Laminated Fuse Manufacturing to Prevent Copper Oxidation
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Solution Overview
Problem
Automotive fuses are prone to oxidation due to exposure during conventional manufacturing processes, which involves surface-mounting copper wires without insulation, leading to potential defects.
Innovation Solution
A fuse manufacturing method using a machine tool with specific assemblies for feeding, cutting, laminating, and winding, ensuring the fuse is fully enclosed by insulating films to prevent oxidation, including a laminating assembly with symmetrically arranged insulating film and metal conductor conveying structures for precise positioning and thermal pressing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional surface-mounting process is used to fix copper wires, then operation simplicity is improved, but oxidation resistance deteriorates due to exposure
Solution Approach 1:
The insulating film is prepared and positioned before the copper wire is mounted onto the substrate. By pre-establishing the protective insulating layer, the copper wire is prevented from oxidizing during subsequent assembly operations, thus resolving the contradiction between operational simplicity and oxidation resistance
Solution Approach 2:
An insulating film is applied to cover the copper wire, forming a protective thin film barrier that prevents oxidation while allowing the wire to maintain its electrical function. This flexible film approach protects the exposed copper surface without complicating the assembly process
2Object-affected harmful factors
If insulating film is applied to cover copper wire, then oxidation resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The insulating film application process is merged with the existing PCB assembly process. The insulating film is integrated into the same manufacturing line where copper wires are mounted, combining two operations into a unified process flow that reduces overall manufacturing complexity while maintaining oxidation protection
Solution Approach 2:
The insulating film is designed to be self-adhering or self-positioning, utilizing its own properties to attach to the copper wire without requiring additional complex bonding equipment or multi-step processes. This self-service characteristic simplifies the manufacturing system while ensuring effective oxidation 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 method effectively prevents oxidation by ensuring the fuse is fully insulated, improving production yield and reducing defects, while allowing for efficient batch production and easy storage.
Implementation Method 1
a first thermal pressing structure, and a traction structure; the support structure is sequentially provided with the first insulating film conveying structure, the first thermal pressing structure, the second insulating film conveying structure, and the traction structure in a first direction
Implementation Method 2
laminating, by the laminating assembly, the plurality of target metal conductors and the insulating film assembly to form the target fuse
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A fuse manufacturing method using a machine tool, the machine tool including a control device, a wire feeding assembly, a circular cutting assembly, a laminating assembly and a wire winding assembly. The fuse manufacturing method includes the following steps. Shapes and sizes of a plurality of target metal conductors in a target fuse are obtained. The circular cutting assembly is selected to match the shapes and sizes. A to-be-processed fuse material is fed from the wire feeding assembly. A metal conductor of the to-be-processed fuse material is processed by the circular cutting assembly to obtain the plurality of target metal conductors corresponding to the target fuse. The plurality of target metal conductors and an insulating film assembly are positioned at a target location on the laminating assembly and laminated by the laminating assembly to form the target fuse. The target fuse is wound by the wire winding assembly.