Pyrotechnic Circuit Interrupter Arc Chamber for EV Arc Restrike Control
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Solution Overview
Problem
Existing circuit interrupters in electric vehicle systems face issues with arc restrikes and back commutation at high voltage levels, leading to potential damage to electrical components and safety hazards due to arcing and ionized particles.
Innovation Solution
A pyrotechnic circuit interrupter with an arc chamber and insulating materials, combined with a pyrotechnic charge and pusher component, directs arcing plasma and ionized gases away from the primary arc path, using insulating plates to separate and exhaust gases, preventing secondary arcs and directing gases safely away from the user.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If circuit breaker-based components are used to provide multi-use circuit interruption, then reliability is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts the arc chamber and ionized particle management system from the traditional circuit breaker design, creating a dedicated component for handling arc suppression and gas direction. This allows the main circuit interruption function to be simplified while maintaining reliability through the specialized arc management subsystem.
Solution Approach 2:
The patent introduces an intermediary system consisting of the arc chamber, insulating plates, and gas direction mechanisms that mediate between the fault condition and the circuit interruption. This intermediary structure manages the ionized particles and arcs separately from the main switching operation, reducing complexity in the primary circuit protection function.
2Reliability
If pyrotechnic charge is used to direct ionized particles away from arc path, then arc restrike prevention is improved, but device complexity increases
Solution Approach 1:
The patent converts the harmful effect of ionized particles and arcs into a beneficial outcome by using pyrotechnic charges to direct these ionized particles away from the primary arc path. The harmful ionized gases are redirected into the arc chamber where they are contained and exhausted safely, preventing arc restrikes while utilizing the pyrotechnic energy to achieve the protective effect.
Solution Approach 2:
The patent employs pneumatic principles by using pyrotechnic charges to generate gas pressure that directs ionized particles and gases through controlled paths. The pusher component and gas direction mechanisms utilize pressure-driven flow to move ionized materials away from critical areas, applying pneumatic concepts to solve the arc restrike problem.
3Object-affected harmful factors
If insulating plates and gas direction mechanisms are added, then safety is improved, but manufacturing complexity increases
Solution Approach 1:
The patent segments the circuit interrupter into distinct functional modules: the arc chamber for containing ionized particles, insulating plates for electrical isolation, gas direction mechanisms for exhaust control, and mounting components for structural support. This segmentation allows each component to be manufactured and tested independently, then assembled into the complete system, improving safety while managing manufacturing complexity through modular construction.
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
Effectively prevents arc restrikes and minimizes damage to components and user safety by containing and directing arcing plasma and gases, enhancing the reliability and safety of electric vehicle charging systems.
Implementation Method 1
a pyrotechnic charge and pusher component located in between the first and second busbar components and the arc chamber
Implementation Method 2
arc chamber for providing a primary arc path for a current between the first and second busbar components
Implementation Method 3
direct ionized particles or resulting gases toward the arc
Data Source
AI summary
A circuit interrupter may include a plurality of mounting components comprised of an insulating material for receiving a first busbar and a second busbar component. A circuit interrupter may include an arc chamber for providing a primary arc path for a current between the first and second busbar components. A circuit interrupter may include a pyrotechnic charge and pusher component located in between the first and second busbar components and the arc chamber. The pusher component may be comprised of an insulating material and can be triggered upon detection of a fault to direct ionized particles or resulting gases toward the arc chamber.