Fuse Resistor With Cavity Protection Layer

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Solution Overview

Problem

Existing fuse resistors face issues with rapid fusing causing spark leakage and residue splashing when high current is applied, leading to potential damage to peripheral devices.

Innovation Solution

A fuse resistor design featuring a protection layer with a cavity over the melting portion of the fuse element, creating a hollow air chamber to contain sparks and residues during the fusing process, thereby enhancing fusing speed and protecting other electronic devices.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If high current is applied to blow the fuse quickly, then the fusing speed is improved, but spark leakage and residue splashing occur causing damage to peripheral devices

Engineering Contradiction:

Improvefusing speedVSAvoidspark leakage and residue splashing

Core Design Contradiction:

SpeedVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a protection layer with a cavity as an intermediary structure between the fuse element and the external environment. This cavity acts as a mediator that captures and contains the harmful sparks and residues generated during rapid fusing, preventing them from reaching peripheral devices while allowing the high current fusing process to proceed at full speed.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent converts the harmful effect of spark and residue generation during rapid fusing into a contained phenomenon within the cavity. By designing the cavity to specifically capture these byproducts, the harmful effects are redirected and contained, transforming what would be damaging external splashing into a controlled internal phenomenon that does not affect peripheral devices.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Object-affected harmful factors

If a protection layer completely covers the fuse element, then peripheral devices are protected from sparks and residues, but the fusing speed decreases due to heat dissipation

Engineering Contradiction:

Improvespark and residue containmentVSAvoidfusing speed

Core Design Contradiction:

Object-affected harmful factorsVSSpeed

Solution Approach 1:

The patent applies local quality by creating a cavity in the protection layer directly over the melting portion of the fuse element. This localized structural feature provides protection precisely where sparks and residues are generated, while maintaining thermal contact between the fuse element and the substrate elsewhere, thus balancing protection needs with heat dissipation requirements for rapid fusing.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The protection layer is segmented into covered regions and a caved-out region. This segmentation allows different portions of the fuse element to experience different conditions: the melting portion benefits from direct exposure and rapid heating in the cavity, while other portions remain protected and thermally managed by the coverage, optimizing both fusing speed and protection.

Inventive Principle:

Principle #1Segmentation

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 design effectively increases the fusing speed of the fuse element while preventing damage to peripheral devices by confining sparks and residues within the air chamber, ensuring safer operation during rapid fusing.

Implementation Method 1

there is a hollow air chamber between the melting portion of the fuse element and the protection layer, such that splashing of spark and/or residues generated during a rapid fusing process of the melting portion can be confined

Methodology Applied

Scientific EffectPhysical containment: Physical Containment

Implementation Method 2

When 10 times rated current is applied to a fast blown fuse resistor, the fuse can be blown in 1 ms

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 3

a fusing speed of the fuse element is increased to effectively protect other electronic devices on a circuit board

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS11569053B2Fuse resistor and method for manufacturing the same

Publication Date: 2023.01.31 YAGEO CORP

AI summary

A fuse resistor includes a substrate, an insulation layer, a fuse element, a protection layer, a first electrode, and a second electrode. The insulation layer covers a surface of the substrate. The fuse element is disposed on a portion of the insulation layer. The fuse element includes a first electrode portion, a melting portion, and a second electrode portion, in which the first electrode portion and the second electrode portion are respectively connected to two opposite ends of the melting portion. The protection layer covers the fuse element and the insulation layer, in which the protection layer has a cavity located on the melting portion. The first electrode is electrically connected to the first electrode portion. The second electrode is electrically connected to the second electrode portion.