High-Current Terminal Fusible Link for Tunable Overcurrent Cutoff
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing circuit protection devices, such as fuses, face challenges in manufacturing for general-purpose use due to varying shapes and structures, making it difficult to create effective overcurrent protection solutions with minimal facilities.
Innovation Solution
A high current terminal with a fusible element between sectional terminals, formed in specific patterns and coupled using methods like E-beam welding, featuring a first metal layer and a second metal layer with adjustable melting points to control disconnection time, allowing for customizable resistance values and melting points based on material and shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If circuit protection devices are designed with different shapes and structures for specific purposes, then the protection effectiveness for specific applications is improved, but the manufacturing complexity increases and general-purpose usability decreases
Solution Approach 1:
The patent applies universality by designing a standardized terminal structure that can serve multiple circuit protection applications. The terminal uses a common body design with configurable fusible elements that can be adjusted to provide different protection characteristics (current ratings, voltage ratings, response times) without requiring different manufacturing facilities or processes. This allows a single manufacturing line to produce terminals for various applications by simply changing the fusible element specifications.
Solution Approach 2:
The patent implements parameter changes by allowing the fusible element's physical and electrical parameters (such as melting point, cross-sectional area, material composition) to be varied while maintaining the same terminal structure. This enables the terminal to provide different protection levels and response characteristics for different applications without changing the overall device design or manufacturing process, thus achieving both specificity and general-purpose usability.
2Adaptability or versatility
If a fusible element is designed with customizable material and shape, then the resistance value and melting point can be adjusted for specific applications, but the manufacturing precision requirements increase
Solution Approach 1:
The patent applies segmentation by separating the terminal into a standardized body portion and a configurable fusible element portion. The fusible element is designed as a distinct component that can be independently manufactured and inserted into the terminal body. This segmentation allows the fusible element to be customized for different applications while the terminal body maintains consistent manufacturing specifications, thereby reducing overall manufacturing precision requirements.
Solution Approach 2:
The patent uses the terminal body as an intermediary structure that houses and connects the fusible element. The body provides standardized connection points and mechanical support, while the fusible element serves as the customizable protection mechanism. This intermediary design allows customization of the fusible element without affecting the precision requirements of the terminal body manufacturing.
3Speed
If the element thickness is reduced to enable quick disconnection, then the response speed to overcurrent is improved, but the mechanical strength and connection reliability decrease
Solution Approach 1:
The patent applies local quality by making the fusible element thinner specifically at the portion that is intended to melt and disconnect during overcurrent conditions, while maintaining adequate thickness in other areas for mechanical strength and proper connection. This localized thinning allows the element to quickly respond to overcurrent by melting at the reduced-thickness section while the rest of the structure maintains sufficient strength for normal operation and reliable connection to terminals.
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
Enables safe and quick protection of electronic circuits from overcurrents, with customizable disconnection times and resistance values, suitable for general-purpose use by determining the resistance and melting point based on material and shape, enhancing circuit protection reliability.
Implementation Method 1
the element disconnects the first sectional terminal and the second sectional terminal by melting when a current exceeding a preset condition flows inside through the first sectional terminal
Implementation Method 2
when a current exceeding a preset condition flows inside through the first sectional terminal
Data Source
AI summary
A high current terminal for electronic circuit protection includes: a first sectional terminal into which a current flows from the outside; a second sectional terminal transmitting a current flowing inside through the first terminal to the outside; and an element coupled between the first sectional terminal and the second sectional terminal, wherein the element disconnects the first sectional terminal and the second sectional terminal by melting when a current exceeding a preset condition flows inside through the first sectional terminal, and is formed to have a thickness that is equal to or less than thicknesses of the first sectional terminal and the second sectional terminal.