Initiator assembly having an initiator cartridge and method for constructing an initiator assembly

An initiator assembly comprising:

• an initiator cartridge having a cartridge housing, an initiation package and an input charge, the cartridge housing being formed of a plastic material and defining an outer circumferential surface, a recess, and a plurality of orientation features, the recess being formed into a first axial end of the cartridge housing, the orientation features being disposed through the first axial end of the cartridge housing and being disposed inwardly of the outer circumferential surface, the initiation package having an exploding foil initiator and a plurality of cartridge terminals, the exploding foil initiator having a bridge, the cartridge terminals being electrically coupled to the bridge, the initiation package being at least partly encapsulated in the plastic material that forms the cartridge housing, the input charge being at least partly formed of a secondary explosive and being received in the recess in the cartridge housing;
• an initiator housing having a housing structure and a plurality of initiator terminals, the housing structure having a housing member, which defines a cavity, and a wall member that bounds a first side of the cavity, wherein a plurality of terminal apertures are formed in the wall member, each of the initiator terminals extending through an associated one of the terminal apertures and being electrically coupled to an associated one of the cartridge terminals, the initiator cartridge being received in the cavity;
• an output charge received in the cavity and disposed adjacent to the initiator cartridge;
• and
• a closure member coupled to the initiator housing to close the cavity in the housing structure.

A method for constructing an initiator assembly, the method comprising:

• providing an initiator cartridge having a cartridge housing, an initiation package and an input charge, the cartridge housing being formed of a plastic material and defining an outer circumferential surface, a recess, and a plurality of orientation features, the recess being formed into a first axial end of the cartridge housing, the initiation package having an exploding foil initiator and a plurality of cartridge terminals, the exploding foil initiator having a bridge, the cartridge terminals being electrically coupled to the bridge, the initiation package being at least partly encapsulated in the plastic material that forms the cartridge housing, the input charge being at least partly formed of a secondary explosive and being received in the recess in the cartridge housing;
• providing an initiator housing having a housing structure and a plurality of initiator terminals, the housing structure having a housing member, which defines a cavity, and a wall member, the wall member bounding a first side of the cavity, wherein a plurality of terminal apertures are formed in the wall member, each of the initiator terminals extending through an associated one of the terminal apertures;
• sliding the initiator cartridge into the cavity along an insertion axis to mechanically and electrically engage the cartridge terminals to the initiator terminals;
• and
• sliding an output charge into the cavity along the insertion axis;
• wherein the initiator cartridge is disposed in the cavity along the insertion axis between the wall member and the output charge.