Battery Fuse Assembly Ignition Protection and Arc Containment
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Solution Overview
Problem
Existing fuse assemblies for storage batteries are susceptible to electrical circumvention and degradation due to ambient particles, leading to potential component damage and lack of ignition protection.
Innovation Solution
A battery fuse assembly with a housing made of heat-resistant materials, such as Polyphenylene Sulfide, that shields the fusible element from ambient particles and includes insulating materials to prevent arc ignition, ensuring reliable operation and protection against rust and corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the ring terminal is brought into contact with the terminal post or mounting stud, then a direct current path is created from the terminal post to the ring terminal, but this causes current to circumvent the fuse and leads to component damage
Solution Approach 1:
An insulating nut is introduced as an intermediary component between the mounting stud and the ring terminal. This insulating nut acts as a mediator that blocks the harmful electrical circumvention path while allowing the mechanical assembly to function. The insulating material in the nut prevents direct electrical contact between conductive parts, thereby protecting the fuse from being bypassed.
2Temperature
If an aperture is disposed between the fault element and the cover to allow ambient air flow, then cooling is improved, but ambient particles can deposit on the fault element causing rust and degradation
Solution Approach 1:
A mesh screen or filter is introduced as a flexible barrier structure that covers the aperture. This thin film structure allows air to pass through for cooling purposes while blocking ambient particles from reaching the fault element. The mesh structure provides selective permeability - allowing thermal energy transfer while preventing particle deposition that would cause rust and degradation.
3Ease of operation
If the fault element is exposed to ambient particles, then access is simplified, but the fault element can rust and degrade due to water and mineral particles
Solution Approach 1:
A mesh screen is positioned to protect the fault element from ambient particles while maintaining accessibility. The mesh structure allows visual inspection and access to the fault element for monitoring purposes while preventing harmful particles from depositing on it. This resolves the contradiction by providing a protective barrier that does not completely seal off the fault element.
4Temperature
If the aperture is open to allow air flow through the fuse, then cooling is enhanced, but the fuse loses ignition protection as sparks can ignite fuel/air mixtures in ambient particles
Solution Approach 1:
A mesh screen or filter is introduced as a protective barrier over the aperture. This thin film structure allows air circulation for thermal management while blocking ambient particles that could form explosive fuel/air mixtures. The mesh prevents sparks from igniting these mixtures, thereby maintaining ignition protection while preserving the cooling function.
Solution Approach 2:
The mesh screen creates a protected environment by preventing harmful ambient particles from entering the fuse interior. While not creating a completely inert atmosphere, the mesh filters out particles that could form explosive mixtures, effectively creating a safer environment that maintains ignition protection while allowing necessary air flow for cooling.
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 solution effectively prevents electrical circumvention and degradation, enhancing the long-term performance and safety of the fuse in marine and other applications by containing arcs and shielding against ambient particles, thus ensuring reliable operation and protection against rust and corrosion.
Implementation Method 1
When electrical current through a fuse exceeds a predetermined limit, the fusible elements melt, disintegrate, fail, or otherwise open to break an electrical and open the electrical circuit associated with the fuse
Implementation Method 2
The housing includes a heat-resistant plastic or another heat-resistant material, such as Polyphenylene Sulfide, configured to contain an arc generated by the fault element in response to the over-current in the circuit. The material is configured to prevent the arc from mixing with ambient particles, thereby making the fuse ignition protected.
Implementation Method 3
The housing also is configured to shield the fusible element from ambient particles, thereby increasing the expected long-term performance of the fusible element. For example, by shielding the fusible element from water and other ambient particles, the housing can protect the fusible element from degradation due to rust, corrosion, etc.
Data Source
AI summary
A fuse includes a fusible element and a body member encased within a heat-resistant housing. The fusible element is configured to open an electrical circuit coupled to a storage battery in response to an over-current in the electrical circuit. The housing is configured to contain an arc generated by the fusible element in response to the over-current and to shield the arc and the fusible element from ambient particles. Thus, the fuse is ignition protected. The body member includes an insulating material configured to interrupt the arc. The housing includes an opening configured to receive a terminal of the storage battery or a terminal of a mounting plate. An insulating material disposed about a first end of the mounting plate terminal is configured to electrically isolate the fuse and a power supply cable in the electrical circuit from the mounting plate terminal.