Integrated Conductor Fuse Structure for Reliable High-Current Breaking
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Solution Overview
Problem
Current-limiting fuses face challenges in reliably interrupting high currents while avoiding premature triggering at lower current values, particularly due to connection failures between the fusible wire and end caps.
Innovation Solution
A current-limiting fuse design featuring an integrally formed electrical conductor element with a melting section of reduced cross-section, which is both the fuse material and the terminal connections, housed within an insulating tubular structure that seals the openings, ensuring reliable high-current interruption without external connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple separate components (fusible wire, end caps, connections) are used, then the fuse can be constructed with modular parts, but the construction becomes complex and manufacturing becomes difficult
Solution Approach 1:
The patent combines multiple separate components (end caps, terminal connections, and fusible wire) into a single integrally formed conductor element. This reduces the number of parts from multiple discrete components to one unified structure, significantly simplifying construction and manufacturing while eliminating assembly steps and potential misalignment issues.
2Ease of operation
If the housing has multiple openings for wire insertion and connection, then the fuse can be assembled, but molten material from the melting section can escape and damage neighboring elements
Solution Approach 1:
The patent extracts the harmful escape path for molten material by sealing the housing openings with the conductor element itself. The conductor element extends through and seals the openings, removing the escape routes that would otherwise allow molten material to damage external components. The housing becomes a contained environment that protects surrounding elements.
Solution Approach 2:
The conductor element acts as an intermediary that both provides the necessary assembly pathway through the housing and simultaneously seals the openings to prevent harmful material escape. The same component that enables assembly also prevents damage, serving as a protective barrier.
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 design enhances reliability and simplicity in manufacturing, prevents damage from molten material, and allows for high current applications up to 10kA, with a non-resettable fuse that maintains high insulating resistance and breaking capacity.
Implementation Method 1
The melting section is located in the interior space and is configured to melt, when a predefined maximum allowable electrical current in the conductor element is exceeded
Data Source
Figure 1~2b
Figure 3a~3d
Figure 4a
AI summary
Current-limiting fuse (20) comprising - an electrically insulating housing (2) with walls surrounding an interior space (6), with a first opening (7) and with a second opening (8) opposite to said first opening, and - an integrally formed electrical conductor element (1) extending from a first terminal area (3) outside said housing, across said first opening, across said interior space, across said second opening and to a second terminal area (4) outside said housing, wherein said conductor element comprises a melting section (5) of reduced cross-section, said melting section being located in said interior space and being configured to melt, when a predefined maximum allowable electrical current in the conductor element is exceeded, and wherein a first sealing section (9) of the conductor element seals said first opening (7) and wherein a second sealing section (10) of the conductor element seals said second opening (9). The invention is further directed to a method of manufacturing the current-limiting fuse.