Fuse With Folded Element And Notched Arc Disc
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Solution Overview
Problem
Existing fuses face challenges in inspecting the solder connection between the fusible element and end cap without destructive testing, leading to potential defects in performance and reliability, especially as they decrease in size and manufacturing costs increase.
Innovation Solution
A fuse design featuring arc discs with notches on the edges of the fuse body, allowing the fuse element to be folded over the arc disc and secured by end caps with a visible hole for solder deposition, enabling easy inspection and ensuring a reliable electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a blind assembly of solder connection is used between fusible element and end cap, then manufacturing process is simplified, but inspection of solder connection becomes difficult or costly
Solution Approach 1:
The patent transitions from a blind (three-dimensional hidden) solder connection to a two-dimensional surface-level connection by forming the solder joint on the outer surface of the end cap, allowing visual inspection while maintaining manufacturing simplicity
Solution Approach 2:
The patent introduces an intermediary structure (the outer surface of the end cap) that serves as both the solder connection substrate and the inspection surface, allowing the solder joint to be both functional and visible for quality control
2Volume of moving object
If fuses decrease in size to accommodate smaller electrical circuits, then circuit protection becomes more compact, but manufacturing costs increase
Solution Approach 1:
The visible solder connection on the end cap surface serves as both the electrical connection and the quality indicator, eliminating the need for separate inspection processes and reducing manufacturing costs for small fuses
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 design allows for easy visual inspection of the solder connection, enhancing quality control, reducing manufacturing costs, and improving the reliability of the fuse by ensuring a secure and continuous electrical path.
Implementation Method 1
the fuse is heated so the solder reflows
Implementation Method 2
the fusible element melts or otherwise opens to interrupt the circuit path
Implementation Method 3
an arc may be formed between the melted portions of the fusible element
Data Source
AI summary
Embodiments of the fuse include a fuse body having a first end and a second end. A fuse element is disposed within a cavity of the fuse body, an end of the fuse element extending beyond an edge of the fuse body. An arc disc is disposed on the edge of the fuse body, and includes a notch such that the end of the fuse element extends to an outer surface of the arc disc. The end of the fuse element is configured to be folded over the outer surface of the arc disc. An end cap is disposed over the end of the fuse body and the arc disc, and the end cap includes a hole at a top surface. Solder deposited within the hole provides an electrical connection between the arc disc, the fuse element, and the end cap.