Miniature Fuse Component Segmented Insulating Body Assembly
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Solution Overview
Problem
Existing miniature fuses are expensive and difficult to assemble, requiring complex automated processes prone to failure, which complicates the production of reliable overcurrent protection devices.
Innovation Solution
A miniature fuse component with a longitudinally divided insulating body comprising two electrically insulating shells that can be easily assembled to form a channel for the fusible conductor, allowing for automated and simplified assembly, and featuring angled ends for secure end cap attachment without additional processing, and indirect soldering for electrical contact without organic residues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sealing stoppers and complex assembly processes are used, then reliable pressure equalization and sealing are achieved, but manufacturing cost increases and assembly difficulty increases
Solution Approach 1:
The insulating body is divided into two separate half-shells that are joined together to form the complete housing. This segmentation allows the fusible conductor to be inserted between the half-shells before final assembly, eliminating the need for complex sealing stoppers and enabling simpler automated assembly processes while maintaining reliable pressure equalization through the design of pressure compensation channels in the half-shells
Solution Approach 2:
The fusible conductor is pre-positioned between the two half-shells before they are joined together. This preliminary action simplifies the assembly process by eliminating the need for separate operations to install and seal the conductor, allowing for straightforward automated assembly while ensuring proper positioning and pressure equalization
2Ease of manufacture
If automated assembly processes are simplified, then manufacturing cost decreases, but assembly reliability may be compromised
Solution Approach 1:
Dividing the insulating body into two half-shells creates a modular structure that is ideal for automated assembly. The half-shells can be easily positioned and joined using simple joining means such as clips or adhesive, which are reliable and easy to automate. This segmentation maintains assembly reliability while enabling cost-effective automated manufacturing
Solution Approach 2:
The joining means for the half-shells are integrated into the design of the half-shells themselves, combining the functions of structural support, alignment, and secure attachment into a single integrated solution. This merging simplifies the automated assembly process while ensuring reliable and consistent joining
3Stress or pressure
If pressure compensation channels are provided, then pressure increase is controlled, but device complexity increases
Solution Approach 1:
The pressure compensation channels are formed as integral features of the half-shells themselves, dividing the pressure management function across the segmented structure. This approach controls pressure increase during fuse operation while avoiding the need for separate, complex pressure management components
Solution Approach 2:
The half-shells serve multiple functions: they provide structural housing, contain the fusible conductor, create pressure compensation channels, and facilitate assembly through their joining mechanism. This multi-functionality reduces overall device complexity while maintaining effective pressure control
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
Enables reliable and cost-effective assembly of miniature fuses with improved arc control and reduced production complexity, allowing for smaller housing dimensions and efficient arc phase management under direct voltage conditions without the need for extinguishing agents.
Implementation Method 1
Fuse components are overcurrent protection devices that interrupt a circuit by melting a fusible conductor as soon as the current exceeds a certain value for a specified time
Implementation Method 2
The pulsed energy supply generates an arc plasma based on impact ionization of the (gas) molecules surrounding the fusible conductor, accompanied by strong heating and pressure development in the interior of the encapsulation
Implementation Method 3
The arc is extinguished by the pressure increase as soon as the arcing voltage exceeds the driving source voltage present at the terminal contacts of the fuse
Data Source
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AI summary
The invention relates to a fuse component (1) having a fuse element (2), wherein the fuse element (2) is located inside an isolating body (3) and the fuse element (2) extends between the two end faces of the isolating body (3), the end faces of the isolating body (3) are closed in each case by electrical conductive end caps (4) and the end caps (4) are in electrical contact with the fuse element (2), wherein the isolating body (3) is composed of at least two shells (5a, 5b), at least in the region of the end caps (4), and the shells (5a, 5b) in the assembled state form a channel (6) to receive the fuse element (2).