Thermally Conductive Fuse Holder for High-Current Heat Dissipation
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Solution Overview
Problem
Legacy fuse holders are limited in high-current applications due to their inability to dissipate the heat generated by the fuse, which restricts the manufacturing of fuses with high voltage ratings.
Innovation Solution
A fuse holder design featuring a housing and knob made of a polymer material with high thermal conductivity (4.0 to 10 W/mK), along with axial fins for enhanced heat dissipation, allowing heat to be conducted away from the fuse during normal operation and overcurrent events.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional fuse holders are used, then they can manage debris flow from breaking fuses, but they cannot dissipate heat generated by fuses in high current applications
Solution Approach 1:
The patent changes the thermal conductivity parameter of the housing material from traditional low thermal conductivity materials to a polymer material with high thermal conductivity (4.0 to 10 W/mK). This parameter change enables the housing to effectively conduct heat away from the fuse, resolving the heat dissipation limitation while maintaining the structural integrity needed for high current applications.
Solution Approach 2:
The patent employs a composite material solution by using a polymer material that combines electrical insulation properties with high thermal conductivity. This composite material approach allows the housing to simultaneously provide electrical isolation and effective heat dissipation, overcoming the limitation of traditional materials that could only manage one function at a time.
2Power
If high current fuses are used, then higher power protection is achieved, but excessive heat is generated that causes premature breaking
Solution Approach 1:
The patent converts the harmful thermal energy generated by high current operation into a manageable parameter by designing the housing as a heat conduction path. The high thermal conductivity polymer material transforms the previously problematic heat accumulation into an effective heat dissipation mechanism, allowing high current fuses to operate reliably without premature breaking.
3Temperature
If metal materials like copper or aluminum are used for heat dissipation, then thermal conductivity is improved, but cost increases
Solution Approach 1:
The patent employs a cost-effective material substitution strategy by replacing expensive metal materials (copper or aluminum) with a polymer material that provides sufficient thermal conductivity at a lower cost. The polymer material achieves the required heat dissipation performance (4.0 to 10 W/mK) without the high manufacturing costs associated with metal components, making high current fuse holders more economically viable.
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
Enables the use of high-current fuses by effectively managing thermal energy, preventing premature breaking and supporting high-current applications without the need for expensive metals like copper or aluminum.
Implementation Method 1
The housing and neck are made of a polymer having a thermal conductivity in a range of 4.0 to 10 W/mK
Data Source
AI summary
A fuse holder includes a housing and a knob. The housing has a telescoping chamber designed to receive a knob terminal, where the knob terminal is adapted to receive a fuse. The knob has a neck which is inserted into the telescoping chamber to enclose the cylindrical fuse. The housing and neck are made of a polymer having a thermal conductivity in a range of 4.0 to 10 W/mK.