Pyrotechnic Squib Dual-Profile Contacts for Automotive Compatibility

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Solution Overview

Problem

Conventional pyrotechnic squibs with round wire-shaped ignition contacts are incompatible with automotive electrical systems that use square connection pins, limiting their application in newer safety-critical systems such as pyromechanical circuit breakers.

Innovation Solution

The pyrotechnic squib design is modified to have connection contacts with an angular cross-sectional profile outside the housing, achieved by plastic deformation of round wires, allowing them to be inserted into square openings, while maintaining a gas-tight and moisture-tight glass bushing for hermetic protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional round wire-shaped ignition contacts are used, then hermetic sealing is maintained, but compatibility with automotive electrical systems using square connection pins is lost

Engineering Contradiction:

Improvecompatibility with automotive electrical systemsVSAvoidcontact geometry

Core Design Contradiction:

Adaptability or versatilityVSShape

Solution Approach 1:

The connection contact is divided into two distinct segments: a first section with a round cross-sectional profile for hermetic sealing within the glass feedthrough, and a second section with a square cross-sectional profile for compatibility with automotive electrical connectors. This segmentation allows each segment to fulfill its specific functional requirement independently.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different cross-sectional profiles are applied to different sections of the same connection contact. The first section (inside housing) has a round profile optimized for hermetic sealing, while the second section (outside housing) has a square profile optimized for connector compatibility. This local differentiation resolves the contradiction between hermetic sealing and system compatibility.

Inventive Principle:

Principle #3Local quality

2Adaptability or versatility

If plastic deformation is applied to round wires to create angular profiles, then compatibility with square connectors is achieved, but manufacturing complexity increases

Engineering Contradiction:

Improveconnector compatibilityVSAvoidmanufacturing process

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The connection contacts are prepared in advance with the desired dual-profile configuration before final assembly. The plastic deformation process is integrated into the manufacturing flow, creating the angular profile as a preliminary step that simplifies subsequent assembly operations with standard square connectors.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If connection contacts are extended outside the housing for connector insertion, then adaptability to automotive plugs is improved, but hermetic sealing may be compromised

Engineering Contradiction:

Improveplug compatibilityVSAvoidhermetic seal integrity

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The connection contact structure is segmented into an internal hermetic section and an external connector section. The transition between these sections is designed to maintain the hermetic boundary while enabling external access for connector insertion.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The glass feedthrough acts as an intermediary structure that maintains hermetic sealing while allowing the connection contact to extend outward. The glass material provides both the seal and the structural pathway for the contact to reach external connectors without compromising the hermetic enclosure.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Enables the use of pyrotechnic squibs in automotive applications with conventional plugs, ensuring reliable ignition and safety by adapting the contact geometry without compromising the hermetic seal.

Implementation Method 1

In a melting process, the glass pellet is melted so that the glass forms a gas-tight seal against the connecting contacts

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 2

the connecting contacts are plastically deformed outside the housing. Through plastic deformation, for example by pressing, the round cross-sectional profile can be reshaped at least along two edges so that it becomes angular

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Data Source

PatentEP3997412B1Pyrotechnic squib and method for producing a pyrotechnic squib

Publication Date: 2023.12.20 AUTO KABEL MANAGEMENT GMBH

Figure 1a
Figure 1b
Figure 2a

AI summary

The invention relates to a pyrotechnic squib (2) comprising a housing (4), an ignition charge (10) housed in the housing, and at least two connection contacts (8) connected to the ignition charge, said connection contacts being guided out of the housing through a glass feedthrough (14). The invention is characterized in that the connection contacts have a round cross-sectional profile in the region of the ignition charge, and the connection contacts have an angular cross-sectional profile outside of the housing.