing the cylinder including the projectile and the igniter from the mold; and a fifth step of crimping a peripheral wall portion on the first opening side of the cylinder to fix the resin portion of the igniter.