Gas-Generating Fuel for Arc Fault Disruption on PCB Wire Bonds
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Solution Overview
Problem
Electrical arc faults in printed circuit boards can lead to unintended current transmission and damage due to the conductive nature of superheated plasma, especially in environments with vibrations or loose connections, posing safety risks and transmission disruptions.
Innovation Solution
Incorporating a gas-generating fuel on the substrate near wire bonds that, upon activation, generates a jet of gas to disrupt and extinguish arc faults by directing it towards the affected area, either passively through heat from the arc or actively via a controller module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire bonds are used to connect electrical components to PCB traces, then electrical connections are established, but arc faults can occur causing unintended current transmission
Solution Approach 1:
The gas-generating fuel is pre-positioned on the substrate proximate to the wire bond before any arc fault occurs. Upon activation by the arc's heat, the fuel rapidly generates gas that directs toward the wire bond to disrupt the arc fault, preventing the harmful current transmission before it can propagate through the system.
Solution Approach 2:
The arc fault's harmful heat, which would normally cause damage, is converted into a beneficial activation mechanism for the gas-generating fuel. The heat from the arc fault triggers the fuel to generate gas that then disrupts and extinguishes the arc, transforming the harmful thermal energy into a protective action.
2Reliability
If traditional arc protection methods are used, then arc faults may be detected, but response time is insufficient to prevent damage
Solution Approach 1:
The system uses the arc fault's own heat to automatically activate the gas-generating fuel without requiring external detection or control systems. This self-activating mechanism eliminates detection and response delays, providing immediate protection the moment an arc fault occurs.
Solution Approach 2:
The gas-generating fuel is pre-positioned and pre-configured in the optimal location proximate to the wire bond. When activated by the arc's heat, it immediately generates protective gas in the precise location needed, eliminating the time loss associated with detecting and responding to arc faults.
3Object-affected harmful factors
If gas-generating fuel is positioned proximate to wire bonds, then arc faults can be disrupted, but device complexity increases
Solution Approach 1:
The gas-generating fuel is designed as a simple, inexpensive, single-use component that is easily disposed of after one activation. This simple disposable approach protects against arc faults without requiring complex reusable systems, maintaining ease of manufacture and low cost despite the added protective function.
Solution Approach 2:
The arc protection function is extracted as a separate, independent gas-generating fuel component rather than integrating it into the wire bond or PCB trace structure. This extraction simplifies the overall design by making the protection mechanism a distinct, easily replaceable element that doesn't complicate the main electrical connection system.
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
Effectively disrupts and extinguishes arc faults, preventing self-sustaining current flow and enhancing safety by addressing the root cause of arcing events, thereby protecting electrical networks and power distribution systems.
Implementation Method 1
activation of the gas-generating fuel generates a jet of gas toward the wire bond
Implementation Method 2
generates a jet of gas toward the wire bond configured to disrupt the arc fault
Implementation Method 3
In the event of an electrical arc fault or other failure condition, high currents might be transmitted through a normally nonconductive medium, such as air
Implementation Method 4
the conductive nature of superheated plasma, especially in environments with vibrations or loose connections
Data Source
AI summary
A method and apparatus for a printed circuit board having a substrate, an electrical component disposed on the substrate and connected to an input, a wire bond connecting the electrical component to an output, and a gas-generating fuel disposed on the substrate proximate to the wire bond to account for an arc fault.