Complex Fusible Link Manufacturing with Segmented Fuse Assemblies
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Solution Overview
Problem
Existing fuse devices with integrally formed input and output terminals and fusible elements face issues such as debris scattering during fusible element melting, leading to unnecessary melting of adjacent elements, and suffer from yield reduction due to dimensional differences between fusible elements and output connectors, resulting in complex and wasteful arrangements during production.
Innovation Solution
A complex type fusible link with an insulative block base, a conductive connecting plate, and fusible elements, where the fusible elements are accommodated in cavities and terminals are embedded, allowing for easy replacement and enhanced yield, with a compact and low-cost design achieved by selecting suitable materials and thicknesses, and a manufacturing method involving hollowing, cutting, insert molding, and electrical connection of fusible elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fuse elements are formed integrally with input and output terminals in a one-piece structure, then mounting efficiency is improved, but debris from melted fuse elements scatters and causes adjacent elements to melt unnecessarily
Solution Approach 1:
The fuse device is divided into multiple independent fuse element assemblies, each containing a fuse element, input terminal, and output terminal. These assemblies are arranged side-by-side within a single housing, allowing each fuse element to be electrically isolated from others while maintaining an integrated structure within each assembly. This segmentation prevents debris from one melted fuse element from affecting adjacent elements.
2Volume of moving object
If the pitch of arrangement of fusible elements is optimized for compact design, then device size is reduced, but dimensional differences cause yield reduction during press-cutting production
Solution Approach 1:
The connecting plate is designed with locally optimized features: the fuse element mounting portions are spaced at compact pitches to minimize device size, while the terminal portions are dimensioned to match standard connector requirements. This local differentiation allows the connecting plate to satisfy both compact design requirements and manufacturing yield requirements without compromise.
3Reliability
If a resin-molded portion is formed around fuse elements to prevent debris scattering, then fuse element isolation is improved, but manufacturing complexity increases
Solution Approach 1:
Instead of forming a single complex resin-molded housing around all fuse elements, the device uses individual protective structures for each fuse element assembly. Each assembly includes its own input terminal, output terminal, and fuse element arranged in a compact unit that inherently contains debris locally, reducing the need for extensive resin molding while maintaining protection.
4Ease of repair
If separate blade fuses are used with individual mounting and screw-fastening, then replaceability is improved, but assembly operation becomes cumbersome
Solution Approach 1:
The fuse element, input terminal, and output terminal are merged into a single integrated assembly for each circuit. This allows the entire assembly to be replaced as one unit, combining the replaceability advantage of separate fuses with the simplicity of an integrated structure, eliminating the need for separate mounting and screw-fastening operations.
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 prevents debris scattering, allows for easy visual confirmation and replacement of melted fusible elements, and enhances yield by avoiding wasteful arrangements, resulting in a compact, low-cost, and efficiently manufactured fuse device with improved performance and reduced production complexity.
Implementation Method 1
when an electric current of above a predetermined level flows through a circuit connected to any of the output terminals, the corresponding fuse element melts
Data Source
AI summary
A manufacturing method of a complex type fusible link. The manufacturing method includes hollowing out a metal plate into a link-like conductor including a connecting plate and a terminal, cutting out the link-like conductor so as to separate the connecting plate and the terminal, forming, by insert molding, a block base including a cavity after setting the connecting plate and the terminal in a mold, and directly connecting a fusible element to an exposed portion of the connecting plate and an exposed portion of the terminal.