Fuse Element Assembly With Local Arc-Quenching Material
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Solution Overview
Problem
High-voltage, direct current (DC) fuses in electric vehicle power systems face challenges in effectively quenching electrical arcs due to their compact size and high voltage operations, which can lead to prolonged arcing and potential rupture of the fuse housing, necessitating enhanced arc-quenching capabilities.
Innovation Solution
The integration of an arc-quenching material, such as silicone, is applied locally to specific regions of the fuse element, including weakened segments and folds, with support structures like rails or clips to ensure adequate coverage and prevent material retreatment, complementing the existing loose matrix for improved arc quenching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the loose matrix of arc-quenching material is used alone, then the fuse structure remains simple and compact, but the arc-quenching capability is insufficient for high-voltage DC fuses
Solution Approach 1:
The patent applies arc-quenching material locally at specific locations where arcs are most likely to occur and persist, such as weakened segments and folds of the fuse element, rather than uniformly throughout the entire fuse structure. This localized application enhances arc-quenching capability at critical points while maintaining overall structural simplicity and compactness.
Solution Approach 2:
The fuse element is divided into multiple segments including weakened segments and folds, with arc-quenching material applied at specific segments. This segmentation allows targeted enhancement of arc-quenching capability at critical locations without requiring the entire fuse structure to be complex or oversized.
2Volume of moving object
If the fuse size is reduced for compact EV power systems, then the mass and space requirements are met, but the arc-quenching performance deteriorates due to insufficient material volume
Solution Approach 1:
By concentrating arc-quenching material at critical locations such as weakened segments and folds where arcs are most likely to occur in compact fuses, the patent achieves effective arc quenching performance without requiring a large overall fuse volume, thus maintaining compact size while ensuring reliability.
Solution Approach 2:
The arc-quenching material is pre-applied to specific locations on the fuse element during manufacturing, preparing these critical areas in advance to quickly suppress arcs when they occur, which is essential for maintaining performance in compact fuse designs.
3Reliability
If arc-quenching material is applied to the fuse element, then the arc-quenching performance is enhanced, but the manufacturing process becomes more complex
Solution Approach 1:
The patent specifies applying arc-quenching material only at particular locations such as weakened segments and folds rather than uniformly across the entire fuse element. This localized application reduces the total amount of material required and simplifies the manufacturing process compared to full-surface coating, while still achieving enhanced arc-quenching performance where it is most needed.
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
This approach enhances the arc-quenching performance, reduces the likelihood of fuse housing rupture, and maintains a compact size while supporting high voltage and current handling, ensuring reliable operation and extended service life.
Implementation Method 1
the matrix absorbs the vaporized metal that sustains the arc over time
Implementation Method 2
an arc-quenching material, such as silicone, is applied locally to specific regions of the fuse element
Data Source
AI summary
A fuse element assembly has been disclosed. The fuse element assembly includes a fuse element having a pair of side edges and at least one weak spot between the side edges. The fuse element assembly also includes an arc-quenching material attached locally to the fuse element adjacent the weak spot.