Fuse Functional Layer Void Absorption
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Solution Overview
Problem
Conventional fuses face issues with deformation, bending, and inconsistent fusing due to shrinkage mismatch between the fuse element and the arc extinguishing and pressure relief layers, leading to poor performance under high voltage and current conditions, with existing solutions failing to provide effective arc extinguishing and stable support during the sintering process.
Innovation Solution
A fuse design incorporating a functional layer with an arc extinguishing material, such as hollow glass or ceramic microspheres, uniformly distributed in a low-temperature co-fired ceramic substrate, which generates voids upon fusion to absorb heat and shock waves, providing stable support and preventing deformation, while also combining pressure relief and arc extinguishing functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If grooves or cavities are introduced around the fused mass for pressure relief, then pressure resistance is improved, but the fuse element deforms and bends due to shrinkage mismatch during sintering
Solution Approach 1:
The patent uses a composite structure consisting of a ceramic substrate with a functional layer containing arc extinguishing material and pressure relief cavity. This composite material approach allows the functional layer to provide both arc extinguishing and pressure relief functions while maintaining structural integrity during sintering, preventing the fuse element deformation caused by shrinkage mismatch in conventional single-material designs.
Solution Approach 2:
The functional layer is positioned between the fuse element and the ceramic substrate, with the pressure relief cavity nested within the functional layer. This nested structure allows the functional layer to support the fuse element during sintering while providing pressure relief through the cavity, solving both the support and pressure relief requirements simultaneously.
2Object-generated harmful factors
If the fuse element penetrates through the pressure relief cavity, then pressure relief function is achieved, but the fuse element cannot shrink with the substrate causing bend and deformation
Solution Approach 1:
The functional layer acts as an intermediary between the fuse element and the ceramic substrate. It provides pressure relief through the cavity while maintaining a stable platform that supports the fuse element during sintering, preventing deformation. The functional layer mediates the shrinkage forces, allowing the fuse element to remain flat and consistent.
3Object-affected harmful factors
If porous slurry is filled in grooves for arc extinguishing, then arc extinguishing capability is improved, but the fuse element diffuses into pores causing defects and increased resistance
Solution Approach 1:
The patent uses arc extinguishing material with controlled porosity in the functional layer. The porous structure provides effective arc extinguishing capability by capturing and quenching arcs, while the controlled pore distribution and material composition prevent fuse element diffusion into pores, maintaining element integrity and preventing resistance increase.
Solution Approach 2:
The arc extinguishing material is localized in the functional layer between the fuse element and substrate. This local concentration of arc extinguishing properties provides effective arc quenching where needed most, while the surrounding dense ceramic material prevents element diffusion and maintains structural integrity.
4Strength
If stamping groove is filled with pore-forming agent slurry, then pressure relief is achieved, but the pressing process squeezes the fuse element causing deformation
Solution Approach 1:
The functional layer with pressure relief cavity is prepared in advance before the fuse element is placed. This preliminary preparation of the support structure eliminates the need for subsequent pressing operations that would squeeze and deform the fuse element. The cavity is formed beforehand, providing pressure relief without requiring post-assembly compression.
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 the fuse's ability to withstand high voltages and currents, ensuring safe breaking during short circuits by quenching arcs and maintaining the integrity and flatness of the fuse element, thereby improving voltage withstand capability and reducing defects.
Implementation Method 1
the cavities preset in the glass body absorb the heat and shock waves generated when the fuse element is fused
Implementation Method 2
the cavities preset in the glass body absorb the heat and shock waves generated when the fuse element is fused
Implementation Method 3
the arc extinguishing material comprises a glass body and/or a ceramic body having sealed cavities... which generates voids upon fusion
Data Source
AI summary
A fuse and a production method therefor. The fuse includes upper and lower insulating layers provided with terminal electrodes, and a fuse element between the upper and lower insulating layers. The fuse further includes a functional layer provided between the fuse element and the insulating layers. The functional layer includes a substrate and an arc extinguishing material uniformly or substantially uniformly distributed in the substrate; the arc extinguishing material includes a sealed cavity; the substrate includes low temperature co-fired ceramic powder, aerosol silicon oxide, silicon oxide, inert resin, phosphoric acid, and phosphate ester polyester; the content of the arc extinguishing material is 1-50 wt %. The fuse overcomes the shortcomings of phenomena such as deformation, bending, and defects occurring to a fuse element caused by the shrinkage mismatch of the fuse element with a buffer layer and an arc extinguishing layer in a sintering process.