Fuse Counter-Bore Body Solder Connection Reliability
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Solution Overview
Problem
Existing fuses face inconsistency and unreliability in wire-to-solder connections due to the lack of a consistent location for solder reflow during assembly, leading to inferior electrical connections.
Innovation Solution
The implementation of counter-bores in the hollow body of the fuse provides additional space for solder to form a more reliable connection between the fusible element and the end caps, ensuring a consistent and robust electrical link.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional hollow tubular body is used without counter-bores, then the fuse structure is simple, but the wire-to-solder connection consistency and reliability are poor
Solution Approach 1:
The hollow body is modified with counter-bores at specific locations where solder connections are needed. This local modification provides concentrated space for solder reflow at the wire-to-solder connection areas, improving connection reliability without requiring a complete redesign of the entire hollow body structure.
Solution Approach 2:
The counter-bores are pre-formed in the hollow body during manufacturing, creating predetermined spaces for solder accumulation before the actual soldering process. This preliminary preparation ensures that solder has a consistent location to reflow and form reliable connections, eliminating the inconsistency of traditional designs.
2Manufacturing precision
If additional space is provided for solder reflow, then the electrical connection consistency improves, but the hollow body manufacturing complexity increases
Solution Approach 1:
The hollow body design incorporates counter-bores with specific dimensional parameters (depth, diameter, location) that are optimized to provide adequate space for solder reflow. By carefully controlling these parameters, the design achieves consistent solder connections while maintaining manufacturability through standard machining or molding processes.
Data Source
Figure 1
Figure 2A~2C
Figure 3
AI summary
An improved fuse having one or more counter bores in an interior wall of a hollow tube used as the fuse housing. The fuse includes a fusible element disposed within a cavity defined by the interior wall. The fusible element is electrically connected to first and second end caps via solder. The first and second end caps are attached to respective ends of the hollow tube. The one or more counter bores provide more space for the solder to cover the fusible element resulting in a more reliable electrical connection.