A combined full-range controllable protection device

Abstract

This application provides a combined full-range controllable protection device, belonging to the field of circuit protection technology, including a trigger, a circuit breaker, and a fuse; the trigger and the circuit breaker are connected in series, and the series-connected trigger and circuit breaker are connected in parallel with the fuse; when the circuit is abnormal, the trigger melts to provide primary protection for the circuit, and the melted trigger also generates an electrical signal and transmits it to the circuit breaker, which cuts off the circuit to provide secondary protection for the circuit. The current flowing through the trigger and the circuit breaker is incorporated into the branch where the fuse is located, causing the fuse to melt, thus forming a three-level protection for the circuit; in this way, multi-level protection is achieved through the trigger, circuit breaker, and fuse. The timing coordination of the multi-level protection actions avoids malfunctions and provides redundant protection in the event of serious faults, thereby maintaining low loss when the circuit is normal, achieving rapid response and reliable disconnection when the circuit is abnormal, and is applicable to the disconnection of high voltage and high current.

Description

Technical Field

[0001] This application belongs to the field of circuit protection technology, and in particular relates to a combined full-range controllable protection device. Background Technology

[0002] In the field of circuit protection, especially in high-voltage, high-current applications, achieving fast and reliable protection against circuit anomalies (overloads or short circuits) while ensuring low losses during normal operation has been a long-standing technical challenge. Traditional protection schemes often employ single protective elements, such as fuses or circuit breakers, but these schemes have significant limitations. While fuses can effectively interrupt abnormal circuits, their response speed is slow, and they may fail to act in time when rapid protection is required, leading to damage to the protected circuit. On the other hand, circuit breakers that use pyrotechnic elements to cut off copper busbars, although with a fast response speed, often cannot interrupt large short-circuit currents, especially in high-voltage, high-inductance applications. Furthermore, existing protection devices typically lack multi-level protection mechanisms, making it difficult to provide full-range protection under complex operating conditions.

[0003] Therefore, there is an urgent need to develop a multi-level protection device that can maintain low losses during normal operation, while responding quickly and reliably cutting off the circuit in the event of a circuit malfunction. Summary of the Invention

[0004] This application provides a combined, full-range controllable protection device to at least solve the aforementioned problems in the related art.

[0005] To achieve the above objectives, this application provides the following technical solution: a combined full-range controllable protection device, the combined full-range controllable protection device comprising a trigger, a circuit breaker, and a fuse;

[0006] The trigger element is connected in series with the circuit breaker, and the series-connected trigger element and circuit breaker are connected in parallel with the fuse;

[0007] When the circuit is normal, a portion of the current flows through the branch where the trigger body and the circuit breaker are located, and another portion of the current flows through the branch where the fuse is located.

[0008] When the circuit malfunctions, the trigger body melts to provide primary protection for the circuit. After melting, the trigger body also generates an electrical signal and transmits it to the circuit breaker. The circuit breaker cuts off the circuit to provide secondary protection. The current flowing through the trigger body and the circuit breaker is incorporated into the branch where the fuse is located, causing the fuse to melt and thus providing tertiary protection for the circuit.

[0009] In some feasible embodiments, the trigger includes a substrate and a tin plating layer, the tin plating layer being bonded to the substrate via a metallurgical effect, the substrate being made of a conductive material.

[0010] In some feasible embodiments, the trigger body is provided with a plurality of through holes that penetrate the trigger body; and / or, the trigger body is provided with a plurality of narrow necks.

[0011] In some feasible embodiments, the resistance ratio of the branch containing the trigger body to the branch containing the fuse is between 1:20 and 1:50.

[0012] In some feasible implementations, the resistance of the circuit containing the fuse is between 2 milliohms and 5 milliohms.

[0013] In some implementable embodiments, the interrupter includes a first copper busbar, a second copper busbar, and an interruption assembly;

[0014] The trigger is connected between the first copper busbar and the second copper busbar;

[0015] The second copper busbar passes through the interrupting assembly, which is used to cut off the second copper busbar.

[0016] In some implementable embodiments, the combined full-range controllable protection device includes a control element electrically connected to the trigger body and used to detect the voltage signal of the trigger body;

[0017] When the circuit is normal, the voltage signal detected by the control element is a normal signal. When the circuit is abnormal, the voltage signal detected by the control element is an abnormal signal, and the control element controls the switching component to cut off the second copper busbar.

[0018] In some implementable embodiments, the second copper busbar has a first groove on the side facing the cutter of the breaking assembly, and the first groove is positioned directly opposite the cutter of the breaking assembly;

[0019] The second copper busbar has a second groove on the side facing away from the cutter of the breaking assembly, and the second groove corresponds to the end corner position of the first groove.

[0020] In some implementable embodiments, the fuse includes a housing and a fusible element;

[0021] The melt is housed within the outer shell, which is filled with an arc-quenching material for covering the melt.

[0022] One end of the melt is connected to the first copper busbar via a conductor, and the other end of the melt is connected to the second copper busbar via a conductor.

[0023] In some feasible embodiments, the combined full-range controllable protection device further includes an insulating housing, which comprises a support plate, an upper housing, and a lower housing;

[0024] The circuit breaker and the fuse are spaced apart along the length of the support plate and are both mounted on the support plate. The support plate is sandwiched between the upper housing and the lower housing, and the upper housing and the lower housing are detachably connected.

[0025] The upper housing, the support plate, and the lower housing form a receiving cavity, which is used to house the trigger, the switch, and the fuse.

[0026] In the aforementioned combined full-range controllable protection device, under normal circuit conditions, the heat loss of the circuit is reduced by parallel current shunting and decreasing the total resistance in the circuit, thereby maintaining low loss during normal operation. When the circuit is abnormal, the trigger element melts first due to a sudden increase in current, which can achieve passive protection of the circuit and also cut off the branch it is in and generate a voltage surge signal. This voltage surge signal is transmitted to the circuit breaker through the line. The circuit breaker cuts off the remaining conductive path, completes secondary protection, and achieves active protection of the circuit. This combination of passive and active protection improves the reliability of the combined full-range controllable protection device. At this time, the current in the branch where the trigger element is located is forced to transfer to the branch where the fuse is located. The total current after superposition surges and exceeds the rated value of the fuse, causing it to melt quickly and form final protection. In this way, multi-level protection is achieved through triggering elements, circuit breakers, and fuses. The timing coordination of the multi-level protection actions not only avoids malfunctions but also provides redundant protection in the event of serious faults. This allows for rapid response and reliable disconnection in the event of circuit abnormalities while maintaining low losses during normal circuit operation, and it is also applicable to the breaking of high voltage and high current.

[0027] It should be understood that the description in this section is not intended to identify key or essential features of the embodiments of this application, nor is it intended to limit the scope of this application. Other features of this application will become readily apparent from the following description. Attached Figure Description

[0028] The above and other objects, features, and advantages of exemplary embodiments of this application will become readily apparent from the following detailed description taken in conjunction with the accompanying drawings. Several embodiments of this application are illustrated in the drawings by way of example and not limitation, wherein:

[0029] In the accompanying drawings, the same or corresponding reference numerals indicate the same or corresponding parts.

[0030] Figure 1 This invention provides a schematic diagram of the structure of the trigger, the circuit breaker, the fuse, and the control element in an embodiment of this application.

[0031] Figure 2 It shows Figure 1 Schematic diagram of the trigger body in the middle;

[0032] Figure 3 It shows Figure 1 Schematic diagram of the structure of the second copper busbar;

[0033] Figure 4 It shows Figure 1 Schematic diagram of the structure of the second copper busbar and the switching assembly;

[0034] Figure 5 It shows Figure 4 Schematic diagram of the drive unit and cutter;

[0035] Figure 6 A schematic diagram of the combined full-range controllable protection device in an embodiment of this application is shown;

[0036] Figure 7 It shows Figure 6 Exploded view of the combined full-range controllable protection device;

[0037] Figure 8 It shows Figure 6 A schematic diagram of the structure of the load-bearing plate.

[0038] The following are the labels in the diagram: 11. Trigger; 111. Through hole; 112. Neck; 12. Breaker; 121. First copper busbar; 122. Second copper busbar; 1221. First groove; 1222. Second groove; 1223. Third groove; 123. Breaking assembly; 1231. Drive element; 1232. Cutter; 1233. Arc extinguishing groove; 1234. Support platform; 13. Fuse; 14. Control element; 15. Insulating housing; 151. Bearing plate; 1511. First mounting hole; 1512. Second mounting hole; 152. Upper housing; 153. Lower housing. Detailed Implementation

[0039] To make the objectives, features, and advantages of this application more apparent and understandable, the technical solutions in the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0040] It should be understood that the various forms of processes shown above can be used to rearrange, add, or delete steps. For example, the steps described in this application can be executed in parallel, sequentially, or in different orders, as long as the desired result of the technical solution of this application can be achieved, and this is not limited herein.

[0041] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "a plurality of" means two or more, unless otherwise explicitly specified.

[0042] In existing technologies, combined full-range controllable protection devices typically rely on a single component to provide protection against circuit anomalies (in this application, circuit anomalies generally refer to the phenomenon of a sudden increase in circuit current caused by overload or short circuit), such as fuses or thermal switches. These devices may experience additional losses during normal operation due to the component's own impedance, and during circuit anomalies, insufficient response speed leads to protection delays. When a circuit needs to balance low loss and fast tripping, existing technologies often require trade-offs between the two protection mechanisms, failing to simultaneously meet the performance requirements under different operating conditions. For example, in electric vehicle charging systems, the main circuit needs to withstand continuous high current transmission while also requiring millisecond-level tripping in the event of a circuit anomaly; traditional protection schemes struggle to balance the contradiction between low impedance and fast action.

[0043] To address the aforementioned issues, the inventors observed that a single protection element could not simultaneously meet the requirements of low loss under normal conditions and rapid disconnection under abnormal conditions. Therefore, they explored the possibility of multi-level coordinated protection. By analyzing the current shunting principle, they discovered that parallel branches can share the current load under normal operating conditions, while the series triggering mechanism enables rapid transmission of abnormal signals. Further considering the combination of fuses and active disconnection devices, they proposed a topology that connects the trigger element and the circuit breaker in series, followed by parallel connection with the fuse. This structure allows for normal current shunting to reduce losses; under abnormal conditions, the fuse element melts to generate an electrical signal, triggering the circuit breaker to perform active disconnection, and finally, the fuse provides backup protection, forming a progressively enhanced protection mechanism.

[0044] Therefore, please combine Figure 1This application proposes a combined full-range controllable protection device comprising a trigger element 11, a circuit breaker 12, and a fuse 13. The trigger element 11 and the circuit breaker 12 are connected in series, and the series-connected trigger element 11 and circuit breaker 12 are connected in parallel with the fuse 13. Under normal circuit conditions, a portion of the current flows through the branch containing the trigger element 11 and the circuit breaker 12, while another portion flows through the branch containing the fuse 13. In the event of a circuit malfunction (e.g., short circuit or overload), the trigger element 11 melts to provide primary protection. The melted trigger element 11 also generates an electrical signal, which is transmitted to the circuit breaker 12. The circuit breaker 12 then cuts off the circuit to provide secondary protection. The current flowing through the trigger element 11 and the circuit breaker 12 is incorporated into the branch containing the fuse 13, causing the fuse 13 to melt, thus providing tertiary protection. The trigger element 11 can both provide primary protection and generate a trigger signal for secondary protection, facilitating a rapid response from the circuit breaker 12.

[0045] In the aforementioned combined full-range controllable protection device, under normal circuit conditions, the heat loss of the circuit is reduced by parallel current shunting and the total resistance in the circuit is decreased, thereby maintaining low loss during normal operation. When the circuit is abnormal, the trigger 11 melts first due to a sudden increase in current, which can achieve passive protection of the circuit and also cut off the branch it is in and generate a voltage surge signal. This voltage surge signal is transmitted to the circuit breaker 12 through the line. The circuit breaker 12 cuts off the remaining conductive path, completes secondary protection, and achieves active protection of the circuit. This combination of passive and active protection improves the reliability of the combined full-range controllable protection device. At this time, the current in the branch where the trigger 11 is located is forced to transfer to the branch where the fuse 13 is located. The total current after superposition surges and exceeds the rated value of the fuse 13, causing it to melt quickly and form final protection. Thus, multi-level protection is achieved through the trigger body 11, the circuit breaker 12 and the fuse 13. The timing coordination of the multi-level protection actions not only avoids malfunctions, but also provides redundant protection in the event of a serious fault. This allows for rapid response and reliable disconnection in the event of a circuit abnormal while maintaining low losses when the circuit is normal, and is also applicable to the disconnection of high voltage and high current.

[0046] In some embodiments, the trigger 11 includes a substrate and a tin-plated layer, the tin-plated layer being bonded to the substrate via a metallurgical effect. The substrate is made of a conductive material and is used to guide the flow of current with low resistance. Exemplarily, the tin-plated layer can be bonded to the substrate via a tin-plating process to achieve a metallurgical effect.

[0047] In this way, the substrate, as the main body for current conduction, achieves low impedance conduction through highly conductive materials when the circuit is working normally. The metallurgical interface between the tin plating layer and the substrate forms a continuous conductive channel, avoiding the interface gaps present in traditional physical plating layers. When the circuit is abnormal, the tin plating layer melts first due to its lower melting point. The metallurgical interface generates a stable electric arc during the melting process, ensuring that a sufficiently strong electrical signal is generated when the circuit is broken.

[0048] It is understandable that the metallurgical effect refers to the metallurgical bond formed by the mutual diffusion of metal atoms at the interface. Specifically, it can be achieved by controlling the plating temperature in the range of 250℃-400℃, so that tin atoms and substrate metal atoms form a solid solution structure.

[0049] In some alternative embodiments, the substrate is made of silver, which has a melting point of about 961.8°C; or the substrate is made of copper, which has a melting point of about 1085°C; wherein tin has a melting point of about 232°C.

[0050] It should be noted that the substrate materials listed above are merely examples, and this application does not limit the specific materials of the substrate, as long as they can meet the requirements of good electrical conductivity.

[0051] When the circuit is normal, the substrate has good conductivity, enabling low-impedance current conduction and thus high-current transmission. When the circuit is abnormal, the tin plating layer has a lower melting point, so the tin plating layer will melt before the substrate. Before the substrate is completely melted, the voltage across the trigger 11 will jump and form an abnormal signal, which will then be transmitted to the circuit breaker 12 so that the circuit breaker 12 can quickly receive the abnormal signal and cut off the remaining circuit. This further improves the ability to maintain low loss during normal operation and to respond quickly and reliably cut off the circuit when the circuit is abnormal.

[0052] Please combine Figure 2 In some embodiments, the trigger body 11 has multiple through holes 111 through the trigger body 11; and / or, the trigger body 11 has a partially narrowed neck 112. That is, the trigger body 11 has only multiple through holes 111; or, the trigger body 11 has only a neck 112; or, the trigger body 11 has both multiple through holes 111 and a neck 112.

[0053] Thus, when the trigger 11 is in normal operating condition, the current is conducted through multiple paths around the via 111, keeping the current density per unit area within a safe threshold and reducing overall resistance loss. When a circuit malfunction occurs, the current path at the edge of the via 111 forms a local high-density region due to geometric abrupt changes, causing Joule heating to occur preferentially in this region and leading to melting. For the narrow neck 112 structure, its narrowed conductive cross-section forms a resistance abrupt change point when the circuit malfunctions, and heat accumulates rapidly at the narrow neck 112, reaching the melting threshold. Both structures can be used individually or in combination, maintaining low resistance characteristics under normal operating conditions while guiding the trigger 11 to melt directionally through geometric structures.

[0054] Preferably, the trigger body 11 is provided with multiple through holes 111 and a narrow neck 112, and the multiple through holes 111 are located in the narrow neck 112 region of the trigger body 11 to form a linear fusing region, thereby achieving rapid fusing.

[0055] Specifically, there can be multiple fusing areas. The fusing areas formed on the trigger body 11 are arranged at intervals, and each group of fusing areas includes multiple through holes 111 and narrow necks 112.

[0056] Preferably, the through hole 111 can be elliptical, circular, or strip-shaped.

[0057] This application maintains low resistance during the normal conduction phase of the trigger body 11, and achieves millisecond-level fuse response through structurally guided current path abrupt change during the circuit abnormal phase. This solves the contradiction between low loss and fast protection in traditional solutions, while avoiding the reliability degradation caused by adding low-melting-point materials.

[0058] Preferably, the through hole 111 is a hole structure that penetrates the thickness direction of the trigger body 11. Specifically, it can be achieved by stamping or laser cutting. By changing the current conduction path distribution inside the trigger body 11, a local current concentration area is formed.

[0059] Preferably, the narrow neck 112 is a narrowed cross-section area formed on the surface of the trigger body 11, which can be achieved by chemical etching or mechanical processing. By using a weak point with a preset conductive cross-sectional area, the current is guided to form a Joule heating effect at a specific location.

[0060] In some embodiments, the resistance ratio of the branch where the trigger body 11 is located to the resistance ratio of the branch where the fuse 13 is located is between 1:20 and 1:50.

[0061] Thus, during normal circuit operation, because the resistance of the trigger element 11 branch is significantly lower than that of the fuse 13 branch, the current mainly flows to the trigger element 11 branch, thereby reducing the conduction loss of the trigger element 11 branch and further reducing energy loss. When the circuit malfunctions, the trigger element 11 overheats and melts, causing its branch resistance to rise sharply. At this time, the current is forced to be transferred entirely to the fuse 13 branch. The low resistance characteristic of the fuse 13 branch causes the current to rapidly increase to the fusing threshold, thereby triggering the fuse 13 to cut off the circuit. This resistance ratio configuration ensures low-energy operation under normal conditions and provides the necessary physical conditions for current transfer under abnormal conditions.

[0062] This application achieves automatic switching of current paths and coordinated triggering of multi-level protection mechanisms by precisely defining the resistance ratio of the two branches without adding complex control circuits. It effectively reduces the energy loss of the trigger body 11 branch during normal operation, while ensuring that the current can be quickly transferred to the fuse 13 branch under abnormal conditions. By combining the resistance ratio with the physical characteristics of the protection device, a progressive protection sequence is formed, which solves the technical contradiction of low loss and fast response that is difficult to balance in traditional solutions.

[0063] Preferably, the resistance of the branch where the trigger body 11 is located is the total impedance of the current path formed by the trigger body 11 and its connecting conductors (i.e., the first copper busbar 121 and the second copper busbar 122). Specifically, this can be achieved by adjusting the material thickness of the trigger body 11 or by adding a parallel conductive structure. This design is used to ensure the proportion of current flowing through the branch of the trigger body 11 under normal operating conditions.

[0064] Preferably, the resistance of the branch where the fuse 13 is located refers to the total impedance of the current path formed by the fuse 13 and its connecting conductors (that is, the conductors at both ends of the fuse 13 connected to the first copper busbar 121 and the second copper busbar 122 respectively). Specifically, this can be achieved by selecting a low-resistance fuse material or optimizing the conductor cross-sectional area. This design forms a low-impedance characteristic in the branch where the fuse 13 is located, which provides a low-impedance path for the current transferred to the branch where the fuse 13 is located after the circuit is abnormal and the branch where the trigger body 11 is located is cut off, so that the current in the branch where the fuse 13 is located can quickly reach the fusing threshold of the fuse 13, thereby accelerating the fusing action of the fuse 13.

[0065] In some embodiments, the resistance of the circuit containing fuse 13 is between 2 milliohms and 5 milliohms, so as to ensure that fuse 13 can melt in time during abnormal current and reduce energy loss during normal circuit. When the resistance of fuse 13 is less than 2 milliohms, the low resistance of fuse 13 cannot heat up and melt quickly. When the resistance of fuse 13 is greater than 5 milliohms, the energy loss of the branch containing fuse 13 is large.

[0066] Thus, during normal circuit operation, the low resistance of fuse branch 13 allows it to form a parallel current-sharing relationship with trigger branch 11. Since the resistance of trigger branch 11 is set to 20 to 50 times that of fuse branch 13, it carries the majority of the current, while fuse branch 13 carries only a very small proportion. When a circuit abnormality occurs, trigger branch 11 melts due to overcurrent, forcing all current to transfer to fuse branch 13. The low resistance of fuse branch 13 ensures that the transferred current quickly reaches its fusing threshold, thereby immediately executing tertiary protection after trigger branch 11 completes secondary protection.

[0067] Please combine Figure 1In some embodiments, the interruptor 12 includes a first copper busbar 121, a second copper busbar 122, and an interruption component 123; a trigger 11 is connected between the first copper busbar 121 and the second copper busbar 122; the second copper busbar 122 passes through the interruption component 123, and the interruption component 123 is used to cut off the second copper busbar 122.

[0068] When the circuit is normal, the current forms a low-impedance path through the first copper busbar 121, the trigger element 11, and the second copper busbar 122, and the switching component 123 is in a non-operating state. When a circuit abnormality occurs, the trigger element 11 melts due to the Joule heating effect, generating a jump voltage across its terminals. This jump voltage is directly conducted to the control circuit of the switching component 123, triggering the switching component 123 to drive its cutter 1232 to cut off the second copper busbar 122 at a preset position. After the second copper busbar 122 is cut off, the current originally flowing through the trigger element 11 branch is forced to transfer to the fuse 13 branch, causing the fuse 13 to complete its melting action within a preset time; at the same time, the physical cutting method of the switching component 123 on the copper busbar eliminates the risk of electromagnetic relay contact sticking.

[0069] Please combine Figure 1 In some embodiments, the combined full-range controllable protection device includes a control element 14, which is electrically connected to the trigger body 11 and is used to detect the voltage signal of the trigger body 11. When the circuit is normal, the voltage signal detected by the control element 14 is a normal signal. When the circuit is abnormal, a jump voltage is generated at both ends of the trigger body 11, forming an abnormal signal. The control element 14 detects the abnormal signal and controls the switching component 123 to cut off the second copper busbar 122. For example, the control element 14 can be a microcontroller or a voltage comparator to detect the voltage state at both ends of the trigger body 11 and determine whether to trigger protection according to preset logic.

[0070] When the circuit is operating normally, the trigger 11 remains in a conducting state, and the voltage across its terminals is within the normal signal range. The control element 14 maintains the stationary state of the switching component 123 by continuously monitoring this voltage signal. When a circuit abnormality occurs, the trigger 11 melts due to excessive current, causing a sudden change in its voltage. The control element 14 identifies this abnormal signal through its built-in voltage comparison circuit and immediately sends a drive signal to the switching component 123. Upon receiving the signal, the switching component 123 drives the cutter 1232 to quickly cut off the second copper busbar 122, allowing the current to be completely transferred to the fuse 13 branch.

[0071] Thus, this application can accurately identify the fuse-broken state of the trigger 11, avoiding misjudgment or delay caused by signal interference; through the linkage mechanism between the control element 14 and the switching component 123, it ensures that the secondary protection starts immediately after the trigger 11 completes the primary protection; at the same time, by utilizing the active monitoring method of voltage signals, it achieves highly reliable judgment and rapid disconnection of abnormal circuit states while maintaining low power consumption operation. This solves the problem that traditional solutions usually rely on the physical signal generated after the trigger 11 fuses to directly drive the switching component 123, such as through current changes at the moment of fuse breaking or mechanical linkage to trigger disconnection. Such methods are easily affected by line impedance or mechanical delay, which can easily cause secondary protection response lag and slow down the response speed.

[0072] In some embodiments, the control element 14 is also connected to an external circuit via a conductor. When the voltage signal of the external circuit is abnormal, the control element 14 controls the interruption assembly 123 to cut off the second copper busbar 122. In this way, the interruptor 12 can also achieve external triggering and cooperate with the triggering structure of the trigger body 11 to achieve internal and external dual triggering, thereby further improving the reliability of the combined full-range controllable protection device.

[0073] Please combine Figure 3 In some embodiments, the side of the second copper busbar 122 facing the cutter 1232 of the breaking assembly 123 is provided with a first groove 1221, and the first groove 1221 is directly opposite to the cutter 1232 of the breaking assembly 123; the side of the second copper busbar 122 away from the cutter 1232 of the breaking assembly 123 is provided with a second groove 1222, and the end corner position of the second groove 1222 corresponds to that of the first groove 1221.

[0074] Thus, when the cutter 1232 of the cutting assembly 123 presses down, the blade first embeds itself in the first groove 1221. Due to the reduced thickness of the copper busbar at this location, the required cutting force is significantly reduced. As the cutter 1232 continues to penetrate deeper, the area corresponding to the second groove 1222 on the back of the copper busbar undergoes tensile deformation due to material extension. At this point, stress concentration lines are formed at the corners of the first groove 1221 and the second groove 1222, and the second copper busbar 122 breaks along a predetermined path under the action of mechanical stress. The synergistic effect of the two grooves ensures a smooth cutting process, thereby guaranteeing the reliability of the cutting of the second copper busbar 122.

[0075] It is understandable that the first groove 1221 refers to the groove structure set on the contact surface of the copper busbar facing the cutter 1232. Its function is to reduce the cutting resistance by locally thinning the copper busbar to form a predetermined weak area. The second groove 1222 refers to the groove structure set on the back of the copper busbar. Its function is to form a stress concentration point with the first groove 1221, and to promote the fracture integrity of the copper busbar during the cutting process through bidirectional structural weakening.

[0076] Preferably, there are two second grooves 1222, and the first groove 1221 has two end corner positions. Each second groove 1222 is located at the end corner position of a corresponding first groove 1221.

[0077] In some embodiments, the fuse 13 includes a housing and a fusible element; the fusible element is housed within the housing, which is filled with an arc-quenching material for covering the fusible element; one end of the fusible element is connected to a first copper busbar 121 via a conductor, and the other end of the fusible element is connected to a second copper busbar 122 via a conductor. Exemplarily, the housing of the fuse 13 may be made of insulating plastic or ceramic material.

[0078] Thus, by combining a sealed shell with composite arc-extinguishing materials, multi-stage dissipation of arc energy is achieved within the same volume. At the same time, the conductor connection structure balances conductivity and assembly reliability within a limited space, solving the protection failure problem caused by arc propagation in traditional fuses 13. Furthermore, the arc generated when the trigger body 11 melts and when the circuit breaker 12 cuts the second copper busbar 122 can be transferred to the molten metal through the conductor and extinguished by the arc-extinguishing material, thereby minimizing the damage caused by arcs in the combined full-range controllable protection device.

[0079] Preferably, the arc-extinguishing material is a granular or powdered medium filled inside the shell, such as quartz sand or spherical steel wire.

[0080] In some embodiments, the interruption component 123 refers to an active interruption device with electrical signal response capability. Specifically, it can be an electromagnetically driven knife switch or an explosive cutter, and its cutter needs to be aligned with the preset interruption position (i.e., the first groove 1221) on the second copper busbar 122. This application does not limit the specific structure of the interruptor 12. As long as the interruptor 12 can receive the voltage change signal generated when the trigger body 11 melts, the interruptor 12 that performs the mechanical interruption action should be included in the protection scope of this application.

[0081] Please combine Figure 4 and Figure 5In some optional embodiments, the interruption assembly 123 includes a drive member 1231, a cutter 1232, and an arc-extinguishing groove 1233. A gap exists in the height direction between the drive member 1231 and the arc-extinguishing groove 1233 to allow the second copper busbar 122 to pass through horizontally. The cutter 1232 is connected to the drive member 1231, and the drive member 1231 drives the cutter 1232 to cut the second copper busbar 122. The drive member 1231 and the cutter 1232 are located on one side of the second copper busbar 122, and the arc-extinguishing groove 1233 is located on the other side of the copper busbar. The cutter 1232 cuts the second copper busbar 122 along its thickness direction. The arc-extinguishing groove 1233 extinguishes the arc through an internally filled arc-extinguishing material. Exemplarily, the drive member 1231 can be a gas generator, an explosive generator, or an electromagnetic drive device.

[0082] Please combine Figure 4 and Figure 5 In some preferred embodiments, the cutter 1232 includes two blades, which are spaced apart along the length of the second copper busbar 122 and face one side of the second copper busbar 122. A support platform 1234 is provided in the arc-extinguishing groove 1233. The support platform 1234 is connected to the groove wall of the arc-extinguishing groove 1233 and abuts against the other side of the second copper busbar 122. The support platform 1234 and the two blades are arranged along the length of the second copper busbar 122 and are located between the two blades. The drive member 1231 is detachably connected to the arc-extinguishing groove 1233 by a stud to facilitate the quick installation of the breaking assembly 123 onto the support plate 151. Thus, when the two blades cut the second copper busbar 122 at the two sides of the support platform 1234, the two blades provide an impact force in the direction of the arc extinguishing groove 1233, and the support platform 1234 can provide a reverse impact force on the second copper busbar 122. The two impact forces are superimposed, making it easier to cut the second copper busbar 122, thereby further improving the breaking reliability of the circuit breaker.

[0083] Please combine Figure 4 and Figure 5 In some preferred embodiments, the second copper busbar 122 is further provided with two third grooves 1223 on the side facing the support platform 1234. The two third grooves 1223 are located on opposite sides of the support platform 1234 along the length of the second copper busbar 122 and are arranged close to the support platform 1234. In this way, when the support platform 1234 provides a reverse impact force to the second copper busbar 122, the third grooves 1223 create a thinning area in the second copper busbar, which helps to further reduce the cutting force required for the second copper busbar 122, thereby further improving the cutting reliability.

[0084] Please combine Figure 6 and Figure 7In some embodiments, the combined full-range controllable protection device further includes an insulating housing 15, which includes a support plate 151, an upper housing 152, and a lower housing 153. A circuit breaker 12 and a fuse 13 are spaced apart along the length of the support plate 151 and are both mounted on the support plate 151. The support plate 151 is sandwiched between the upper housing 152 and the lower housing 153, which are detachably connected, specifically by bolts. The upper housing 152, the support plate 151, and the lower housing 153 form a receiving cavity for housing the trigger 11, the circuit breaker 12, and the fuse 13. Exemplarily, the support plate 151, the upper housing 152, and the lower housing 153 can be made of insulating plastic or ceramic material.

[0085] Thus, the split-shell design allows the upper shell 152 and lower shell 153 to be disassembled independently. During maintenance, only partial disconnection is required to operate on specific components, while the remaining components remain fixed. Simultaneously, the support plate 151 serves as an independent mounting base, enabling the assembly of the circuit breaker 12 and fuse 13 to be completed separately before shell assembly, thus enhancing the modularity of the production process.

[0086] Please combine Figure 8 In some embodiments, the carrier plate 151 is provided with a first mounting hole 1511 and a second mounting hole 1512 that are interconnected. The first mounting hole 1511 extends along the length direction of the carrier plate 151 and passes through the carrier plate 151. The second mounting hole 1512 extends along the thickness direction of the carrier plate 151 and passes through the carrier plate 151. The first copper busbar 121 is inserted into the second mounting hole 1512 along one end of the first mounting hole 1511. The second copper busbar 122 is inserted into the second mounting hole 1512 along the other end of the first mounting hole 1511, so that the first copper busbar 121 and the second copper busbar 122 meet inside the second mounting hole 1512. The trigger body 11 is located inside the second mounting hole 1512 and is connected between the first copper busbar 121 and the second copper busbar 122.

[0087] Thus, the first copper busbar 121 and the second copper busbar 122 are positioned in the thickness and width directions of the support plate 151 through the first mounting hole 1511, and the spacing is adjusted in the length direction of the support plate 151 to facilitate precise docking of the trigger body 11 between the first copper busbar 121 and the second copper busbar 122, improving the installation accuracy and convenience of the trigger body 11. At the same time, the insulation of the support plate 151 can be used to cover and protect the first copper busbar 121 and the second copper busbar 122, preventing displacement or bending of the trigger body 11, the first copper busbar 121 and the second copper busbar 122 due to circuit vibration and external impact. In addition, the second mounting hole 1512 can make the trigger body 11 visible for inspection, which can significantly shorten the troubleshooting time.

[0088] Preferably, the trigger body 11 can be fixed to the first copper busbar 121 and the second copper busbar 122 by welding.

[0089] Preferably, after the first copper busbar 121 is inserted into the second mounting hole 1512 along one end of the first mounting hole 1511, it is fixedly connected to the carrier plate 151 by screws.

[0090] Preferably, after the second copper busbar 122 is inserted into the second mounting hole 1512 along the other end of the first mounting hole 1511, it is fixedly connected to the carrier plate 151 by screws.

[0091] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A combined full-range controllable protection device, characterized in that, The combined full-range controllable protection device comprises a trigger body, a breaker and a fuse; The trigger body and the breaker are connected in series, and the trigger body and the breaker connected in series are connected in parallel with the fuse; When the circuit is normal, part of the current flows through the branch where the trigger body and the breaker are located, and the other part of the current flows through the branch where the fuse is located; When the circuit is abnormal, the trigger body is fused to provide primary protection for the circuit, the fused trigger body further generates an electrical signal and transmits it to the breaker, the breaker cuts off the circuit to provide secondary protection for the circuit, the current flowing through the trigger body and the breaker is merged into the branch where the fuse is located, and the fuse is fused to provide tertiary protection for the circuit; The breaker comprises a first copper bar, a second copper bar and a breaking assembly, the trigger body is connected between the first copper bar and the second copper bar, the second copper bar passes through the breaking assembly, and the breaking assembly is used to cut off the second copper bar.

2. The combined full-range controllable protection device according to claim 1, wherein The trigger body comprises a base material and a tin plating layer, the tin plating layer is combined with the base material through metallurgical effect, and the base material is made of conductive material.

3. The combined full-range controllable protection device according to claim 2, wherein A plurality of through holes are arranged on the trigger body, and the through holes penetrate the trigger body; and / or A plurality of narrow necks are arranged on the trigger body.

4. The combination full-range controllable protector of claim 1, wherein, The resistance of the branch where the trigger body is located is 1:20 to 1:50 times the resistance of the branch where the fuse is located.

5. The combination full-range controllable protector of claim 4, wherein, The resistance of the circuit where the fuse is located is 2 to 5 milliohms.

6. The combination full-range controllable protector of claim 1, wherein, The combined full-range controllable protection device comprises a control element, the control element is electrically connected to the trigger body and is used to detect the voltage signal of the trigger body; When the circuit is normal, the voltage signal detected by the control element is a normal signal, when the circuit is abnormal, the voltage signal detected by the control element is an abnormal signal, and the control element controls the breaking assembly to cut off the second copper bar.

7. The combination full-range controllable protector of claim 1, wherein, One side of the second copper bar facing the cutter of the breaking assembly is provided with a first groove, and the first groove is arranged opposite to the cutter of the breaking assembly; The other side of the second copper bar away from the cutter of the breaking assembly is provided with a second groove, and the second groove corresponds to the end angle position of the first groove.

8. The combination full-range controllable protector of claim 1, wherein, The fuse comprises a shell and a fuse body; The fuse body is received in the shell, and the shell is filled with arc extinguishing material for covering the fuse body; One end of the fuse body is connected to the first copper bar through a conductor, and the other end of the fuse body is connected to the second copper bar through a conductor.

9. The combination full-range controllable protector of claim 1, wherein, The combined full-range controllable protection device further comprises an insulating housing, the insulating housing comprises a bearing plate, an upper housing and a lower housing; The breaker and the fuse are arranged at intervals along the length direction of the bearing plate and are both mounted on the bearing plate, the bearing plate is clamped between the upper housing and the lower housing, and the upper housing and the lower housing are detachably connected; wherein The upper shell, the bearing plate and the lower shell surround a containing cavity for accommodating the trigger body, the breaker and the fuse.

Images