Initiator assembly having low-energy exploding foil initiator header and cover with axially threaded portion

An initiator assembly comprising:

• a weldment having an externally threaded portion, an internal cavity and a bore that extends out of an end of the threaded portion;
• an insulating spacer received in the internal cavity;
• an initiator that forms at least a portion of an exploding foil initiator, the initiator including a plurality of electric interfaces, the initiator being disposed on a side of the insulating spacer that faces the bore in the weldment;
• a plurality of terminals that extend through the weldment into the internal cavity;
• a plurality of contacts that electrically couple the electric interfaces to the terminals;
• an input charge formed of a secondary explosive and being disposed proximate the initiator so as to be capable of detonating to release energy upon activation of the initiator;
• and
• an output charge received in the bore and being formed of an energetic material, the output charge being configured to at least one of detonate, deflagrate and combust in response to receipt of energy released from detonation of the input charge;
• and
• a closure member that is fixedly coupled to the weldment to close the bore, the output charge being disposed between the closure member and the initiator.

An initiator assembly comprising:

• a header assembly having a header body, an insulating spacer that is coupled to the header body, an initiator, a plurality of terminals that extend through the header body, and a plurality of contacts, the initiator forming at least a portion of an exploding foil initiator, the initiator including a plurality of electric interfaces, the initiator being disposed on a side of the insulating spacer opposite the header body, the contacts electrically coupling the electric interfaces to the terminals, each of the terminals has a first terminal portion and a second terminal portion, wherein the first terminal portion has a first diameter and the second terminal portion has a second diameter that is smaller than the first diameter;
• an input charge formed of a secondary explosive and being disposed proximate the initiator so as to be capable of detonating to release energy upon activation of the initiator;
• an output charge formed of an energetic material, the output charge being configured to at least one of detonate, deflagrate and combust in response to receipt of energy released from detonation of the input charge;
• and
• a cover that is welded coupled to the header body, the cover cooperating with the header body to form a hermetically sealed cavity that houses the insulating spacer, the initiator, the contacts, the input charge and the output charge, wherein the cover comprises an exterior threaded portion into which the output charge is housed, the threaded portion having a major diameter that is less than or equal to ½ inch, wherein the cover defines first and second counterbores, wherein the header body has first and second axially spaced apart end faces, wherein the first axial end face is seated against the first counterbore and wherein the second axial end face is axially spaced apart from the second counterbore.