阅读说明：本技术 具有烟火致动器的开关 (Switch with pyrotechnic actuator ) 是由 R·伯克特 S·凯萨卡 V·赛巴勒 A·穆贾瓦尔 于 2019-09-20 设计创作，主要内容包括：提供一种用于打开电流传导路径的开关。所述开关包括点火室和布置成在点火时将气体释放到所述点火室中的烟火致动器。所述开关包括第一导体和第二导体,所述第一导体和所述第二导体各自包括连接触点。在第一位置中,所述开关的第三可移动导体布置在所述第一导体与所述第二导体之间,且与所述第一导体和所述第二导体电接触和实体接触以限定电流传导路径；在第二位置中,所述第三导体布置成与所述第一导体和所述第二导体电分离和实体分离。所述第三导体能够响应于所述烟火致动器的致动而在从所述第一位置朝向所述第二位置的方向上移动。所述开关包括至少一个可断开(任选地可剪切)保持部件,所述保持部件布置成将所述第三导体保持在所述第一位置中,直到所述烟火致动器的致动为止。还提供一种包括所述开关的车辆和一种操作所述开关的方法。(A switch for opening a current conduction path is provided. The switch includes an ignition chamber and a pyrotechnic actuator arranged to release gas into the ignition chamber upon ignition. The switch includes a first conductor and a second conductor that each include a connection contact. In a first position, a third movable conductor of the switch is disposed between and in electrical and physical contact with the first and second conductors to define a current conduction path; in the second position, the third conductor is arranged to be electrically and physically separated from the first and second conductors. The third conductor is movable in a direction from the first position toward the second position in response to actuation of the pyrotechnic actuator. The switch comprises at least one breakable (optionally shearable) retaining member arranged to retain the third conductor in the first position until actuation of the pyrotechnic actuator. A vehicle including the switch and a method of operating the switch are also provided.)

1. A switch, comprising:

an ignition chamber;

a pyrotechnic actuator arranged to release gas into the ignition chamber upon ignition;

a first conductor and a second conductor, the first conductor and the second conductor comprising connection contacts;

a third conductor movable in a direction from a first position toward a second position upon actuation of the pyrotechnic actuator; and

a breakable holding member arranged to hold the third conductor in the first position prior to actuation of the pyrotechnic actuator, wherein the holding member is arranged to break to allow movement of the third conductor depending on actuation of the pyrotechnic actuator,

wherein in the first position, the third conductor is disposed between and in electrical and physical contact with the first and second conductors to define a current conduction path, and

wherein in the second position, the third conductor is electrically and physically separated from the first conductor and the second conductor.

2. The switch of claim 1, further comprising a housing arranged to enclose at least the third conductor and the retention member, wherein the retention member is supported by the housing.

3. A switch according to claim 1 or claim 2, wherein the retaining member is formed at least in part from plastic.

4. A switch according to any preceding claim, wherein the retaining member is arranged to shear upon actuation of the pyrotechnic actuator, thereby allowing said movement of the third conductor.

5. The switch of claim 4, wherein the retention member comprises:

a support element configured to hold the third conductor portion against the first conductor portion and the second conductor portion prior to actuation of the pyrotechnic actuator; and

a shearable portion arranged to shear around the support element upon actuation of the pyrotechnic actuator, thereby allowing the movement of the third conductor.

6. The switch of claim 5, wherein the support element comprises:

a threaded portion; and

a threaded element configured to engage with the threaded portion, the threaded element configured to retain the third conductor portion against the first conductor portion and the second conductor portion prior to actuation of the pyrotechnic actuator.

7. The switch of any preceding claim, wherein a contact surface of the first conductor contacting the third conductor and the second conductor contacting the third conductor extends generally perpendicular to a direction of movement of the third conductor.

8. A switch according to any preceding claim, wherein the retaining member is arranged to exert a force to retain the third conductor in a direction substantially opposite to the direction of movement of the third conductor.

9. The switch of any of the preceding claims, further comprising a piston disposed between the third conductor and the pyrotechnic actuation, the piston including a void at least partially defining the ignition chamber.

10. The switch of any preceding claim, further comprising an arc quenching medium arranged to be disposed between the first conductor and the second conductor when the third conductor is in the second position.

11. A switch according to any preceding claim, wherein the holding member and the pyrotechnic actuator are arranged on opposite sides of the third conductor.

12. A system, comprising:

a switch according to any preceding claim; and

a controller arranged to provide a signal to the pyrotechnic actuator to ignite the pyrotechnic actuator.

13. A vehicle comprising the switch of any one of claims 1 to 11 or the system of claim 12, optionally wherein the vehicle is an electric vehicle.

14. A method for operating a switch, comprising:

igniting the pyrotechnic actuator to release gas into the ignition chamber;

applying pressure to the third movable conductor held in the first position by the breakable holding member depending on the released gas;

wherein in the first position, the third conductor is disposed between and in electrical and physical contact with the first and second conductors to define a current conduction path;

disconnecting the retention member and displacing the third conductor from the first position to a second position by the applied pressure, wherein in the second position the third conductor is electrically and physically separated from the first and second conductors; and

opening the current conduction path of the conductor by the displacement of the third conductor.

15. The method of claim 14, wherein breaking the retention member comprises shearing the retention member.

Technical Field

This involves opening or interrupting the current conduction path. In particular, this relates to a switch comprising a pyrotechnic actuator for opening a current conduction path, and a method for operating a switch involving ignition of the pyrotechnic actuator.

Background

The current conduction path may be opened by breaking a continuous conductor defining the current conduction path. One approach is to use a pyrotechnic-based switch to break the continuous conductor.

It is desirable to provide an improved device for opening a current conduction path. This improved device is desirable for applications requiring reliable and rapid opening of a current conduction path (e.g., a battery in an electric vehicle or an electrical overload mechanism for an industrial process).

Disclosure of Invention

In a first aspect, there is provided a switch having the optional features defined in the appended dependent claims, as defined in the appended independent device claim. In a second aspect, there is provided a method of operating the switch of the first aspect, as defined in the accompanying independent method claim.

In the following description, a switch for opening a current conduction path is described. The switch includes: an ignition chamber; a pyrotechnic actuator arranged to release gas into the ignition chamber upon ignition; a first conductor and a second conductor, the first conductor and the second conductor comprising connection contacts; and a third conductor movable in a direction from a first position toward a second position upon (i.e., in response to) actuation of the pyrotechnic actuator. The switch comprises at least one breakable retention member arranged to retain the third conductor in the first position prior to (i.e. until) actuation of the pyrotechnic actuator; the holding member is arranged to open to allow movement of the third conductor in dependence on actuation of the pyrotechnic actuator. In the first position, the third conductor is disposed between and in electrical and physical contact with the first and second conductors to define a current conduction path; in the second position, the third conductor is electrically and physically separated from the first and second conductors.

Previous pyrotechnic-based switches (or automatic pyrotechnic-based circuit breakers) have relied on linear arrangements to break single or continuous conductors. For example, linear displacement of a pyrotechnically actuated piston will cut the conductor into two sections in a wedge-type action to interrupt the current. This arrangement may be suitable for some low current applications. However, for higher current applications, the conductors to be broken are typically thicker or wider, and therefore require higher force in order to break the conductors. Such switches therefore typically utilize large pyrotechnic actuators, which results in expensive and bulky switch arrangements. By using three separate conductor sheets that engage only with the temporary joint provided by pushing the third conductor against the first and second conductors, significantly less force is required to break the electrical contacts of the different conductors and open the current conduction path. This can result in a smaller and cheaper switch suitable for a range of current loads.

In particular, by holding the third movable conductor in the first position with the breakable holding member, sufficient force can be applied to the third conductor to ensure that electrical contact between the first, second and third conductors is maintained, while facilitating quick and easy opening of the current conduction path upon actuation of the pyrotechnic actuator by the breaking of the breakable holding member (and thus by the breaking of the temporary conductor joint by subsequent movement of the third conductor). Since no mechanism is required to hold the third conductor in a position other than the breakable holding member and no permanent conductor connection (or continuous conductor) needs to be broken, less force is required and a smaller pyrotechnic actuator can be used, helping to provide a smaller and less expensive switch.

Separating the different conductors in the manner described herein may also help to reduce arcing (or arcing) that forms when the different conductors are separated from each other. In particular, movement of the movable third conductor relative to the first and second conductors (i.e., linear translation of the third conductor) in response to actuation can rapidly stretch the arc, thereby increasing arc resistance. The increased arc resistance causes a corresponding increase in arc voltage and a decrease in arc current (since the arc exhibits a negative resistance). In the case of a physical separation between the conductors, which can be achieved with the switch of the first aspect, the arc resistance can increase rapidly over time, and the current correspondingly decreases to a value at which the heat formed by the current passing through the air is insufficient to sustain an arc, which is thus extinguished. Thus, a more efficient interruption of the arc may be provided. A safer and more robust switch may be provided.

Optionally, the switch further comprises an arc-extinguishing medium arranged to be disposed between the first conductor and the second conductor when the third conductor is in the second position. The presence of the arc-extinguishing medium may increase the interruption of the arc, thereby helping to provide a safer switch. In some arrangements, the switch further includes an arc-extinguishing medium element coupled to the third conductor; the arc-extinguishing medium element is arranged to move into a position between the first conductor and the second conductor when the third conductor moves towards the second position. In other arrangements, a reservoir of arc quenching medium is optionally disposed within the ignition chamber or disposed outside the ignition chamber but between the pyrotechnic actuator and the third conductor; the arc quenching medium is arranged to be pushed between the first conductor and the second conductor by actuation of the pyrotechnic actuator when the third conductor is moved from the first position to the second position. Optionally, the arc-extinguishing medium includes silica, and may be provided in any suitable form, such as a liquid, powder or other solid form, or a thick viscous semi-solid liquid.

Optionally, the contact surface of the first conductor contacting the third conductor and the second conductor contacting the third conductor extends generally perpendicular to the direction of movement of the third conductor. This may improve the electrical contact between the conductors. Generally perpendicular as used herein means substantially 90 degrees, optionally up to and including ± 45 degrees. Optionally, the holding member and the pyrotechnic actuator are arranged on opposite sides of the third conductor; this may provide a switch that is easier to assemble. Optionally, the breakable holding member is arranged to exert a force to hold the third conductor in a direction substantially opposite to the direction of movement of the third conductor. In particular, when the third conductor is provided as described above, this arrangement may exert a more efficient holding force on the third conductor, thereby improving electrical contact.

Optionally, the pyrotechnic actuator is arranged to release gas into the ignition chamber in a direction substantially parallel to the direction of movement of the third conductor to actuate the third conductor. This arrangement may provide the most efficient transfer of energy between the pyrotechnic actuator to the third conductor. Substantially parallel as used herein means substantially 0 degrees, optionally up to and including ± 45 degrees.

Optionally, a piston is disposed between the third conductor and the pyrotechnic actuation, the piston including a void at least partially defining an ignition chamber. Actuation force from the pyrotechnic actuator is transferred to the third conductor through the piston. A smaller ignition chamber may be provided when the ignition chamber is at least partially defined by a void in the piston (at least initially, it will be understood that the ignition chamber will expand in size as the piston moves). Thus, less explosive may be required to generate the required pressure on the piston, which may provide a more efficient switch. Alternatively, the third conductor may be directly actuated by a pyrotechnic actuator.

Optionally, the switch further comprises a housing arranged to enclose the third conductor, and at least a portion of each of the first and second conductors, and optionally an ignition chamber. Optionally, the housing may enclose at least a portion of the pyrotechnic actuator. The housing is arranged to support the breakable holding part. This structural support of the breakable retention member helps to apply sufficient force efficiently to the third conductor to retain the third conductor in the first position until the pyrotechnic actuator is actuated and the retention member is broken. Assembly and manufacture may also be easier and more efficient using this configuration.

Optionally, the holding member is arranged to shear upon actuation of the pyrotechnic actuator, thereby allowing movement of the third conductor. The shearing of the retaining member may be provided by form and/or material. Optionally, the retention member is at least partially formed of plastic; i.e. at least the part of the breakable holding part that is arranged to be sheared off can be made of plastic. Plastics can be lightweight, inexpensive, and easily formed, and are therefore well suited as sacrificial parts; thus providing a cheaper switch suitable for a range of current loads. Alternatively, the breakable holding member can be made of any brittle material.

Optionally, the (shearable) retaining member comprises: a support element configured to hold the third conductor portion against the first and second conductor portions prior to actuation of the pyrotechnic actuator; and a shearable portion arranged to shear around the support element upon actuation of the pyrotechnic actuator. Optionally, the support element comprises a threaded portion and a threaded element configured to engage with the threaded portion, the threaded element configured to retain the third conductor portion against the first and second conductor portions prior to actuation of the pyrotechnic actuator. The use of a threaded element may help to adjust the force provided to the third conductor, which may easily and simply take into account any manufacturing tolerances and improve the utility of the switch. Furthermore, the switch may be faster and easier to assemble, thereby improving manufacturing.

There is provided a system comprising a switch as described above and a controller arranged to provide a signal to a pyrotechnic actuator to ignite the pyrotechnic actuator. Such a system may be used in any suitable application where a switch (or automatic circuit breaker, where an activation trigger is provided) is required, for example for overload in industrial applications.

There is provided a vehicle comprising a switch as described above. Optionally, the vehicle may further comprise a controller arranged to provide a signal to the pyrotechnic actuator to ignite the pyrotechnic actuator. Optionally, the vehicle is an electric vehicle. The switch may for example be used to break a circuit in a battery of the vehicle in case of an accident. This may improve safety.

In the following description, a method for operating a switch is described. The method is optionally a method for operating the switch of the first aspect. The method comprises the following steps: igniting the pyrotechnic actuator; releasing gas into the ignition chamber by ignition; applying pressure to a third movable conductor held in a first position within the ignition chamber by a breakable holding member depending on the released gas; wherein in the first position, the third conductor is disposed between and in electrical and physical contact with the first and second conductors to define a current conduction path; disconnecting the retention member and moving (or displacing) the third conductor from the first position and toward a second position by (i.e., in response to) the applied pressure, wherein in the second position the third conductor is electrically and physically separated from the first and second conductors; and opening the current conduction path of the conductor by the displacement of the third conductor. Optionally, a third conductor is disposed within the ignition chamber. Optionally, pressure is applied to the third conductor by means of a piston comprising a void at least partially defining an ignition chamber.

It will be appreciated that any of the features described above with reference to the switch of the first aspect may be provided in any suitable combination. Furthermore, any such feature may be combined with any feature of the method of the second aspect, or vice versa, where appropriate.

Drawings

The following description refers to the following figures:

FIG. 1: fig. 1A shows a schematic cross-section (a-a) of a switch according to an embodiment of the first aspect, wherein the switch is in a first closed position, and fig. 1B shows a schematic cross-section (a-a) of the switch of fig. 1A, wherein the switch is in a second open position;

FIG. 2: FIG. 2A shows a perspective view of the switch of FIG. 1A, FIG. 2B shows a perspective view of the switch in an intermediate position between closed and open, and FIG. 2C shows a perspective view of the switch of FIG. 1B;

FIG. 3: FIG. 3A illustrates elements of a breakable holding member according to an embodiment of the first aspect, and FIG. 3B illustrates the breakable holding member of FIG. 1A without threaded elements;

fig. 4 illustrates a plan view (upper left), a schematic cross-section (B-B) (lower left), and a perspective view (right) of the shearable portion of the breakable holding member of fig. 3;

FIG. 5 illustrates an exploded perspective view of the switch of FIG. 1A;

FIG. 6 illustrates a vehicle including the switch of the first aspect; and is

Fig. 7 illustrates a method according to the second aspect.

Detailed Description

Referring to fig. 1 (fig. 1A and 1B) and fig. 2 (fig. 2A, 2B, and 2C), a switch 100 for opening a current conduction path is described. The current conduction path is defined by a first conductor 106, a second conductor 108, and a third conductor 110. These conductors are separate components arranged to define a current conduction path by means of temporary joints between the first conductor 106, the second conductor 108 and the third conductor 110.

The switch 100 includes a housing 114 arranged to enclose at least a portion of each of the third and first conductors 106, 108. Here, the first conductor 106 and the second conductor 108 comprise connection contacts 106a, 108a, said connection contacts 106a, 108a being arranged outside the housing 114 for connecting the switch 100 to one or more circuits.

The temporary joint is provided by means of a breakable holding member 112 (shown within the dashed box of fig. 1), said breakable holding member 112 being used to hold the third conductor 110 in electrical contact in direct and physical contact with the first conductor 106 and the second conductor 108 to define a current conduction path. The contact surfaces of first conductor 106 contacting third conductor 110 and second conductor 108 contacting third conductor 110 may extend generally parallel to each other to facilitate this direct electrical and physical contact.

The breakable holding member (or holding member) 112 may be broken by material and/or form. In the arrangement described with reference to fig. 1 and 2, the retention member 112 is primarily breakable by form due to the introduction of mechanical weakness within the retention member 112. The retaining member 112 may be electrically conductive or electrically insulating; however, the retention member 112 may be electrically isolated from the third conductor 110 in order to maintain good electrical contact between the first, second, and third conductors 106, 108, 110. At least one breakable retention member 112 may be provided; for example, there may be one retaining member, or a plurality of retaining members (two, three, four, or more) as desired.

When the switch is in operation, the holding member 112 holds the third conductor 110 by applying (energizing) or applying (applying) a force in a direction substantially opposite to the direction of movement of the third conductor 110; the reaction force between the retaining member 112 and the portion of the switch housing 114 supporting the retaining member acts to resist movement of the third conductor until an actuation force is applied that is greater than the force supplied by the retaining member 112. In particular, the retaining member 112 is held in a fixed position by the housing 114, i.e., rigidly fixed or secured to the housing; in this manner, the third conductor 110 may be held in the first closed position by the holding member 112 and may therefore be subjected to relatively large vibrations from the environment in which it is deployed without opening the switch (provided that the vibrations are not so great as to cause the breakable holding member 112 to open). This may improve the flexibility and utility of the switch 100.

Here, the actuating force is provided by a pyrotechnic actuator 102 arranged to release gas into the ignition chamber 104 upon ignition. The pyrotechnic actuator 102 includes a connector pin 102a and an igniter 102 b. Upon receiving the ignition signal, the connector pin 102a activates the charge inside the igniter 102 b. The pyrotechnic actuator 102 is arranged to discharge gas into the ignition chamber 104 upon activation or ignition of the charge. In this arrangement, the switch includes a piston 120, the piston 120 including a void defining an ignition chamber. However, it should be understood that the piston may not be disposed within the switch, and the ignition chamber may be defined in other ways (e.g., it may be defined by a void disposed within the housing).

The high pressure gas exhausted into the ignition chamber 104 generates an actuation force acting on the third conductor 110 to cause the third conductor to move in a movement direction 130 from a first position (shown in fig. 1A and 2A) toward a second position (shown in fig. 1B and 2C). The intermediate position is shown in fig. 2B. The pyrotechnic actuator is arranged to release gas into the ignition chamber in a direction substantially parallel to the direction of movement 130 of the third conductor to actuate the third conductor. In this arrangement, the force acts on the third conductor 110 via the piston 120, but it should be understood that the force may act directly on the third conductor 110, or on the third conductor 110 via any other suitable component disposed between the pyrotechnic actuator 102 and the third conductor 110. The switch is closed when the third conductor is in the first position and open when the third conductor is in the second position. In the second open position, the third conductor is electrically separated from the first and second conductors such that no current can flow through the current conduction path.

The opening of the temporary joint between the first, second, and third conductors and the subsequent opening of the current path may result in the formation of an arc between the end of the third conductor 110 and the respective ends of the first conductor 106 and the second conductor 108. This phenomenon can occur as long as the conductors are physically separated from each other. The linear displacement of the third conductor relative to the first and second conductors can help to reduce this arcing (or arcing) by rapidly stretching the arcing, thereby increasing arc resistance. The increased arc resistance causes a corresponding increase in arc voltage and a decrease in arc current (since the arc exhibits a negative resistance). Due to the dynamic nature of the force exerted by the pyrotechnic actuator and the fact that the conductors do not need to be physically disconnected in any way, the speed of displacement that occurs can be used to increase the physical separation of the respective conductors more rapidly than in previous linear methods, causing a more effective interruption of the arc. A safer and more robust switch may be provided.

Arc interruption or quenching can be further improved by using an arc-extinguishing medium. In this arrangement, the reservoir of arc quenching medium 116 may be disposed in a void around the piston 120, as illustrated in fig. 1A. When the third conductor is displaced upon actuation of the pyrotechnic actuator 102 (i.e., in response to actuation of the pyrotechnic actuator 102), the medium 116 is correspondingly displaced to fill the gap vacated by the third conductor 110; this displacement may be caused by high pressure gas emitted by the pyrotechnic actuator 102 or may be caused by the piston 120 when the piston is disposed within the switch. Alternatively, in other sets of embodiments, an arc-extinguishing medium element 116 may be provided, the arc-extinguishing medium element 116 being coupled to the third conductor 110 and arranged to move into the gap vacated by the third conductor 110 when the third conductor moves. It should be appreciated that the arc quenching medium may be provided in any other suitable arrangement to facilitate interruption or extinguishing of the arc. In this set of embodiments, the arc quenching medium 116 includes silicon dioxide. The silica media may be provided in any suitable form, for example as a liquid, powder or other solid, or as a thick viscous semi-solid liquid. However, it should be understood that the arc-extinguishing medium 116 may include silicon dioxide in any suitable form. Alternatively, any other suitable arc quenching medium may be used.

Referring to fig. 3 (fig. 3A and 3B), an example disconnectable holding member (or holding member) 112 is described. Prior to actuation of the pyrotechnic actuator 102, the retaining member 112 (shown in phantom) is supported by the housing 114, i.e., rigidly held in a fixed position within the switch 100 by the housing 114. The holding member 112 is arranged to exert a force on the third conductor 110 in a direction 132 to hold the third conductor in physical and electrical contact with the first conductor 108 and the second conductor 106, which direction is substantially opposite to the direction of movement 130 of the third conductor 110. Substantially parallel as used herein means substantially 0 degrees, optionally up to and including ± 45 degrees.

The retention member 112 of this set of embodiments includes a "shear insert" 310 (shown within a small dashed box). The shear insert 310 is a sacrificial portion that is inserted within the housing 114 and supported by the housing 114 and is arranged to shear in response to an actuation force from the pyrotechnic actuator 102. The shearing of the shear insert 310 may be caused by one or more mechanical weak points within the shear insert 310, such as by the geometry of the components, and/or as a result of material selection.

The shear insert 310 described herein includes a shearable portion 312, the shearable portion 312 being disposed about a support element 314 (shown within a large dashed box). Shearable portion 312 includes a groove that introduces a mechanical disadvantage into shear insert 310 due to the reduction in material thickness. The shear insert is also at least partially formed of plastic to aid in shearing. Furthermore, plastics are lightweight and inexpensive, helping to provide lighter and less expensive switches. However, any suitable material and/or structure for the retaining member 112 may be used to provide an assembly capable of applying sufficient force to retain the third conductor 110 in the first position until actuation of the pyrotechnic actuator 102, but which is also capable of easily shearing under an actuation force caused by high pressure gas generated by the actuator 102. For example, any brittle material may be used to form the shearable sections 312 of the breakable retention members 112.

The support element 314 is arranged to hold the third conductor 110 by applying a force to the third conductor 110, optionally in direction 132. In this set of embodiments, the support element 314 comprises a threaded portion 316 of the shear insert, which is arranged to receive a threaded element. The support element further comprises a threaded element 320 arranged to engage with the threaded portion 316. In this example, the threaded element 320 is a grub screw, but any other suitable threaded element may be used, such as a bolt or other screw.

The use of the threaded portion 316 and the threaded element 320 may help provide an adjustable force to the third conductor 110, which may help ensure good contact between the third conductor 110 and the first and second conductors 108 and 106. This may improve the utility of the switch 100. However, in some embodiments, a solid non-adjustable support element 314 may be provided instead. In other embodiments, the support element may be formed by a resilient element (resilient pass-through structure and form and/or pass-through material) that applies a spring-like force to retain the third conductor 110 (the force being responsive to compression of the resilient element between the portion of the housing 114 supporting the breakable retention feature 112 and the third conductor 110 in contact therewith). For example, elastic elements such as springs or rubber protrusions may be used.

It should be understood that regardless of the material used to provide the breakable retention member 112, or the form or structure of any component of the breakable retention member, the retention member 112 may be electrically isolated from the third conductor 110 so as to provide a good conduction path between the first, second, and third conductors. Electrical isolation (i.e., insulation) may be provided by the insulating breakable holding member, or by the use of an insulating layer or section between the breakable holding member 112 and the third conductor 110. Optionally, the switch 100 includes an insulating layer disposed between the breakable retention member 112 and the third conductor 110. Optionally, the breakable holding part is insulated; for example, the support element 314 may be insulating. Optionally, in some sets of embodiments, the threaded element 320 in contact with the third conductor 110 may be insulated; for example, the threaded element may be formed of plastic.

Referring to fig. 4, the shear insert 310 of the breakable retention member 112 is described in more detail. The shear insert includes a threaded portion 316, a shearable portion 312 surrounding the threaded portion, and a plate 318. The shearable portions 312 are provided by means of grooves in the plate 318. The plate 318 is arranged to be rigidly supported by the housing so as to provide the necessary reaction force on the shear insert for the breakable holding member 112 to apply sufficient force to hold the third conductor 110 in physical and electrical contact with the first conductor 106 and the third conductor 108.

Referring to fig. 5, the assembly and manufacture of the switch 100 of the above-described set of embodiments is described.

The first conductor 106 and the second conductor 108 are insert molded into the portion 114a of the housing 114 (the conductors 106, 108 are placed in a mold, and then plastic is poured into the mold to create the housing portion 114 a). The pyrotechnic actuator 102 is placed into the housing portion 114a and the piston 120 is added. The piston 120 is arranged to fit against the housing portion 114a and the side of the pyrotechnic actuator so as to provide a substantially sealed ignition chamber through a void in the piston 120.

Optionally, an arc-extinguishing medium may be placed into the hollow surrounding the piston. A third conductor 110 is then added, and then a shear insert is added. These components are inserted from the bottom of housing portion 114 a. The third conductor is held in place against the first and second conductors by a threaded element 320 that engages the threaded portion of the shear insert. The applied force can be adjusted by adjusting the threaded element 320 at this stage of manufacture.

Alternatively, the portion 114b of the housing 114 may be applied prior to adjusting the threaded element. Housing portion 114b may optionally be ultrasonically welded to housing portion 114a, or may be secured to housing portion 114a in any suitable manner. After engagement, the plate of the shear insert 310 is then rigidly supported in position between the two housing portions 114a, 114 b. The threaded member 320 is adjustable through an aperture in the base of the housing portion 114 b. For example, when the threaded element is a grub screw, Allen wrench (Allen), or hex wrench (hex), a key may be used to adjust the threaded element 320. After adjustment, a cover 318 may be provided to close the aperture in the housing portion 114b to prevent any arc quenching medium from leaking during use.

Referring to fig. 6, a power system 640 including the switch 100 is depicted. In particular, the powertrain 640 may be a powertrain of the vehicle 600. With respect to vehicles (e.g., motor vehicles, boats or ships, or airplanes, etc.), the power system encompasses the primary components that generate and transfer electrical power to the road surface, water, or air. This includes the engine, gearbox, drive shaft and drive wheels (or other drive mechanism, such as a propeller). In an electric or hybrid vehicle, the powertrain 600 also includes, for example, a battery 660 and an electric motor. The switch 100 may be connected via the connection contacts 106a, 108a of the first and second conductors to an electrical circuit 650 within the vehicle 600, which may optionally include a battery 660. Alternatively, vehicle 600, which may be an electric vehicle, may include switch 100 in the absence of power system 640, as illustrated in fig. 6.

The ignition signal may be provided to the connector pin 102a of the pyrotechnic actuator 102 from a remote controller or a remote power distribution unit 670 within the vehicle 600. This ignition signal may be emitted in response to an external event. For example, when the switch 100 is connected to a battery 660 installed in the vehicle 600, an ignition signal may be sent to the pyrotechnic actuator 102 in response to a collision of the vehicle; activation of the charge inside the igniter 102b may cause the third conductor 110 to separate from the first and second conductors in order to open the electrical circuit 650 and prevent current flow through the battery 660. This arrangement may improve safety in the event of a collision. Alternatively, the switch 100 and the remote control 670 may be deployed in any other application that requires such disconnection of a circuit.

Referring to fig. 7, a method 700 for opening a current conduction path using a switch 100 (e.g., the switch 100 of the first aspect) is described.

At step 710, the method includes optionally igniting a pyrotechnic actuator in response to a crash or other external event that triggers an ignition signal received by the pyrotechnic actuator. Any other trigger may be used to ignite the pyrotechnic actuator. At step 720, upon ignition of the pyrotechnic actuator, high pressure gas is released into the ignition chamber. At step 730, this released gas exerts pressure (directly or indirectly) on the third movable conductor 110, which is disposed and held in the first position by the breakable holding member 112. Optionally, a third conductor is disposed within the ignition chamber. Optionally, the pressure is applied by means of a piston comprising a void at least partially defining an ignition chamber. In the first position, the third conductor 110 is disposed between the first conductor 106 and the second conductor 108 and is in (direct or indirect) electrical contact with the first conductor 106 and the second conductor 108 to define a current conduction path.

Optionally, in this example, the piston 120 accelerates downward due to the high pressure gas, and the third conductor 110 moves in the direction 130 as the piston moves downward. The movement of the third conductor in turn pushes on the support element 314 of the breakable holding member 112 and causes shearing of the shearable portion 312 of the breakable holding member, thereby breaking the breakable holding member 112.

At step 740, the breakable holding member is broken (optionally sheared) by the actuating force and the third conductor is correspondingly moved, i.e., displaced from the first position and toward the second position. In the second position, the third conductor 110 is electrically separated from the first conductor 106 and the second conductor 108; in other words, the switch 100 is open. Accordingly, in response to the pressure applied at step 730 and the corresponding displacement or movement of the third conductor, the opening of the retention member at step 740 causes the opening of the current conduction path (step 750).

Optionally, at step 760, an arc formed when the third conductor is separated from the first and second conductors is suppressed or interrupted. This interruption can be achieved by the relative movement of the third conductor alone (which lengthens the arc) or by releasing an arc-extinguishing medium (e.g., a medium comprising silica), which can serve to cool (and thus interrupt) the arc.

It should be noted herein that while various examples of the disconnector of the first aspect are described above, these descriptions should not be viewed in a limiting sense. Indeed, there are several variations and modifications which may be made without departing from the scope of the present invention as defined in the appended claims.