Coiled Fuse Element Structure for Faster Arc Quenching
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Solution Overview
Problem
Existing fuses face challenges in quickly extinguishing arcs formed during overcurrent conditions and require cost-effective manufacturing with reduced components and steps, especially as they shrink in size to accommodate smaller electrical circuits.
Innovation Solution
A fuse design featuring a coiled fusible element with diagonal central wire, which enhances thermal cycling reliability, mechanical bonding, and arc confinement through magnetic fields, allowing for higher surge current handling and faster arc quenching using arc quenching materials like silicone.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional straight fusible elements are used, then manufacturing is simpler, but arc extinguishing capability is insufficient
Solution Approach 1:
The fusible element is formed into a coiled configuration instead of a straight wire, creating curvature that increases the path length and improves arc extinguishing capability through extended arc path and better arc quenching material interaction
2Adaptability or versatility
If fuse size is reduced to accommodate smaller circuits, then adaptability improves, but manufacturing cost reduction becomes more difficult
Solution Approach 1:
The coiled fusible element is nested within the fuse body, allowing the fuse to maintain functional performance in a compact size. The coil structure fits efficiently within the available space, enabling smaller overall fuse dimensions while preserving arc extinguishing capabilities
Solution Approach 2:
The fusible element is integrated directly into the fuse body without requiring separate arc quenching chambers or additional components. The coil structure itself serves both as the current-carrying element and as a means to generate magnetic fields for arc control, reducing total component count
3Reliability
If coiled fusible element is used, then arc extinguishing capability improves, but manufacturing complexity increases
Solution Approach 1:
The coiled fusible element generates its own magnetic field during operation, which automatically confines and controls the arc without requiring external magnetic shielding or additional arc control components. The structure serves its own arc containment needs through electromagnetic induction
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 coiled fusible element design improves arc extinguishing capabilities, increases surge current handling capacity, and reduces manufacturing complexity while ensuring faster and safer operation in high surge applications.
Implementation Method 1
the coiled fusible element promotes robust element-termination bonding/connection beneficial for thermal cycling reliability
Implementation Method 2
When an overcurrent condition occurs, an arc may be formed between the melted portions of the fusible element
Implementation Method 3
the fusible element melts or otherwise opens to interrupt the circuit path
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A fuse 100 includes a body 102 including a center portion 132 extending between a first end 106 and a second end 110, and a first endcap 104 surrounding the first end and a second endcap 108 surrounding the second end. A fusible element 120 is disposed within a central cavity of the body 102, wherein the fusible element includes a first coil 122 disposed within the first endcap 104 and a second coil 124 disposed within the second endcap 108. The fusible element further includes a central wire 128 extending diagonally between the first and second coils. Solder 130 may be disposed between the first end and the first endcap, and between the second end and the second endcap. In case of a solderless design, the coiled free ends of the fusible element provide a good mechanical bond with mechanical structures of the endcaps such as tubes (234, 236).