Electrical Fastener With Meltable Solder Ring for Thermal Protection
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Solution Overview
Problem
In electrical power systems, such as those in aircraft, high current flow due to electrical shorts or failures can lead to excessive heat generation, causing potential electrical or thermal damage.
Innovation Solution
An electrical fastener assembly featuring a solder washer assembly with a meltable solder ring that breaks the electrical connection between the DC contactor and bus bar support when excessive heat is generated, disrupting current flow and preventing further damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high current flow protection is implemented using traditional fuses or circuit breakers, then electrical safety is improved, but device complexity and response time are worsened due to additional components and potential delay
Solution Approach 1:
The patent combines the electrical connection function (bus bar support) and the thermal protection function (fuse element) into a single integrated fastener assembly. The fuse element is positioned within the bus bar support structure, allowing simultaneous electrical conduction and thermal protection without requiring separate protection devices, thereby reducing overall system complexity while maintaining safety
Solution Approach 2:
The fastener assembly performs dual functions: it provides mechanical fastening/electrical connection through the bus bar support while simultaneously providing thermal protection through the integrated fuse element. The system serves itself by having the connection component also act as the protection component, eliminating the need for additional dedicated protection devices
2Object-affected harmful factors
If thermal protection is added to electrical fasteners, then damage prevention is improved, but manufacturing complexity increases
Solution Approach 1:
The fuse element and bus bar support are manufactured as separate components that are assembled together through standard fastening procedures. The fuse element is positioned within the bus bar support and secured using existing fastening mechanisms, allowing both components to be manufactured using conventional processes without requiring complex integrated manufacturing
Solution Approach 2:
The protection system is divided into distinct modular components: the bus bar support structure and the separate fuse element. This segmentation allows each component to be manufactured independently using standard processes, then assembled together, simplifying manufacturing while providing integrated thermal protection functionality
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 effectively prevents damage by disrupting current flow during faults, reducing the risk of smoke and fire, thereby enhancing safety in electrical power distribution systems.
Implementation Method 1
a meltable solder ring (42) positioned between the DC contactor (26) and the bus bar support (28) such that the meltable solder ring (42) disrupts electrical contact between the DC contactor (26) and the bus bar support (28) when excessive heat is generated
Implementation Method 2
In the event of an electrical short or other failure condition, high voltage components may be shunted across unintended electrical contacts, resulting in high current flow at the failure of the power distribution system. The high current flow, in turn, generates excessively high levels of heat
Data Source
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AI summary
An electrical fastener assembly (24) for coupling first and second electrically conductive terminals (28,32) includes a fastener coupling the first and second terminals to each other, and a meltable element (42). The meltable element (42) melts in response to heat to disrupt, or break, the conductive path in response to an overheating or over-temperature condition.