Terminal-Integrated Chip Fuse Manufacturing Simplification
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing manufacturing process for chip-type fuses with integrally formed fuse and terminals is cumbersome, requiring copper plating, etching, and additional layer formation, making it a complex and time-consuming process.
Innovation Solution
A chip-type fuse design featuring a terminal-integrated fuse with planar members and a casing, where the fuse is positioned between the members, allowing for easy manufacturing by pressing conductive metal, and utilizing an arc suppressing material to enhance thermostability and prevent chemical reactions, with options for sealing the casing to improve performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If copper plating and etching processes are used to form fusible link and pads, then integral formation of fuse and terminals is achieved, but manufacturing complexity increases
Solution Approach 1:
The fuse body and terminal electrodes are merged into a single integral structure formed by one pressing operation from a conductive metal plate, eliminating the need for separate copper plating and etching processes to create these components
Solution Approach 2:
The complex multi-step copper plating and etching processes are extracted and removed from the manufacturing workflow, replacing them with a single pressing operation that directly forms the integral fuse and terminal structure
2Productivity
If additional conductive metal layers are formed by photoetching, then electrical connectivity is enhanced, but manufacturing time increases
Solution Approach 1:
The manufacturing process is segmented into a single pressing operation rather than multiple sequential steps including photoetching, thereby reducing total manufacturing time while maintaining electrical connectivity through the integral structure design
3Ease of manufacture
If protective layer is formed over fusible link and pads, then component protection is achieved, but manufacturing steps increase
Solution Approach 1:
The protective function is merged into the casing structure that houses the terminal-integrated fuse, rather than requiring a separate protective layer formation step, thus maintaining component protection while reducing manufacturing 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
This design simplifies the manufacturing process, enhances thermostability, and allows for the production of reliable fuses with higher rated allowable currents without unnecessary resistive components, resulting in smaller and more efficient fuse designs.
Implementation Method 1
An arc suppressing material portion is provided for the fuse in this casing
Data Source
AI summary
A terminal-integrated fuse (2) includes two planar members (10), (10) serving as terminals for mounting on a substrate. The two planar members (10), (10) are spaced on a same horizontal plane. A fuse body (4) is located on a horizontal plane at a level different from the level of the said horizontal plane and between the planar members (10), (10). The fuse body (4) is formed integral with the planar members (10), (10). A casing (14) has side walls (18), (20) and end walls (22), (24) disposed around an opening. The fuse body (4) is positioned in the casing (14), and the two planar members (10, (10) are in contact with the end walls (22), (24), respectively. An arc suppressing material portion (26) is provided in the casing (14) in such a manner the fuse body (4) is embedded therein.