Insertion Fuse With Bi-Directional SMD LED Breakage Indicator
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Solution Overview
Problem
Existing fuses, particularly blade fuses, face issues with unidirectional installation requirements, loose LED connections, and hidden fusible elements, making it difficult to locate blown fuses and requiring lengthy repair times due to the vulnerability of incandescent bulbs to overcurrents.
Innovation Solution
An insertion type fuse with a bi-directional SMD LED set is used, featuring a high-temperature tolerant LED set connected in series with a voltage divider resistor and securely buckled to the fuse, allowing bi-directional use and easy assembly, with the LED indicating fuse breakage by emitting light when the fuse wire breaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a small bulb is used to indicate fuse breakage, then the breakage can be indicated, but the bulb easily burns due to overcurrent and requires lengthy repair time
Solution Approach 1:
The patent replaces the fragile incandescent bulb with an LED indicator that has significantly longer lifespan and higher overcurrent tolerance. The LED can withstand the surge current when fuse breaks without burning out, eliminating the need for frequent replacement and reducing repair time.
Solution Approach 2:
The patent changes the electrical parameters of the indication device by using LED instead of incandescent bulb. The LED operates at lower voltage and current levels, and its non-linear V-I characteristics allow it to handle overcurrent conditions better, transforming the indication system into a more reliable configuration.
2Reliability
If a unidirectional LED is used for indication, then the indication function works, but the fuse must be installed in a predetermined orientation which complicates installation
Solution Approach 1:
The patent uses two LEDs connected in parallel with opposite polarities, creating a bidirectional indication system. This allows the fuse to be installed in either orientation while still providing reliable indication, making the device universal and eliminating installation orientation constraints.
Solution Approach 2:
The patent employs asymmetric connection of two LEDs with opposite polarities in parallel. This asymmetric configuration ensures that regardless of which direction current flows, at least one LED will conduct and provide indication, thereby solving the orientation problem.
3Ease of manufacture
If the LED is loosely connected to the fuse, then the assembly is simple, but the connection is not tight and may fail under vibration or stress
Solution Approach 1:
The patent integrates the LED mounting structure with the fuse body itself, combining the indication device and the fusible element into a single unified component. The LED is securely mounted within the fuse housing with proper mechanical support and electrical connection, eliminating loose connections while maintaining manufacturing simplicity.
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 enables rapid identification of broken fuses, secure LED mounting, and cost-effective, high-production-rate manufacturing, suitable for automotive use with reduced power consumption and clear indication of fuse damage, overcoming the limitations of prior art fuses.
Implementation Method 1
an rectangular bi-directional SMD form LED set being located on the buckle portions; the LED set being a coating device and being high temperature tolerant; the LED set being connected to a circuit; the LED including two LEDs and being serially connected with a voltage divided resistor
Data Source
AI summary
An insertion type fuse with breakage indication comprises a seat having a long receiving chamber for receiving a metal fuse; an rectangular bi-directional SMD form LED set being located on the buckle portions; the LED set being a coating device and being high temperature tolerant; the LED set being connected to a circuit; the LED including two LEDs and being serially connected with a voltage divided resistor; a fuse wire being connected between the LED set and a load; the LED set being buckled to the buckle portions; when the fuse wire breaks, light will emit out so as to show that the fuse wire breaks; thereby a break fuse can be fined rapidly. In assembly, the seat and the cover are integrally formed. The LED set is adhered to the metal fuse and then the metal fuse is assembled into the long receiving chamber.