Fuse Element Rupture Mechanism to Prevent Conductive Carbide
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Solution Overview
Problem
Existing fuse elements, such as chip fuses and FPC fuses, form electrically conductive carbide when fused and cut, creating a conduction path that prevents the electrical circuit from being interrupted during abnormal currents.
Innovation Solution
A fuse element with a conductor layer on an insulating base material that physically ruptures at a lower temperature than fusion, using a foaming agent in a foam layer to interrupt the circuit by gas pressure without forming carbide.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the conductor layer is fused and cut by heat generation to interrupt the electrical circuit, then the electrical circuit is interrupted, but electrically conductive carbide forms creating a new conduction path that prevents reliable circuit interruption
Solution Approach 1:
The invention changes the operating temperature parameter by using a foaming agent that decomposes at a lower temperature than the conductor layer's fusion temperature. This temperature parameter change allows the fuse to rupture the conductor layer before it reaches the temperature required for carbide formation, thereby resolving the contradiction between circuit interruption and carbide prevention
Solution Approach 2:
The foaming agent acts as an intermediary substance that mediates between the electrical current and the conductor layer. When abnormal current flows, the foaming agent decomposes and generates gas pressure that physically ruptures the conductor layer, preventing direct thermal contact between the conductor and organic polymer materials, thus preventing carbide formation while still achieving circuit interruption
2Object-generated harmful factors
If the conductor layer is physically ruptured at lower temperature using a foaming agent, then carbide formation is suppressed, but the device structure becomes more complex with additional foam layer
Solution Approach 1:
The invention merges the protective function with the fusing function by integrating the foaming agent into the existing protective layer structure. The protective layer that would normally only protect the conductor is transformed into a dual-functional layer that both protects and actively participates in the fusing process by generating gas pressure to rupture the conductor, thereby adding minimal structural complexity while achieving carbide suppression
Solution Approach 2:
The protective layer is given multiple functions: it continues to provide mechanical protection to the conductor layer while simultaneously serving as the medium for the foaming agent that enables low-temperature rupture. This multi-functionality reduces the need for separate components and minimizes overall device complexity
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 fuse element effectively interrupts the electrical circuit by physical rupture, preventing the formation of carbide and ensuring reliable circuit disconnection during abnormal currents.
Implementation Method 1
a foaming agent in a foam layer provided on a surface of the conductor layer, the foam layer being foamed when the foaming agent is heated
Implementation Method 2
the conductor layer being physically ruptured at a temperature lower than a temperature, at which the conductor layer is fused and cut
Data Source
AI summary
It is aimed to provide a fuse element capable of interrupting an electrical circuit while suppressing the formation of carbide when an abnormal current is generated. A fuse element 10 is provided with an insulating base material 3 and a conductor layer 1 provided on a surface of the base material 3. The conductor layer 1 is physically ruptured at a temperature lower than a temperature, at which the conductor layer 1 is fused and cut, when the conductor layer 1 is energized and generates heat.