Miniature Super Surface Mount Fuse with Segmented Fusing Points
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing miniature fuses fail to meet safety and quality requirements for modern electronic devices, particularly in high overload conditions, due to issues such as arc leakage, inconsistent breaking characteristics, and inability to handle extreme short-circuit scenarios without causing fires or explosions.
Innovation Solution
A miniature super surface mount fuse design featuring a fuse element with low overload and high breaking capacity fusing points, cavity plates, substrates, and a filler with unequal particle sizes to absorb and extinguish arc energy, ensuring safe operation under various overload conditions without jetting, smoking, or cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single wire wound fuse element is used, then the fuse structure is simple, but the fusing and breaking characteristics are inconsistent and quality stability is poor
Solution Approach 1:
The fuse element is divided into multiple parallel wires instead of a single wire, with each wire contributing to the overall fusing characteristics. This segmentation provides redundancy and consistency, ensuring reliable breaking characteristics while maintaining structural simplicity
Solution Approach 2:
The fuse element uses composite construction with multiple parallel wires of specific materials (e.g., tin-clad copper) to achieve consistent electrical and thermal properties, improving quality stability while keeping the design straightforward
2Ease of manufacture
If fillers are filled tightly by vibration in conventional ceramic tube fuses, then the filling process is simple, but the tube orifice cannot be filled effectively, reducing high breaking capacity
Solution Approach 1:
The tube orifice is pre-filled with filler material before the main filling process, ensuring that the critical orifice region is properly filled. This preliminary action enables effective arc containment and high breaking capacity while maintaining manufacturing simplicity
Solution Approach 2:
Different regions of the fuse body receive different filling treatments, with the tube orifice receiving special attention to ensure proper filler placement. This local quality approach optimizes arc extinguishing performance without complicating the overall manufacturing process
3Strength
If a large amount of high-temperature soldering tin is used, then the welding strength is improved, but the fuse explodes and ignites under extreme short-circuit conditions
Solution Approach 1:
The soldering tin quantity and composition are optimized to achieve adequate welding strength with reduced material amount. By adjusting the tin content and welding parameters, the design achieves reliable electrical connections while minimizing the risk of explosion and ignition under extreme conditions
Solution Approach 2:
The design accepts that some soldering material may melt under extreme conditions but channels this energy harmlessly through proper filler placement and cavity design, converting the potential harmful effect into a controlled thermal management solution
4Reliability
If the fuse element and soldering tin are melted and gasified under extreme conditions, then the breaking capacity is achieved, but huge pressure is generated causing the fuse to ignite and explode
Solution Approach 1:
The filler material is designed with porous structure and appropriate composition to absorb and distribute the pressure generated during fuse breaking. This porous filler system allows controlled gas expansion while preventing dangerous pressure buildup that could cause explosion, jets, or cracking
Solution Approach 2:
The filler material acts as an intermediary between the fuse element and the external environment, absorbing the energy from melted and gasified materials. This intermediary layer prevents direct transmission of harmful pressure and heat, eliminating ignition and explosion risks while maintaining effective breaking capacity
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 effectively controls fusing under different conditions, prevents explosions, and enhances arc extinguishing capabilities, meeting stringent safety standards while improving production efficiency through modular design and thin film technology.
Implementation Method 1
a filler, the filler being filled in the first cavity and the second cavity, and the filler comprising a powder having unequal particle sizes
Implementation Method 2
the surface of the low overload fusing point is coated by a low-melting-point metal layer
Implementation Method 3
the surface of the low overload fusing point is coated by a low-melting-point metal layer
Data Source
AI summary
The present disclosure discloses a miniature super surface mount fuse, comprising: a fuse element provided with a low overload fusing point and at least two high breaking capacity fusing points connected in series with the low overload fusing point and respectively arranged on two sides of the low overload fusing point, at least two cavity plates provided with cavities, the low overload fusing point and the high breaking capacity fusing points being located at corresponding positions of the cavities; the present disclosure further provides a manufacturing method for a surface mount fuse; the miniature super surface mount fuse of the present disclosure can provide the protection for the civil consumer electronic circuit under various overload conditions without the occurrence of safety hazards such as smoking or cracking of the housing or explosion.