Fiber-Reinforced Pyrotechnic Switch Housing for EV Isolation
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Solution Overview
Problem
Conventional polymer systems used in pyrotechnic switches for electric vehicles lack the necessary mechanical, insulative, and ignition resistance, particularly for small-sized components, leading to inadequate performance in preventing anomalies such as overcurrent.
Innovation Solution
A pyrotechnic switch with a fiber-reinforced polymer composition comprising a high-performance thermoplastic polymer matrix and long reinforcing fibers, providing enhanced mechanical and insulative properties, including high deflection temperature under load, comparative tracking index, and flame retardancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional polymer systems are used in pyrotechnic switches, then manufacturing is easier and cost is lower, but mechanical strength, insulative properties, and ignition resistance are insufficient
Solution Approach 1:
The patent employs a fiber-reinforced polymer composite material consisting of a thermoplastic polymer matrix reinforced with long continuous fibers. This composite structure provides enhanced mechanical strength, rigidity, and thermal stability while maintaining manufacturability through conventional molding processes. The fiber reinforcement specifically addresses the insufficient mechanical strength of conventional polymers in pyrotechnic switch applications.
2Reliability
If conventional polymer systems are used in pyrotechnic switches, then manufacturing is easier, but insulative properties and ignition resistance are inadequate
Solution Approach 1:
The fiber-reinforced polymer composite provides superior ignition resistance and thermal stability compared to conventional polymers. The thermoplastic polymer matrix combined with fiber reinforcement creates a material with higher flame retardancy and thermal endurance, which is critical for pyrotechnic switch safety. The composite structure maintains ease of manufacture through standard composite molding techniques.
Solution Approach 2:
The patent modifies the material parameters by selecting a thermoplastic polymer with specific properties (melting point, thermal stability) and combining it with fiber reinforcement. This parameter optimization ensures the material meets the required ignition resistance and insulative properties while remaining manufacturable.
3Volume of moving object
If small-sized pyrotechnic switches are designed, then space efficiency is improved, but mechanical properties and insulative performance deteriorate
Solution Approach 1:
The fiber-reinforced polymer composite enables miniaturization of the pyrotechnic switch while maintaining mechanical integrity. The long continuous fiber reinforcement provides high strength-to-weight ratio and structural rigidity, allowing the switch to be made smaller without sacrificing mechanical properties or insulative performance.
Solution Approach 2:
The patent optimizes material parameters including fiber orientation, fiber length, and polymer matrix selection to achieve the required mechanical properties in a compact form factor. The thermoplastic polymer's thermal stability and the fiber reinforcement work together to maintain performance in small-sized applications.
Data Source
AI summary
A pyrotechnic switch comprising a pyrotechnic actuator that is electrically coupled to a conductive member and a fuse element element that is electrically coupled or capable of being electrically coupled to the pyrotechnic actuator. The pyrotechnic actuator has an initial state in which a conductive path couples the actuator to the conductive member and an actuated state in which a gap is formed in the conductive member. The pyrotechnic switch comprises a fiber-reinforced polymer composition comprising a polymer matrix that contains a high performance thermoplastic polymer and a plurality of long reinforcing fibers.