High-Voltage DC Thermal Fuse U-Shaped Fusible Component
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Solution Overview
Problem
Existing high-voltage thermal fuses face issues with the fluxing agent either causing the fusing cavity to burst due to excessive volume or failing to activate the oxide layer sufficiently, leading to inadequate current cutoff under high-voltage conditions.
Innovation Solution
A high-voltage direct-current thermal fuse design with a U-shaped fusible component, controlled fluxing agent volume ratio of 50% or less, and an insulation block to generate a high-strength electromagnetic field, accelerating arc cutoff and enhancing oxide layer activation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fluxing agent fills the entire fusing cavity or at least 80% of it, then the oxide layer on the fusible alloy surface is activated effectively, but the fusing cavity may burst under high-voltage conditions due to gasification and expansion of the fluxing agent
Solution Approach 1:
The patent changes the volume ratio parameter of the fluxing agent from the conventional 80% or more to 50% or less of the fusing cavity volume. This parameter adjustment reduces the risk of cavity burst while maintaining effective oxide layer activation through the optimized spatial arrangement and increased gap surface area of the U-shaped fusible component.
2Object-affected harmful factors
If the fluxing agent amount is reduced to prevent fusing cavity burst, then the oxide layer activation may be insufficient, but the current cutoff speed decreases
Solution Approach 1:
The patent transitions from a linear fusible component structure to a U-shaped structure with two support arms arranged opposite to each other. This dimensional change increases the gap surface area between the fusible component and insulation block, thereby increasing the contact surface between the fluxing agent and fusible component, which accelerates oxide layer activation and maintains fast current cutoff speed despite reduced fluxing agent volume.
3Device complexity
If the fusible component uses a traditional linear structure, then the structure is simple, but the gap surface between the fusible component and insulation block is limited, reducing fluxing agent contact efficiency
Solution Approach 1:
The patent employs a U-shaped fusible component structure with two support arms arranged opposite to each other, transforming a one-dimensional linear structure into a two-dimensional spatial configuration. This increases the gap surface area between the fusible component and insulation block from a single contact point to multiple contact points along the U-shaped structure, enhancing fluxing agent contact efficiency without significantly increasing 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
Prevents fusing cavity bursting and ensures rapid current cutoff, providing effective thermal protection for high-voltage circuits by elongating the arc and increasing the contact surface for fluxing agent activation.
Implementation Method 1
The fluxing agent can effectively activate the oxide layer on the surface of the fusible alloy, thereby increasing the contraction rate of the fusible alloy
Implementation Method 2
When the arc is cut off, a high-strength electromagnetic field is generated, and the electrons repel each other, thereby elongating the arc, and quickly cutting off the arc
Implementation Method 3
the fusible alloy is arranged in a fusing cavity... the contraction rate of the fusible alloy
Data Source
AI summary
A high-voltage direct-current thermal fuse includes one or more fusible components each having two fusible alloy support arms, a fluxing agent, a fusing cavity, two pins, and an insulation block. Two fusible alloy support arms are arranged opposite, and the fusible component is U-shaped. The fusible component and the fluxing agent are sealed within the fusing cavity. The two pins are respectively connected to the two fusible alloy support arms. The insulation block is arranged between the two fusible alloy support arms and separates the two pins. A volume ratio of the fluxing agent to the fusing cavity is approximately 50% or less, preferably, 10%-50%. The number of the one or more fusible components is at least two, and the at least two fusible components are arranged separately. The thermal fuse can avoid the burst and quickly cut off the current, which provides effective thermal protection for a circuit.