Method for forming a fuse having a silicone element

Abstract

A method of forming a fuse having a silicone element is provided, the method comprising: providing a fusible element; and depositing a silicone material on the fusible element, wherein the silicone material is delivered to the fusible element at a plurality of angles.

Description

TECHNICAL FIELD

[0001] The present disclosure relates generally to circuit protection devices, and more particularly, to methods for forming a fuse device having a silicone element. BACKGROUND

[0002] Fuses are widely used in overcurrent protection devices to prevent damage to expensive circuits. A fuse terminal typically forms an electrical connection between a power source or power supply and a combination of electrical components or components arranged in a circuit. One or more fusible elements are connected between the fuse terminals such that when the current flowing through the fuse exceeds a predetermined limit, the fusible element(s) melt and break one or more circuits through the fuse to prevent damage to the electrical components.

[0003] An arc is sometimes generated along the fusible element, particularly at the location of the melt under overcurrent conditions. If the arc is allowed to persist for a long time, it can cause the housing containing the fusible element to rupture. To minimize the duration of the arc event, the fusible element can be embedded in an arc quenching material disposed within the housing, which absorbs the evaporated metal that sustains the arc over time. However, the arc quenching material alone can not be sufficient to conveniently extinguish arcs generated within certain fuses, such as, for example, small, high voltage, direct current (DC) fuses. It is therefore desirable in certain applications to supplement the arc quenching capability of the fuse assembly. SUMMARY

[0004] In some embodiments, a device can include providing a fusible element, and depositing a silicone material on the fusible element, wherein the silicone material is delivered to the fusible element at a plurality of angles.

[0005] In some embodiments, a method for depositing a silicone material on a fusible element can include providing a fusible element, the fusible element including a series of solid portions connected by bridges, and depositing a silicone material on the fusible element. The silicone material can be delivered to the fusible element at a plurality of angles to form the silicone material along each of: an upper surface of the fusible element, a lower surface of the fusible element, and a side surface of the fusible element.

[0006] In some embodiments, a method of forming a fuse assembly can include providing a fusible element, and forming an arc quenching band around the fusible element, wherein a material of the arc quenching band is delivered to the fusible element at a plurality of angles. BRIEF DESCRIPTION OF DRAWINGS

[0007] Figures 1A-1B is an isometric view showing a fuse device according to an example embodiment.

[0008] Figure 2 is a flowchart of a method for forming a fuse device according to an example embodiment.

[0009] The drawings are not necessarily to scale. The drawings merely represent typical embodiments of the disclosure and therefore should not be considered limiting of the scope of the disclosure. The drawings are intended to depict only typical embodiments of the disclosure and therefore should not be considered as limiting the scope of the disclosure. In the drawings:

[0010] In addition, some of the elements in some of the figures can be omitted or not drawn to scale for the sake of clarity. Cross-sectional views can be in the form of "sliced" or "close-up" cross-sectional views that omit certain background lines for the sake of clarity. In addition, some reference numbers can be omitted from certain drawings for the sake of clarity. DETAILED DESCRIPTION

[0011] Fusible element assemblies and components according to the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which embodiments of systems and methods are shown. The fusible element assemblies and components may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the systems and methods to those skilled in the art.

[0012] The methods herein provide a solution for forming a silicone ring around a fusible element using a silicone jetting process. The silicone jetting process can include a jetting dispenser that repeatedly cycles on and off at a high frequency, thereby breaking the silicone stream into a series of small beads or droplets. The jetting dispenser can accelerate and deliver the silicone droplets onto the fusible element at various angles. This silicone jetting process can be a non-contact and selective silicone formation process.

[0013] Reference Figures 1A-1B An exemplary embodiment of a fuse device / component (hereinafter, "component") 100 according to the present disclosure is shown in FIG. 1. The exemplary component 100 can include one or more fusible elements 110 extending between a first end 112 and a second end 114. The fusible elements 110 can be adapted to be within, for example, a fuse link, but are not so limited. In the exemplary embodiment, the fusible elements 110 are contained within a housing (not shown). Although the fusible elements 110 have a generally rectangular planar shape in the illustrated embodiment, the fusible elements 110 can have any suitable planar shape in other embodiments. Further, the fusible elements 110 can be folded to define any suitable number of segments that are shaped and oriented relative to one another to define any suitable surface profile.

[0014] In some embodiments, each of the fusible elements 110 can include a plurality of solid portions 118 joined together by conductive bridges 120, which can include a set of openings disposed therebetween. In various embodiments, the solid portions 118 and / or the conductive bridges 120 can have the same or a reduced thickness compared to the rest of the fusible elements 110. Further, each of the fusible elements 110 can have a curved or arcuate portion 124. Each of the fusible elements 110 can have portions with a smaller cross-section, and / or regions with a lower melting point, such as tin, silver, lead, nickel, or alloys thereof. Although not shown, the housing can include a filler proximate to the fusible elements 110. Various components of the housing can be made of an insulating material, such as an insulating plastic, for example, nylon, glass-filled nylon, polyester, and polycarbonate.

[0015] During operation of the assembly 100, electrical arcs can be generated along the fusible elements 110. Electrical arcs tend to occur more frequently on the weakened conductive bridges 120. To address these electrical arcs, the assembly 100 can further include a plurality of arc runners or bands 140 formed around the fusible elements 110. As shown, the arc runner bands 140 can be formed along the fusible elements 110 at different points between the first end 112 and the second end 114. In some embodiments, the arc runner bands 140 are formed from a silicone material delivered to the fusible elements 110 via a plasma jet 145. By cycling the plasma jet 145 between an “on” and “off” state to break up the flow of the silicone material, the silicone material can be delivered as a series of droplets 146. As shown, the plasma jet 145 can be spaced apart from the fusible elements 110 such that the deposition is selective and non-contacting.

[0016] During formation of the arc runner bands 140, the fusible elements and / or the plasma jet 145 can be rotated relative to one another such that the silicone material completely encircles the fusible elements 110. For example, the arc runner bands 140 can be formed along each of the upper surface 148, the lower surface 150, and the side surfaces 152. In some embodiments, the silicone material can be delivered while the plasma jet 145 is held in at least four different positions relative to the fusible elements 110. Accordingly, the droplets 146 can be delivered to the fusible elements 110 at a plurality of different angles to ensure the desired formation. The arc runner bands 140 can be generally square, rectangular, or cuboid in shape, but are not limited thereto. In other embodiments, the arc runner bands 140 can be generally cylindrical or disc-shaped.

[0017] In some embodiments, the droplets 146 can be delivered to the fusible element 110 while the silicone material is in its liquid state. Thereafter, the silicone material can then be cured (or otherwise allowed to harden) into a rigid or semi-rigid coating to form the arc runner 140. To not encase too much of the fusible element 110, and thus, not hinder the normal functioning of the fusible element 110, the arc runner 140 can be attached to only one or more selected regions of the fusible element 110.

[0018] As shown in Figure 1A the droplets 146 can be delivered in the negative y direction to form the silicone material on the upper surface 148 of the fusible element 110. As shown in Figure 1B the droplets 146 can be delivered in the positive x / z direction to form the silicone material along the side surface 152 of the fusible element 110. In still other embodiments, the plasma jet 145 can be oriented to deliver the droplets 146 onto the corner portion 158 of the arc runner 140. It should be appreciated that both the plasma jet 145 and the fusible element 110 can be translated, rotated, displaced, etc. relative to one another to direct the formation of the arc runner 140 along the fusible element 110.

[0019] Turning now to Figure 2 a method 200 according to embodiments of the present disclosure will be described. At block 201, the method 200 can include providing a fusible element. In some embodiments, the fusible element can include a plurality of solid portions separated by bridges.

[0020] At block 203, the method 200 can include depositing a silicone material on the fusible element, wherein the silicone material is delivered to the fusible element at a plurality of angles. In some embodiments, the silicone material forms a plurality of bands around the fusible element. In some embodiments, the silicone material is formed along each of: an upper surface of the fusible element, a lower surface of the fusible element, and a side surface of the fusible element. In some embodiments, the silicone material is deposited using a plasma jet. In some embodiments, the method includes cycling the plasma jet between an “on” and an “off” state while depositing the silicone material. In some embodiments, the method can include rotating the plasma jet and the fusible element relative to one another to form the silicone material around the fusible element. In some embodiments, the method can include depositing the silicone material as a series of droplets. In some embodiments, the method can further include spacing the plasma jet from the fusible element while depositing the silicone material. In some embodiments, the method can include delivering the silicone material to the fusible element while the plasma jet is held in each of at least four different positions relative to the fusible element. In some embodiments, the method can include forming the silicone material around the fusible element at a plurality of points between a first end and a second end of the fusible element.

[0021] The above discussion is meant to be illustrative and descriptive only and is not intended to be limiting of the disclosure to the forms disclosed herein. For example, various features of the disclosure can be combined in one or more aspects, embodiments, or configurations of the disclosure for purposes of simplifying the disclosure. However, it is to be understood that the various features of the aspects, embodiments, or configurations of the disclosure can be combined in alternative aspects, embodiments, or configurations of the disclosure. Furthermore, the appended claims are hereby incorporated into this detailed description, where each claim stands as a separate embodiment of the disclosure.

[0022] As used herein, an element or step recited in the singular and preceded with the word "a" or "an" should be understood as not excluding plural elements or steps, unless such exclusion is explicitly recited. Furthermore, references to "one embodiment" are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.

[0023] Use of the word "including" or "containing" or "having" and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Therefore, the terms "including," "containing," or "having" and variations thereof are open-ended expressions and can be used in this document in the same manner as the term "comprising" is used.

[0024] As used herein, the phrases "at least one", "one or more" and "and / or" are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions "at least one of A, B, and C", "at least one of A, B, or C", "one or more of A, B, and C", "one or more of A, B, or C" and "A, B, and / or C" means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B, and C together.

[0025] All directional references (e.g., proximal, distal, upper, lower, upward, downward, left, right, lateral, longitudinal, anterior, posterior, top, bottom, above, below, vertical, horizontal, radial, axial, clockwise, and counterclockwise) are only used for identification purposes to aid the reader's understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of the disclosure. Connection references (e.g., attached, coupled, connected, and joined) are to be construed broadly and will be given their ordinary and accustomed meaning to an artisan of ordinary skill in the art, and will include intermediate members between the elements that are connected and relative movement between elements unless otherwise specified. As such, connection references do not necessarily infer that two elements are directly connected to each other and in fixed relation to each other.

[0026] Furthermore, the identification of references (e.g., primary, secondary, first, second, third, fourth, etc.) is not intended to denote importance or priority, but is used to distinguish one feature from another. The drawings are for purposes of illustration only and the dimensions, positions, order and relative sizes reflected in the drawings attached hereto can differ from actual ones.

[0027] Furthermore, the terms "substantial" or "substantially" and the term "approximately" or "about" can be used in various embodiments and can describe amounts or percentages that are acceptable within manufacturing tolerances, measurement error, or other factor or factors that are acceptable for one of ordinary skill in the art. For example, these terms can be used as a comparison to a reference parameter to indicate a deviation that is capable of providing an intended function. Although not a limitation, the deviation from the reference parameter can be, for example, less than 1%, less than 3%, less than 5%, less than 10%, less than 15%, less than 20%, and the like.

[0028] The scope of the disclosure is not intended to be limited to the particular embodiments described herein. Indeed, a variety of alternatives and modifications can be apparent to those of ordinary skill in the art in view of the foregoing description and accompanying drawings. Accordingly, such alternatives and modifications are intended to fall within the scope of the present disclosure. Further, the disclosure is described, by way of example only, in the context of specific implementations for specific purposes in specific environments. One of ordinary skill in the art will recognize that the usefulness thereof is not so limited and that the disclosure can be beneficially implemented for any purpose in any number of environments. Therefore, the claims set forth below should be construed in view of the full scope of the disclosure as described herein.

Claims

1. A method of forming a fuse assembly, comprising: providing a fusible element; and depositing silicone material on the fusible element as a plurality of individual droplets, wherein the silicone material is delivered to the fusible element at a plurality of angles, and wherein the plurality of individual droplets are formed by cycling a plasma torch between "on" and "off" states multiple times to break up a flow of the silicone material, wherein the method further comprises: rotating the plasma torch and the fusible element relative to each other to form the silicone material around the fusible element; spacing the plasma torch from the fusible element while depositing the silicone material; and delivering the silicone material to the fusible element while the plasma torch is held at each of at least four different positions relative to the fusible element.

2. The method of claim 1, wherein the silicone material is formed along each of: an upper surface of the fusible element, a lower surface of the fusible element, and a side surface of the fusible element.

3. A method for depositing silicone material on a fusible element, comprising: providing the fusible element, the fusible element comprising a series of solid portions connected by bridges; and depositing silicone material on the fusible element as a plurality of individual droplets, wherein the silicone material is delivered to the fusible element at a plurality of angles to form the silicone material along each of: an upper surface of the fusible element, a lower surface of the fusible element, and a side surface of the fusible element, and wherein the plurality of individual droplets are formed by cycling a plasma torch between "on" and "off" states multiple times to break up a flow of the silicone material, wherein the method further comprises: rotating the plasma torch and the fusible element relative to each other to form the silicone material around the fusible element; spacing the plasma torch from the fusible element while depositing the silicone material; and delivering the silicone material to the fusible element while the plasma torch is held at each of at least four different positions relative to the fusible element.

4. The method of claim 3, further comprising forming the silicone material around the fusible element at a plurality of points between a first end and a second end of the fusible element.

5. A method of forming a fuse assembly, comprising: providing a fusible element; and forming an arc suppression band around the fusible element, wherein a material of the arc suppression band is delivered to the fusible element at a plurality of angles, wherein forming the arc suppression band comprises depositing silicone material on the fusible element as a plurality of individual droplets using a plasma torch, wherein the silicone material is deposited while the plasma torch and the fusible element are rotated relative to each other, and wherein the plurality of individual droplets are formed by cycling the plasma torch between "on" and "off" states multiple times to break up a flow of the silicone material, wherein the method further comprises: rotating the plasma torch and the fusible element relative to each other to form the silicone material around the fusible element; spacing the plasma torch from the fusible element while depositing the silicone material; and delivering the silicone material to the fusible element while the plasma torch is held at each of at least four different positions relative to the fusible element. rotating the plasma torch and the fusible element relative to one another to form the silicone material around the fusible element; spacing the plasma torch from the fusible element while depositing the silicone material; and delivering the silicone material to the fusible element while the plasma torch is held at each of at least four different positions relative to the fusible element.

6. The method of claim 5, further comprising forming the arc mitigation band along each of: an upper surface of the fusible element, a lower surface of the fusible element, and a side surface of the fusible element.

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