Patent Application
20230260727
The present invention relates in general to a pyrotechnic circuit breaker intended to be mounted for example on a motor vehicle, and in particular in an electrical power circuit of a motor vehicle, for example a hybrid vehicle or an electric vehicle.
Circuit breaker devices, such as the one described in document US20130175144, which proposes to use a flowable insulating material are known in the prior art. On the other hand, this system notably has the drawback of requiring a lot of flowable insulating material, which requires large quantities, can generate leaks. In the case of a material containing silicone, precautions and authorizations will be necessary for automotive use (due to not being compatible with the paint for example). Furthermore, the applicant has noticed that such a flowable insulating material can generate longer opening times and/or degraded performance during the operation of the circuit breaker (the time taken to effectively cut off the passage of a high-power current (for example at least 100 A/100 V, or for example 800 A/450 V)). Finally, it is important to be able to guarantee good insulation resistance after operation.
One aim of the present invention is to address the disadvantages of the prior art mentioned above and in particular, first of all, to propose a pyrotechnic circuit breaker that is simple to manufacture, having high cutting capacities, a rapid opening time during operation, and good insulation resistance after opening.
A first aspect of the invention therefore relates to a pyrotechnic circuit breaker comprising:
According to the embodiment hereinbefore, the internal chamber may comprise or contain at least one wall formed with a plastic material comprising silicone, arranged opposite the portion to be broken. According to this implementation, at least one wall of the internal chamber comprises silicone and this wall can typically form or support a leakage current route. The applicant has found that adding silicone to a material forming the wall makes it possible to guarantee high insulation resistances after use, in comparison with the same circuit breaker not comprising silicone in a wall of the internal chamber. In other words, providing silicone in the material of one of the walls that can support or form a leakage current route after the cut-off makes it possible to significantly reduce leakage currents once the cut-off has been performed.
In other words, the internal chamber comprises or contains at least one wall formed with a plastic material comprising an additive, the additive comprising silicone or being silicone.
According to one embodiment, the internal chamber can be intended to be exposed to a pressure generated by the pyrotechnic actuator. In particular, the pressure generated by the pyrotechnic actuator may be greater than 5 MPa, preferably greater than 10 MPa. As a consequence, the wall formed with a plastic material comprising the silicone may also be exposed to the pressure generated by the pyrotechnic actuator. In particular, the wall formed with a plastic material comprising the silicone may be intended to withstand the pressure generated by the pyrotechnic actuator. In other words, the wall formed with a plastic material comprising the silicone is part of the structure of the circuit breaker and participates in withstanding the pressure generated by the pyrotechnic actuator.
According to one embodiment, the pyrotechnic circuit breaker may comprise at least one support, and the plastic material comprising silicone may be over-molded or attached to the support. Such an implementation makes it possible to position the plastic material comprising silicone only where it will have a notable effect on the insulation resistance, without providing an additional part
According to one embodiment, the support may comprise a portion of the electrical conductor.
According to one embodiment, the support may comprise a portion of the housing.
According to one embodiment, the support may comprise a portion of the opening member.
According to one embodiment, the wall formed with the plastic material comprising silicone may support a leakage current route between the two discrete portions of conductor after opening, and preferably the shortest leakage current route between the two discrete portions of conductor after opening. Such an implementation, with the addition of silicone in the wall supporting the shortest leakage current route makes it possible to effectively break the leakage current route which would be taken by a leakage current.
According to one embodiment, the wall formed with the plastic material comprising silicone may cover less than 50% of a total surface area of the internal chamber. Such an implementation makes it possible to limit the use or the addition of silicone only where this will have a notable effect on the insulation resistances.
According to one embodiment, the plastic material comprising silicone may comprise a polyamide-type polymer, preferably a polyphthalamide of type PA6T/XT. In other words, the plastic material may be a polyamide-type polymer, preferably a polyphthalamide of PA6T/XT type, with an additive comprising silicone. It may be intended to have predominantly (for example more than 80% by weight, preferentially more than 90% by weight) a polyamide-type polymer, preferably a polyphthalamide of PA6T/XT type, and a minor additive comprising silicone.
According to one embodiment, the plastic material comprising silicone may comprise silicone and/or polysiloxane, in a proportion ranging from 3.5% to 6.5% by weight, and preferentially from 4.25% to 5.75% by weight.
According to one embodiment, the internal chamber may comprise or contain at least one internal surface formed by a wall formed with a second plastic material comprising a flame retardant.
According to the implementation hereinbefore, the circuit breaker comprises a wall arranged in the internal chamber, that is, facing the part to be cut, and which contains a flame retardant. The applicant has found that the insulation resistances after operation were higher than those measured on circuit breakers having the same geometric configuration, but no material with a flame retardant. In other words, providing a flame retardant in the material of one of the walls exposed to the electric arc formed during the breaking makes it possible to significantly reduce the leakage currents once the breaking has been performed. In addition, the applicant has found that combining a wall with silicone and another wall with flame retardant makes it possible to amplify the effects on the insulation resistance. In other words, a synergism has been noted by combining these two characteristics.
According to one embodiment, said second plastic material comprising the flame retardant may be a polymer, such as a polyamide, and preferably a polyphthalamide such as PA 6T/66.
According to one embodiment, said second plastic material comprising the flame retardant may be a polymer forming a matrix, and comprising a filler material, such as fibers, preferably inorganic fibers, for example glass fibers, in a proportion ranging from 10% to 70% by weight and preferably in a proportion ranging from 45% to 55% by weight.
According to one embodiment, said second plastic material comprising the flame retardant can self-extinguish after 10 seconds, during a flammability test according to standard UL94 (6th edition of Mar. 28, 2013) performed on a vertical test specimen, particle losses being permitted as long as the particles lost are not ignited.
According to one embodiment, the flame retardant may be a non-halogenated compound, selected from:
According to one embodiment, the flame retardant may be a non-halogenated compound, selected from the following compounds and the mixtures thereof:
melamine cyanurate, melamine phosphate, melamine pyrophosphate, melamine polyphosphate, melem phosphate (that is, 2,5,8-triaminoheptazine phosphate), melem pyrophosphate, dimelamine pyrophosphate, dimelamine phosphate, melem polyphosphate, phosphaphenanthrenes, metal hydroxides, phosphinic acid salts, diphosphinic acid salts.
According to one embodiment, the pyrotechnic circuit breaker may comprise a base part formed by a third plastic material and said second plastic material comprising the flame retardant may be attached to or over-molded on the base part. Such an implementation makes it possible to position the second plastic material comprising the flame retardant only where it will be correctly exposed to the electric arc, without providing an additional part.
According to one embodiment, the opening member may comprise:
According to one embodiment, said third material may be a polyamide, preferably a polyphthalamide (PA 6.T/XT) forming a matrix, and able to comprise glass fibers, in a proportion ranging from 40% to 50% by weight. The third material makes it possible to provide a robust opening body that withstands the mechanical forces well.
According to one embodiment, the pyrotechnic circuit breaker can be arranged to produce an electric arc between the two discrete portions of conductor during the movement of the opening member between the initial position and the final position, when the circuit breaker is connected to a live electric circuit,
and the second plastic material comprising the flame retardant can be arranged in order to be removed by ablation by the electric arc. In detail, the second plastic material comprising the flame retardant arranged to be removed by ablation is transformed (for example, sublimed) under the action of the intense heat flux of the electric arc. This second material, removed by ablation, can then condense or deposit on the walls of the internal chamber, and this provides high insulation resistances. Furthermore, such an implementation can modify the composition of the electric arc plasma and its conductivity and makes it possible to increase the electric arc voltage. Such electric arcs can be created when the circuit breaker is connected to a live electric circuit, with voltages ranging from 0 V to 1000 V and currents ranging from 0 A to 25000 A on inductive loads ranging up to 2500 µH (micro-Henry) for an intensity of less than 500 A and up to 5 µH for an intensity of 25000 A. The circuit breaker according to the invention makes it possible to reliably break the current in less than 10 ms and even less than 5 ms, in a permanent manner, because the circuit breaker, comprising a pyrotechnic actuator, can only be used once. Once used, the circuit breaker also has good insulation resistance.
According to one embodiment, the pyrotechnic circuit breaker may comprise at least one passage arranged to guide the electric arc between the two discrete portions of conductor, and the second plastic material comprising the flame retardant may be arranged to form or delimit at least partially the passage. According to this implementation, the second plastic material comprising the flame retardant is necessarily exposed to the electric arc.
According to one embodiment, the passage may be at least partially formed on the opening member.
According to one embodiment, once the opening member is in the final position, an insulation resistance between the connection terminals may be greater than 30 Mohms, preferably greater than 50 Mohms, preferably greater than 100 Mohms, preferably greater than 500 Mohms, and very preferentially greater than 1 Gohms.
Another aspect of the invention relates to a method for manufacturing a circuit breaker according to the first aspect, comprising the steps of:
In other words, the method according to the invention comprises a step consisting in mixing, before the manufacture of the internal chamber, the first raw material, for example granulated, intended to form the internal chamber, with the second raw material, for example granulated, comprising between 40% and 60% by weight of silicone. Typically, the wall comprising the silicone is formed by an injection-molding method, and the manufacturing method comprises a step of preparing the material to be injected by mixing two types of granules; the first raw material and the second raw material which contains the silicone. There is therefore no pure silicone to be provided or handled, simply solid granules already comprising the silicone. This implementation makes it possible to maintain a simple method.
Another aspect of the invention relates to a motor vehicle comprising at least one circuit breaker according to the first aspect.
Other characteristics and advantages of the present invention will become more apparent upon reading the detailed description of an embodiment of the invention, which is provided by way of example but in no manner limited thereto, and illustrated by the attached drawings, in which:
The circuit breaker of
In order to address the opening function, the pyrotechnic actuator 50 (typically an electro-pyrotechnic igniter) is triggered and a high pressure is generated in the space between the pyrotechnic actuator 50 and the opening member 40, which pushes the latter towards the top of
During this movement, the opening member 40 comes into contact with the part to be opened 31A of the electrical conductor, and therefore opens the internal electric circuit by cutting the electrical conductor 31, by a mechanical shearing. However, an opening may be alternatively provided by pushing one of two strands that are initially discrete and in contact with one another, in order to separate them.
As shown in
When the opening member 40 moves from the initial position to the final position, the projections 45 of the opening member 40 bear on the non-supported parts of the electrical conductor 31 and shear it on both sides of the bar 14 and the return 13 (at the part to be opened 31A opposite the upper chamber 61). However, having a single projection 45 or more than two projections 45 may be alternatively provided, the number of projections 45 defining the number of breaks made on the electrical conductor 31 during the movement of the opening member 40.
As shown in
Furthermore, at the very beginning of opening, when the inner ends 34 are still in the vicinity of the central portion 33, an electric arc can form (depending on whether current passes through the electrical conductor 31 or not) between each inner end 34 and the central portion 33, at an arc path TA shown in dotted lines in
The opening member 40 is therefore mounted in a sliding or translational connection relative to the housing 10 and slides during its movement from the initial position to the final position, which provides a reproducible, controlled final operation and position in order to guarantee rapid opening and arc extinguishing at the end of operation with a sufficient free distance.
However, the operation of the pyrotechnic actuator 50 can generate numerous hot particles and gases which are projected into the internal chamber 60, and which typically cover or condense on the walls of the latter, and in particular the walls 611, the lateral projections 43 and the lateral grooves 613. Such deposits can form an electrically conductive or slightly electrically conductive layer, and an insulation resistance, after opening of the electrical conductor 31, may be affected.
Furthermore, the electric arc may remove by ablation material of the opening member 40 and/or of the housing 10 (return 13 or bar 14 especially), which can generate gases or particles which will also cover and/or condense on the walls of the internal chamber 60 and also affect the insulation resistance.
Such an insulation resistance, measured after operation, between the connection terminals 21 and 22 must be high, to guarantee an absence of leakage current between the connection terminals 21 and 22 after opening the internal electric circuit of the circuit breaker.
Such leakage currents typically pass through leakage current routes between the discrete portions of conductor after opening, which extend along the inner wall of the internal chamber 60.
The electrical conductor 31 has therefore been opened in three discrete portions of conductor, that is, two discrete lateral portions 32 and a central portion 33. The central portion 33 is separated from the two discrete lateral portions 32 by the lateral projections 45 of the opening member 40.
Detail A and detail B of
It should be noted that the function of providing good insulation resistance is to be ensured after operation, once the electrical conductor 31 has been broken or opened. Typically, a leakage current cannot be established along the arc path TA because the resistivity of the air is too great. As a consequence, a leakage current can only run along the walls of the circuit breaker, in particular the inner walls of the internal chamber 60 or the walls of the opening member 40, and this preferably on the shortest route, which has the lowest insulation resistance.
As shown in details A and B of
In order to guarantee good insulation resistance, it may be proposed, in a first alternative, to provide in the internal chamber 60 a wall formed with a plastic material comprising silicone. Indeed, the applicant has found that the addition of silicone, in particular in a wall on which a leakage current could run after the operation of the circuit breaker, makes it possible to significantly increase the insulation resistances after operation.
In particular, the plastic material comprising silicone comprises a polyamide-type polymer, preferably a polyphthalamide, such as PA6T/XT. In detail, the plastic material comprising silicone comprises silicone and/or polysiloxane, in a proportion ranging from 3.5% to 6.5% by weight, and preferentially from 4.25% to 5.75% by weight.
In the example depicted, provision may be made for the plastic material comprising the silicone to be used for the over-molding the electrical conductor 31, that is to say in order to produce the over-molded body 15 visible in
The applicant has found that the addition of silicone in this over-molding made it possible to increase the insulation resistances. For example, after operating tests (breaking of a live circuit), insulation resistances were measured on reference circuit breakers, and circuit breakers with over-molded body 15 comprising 10% silicone. The results are shown in Table 1: Tests carried out under 450 V / 8000 A / 20 µH / +125° C.
It may be noted that the insulation resistances after opening are significantly higher with the parts of which over-molded body 15 comprises 10% silicone, than on the reference parts of which the over-molded body 15 does not comprise silicone.
In order to guarantee good insulation resistance, it may be proposed, in a second alternative, to provide in the internal chamber 60 another wall formed with a second plastic material comprising a flame retardant. Indeed, the applicant has found that the addition of a flame retardant, in particular in a wall forming a surface exposed to the electric arc during the operation of the circuit breaker, makes it possible to significantly increase the insulation resistances after operation.
The second plastic material comprising the flame retardant may typically be a polyamide, and preferably a polyphthalamide (such as PA6T/66). It is possible to provide reinforcing fibers, for example glass fibers in a ratio of 45% to 55% by weight.
The flame retardant is typically a non-halogenated compound selected from the following materials and the mixtures thereof:
In particular, provision may be made for the flame retardant to be a non-halogenated compound, selected from the following compounds and the mixtures thereof:
melamine cyanurate, melamine phosphate, melamine pyrophosphate, melamine polyphosphate, melem phosphate, melem pyrophosphate, dimelamine pyrophosphate, dimelamine phosphate, melem polyphosphate, phosphaphenanthrenes, metal hydroxides, phosphinic acid salts, diphosphinic acid salts.
The second plastic material comprising the flame retardant may comprise the flame retardant between 2% and 30% by weight, and preferably between 5% and 30% by weight and more preferentially between 8% and 25% by weight.
The flame retardant may further comprise at least one synergist (or synergistic compound, which further improves the ignition resistance), said at least one synergist being selected from the group consisting of compounds containing nitrogen, compounds containing nitrogen and phosphorus, metal borates, metal carbonates, metal hydroxides, metal hydroxyoxides, metal nitrides, metal oxides, metal phosphates, metal sulfides, metal stannates, metal hydroxystannates, silicates, zeolites, basic zinc silicates, silicic acids and combinations thereof, in particular triazine derivatives, melamine, guanidine, guanidine derivatives, biuret, triuret, tartrazine, glycoluril, acetoguanamine, butyroguanamine, caprinoguanamine, benzoguanamine, melamine derivatives of cyanuric acid, melamine derivatives of isocyanuric acid, melamine cyanurate, melamine condensation products, melamine pyrophosphate, pyrophosphates of melamine condensation product, dimelamine phosphate, dimelamine pyrophosphate, melamine polyphosphate, dicyandiamide, ammonium polyphosphate, ammonium hydrogen phosphate, ammonium dihydrogen phosphate, polyphosphates of melamine condensation product, melamine sulfate, allantoin, aluminum hydroxide, synthetic aluminum hydroxide, synthetic aluminum metahydroxide, natural aluminum hydroxide, natural aluminum metahydroxide, aluminum oxide, calcium borate, calcium carbonate, calcium and magnesium carbonate, calcium oxide, calcium sulfide, iron oxide, magnesium borate, magnesium carbonate, magnesium hydroxide, magnesium nitride, magnesium oxide, magnesium sulfide, manganese hydroxide, manganese oxide, titanium nitride, titanium dioxide, zinc borate, zinc metaborate, zinc carbonate, zinc hydroxide, zinc nitride, zinc oxide, zinc phosphate, zinc sulfide, zinc stannate, zinc hydroxystannate, basic zinc silicate, tine oxide hydrate and combinations thereof.
Typically, the second plastic material comprising the flame retardant self-extinguishes after 10 seconds, during a flammability test conducted according to standard UL94 (6th edition of Mar. 28, 2013) performed on a vertical test specimen, particle losses being permitted as long as the particles lost are not ignited. In particular, the length of the sample is 5”″ (127 mm) and its width is 0.5” (12.7 mm). Its thickness should not exceed 0.5” (12.7 mm). It is fixed at ¼ of its upper end in the vertical position. A metal mesh covered with surgical cotton is placed 12″ (305 mm) under the sample. The burner is set to form a ¾″ (19 mm) blue flame. This flame is directed from below onto the bottom edge of the plastic sample at a distance of ⅜″ (9.5 mm). It is applied for 10 seconds, then removed. The combustion time of the sample is measured. Once combustion stops, the flame is reapplied for 10 seconds. As soon as removed, the combustion time and incandescence time are measured again. The complete test is performed on five samples.
The tested material is classified as UL 94 V-0 if: A) None of the five samples burns for more than 10 seconds after the burner flame has been removed.
B) The total combustion time over the 5 tests does not exceed 25 seconds.
C) None of the tested samples burns, either with a flame, or by incandescence, until the holding jaw.
D) No incandescent drop, which might ignite the cotton placed below, falls from any sample.
E) No sample has an incandescence time exceeding 30 seconds.
In the example depicted, the opening member 40 may be provided with an opening body 41 (forming a base part), on which an exposed face 42 is over-molded, formed with the second plastic material comprising the flame retardant. Alternatively, the second plastic material comprising the flame retardant could be provided at another wall facing into the internal chamber, such as on the housing 10 or on the over-molded body 15.
The base part, that is, herein the opening body 41, may be a third plastic material, such as a polyamide, preferably a polyphthalamide such as PA 6.T/XT forming a matrix, and comprising glass fibers, in a proportion ranging from 40% to 50% by weight.
For example, after operating tests (breaking of a live circuit) carried out under varied conditions, insulation resistances were measured on reference circuit breakers, and circuit breakers with an opening member comprising a flame retardant (to form an exposed face 42 attached to the opening member 40). The results are shown in Tables 2, 3 and 4: Tests carried out under 450 V / 8000 A / 15 µH / +125° C.
Tests carried out under 475 V / 8000 A / 20 µH / +125° C.
Tests carried out under 450 V / 8000 A / 20 µH / +125° C.
It may be noted that in each series of tests, the insulation resistances after opening are significantly higher with the parts of which the internal chamber comprises a surface exposed to the electric arc formed by the second material comprising the flame retardant, than on the reference parts not comprising flame retardant.
It should be noted that the second plastic material containing the flame retardant is positioned as close as possible to the arc path TA, and to this end, a passage 44 is provided on the opening member 40 to guide the electric arc, the passage 44 being directly formed in the second plastic material containing the flame retardant. In practice, the passage 44 is a groove of small dimensions (a few tenths of millimeters wide and/or deep) formed in the second plastic material containing the flame retardant, in order to provide a free space even when the opening member 40 is in the final position in abutment against the return 13, so that an electric arc preferentially passes through this passage 44 and will remove the second plastic material containing the flame retardant by ablation.
Finally, the applicant has found that there was a strong increase in insulation resistances if the two alternatives are combined, that is to say providing in the internal chamber;
Indeed, in the context of the tests reported in Tables 1 and 4, the applicant also tested circuit breakers with a wall of the internal chamber comprising flame retardant (the exposed face 42 of the opening member 40) and another wall comprising silicone (in the over-molded body 15), and the results are given in Table 5. Tests carried out under 450 V / 8000 A / 20 µH / +125° C.
It may be noted from the results of Table 5 that the effect on the insulation resistance by combining a wall of the internal chamber comprising flame retardant and another wall comprising silicone goes well beyond the simple addition of the effects measured on parts comprising only either one of the alternatives. As a consequence, synergism has been observed and this configuration (a wall of the internal chamber comprising flame retardant and another wall comprising silicone) has a proven advantage.
It will be understood that various modifications and/or improvements which are obvious for the person skilled in the art may be made to the different embodiments of the invention described in the present description, without departing from the scope of the invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| FR2007813 | Jul 2020 | FR | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2021/069250 | 7/12/2021 | WO |
