Multiple squib assembly

A multiple squib assembly for use in a chaff deployment system having a chaff cartridge with first and second chaff chambers, the multiple squib assembly consisting essentially of:

• a base plate having an orifice formed therein;
• a center contact positioned in the orifice in the base plate said center contact and said orifice defining an insulative space therebetween;
• a first squib and a second squib positioned in complementary relationship, each squib having a first end, a second end, a ground lead and a positive lead, the ground lead of each squib being attached to the base plate, and the positive lead of the first squib being attached to the center contact, and wherein each of said second ends of said first and second squibs are insertable into said respective first and second chaff chambers;
• a discriminating element operatively coupled to the second squib and to the center contact;
• and
• potting material engaging the first ends of the first and second squibs, the base plate, the center contact the ground leads, the positive leads, and the discriminating element, said potting material being shaped to form a first seal around said first squib and a second seal around said second squib, each of said first and second seals sealably insertable insertion into said respective first and second chaff chambers of said chaff cartridge, and wherein said potting material is disposed in said insulative space so as to insulate said center contact from said base plate.

A method of manufacturing a dual squib assembly, comprising:

• providing a first squib and a second squib, each squib having a first end, a second end, a ground lead and a positive lead, and wherein each of said second ends of said first and second squibs are insertable into a payload chamber of a payload deployment system;
• connecting an anode of a zener diode to the positive lead of the second squib and connecting the cathode of the zener diode to a center contact;
• connecting the positive lead of the first squib to the center contact;
• connecting the negative leads of both squibs to a base plate having an orifice formed therein;
• positioning the squibs, the zener diode, the base plate, the ground leads, the positive leads and the center contact in a fixture so that said center contact is positioned in the orifice in such a way to define an insulative space between said orifice and said center contact, the fixture being adapted to receive potting compound and to mold the potting compound to engage the first ends of said first and second squibs, the zener diode, the base plate, the ground leads, and the positive leads, and the center contact, and so that it forms a first squib sealing structure around said first squib and a second squib sealing structure around said second squib, each of said first and second squib sealing structures sealably insertable into a payload chamber of said payload deployment system;
• injecting potting compound into the fixture such that it engages the first ends of said first and second squibs, the zener diode, the base plate, the ground leads, the positive leads, and the center contact, and wherein the potting compound fills said insulative space so as to insulate said center contact from said base plate and forms said first and second sealing structures;
• and
• removing the completed assembly from the fixture.

A squib assembly, comprising:

• a base plate having an orifice formed therein;
• a center contact positioned in the orifice, said center contact and said orifice defining an insulative space therebetween;
• one or more squibs, each having a first end, a second end, a first contact and a second contact, said first contact and said second contact connected adjacent said first end, each said first contact connected to the baseplate and each said second contact connected to the center contact, and wherein each of said second ends of said one or more squibs are insertable into a payload chamber;
• and
• insulating material engaging and retaining the baseplate, the center contact, the first contact, the second contact, and the first ends of each of said one or more squibs, said insulating material terminating at a point between said first and second ends of said squibs so that said second ends of said squibs extend free of said insulating material from said point, and wherein said insulating material is disposed in said insulative space.