Layered Fuse Element for Fast Cutting at Lower Material Cost
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Solution Overview
Problem
Existing fuse elements face challenges in achieving quick cutting during overcurrents while maintaining low production costs, particularly when using copper or copper alloys for high-melting-point metal layers, which form oxide films, and silver alloys increase material costs.
Innovation Solution
A fuse element design with a low-melting-point metal layer, a high-melting-point metal layer, and an intermediate layer with controlled melting points and thickness ratios, where the intermediate layer's melting point is between the other two, allowing for rapid cutting and reduced material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If copper or copper alloy is used as high-melting-point metal layer material, then production costs are reduced, but oxide film formation hinders liquefaction and decreases cutting speed
Solution Approach 1:
A zinc intermediate layer is introduced between the low-melting-point metal layer and the copper-based high-melting-point metal layer. This intermediate layer acts as a mediator that prevents oxide film formation on the copper layer while allowing efficient heat transfer from the molten low-melting-point layer to liquefy the high-melting-point layer, thus resolving the contradiction between cost reduction and cutting speed maintenance
2Speed
If silver or silver alloy is used as high-melting-point metal layer material, then liquefaction speed is accelerated, but material costs increase
Solution Approach 1:
The invention changes the material parameter of the high-melting-point metal layer from expensive silver to cost-effective copper or copper alloy, while compensating for the reduced liquefaction efficiency by introducing a zinc intermediate layer that enhances heat transfer and prevents oxide film formation, thus achieving fast liquefaction at lower material cost
3Ease of manufacture
If high-melting-point metal layer thickness is reduced to decrease material costs, then production costs are reduced, but fuse element strength decreases
Solution Approach 1:
The invention creates a composite layered structure consisting of a low-melting-point metal layer, a zinc intermediate layer, and a copper-based high-melting-point metal layer. This composite structure allows the high-melting-point layer to be thinner while maintaining overall strength through the synergistic combination of layers, each contributing different properties (melting characteristics, oxide prevention, structural support)
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 enables quick cutting during overcurrents with maintained strength and reduced production costs by using a layered structure with optimized melting points and thicknesses, ensuring efficient operation and cost-effectiveness.
Implementation Method 1
the low-melting-point metal layer melts, and this melted substance liquefies the high-melting-point metal layer, thereby cutting the fuse element
Implementation Method 2
this melted substance liquefies the intermediate layer and the high-melting-point metal layer
Implementation Method 3
This causes the heating body to generate heat
Implementation Method 4
the low-melting-point metal layer is melted by heat emitted by the heating body
Data Source
AI summary
A fuse element includes: a low-melting-point metal layer; a high-melting-point metal layer provided over at least one surface of the low-melting-point metal layer; and an intermediate layer disposed between the low-melting-point metal layer and the high-melting-point metal layer. Each of the high-melting-point metal layer and the intermediate layer is made of a metal that is liquefied by contacting a molten form of the low-melting-point metal layer. The high-melting point metal layer is made of silver or an alloy comprising silver as a main component thereof. A melting point of a material constituting the intermediate layer is higher than a melting point of a material constituting the low-melting-point metal layer and lower than a melting point of a material constituting the high-melting-point metal layer.