Fuse End Cap Assembly Without Binders or Intermediate Parts
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Solution Overview
Problem
Existing electric fuses face issues such as material spilling, excess space, complex assembly due to intermediate elements, and high costs from binders like adhesives or mortar, and previous solutions like US8937524B2 do not fully address these problems.
Innovation Solution
A fuse design featuring a cylindrical housing with a conductive core and end caps, using an arc-extinguishing material between the core and housing, and non-conductive inserts, with conductive end caps and a star-shaped core, eliminating the need for intermediate parts and binders, and utilizing frictional forces for assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If intermediate elements are used between the core and outer end caps, then the structural integrity is improved, but the device complexity increases
Solution Approach 1:
The patent removes intermediate elements (binders, adhesives, mortar) from the fuse structure, replacing them with a direct integration approach where the arc-extinguishing material fills the space between the core and outer end caps. This extraction of unnecessary components simplifies the assembly process while maintaining structural integrity through the unified design.
2Strength
If binders like adhesive or mortar are used, then the components are securely fixed, but the manufacturing cost increases
Solution Approach 1:
The patent replaces expensive binders (adhesive, mortar) with a cost-effective arc-extinguishing material that serves dual purposes: both as a filling material and as a securing medium. The sand or similar material is inexpensive and provides sufficient mechanical retention without requiring additional bonding agents, thereby reducing manufacturing costs while maintaining component fixation.
3Reliability
If the housing is completely filled with arc-extinguishing material, then the arc extinguishing effectiveness is improved, but the risk of material spilling out increases
Solution Approach 1:
The patent applies local quality by providing arc-extinguishing material in specific zones rather than uniformly filling the entire housing. The material is contained in controlled areas defined by the inner end caps and outer end caps, ensuring adequate arc extinguishing coverage while preventing overflow. The selective placement of material in critical regions maintains effectiveness without causing spilling hazards.
4Device complexity
If no intermediate parts are used, then the assembly process is simplified, but the structural stability may be compromised
Solution Approach 1:
The patent merges multiple functions into unified components. The outer end caps serve both as structural closures and as retaining structures for the arc-extinguishing material. The inner end caps integrate the functions of electrical connection and mechanical support. This merging of functions eliminates the need for separate intermediate elements while maintaining structural stability through the coordinated design of integrated components.
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 provides a simpler, cost-effective assembly process with reduced material consumption and improved structural integrity, ensuring effective arc extinguishing without material spilling and excess space, while maintaining electrical conductivity.
Implementation Method 1
utilizing frictional forces for assembly
Data Source
Figure 1
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AI summary
The invention relates to a fuse comprising electrically non-conductive inserts (6) and two end caps (2) of the core (1) made of an electrical conductor, wherein the end caps (2) of the core (1) are basically cylindrical in shape with a single base which includes an opening in the axis of the housing (3), and the end caps (2) of the core (1) include an arm (2a), wherein the core (1) is located between the bases of the inner end caps (4) inside the housing (3), wherein the end caps (2) of the core (1) are put on the both ends of the core (1), wherein the fuse element is connected to the end caps (2) of the core (1), and each of the end caps (2) of the core (1) is affixed through an arm (2a) to the corresponding inner end cap (4), and an insert (6) is provided between each inner end cap (4) and the outer end cap (5).