Electric Fuse Barrier Structure for Arc and Pressure Containment
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Solution Overview
Problem
Conventional electric fuses with ceramic insulating casings are prone to mechanical damage and arc-induced combustion during overloads, as the pressure increase can cause the casing to break or crush, leading to potential external arc formation and conductive carbonization of the casing surface, compromising safety and functionality.
Innovation Solution
A cylindrical fuse design featuring a conductive melting member within an insulating casing filled with fireproof granules, incorporating a conductive and plastically deformable separating barrier with an elastic insulating layer, which directs thermal energy away from the casing and reduces arc formation by increasing the gap between melting member sections during overload, thus preventing external arc access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ceramic insulating casing is used in conventional electric fuses, then electrical insulation is provided, but the casing is fragile and may be damaged by increasing pressure during explosions or overheating, leading to mechanical damage and arc-induced combustion
Solution Approach 1:
The patent changes the material parameter of the casing from fragile ceramic to flexible polymer material that can withstand pressure increases during explosions without breaking. The polymer casing maintains its integrity under stress while providing the necessary electrical insulation, thereby resolving the contradiction between reliability and mechanical strength.
Solution Approach 2:
The patent employs a composite structure where the casing is made of polymer material that combines flexibility and electrical insulation properties. This composite approach allows the casing to resist mechanical damage from pressure increases while maintaining its insulating function, addressing both reliability and strength requirements.
2Reliability
If the casing material becomes carbonized due to burning from electric arc, then the material structure is altered, but the carbonized surface becomes electrically conductive, causing the fuse to still conduct current despite melting member interruption
Solution Approach 1:
The patent addresses the harmful effect of arc-induced carbonization by using polymer casing material that, when exposed to high temperatures, forms a charred layer that maintains electrical insulation properties unlike carbonized ceramic or duroplastic materials. This converts the potential harmful carbonization process into a beneficial protective layer that preserves circuit interruption reliability.
Solution Approach 2:
The patent changes the chemical composition parameter of the casing material from ceramic or duroplastic to specific polymer materials that resist carbonization or form insulating char layers when exposed to electric arcs. This parameter change ensures that even under extreme thermal conditions, the casing maintains its electrical insulation properties.
3Object-affected harmful factors
If the fuse casing is broken or crushed by explosion or catastrophic event, then the structure is compromised, but an electric arc may freely access the surrounding area, causing combustion or other damage
Solution Approach 1:
The patent changes the mechanical property parameter of the casing from rigid and fragile (ceramic) to flexible and explosion-resistant (polymer). The polymer casing can deform under explosion pressure without breaking, maintaining its containment function and preventing electric arcs from escaping to the surrounding area.
Solution Approach 2:
The patent employs a casing material that beforehand absorbs and dissipates explosion energy through deformation rather than fracture. The flexible polymer casing acts as a cushion that prevents catastrophic failure, thereby protecting against arc escape and combustion before the harmful effects can occur.
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 design effectively prevents mechanical damage and arc-induced combustion by managing pressure and thermal energy, maintaining the insulating integrity and ensuring safe circuit interruption without external arc formation, even under high voltage and current conditions.
Implementation Method 1
The melting member may be heated up to the melting temperature thereof, upon which at least one section thereof becomes molten and broken
Implementation Method 2
a layer consisting of an elastic and electrically insulating material is available and is connected therewith in a non-detachable manner, so that the melting member is on each terminal portion of said fuse electrically connected with each belonging electrically conducting cover via said electrically conductive separating barrier and simultaneously extends also through said electrically insulating layer of elastic material, such that in the area within said layer is furnished with at least one bendable member, by means of which it is anchored therein and secured against being pulled-out
Implementation Method 3
a separating barrier is inserted, which consists of an electrically conductive and plastically deformable material
Data Source
AI summary
The present disclosure describes an electric fuse, comprising a melting member contained within an insulated cylindrical casing, which is sealed at each end by an electrically conductive cover electrically connected to said melting member. On each end of the fuse casing, between said casing and said cover, is installed an electrically conductive and plastically deformable separating barrier. On the side of separating barrier facing the interior of the casing is affixed a layer of an elastic and electrically insulating material. The melting member is on each end portion of said fuse electrically connected with each cover via said separating barrier and proceeds through said electrically insulating layer. Within said layer the melting member has at least one bend, by which it is anchored therein and secured against being pulled out.