Air Split Fuse With Segmented Arc Barriers
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Solution Overview
Problem
High-voltage applications require fuses with high breaking capacities and effective arc quenching to prevent damage to metal and plastic components, which existing fuses often fail to achieve without causing extensive damage.
Innovation Solution
A circuit protection device with a housing containing first and second arc barriers and a fuse element that traverses over and under these barriers, surrounded by air and filled with an arc-quenching material, such as quartz sand or ceramic powders, to prevent arcing and enhance breaking capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fuse is designed for high-voltage applications with high breaking capacity, then arc quenching effectiveness is improved, but device complexity increases
Solution Approach 1:
The housing is divided into a first housing portion and a second housing portion that can be separated, allowing the fuse element to be accessed and replaced without removing the entire fuse device. Arc barriers are positioned to segment the cavity into multiple regions, controlling arc propagation paths independently.
Solution Approach 2:
The fuse element is nested within the housing cavity and can be electrically connected to terminals through direct contact or welding. The arc barriers are positioned within the cavity to create nested protective structures around the fuse element.
2Object-affected harmful factors
If arc barriers are added to prevent arcing, then protection of metal and plastic portions is improved, but manufacturing complexity increases
Solution Approach 1:
Arc barriers are strategically positioned only in specific regions where arc propagation is most likely to occur, rather than providing uniform protection throughout the entire housing. This localized approach reduces material usage and manufacturing complexity while maintaining effective arc quenching where needed.
Solution Approach 2:
The housing can be constructed from composite materials or multi-layer structures that combine different properties (e.g., electrical insulation, mechanical strength, heat resistance) in a single integrated component, reducing the number of separate parts and assembly steps.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device effectively prevents arcing and reduces damage during overcurrent conditions, achieving a breaking capacity of greater than 350 volts direct current while maintaining a compact design suitable for automotive environments.
Implementation Method 1
a portion of the cavity can be filled with an arc-quenching material
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
A circuit protection device including a housing having a top section mounted to a bottom section, a first arc barrier extending from the bottom section, a second arc barrier extending from the top section, the top and bottom sections mounted together to define a cavity between the first arc barrier separated a distance from the second arc barrier, a first terminal and a second terminal secured to the bottom section, and a fuse element comprising a body of metallic material arranged in one of a plurality of geometric configurations mounted within the top section and the bottom section of the housing, extending through the first arc barrier and the second arc barrier and connected to the first and second terminals, wherein the first and second arc barriers resist arcing upon activation of the fuse and the fuse element melts upon occurrence of an overcurrent condition.