Compact High Voltage Fuse Using Silicated Quartz Sand
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Solution Overview
Problem
High voltage electrical power systems in electric vehicles require smaller, lighter, and more cost-effective circuit protection fuses that can handle high currents and voltages while maintaining effective interruption performance, which is challenging for conventional fuses due to their larger size and weight.
Innovation Solution
The development of a compact high voltage power fuse with a smaller physical package size, utilizing a silicated quartz sand filler material and unique fuse element geometry to achieve higher power handling capacity, full-range time-current operation, and longer service life, along with arc extinguishing features to reduce arcing and material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fuse designs are used to handle high voltage and high current, then the fuse can provide adequate circuit protection, but the fuse size and weight increase significantly
Solution Approach 1:
The patent changes the physical and chemical parameters of the filler material by using silicated quartz sand instead of conventional filler materials. This parameter change allows for more efficient arc extinction and heat dissipation, enabling the fuse to maintain high voltage and current handling capabilities with reduced size and weight
Solution Approach 2:
The patent employs composite materials by combining silicated quartz sand with specific binder materials to create a filler composite that optimizes both arc extinction performance and thermal management. This composite structure allows the fuse to achieve superior protection performance in a more compact form factor
2Reliability
If conventional fuse designs are used to handle high voltage and high current, then the fuse can provide adequate circuit protection, but the fuse physical size increases
Solution Approach 1:
The patent modifies the filler material parameters by using silicated quartz sand with specific particle size distributions and silication treatments. These parameter changes improve arc channel confinement and extinction efficiency, allowing the fuse to maintain high voltage interrupting capability in a reduced volume
Solution Approach 2:
The patent applies local quality optimization by strategically positioning fuse elements, filler materials, and arc extinguishing structures within the fuse body. This localized optimization ensures that critical protection functions are concentrated in specific regions, reducing overall fuse volume while maintaining performance
3Volume of moving object
If compact fuse design is implemented to reduce size and volume, then the fuse meets space constraints, but handling high currents and voltages becomes challenging
Solution Approach 1:
The patent uses parameter changes in the silicated quartz sand filler, including particle size, shape, and silication degree, to optimize dielectric strength and arc extinction properties. These changes enable the compact fuse body to withstand high voltage stresses and extinguish arcs effectively despite reduced dimensions
Solution Approach 2:
The patent incorporates preliminary arc extinguishing features and filler material configurations that are pre-designed to handle high voltage and current stresses. The silicated quartz sand is pre-positioned and pre-silicated to create optimal arc channel conditions before fault occurrence, enabling the compact fuse to reliably interrupt high power faults
4Volume of moving object
If compact fuse design is implemented to reduce size and volume, then the fuse meets space constraints, but weight reduction is also achieved
Solution Approach 1:
The patent changes the density and composition parameters of the filler material by using silicated quartz sand, which provides high dielectric strength and arc extinction capability with lower density compared to conventional filler materials. This parameter change enables simultaneous reduction in both volume and weight
Solution Approach 2:
The patent extracts unnecessary material from conventional fuse designs by using a more efficient filler material system. The silicated quartz sand requires less material volume to achieve the same protection performance, effectively removing excess weight and volume from the fuse construction
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 provides a 50% reduction in size and 87% reduction in volume compared to conventional fuses, offering higher power density, lower short-circuit let-through energy, and improved reliability, while maintaining comparable protection performance, thus addressing the need for smaller, lighter, and more efficient fuses for high voltage applications.
Implementation Method 1
utilizing a silicated quartz sand filler material and unique fuse element geometry to achieve higher power handling capacity, full-range time-current operation, and longer service life, along with arc extinguishing features to reduce arcing and material usage
Implementation Method 2
when electrical current flow through the fuse exceeds a predetermined limit, the fusible elements melt and opens one or more circuits through the fuse to prevent electrical component damage
Data Source
AI summary
A high voltage power fuse having a dramatically reduced size facilitated by silicated filler material, a formed fuse element geometry, and arc barrier materials. Methods of manufacture are also disclosed.