Multilayer Fuse with Anti-Arc Cavity for Compact Current Protection
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Solution Overview
Problem
Conventional current protection fuses face issues with reliability due to non-uniform ceramic powder and temperature distribution, leading to safety concerns, large size, high cost, and low yield, as well as inability to prevent electric arcs in compact and lightweight electronic devices with high rated currents.
Innovation Solution
A current protection device comprising a substrate with a fusing layer and cavity for space provision, an anti-electric arc layer to absorb arcs, and end electrodes with silver, nickel, and tin layers, allowing for increased rated current and efficient protection in a compact, low-cost design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional integral forming method is used, then manufacturing process is simplified, but reliability is low due to non-uniform temperature distribution and ceramic powder uniformity
Solution Approach 1:
The fuse structure is divided into multiple independent layers (first fuse layer, second fuse layer, third fuse layer) that can be manufactured separately and then assembled. This segmentation allows each layer to be controlled independently, improving temperature uniformity and ceramic powder consistency while maintaining manufacturing efficiency through modular production.
Solution Approach 2:
A middle layer is introduced between the first and second fuse layers to act as an intermediary component. This middle layer serves as a buffer that helps distribute and equalize temperature distribution during manufacturing, thereby improving the overall reliability of the fuse structure without significantly complicating the manufacturing process.
2Volume of moving object
If fuse size is reduced for compact electronic products, then device compactness is improved, but electric arc prevention capability deteriorates
Solution Approach 1:
The fuse structure employs a nested configuration where multiple fuse layers are stacked within a compact housing. The first, second, and third fuse layers are arranged in sequence, with each layer containing smaller arc suppression elements. This nested arrangement maximizes the arc suppression capability within a minimized volume, allowing compact electronic products to maintain effective electric arc prevention.
Solution Approach 2:
The fuse incorporates composite material structures combining different ceramic powders and metallic elements in specific ratios across multiple layers. This composite approach enhances the arc suppression performance per unit volume, enabling smaller fuse dimensions while maintaining or improving electric arc prevention capability through optimized material composition and layering.
3Power
If multilayer structure with more materials is used, then rated current can be increased, but manufacturing cost and complexity increase
Solution Approach 1:
Different fuse layers are designed with locally optimized properties - the first fuse layer contains specific ceramic powders for low-voltage protection, the second layer contains different ceramic compositions for medium-voltage protection, and the third layer contains materials optimized for high-voltage protection. This local quality differentiation allows the fuse to handle higher rated currents through specialized zones without requiring a uniformly complex structure throughout, thereby managing manufacturing complexity while increasing power capability.
4Ease of manufacture
If conventional fuse structure is used, then manufacturing process is simple, but yield ratio is low due to reliability issues
Solution Approach 1:
The fuse structure incorporates preliminary protective measures through the middle layer and arc suppression elements that are pre-configured to prevent common failure modes. The middle layer is designed in advance to compensate for potential temperature non-uniformities, and the multi-layer ceramic structure is pre-engineered to ensure uniform powder distribution. These preliminary actions prevent defects before they occur during operation, thereby improving yield ratio without significantly complicating the manufacturing process.
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 solution enhances safety by preventing electric arcs, supports compact and lightweight designs, and improves manufacturing efficiency and cost-effectiveness while maintaining high reliability.
Implementation Method 1
the anti-electric arc layer serves to absorb the electric arc as the fuse breaks to protect the circuit
Implementation Method 2
If the current past is too large, the fused portion will fuse so as to prevent the circuit to short-circuit
Data Source
AI summary
A current protection device comprises a substrate having an upper portion and a lower portion; a fusing layer installed between the upper portion and the lower portion; ends of the fusing layer exposed from the substrate; a cavity formed near surfaces of the fusing layer for providing a space to receive the fusing layer as the fusing layer fuses; and an end electrode having three layers including a silver thin layer, a nickel thin layer and a tin thin layer; the end electrode being formed as a conductive electrode. The method for forming the same is provided.