Three-Dimensional Fuse Element With Narrowed Sections
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Solution Overview
Problem
Existing in-vehicle fuse elements require complex and skill-intensive fabrication processes, leading to low productivity and high costs, and are prone to casing damage from Joule heat and arc energy during normal and high current flows.
Innovation Solution
A fuse element with elements bent into a three-dimensional shape, where one element away from the central one has a smaller width, ensuring uniform arc-extinguishing sand distribution and reducing thermal stress on the casing, fabricated using a simplified process that eliminates the need for complex positioning and multiple fabricating steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple elements are arranged in parallel to increase rated current, then the current carrying capacity is improved, but the fabrication complexity and processing time increase significantly
Solution Approach 1:
The patent merges multiple separate elements into a single integrated element structure. Instead of fabricating and assembling multiple separate elements in parallel, the invention creates one element with multiple fused sections that function together to carry higher current, thereby reducing fabrication complexity while maintaining increased rated current capability
Solution Approach 2:
The element is divided into multiple fused sections along its length, where each section can independently contribute to current carrying capacity. This segmentation allows the single element to achieve the current handling capability of multiple elements while simplifying the overall fabrication process
2Power
If multiple elements are arranged in parallel to increase rated current, then the current carrying capacity is improved, but the production time and cost increase
Solution Approach 1:
By combining multiple current-carrying functions into a single element, the production process is simplified from assembling multiple components to manufacturing one integrated component, significantly reducing production time and improving productivity while maintaining the ability to handle high currents
3Ease of manufacture
If uniform width elements are used, then manufacturing is simpler, but arc-extinguishing sand distribution is non-uniform causing casing damage
Solution Approach 1:
The element width is varied locally along its length, with narrower sections positioned at specific locations. This local variation in geometry ensures uniform distribution of arc-extinguishing sand in the casing, preventing hot spots and casing damage, while the overall manufacturing process remains relatively simple
4Manufacturing precision
If complex positioning steps are used for soldering, then assembly precision is improved, but the skill requirement and time consumption increase
Solution Approach 1:
By merging multiple elements into a single integrated element, the patent eliminates the need for complex positioning and soldering operations between multiple components. The single element structure requires minimal assembly steps, dramatically reducing both assembly time and the skill level required while maintaining precise electrical connections
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 enhances productivity, reduces casing damage from Joule heat and arc energy, and improves arc-extinguishing performance, resulting in a high-quality fuse element with improved dimensional accuracy and extended lifespan.
Implementation Method 1
the arc-extinguishing sand might prevent these fused sections from generating an arc with great thermal energy
Implementation Method 2
When a normal current flows through the elements, the fused sections, which are the smallest in cross-section, generate Joule heat
Data Source
Figure 1
Figure 2(a)~2(b)
Figure 3
AI summary
Disclosed is a fuse element in which a plurality of parallel rows of elements connect a pair of terminal sections and which allows for a big improvement in part of processing, exhibiting superior productivity at an extremely low cost. A fuse element (10) according to the present invention includes: a plurality of parallel rows of elements (12, 12 •••) arranged at a predetermined spacing (H) which connect terminal sections (11, 11) positioned at both ends; and a plurality of fused sections formed in substantially central sections (13) of the elements (12). All of the terminal sections (11, 11) positioned at both ends and the elements (12c, 12d, 12e) or the elements (12c, 12d, 12e) alone are each formed by stamping a single metal plate to separate a piece having a preset shape therefrom and bending the piece into a predetermined three-dimensional shape.