Integrally Fused Conductor for Compact Electrical Devices
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Solution Overview
Problem
Existing electrical devices face challenges in integrating fuses reliably and efficiently, particularly in compact designs where auto-splice members are costly, complex, and difficult to attach, or where space is limited, such as in lighting systems, cell phones, and telecom units.
Innovation Solution
An integrally fused electrical device is developed, where a conductor is thinned to form a fuse element, eliminating the need for auto-splice members, and this fuse element is sized to rated amperage levels, allowing it to open upon overcurrent conditions, providing protection to the device and connected units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If auto-splice members are used to attach fuse leads to conductors, then reliable electrical connection is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The fuse lead and conductor are merged into a single integral structure where the conductor itself forms the fuse element. This eliminates the need for separate auto-splice members and their associated attachment mechanisms, thereby reducing assembly complexity while maintaining electrical connection reliability through the continuous conductive path.
Solution Approach 2:
The conductor serves multiple functions: it acts as both the electrical connection element and the fuse element. By making the conductor multi-functional, the patent eliminates the need for separate fuse leads and attachment members, simplifying the overall assembly while ensuring reliable electrical connection and overcurrent protection.
2Reliability
If auto-splice members are used to attach fuse leads to conductors, then reliable electrical connection is achieved, but manufacturing cost increases
Solution Approach 1:
The fuse lead and conductor are merged into a single integral structure where the conductor itself forms the fuse element. This eliminates the need for separate auto-splice members and their associated attachment mechanisms, thereby reducing assembly complexity while maintaining electrical connection reliability through the continuous conductive path.
Solution Approach 2:
The conductor serves multiple functions: it acts as both the electrical connection element and the fuse element. By making the conductor multi-functional, the patent eliminates the need for separate fuse leads and attachment members, simplifying the overall assembly while ensuring reliable electrical connection and overcurrent protection.
3Reliability
If auto-splice members are used to attach fuse leads to conductors, then fuse protection is achieved, but available space in compact devices is reduced
Solution Approach 1:
The fuse lead and conductor are merged into a single integral structure where the conductor itself forms the fuse element. This eliminates the need for separate auto-splice members and their associated attachment mechanisms, thereby reducing assembly complexity while maintaining electrical connection reliability through the continuous conductive path.
Solution Approach 2:
The patent extracts and eliminates the unnecessary auto-splice members from the assembly, keeping only the essential conductor that serves as the fuse element. This removal of redundant components reduces the overall volume required for the fuse assembly, making it suitable for compact devices while maintaining effective overcurrent protection.
4Reliability
If auto-splice members are used to attach fuse leads to conductors, then fuse protection is achieved, but difficulty of attachment increases
Solution Approach 1:
The fuse lead and conductor are merged into a single integral structure where the conductor itself forms the fuse element. This eliminates the need for separate auto-splice members and their associated attachment mechanisms, thereby reducing assembly complexity while maintaining electrical connection reliability through the continuous conductive path.
Solution Approach 2:
The patent extracts and eliminates the unnecessary auto-splice members from the assembly, keeping only the essential conductor that serves as the fuse element. This removal of redundant components reduces the overall volume required for the fuse assembly, making it suitable for compact devices while maintaining effective overcurrent protection.
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 solution enables reliable and space-efficient fuse protection in electrical devices, ensuring safe operation by automatically opening at rated amperage levels, thus preventing damage from overcurrent conditions without the need for additional attachment devices.
Implementation Method 1
the thinned portion configured to open upon an overcurrent event
Data Source
AI summary
A fused conductor includes a first conductor portion, a second conductor portion, and a fuse element in electrical communication with the first and second conductor portions via at least one dual metal wire, the fuse element protected by a glass body bonded chemically to the dual metal wire.