Pyrotechnic Charging Disconnect for Battery Overcharge Isolation
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Solution Overview
Problem
Existing pyrotechnic separation devices for electrical charging systems lack a reliable and efficient method to prevent overcharging and uncontrolled chemical reactions in electrochemical energy cells, requiring a solution that can be mass-produced with low effort and ensure reliable separation with various charging systems.
Innovation Solution
A pyrotechnic separation device with a conductive connecting section and a pyrotechnic agent housed in a sealed, pressure-tight container, which activates to interrupt electrical conductivity when a predetermined state is reached, such as a specific temperature, to prevent overcharging and uncontrolled reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pyrotechnic separation device is used to interrupt electrical charging connection, then reliability of separation is improved, but device complexity increases
Solution Approach 1:
The patent combines the pyrotechnic agent, electrically conductive connecting section, and housing into a single integrated separation device. The connecting section is positioned within the housing alongside the pyrotechnic agent, creating a compact unit that performs both electrical connection and pyrotechnic separation functions without requiring additional separate components.
Solution Approach 2:
The separation device serves multiple functions: it provides electrical connection during normal operation through the conductive connecting section, and performs separation when activated by the pyrotechnic agent. The housing simultaneously protects both the electrical components and contains the pyrotechnic agent, making the device versatile for various charging systems.
2Reliability
If a pyrotechnic agent is used to interrupt electrical connection, then separation effectiveness is improved, but manufacturing effort increases
Solution Approach 1:
The patent divides the separation device into distinct functional segments: the pyrotechnic agent section, the electrically conductive connecting section, and the housing. This segmentation allows each component to be manufactured separately using standard processes and then assembled, reducing overall manufacturing complexity while maintaining separation effectiveness.
Solution Approach 2:
The pyrotechnic separation device is designed as a disposable safety component that is replaced rather than repaired after activation. This approach simplifies manufacturing by eliminating the need for complex recovery or resetting mechanisms, allowing the use of cost-effective materials and assembly methods suitable for mass production.
3Object-affected harmful factors
If the housing is made pressure-tight to contain pyrotechnic effect, then safety is improved, but manufacturing complexity increases
Solution Approach 1:
The housing integrates multiple functions: it provides structural support, contains the pyrotechnic agent, and forms a pressure-tight barrier. By combining these functions into a single component rather than using separate structures, the patent reduces the number of assembly steps and sealing requirements, simplifying manufacturing while maintaining safety.
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
Ensures immediate and reliable electrical separation during critical charging processes, preventing damage to energy cells and neighboring components by effectively interrupting electrical connections, and can be easily replaced or reactivated.
Implementation Method 1
a pyrotechnic agent accommodated in the housing and designed and/or controllable to exert its pyrotechnic effect upon reaching a predetermined operating state
Implementation Method 2
Pyrotechnic agents, substances, compositions, or mixtures of substances are known and can exert a predetermined pyrotechnic effect after their ignition or igniting
Data Source
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AI summary
In a pyrotechnic disconnecting device for interfering with, preferably interrupting, an electrical charging coupling between a chargeable electrical energy cell, which comprises, in particular, an electrochemical energy store and an energy converter, and an electrical energy supply, such as a charging unit, an electrically conductive connecting section, such as an electrically conductive cable, an electrically conductive track or the like, is provided, by means of which electrical charging energy is fed from the energy supply to the electrical energy cell, comprises a housing in which the connecting section is arranged and a pyrotechnic means housed in the housing and designed for this purpose and/or able to be actuated in such a way that it deploys the pyrotechnic effect thereof when a predetermined operating state is reached, wherein the pyrotechnic means is assigned to the connecting section in such a way that the pyrotechnic effect of the pyrotechnic means at least limits, in particular eliminates, the electrical conductivity of the connecting section within the housing.