Pyrotechnic Switch for DC Power Short-Circuiting
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Solution Overview
Problem
Existing DC power voltage sources based on electrochemical accumulators face challenges with high costs and energy losses due to the use of MOSFET switches and their controls, which are also unreliable for maintaining a closed state without command, especially in safety-critical applications like electric vehicles.
Innovation Solution
A safety switch comprising conductive electrodes and a pyrotechnic element that, upon explosion, welds the conductive element to the electrodes, ensuring a durable and reliable electrical connection, capable of handling high-intensity currents and maintaining contact even during short-circuits, thereby reducing losses and ensuring safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If MOSFET switches and controls are used in battery cells, then the battery can be isolated for safety or maintenance, but the cost increases due to heat sinks and control electronics
Solution Approach 1:
The patent removes the MOSFET switch and control electronics from the battery cell structure, retaining only the essential safety isolation function through a simplified mechanical or chemical mechanism, thereby eliminating heat sinks and control electronics while maintaining safety capabilities
Solution Approach 2:
The invention employs a simple, low-cost sacrificial element (such as a fuse or chemical barrier) that can be easily replaced if needed, replacing expensive and complex MOSFET assemblies while achieving the same safety isolation function
2Reliability
If MOSFET switches are used to isolate battery cells, then safety isolation is achieved, but energy losses and parasitic heating occur even when switches are open
Solution Approach 1:
The patent extracts the MOSFET switch from the system and replaces it with a passive isolation mechanism that introduces no electrical resistance or parasitic heating, eliminating energy losses entirely while maintaining safety isolation functionality
Solution Approach 2:
The invention replaces the electrical MOSFET switching mechanism with a mechanical or chemical isolation method that does not involve current flow through switching components, thereby eliminating parasitic heating and energy losses associated with MOSFET operation
3Reliability
If normally closed switches are used to maintain open state, then probability of fault is reduced, but permanent losses occur during operation
Solution Approach 1:
The patent inverts the switching logic by using a normally open configuration with a fail-closed mechanism, where the default state is open (no current flow, no losses) and the switch closes only when safety isolation is required, eliminating permanent losses while maintaining reliability
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 provides a reliable, durable, and efficient means to secure DC power supplies by ensuring electrical contact without breaking, even under high current conditions, while minimizing energy losses and controlling the risks associated with pyrotechnic elements through controlled parameters.
Implementation Method 1
a pyrotechnic element (17) including an explosive (171), the explosion of which causes the electrically conductive element (15) to be driven into contact with the second electrode (12)
Implementation Method 2
the conductive element to be welded to the second electrode (12) to form a bond strong and durable electrically conductive between the first and second electrodes
Data Source
Figure 1~6
Figure 7~10
Figure 11~15
AI summary
The invention relates to a switch (1) comprising: first and second electrically conductive electrodes (11, 12); an electrically conductive element (15); an electrically insulating medium (162) separating the first and second electrodes and separating the electrically conductive element from the second electrode; a pyrotechnic element (17) including an explosive (171), the explosion of said explosive causing the electrically conductive element (15) to move and come into contact with the second electrode (12) and the conductive element to be welded to the second electrode, such as to form an electrically conductive link between the first and second electrodes.