48V Battery Fuse Segmentation for High Breaking Capacity
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Solution Overview
Problem
Conventional fuses for 48V battery systems in electric vehicles fail to meet requirements for smaller size, higher temperature rise, strict overload fusing time, and high breaking capacity, as well as durability in severe environmental conditions such as high and low temperatures, mechanical impacts, and chemical corrosion.
Innovation Solution
A fuse design featuring a housing with a fusing body comprising a fusing portion and two heating portions, where the fusing portion has a larger width than the heating portions and is divided by holes, providing narrow sections that break under high current, along with integral formation and precise terminal connections for enhanced performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the fuse size is reduced to meet compact vehicle requirements, then the fuse can be integrated into smaller battery systems, but the breaking capacity and temperature rise performance deteriorate
Solution Approach 1:
The fusing body is divided into distinct functional segments: heating portions (first and second) and a fusing portion with narrow sections. This segmentation allows each part to perform its specific function optimally - the heating portions generate heat efficiently while the narrow fusing portion breaks at precise current levels, achieving high breaking capacity in a compact form
Solution Approach 2:
Different sections of the fusing body have different cross-sectional areas - the heating portions have larger areas for heat generation while the fusing portion has narrow sections with smaller areas for controlled breaking. This local quality variation enables the small fuse to achieve high breaking capacity through optimized material distribution rather than uniform size
2Volume of moving object
If the fusing portion is made narrower to reduce fuse size, then the fuse can fit compact spaces, but the temperature rise performance and overload protection capability worsen
Solution Approach 1:
The fusing body is segmented into heating portions and a fusing portion, with the heating portions having larger cross-sectional areas dedicated to heat generation. This segmentation ensures sufficient temperature rise for reliable operation while keeping the overall fuse size compact through the narrow fusing portion
Solution Approach 2:
The heating portions are designed with larger cross-sectional areas to generate adequate heat for temperature rise, while the fusing portion has narrow sections for size reduction. This local quality differentiation resolves the contradiction between compact size and temperature rise performance
3Reliability
If the fuse is designed for high breaking capacity to protect battery systems, then the protection capability improves, but the fuse size and complexity increase
Solution Approach 1:
The fusing body features narrow sections with reduced cross-sectional areas in the fusing portion, allowing high breaking capacity to be achieved through optimized local material properties and geometry rather than increasing overall fuse size. The narrow portions break at precise current levels while maintaining compact dimensions
Solution Approach 2:
The fuse is segmented into heating portions and a fusing portion with narrow sections, allowing high breaking capacity to be achieved through the concentrated heating effect in the narrow sections without requiring a larger overall fuse structure
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 achieves small size, excellent temperature rise performance, high breaking capacity, and reliability in severe environments without failure, as demonstrated by mechanical shock and vibration tests across varying temperatures.
Implementation Method 1
the fusing body comprises a fusing portion as well as a first heating portion and a second heating portion respectively connected to both sides of the fusing portion
Data Source
Figure 1~2
Figure 3~4
AI summary
The utility model provides a fuse for protecting a 48V battery system of an electric vehicle. The fuse includes a housing and a fusing body disposed within the housing. The fusing body includes a fusing portion as well as a first heating portion and a second heating portion respectively connected to both sides of the fusing portion. A width of the fusing portion is larger than a width of the first heating portion and that of the second heating portion. The fusing portion includes at least one hole. The at least one hole divides the fusing portion into narrow portions having a width smaller than that of the first heating portion or the second heating portion. The fusing portion, the first heating portion, and the second heating portion are integrally formed.