Pyrotechnic Current Disconnector Signal Line Loop Mechanism
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Solution Overview
Problem
Current pyrotechnic current isolators for hybrid vehicles are costly to produce and have limited water protection due to complex structures and additional manufacturing requirements, with inadequate proof of triggering for the signal line.
Innovation Solution
A pyrotechnic current isolator design featuring a signal line loop that engages with a pin of the separating piston, ensuring reliable disconnection of the signal line only after the conductor has been separated, eliminating the need for additional manufacturing components like magnetic switches or top plates, and allowing for a common connector for the igniter and signal line.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a magnet and external magnetic switch are added to trigger a signal line, then proof of triggering is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the signal line triggering function with the existing separating piston structure. The pin on the separating piston directly engages with the signal line loop, eliminating the need for separate magnetic switches and magnets. This merging of functions reduces device complexity while maintaining reliable proof of triggering through the mechanical engagement of the pin with the signal line.
2Reliability
If a top plate with guide is added to cut the signal cable, then signal line disconnection is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent integrates the signal line cutting function into the separating piston assembly. The pin on the separating piston engages with the signal line loop and cuts it during the normal separation operation. This eliminates the need for a separate top plate with guide, reducing device complexity while ensuring reliable signal line disconnection as part of the conductor separation process.
3Ease of manufacture
If a loop is used for the signal line instead of a straight cable, then manufacturing effort is reduced, but the loop may be pressed into the gap between piston and housing and not severed
Solution Approach 1:
The patent introduces a pin on the separating piston as an intermediary element that engages with the signal line loop. The pin acts as a mediator that reliably engages the loop and applies sufficient force to sever it during separation. This intermediary pin ensures that the loop configuration, which simplifies manufacturing, does not compromise the reliability of signal line severing.
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
This design simplifies manufacturing, reduces costs, and ensures accurate signaling of conductor disconnection while providing insulation and watertightness, enhancing the reliability and efficiency of the isolator.
Implementation Method 1
a pyrotechnic current isolator which has a housing with an igniter which, in order to disconnect a conductor, applies pressure to a separating piston which can be displaced in the housing
Data Source
Figure 1~2
Figure 3~4
AI summary
A pyrotechnic current disconnector (1), comprising a housing with an igniter (7) which pressurizes a separating piston (8) movable within the housing to disconnect a conductor (2), further comprises a signal line (18) which is also interrupted upon activation. For a simple design, the invention provides that the signal line (18) is formed as a loop into which a pin (21) of the separating piston (8) engages. If the current disconnector (1) is composed of an upper part (5) and a lower part (6) and the igniter is overmolded in the upper part, the signal line (18) is preferably also overmolded with the upper part (5), with the loop exiting at the parting surface to the lower part (6) and being guided between the upper part (5) and the lower part (6) to the separating piston (8). In this case, the signal line (18) and the igniter (7) can have a common connector for connection, the connector being part of the housing.The signal line can also be overmolded in the lower part (6).