Multi-layer Fuse Wire Head-to-tail Connection for Anti-surge Capability
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Solution Overview
Problem
Current fuse manufacturing methods are complex, costly, and time-consuming, limiting the widespread use of high anti-surge capability fuses due to their multi-layered structure and lengthy production processes.
Innovation Solution
A multi-layer fuse design utilizing conventional single-layer printing technology for back and front electrodes and metal ends, with a head-to-tail connection of fuse wire layers and protective layers, enhancing anti-surge capability while simplifying the manufacturing process and reducing equipment investment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If monolithic multi-layer structure is adopted to enhance anti-surge capability, then anti-surge capability is improved, but device complexity and manufacturing complexity increase
Solution Approach 1:
The fuse wire is divided into multiple separate layers instead of forming a monolithic multi-layer structure. Each layer can be independently manufactured and then assembled together, simplifying the manufacturing process while maintaining the multi-layer configuration that provides enhanced anti-surge capability
Solution Approach 2:
Multiple fuse wire layers are combined through assembly rather than requiring a complex monolithic manufacturing process. The layers are merged into a functional multi-layer fuse structure using simpler techniques such as stacking and bonding, reducing manufacturing complexity while achieving the desired reliability
2Reliability
If monolithic multi-layer structure with multiple deposition processes is used, then anti-surge capability is improved, but manufacturing duration increases
Solution Approach 1:
The fuse wire layers are prepared separately in advance through independent manufacturing processes, allowing parallel production of multiple layers. This preliminary preparation of individual layers significantly reduces the total manufacturing duration compared to sequential monolithic multi-layer deposition, while still achieving the required anti-surge capability through the final assembled multi-layer structure
3Ease of manufacture
If conventional single-layer printing technology is used, then equipment investment is reduced, but fuse wire length and anti-surge capability are limited
Solution Approach 1:
The fuse wire is extended from a single-layer two-dimensional pattern into a three-dimensional multi-layer structure. By stacking multiple layers vertically, the total fuse wire length is significantly increased without requiring more complex printing equipment, thereby enhancing anti-surge capability while maintaining simplicity in manufacturing equipment
Solution Approach 2:
Multiple fuse wire layers are nested one above another in a vertical arrangement, with each layer contributing to the total length. This nested multi-layer configuration effectively multiplies the fuse wire length compared to a single-layer design, using only conventional printing technology for each layer
Data Source
AI summary
A multi-layer fuse and its manufacturing method are provided. The multi-layer fuse comprises a ceramic substrate, back electrodes, front electrodes, fuse wire, protective layers and metal ends, wherein the fuse wire is prepared in multiple layers and the adjacent layers of fuse wire are connected in a head-to-tail style; the two lead-outs of the fuse wire as a whole are respectively connected to the two front electrodes located at the two ends of the substrate, and each layer of the fuse wire is deposited with a protective layer. During manufacturing, all protective layers but the upmost one leaves the tail of each layer of fuse wire uncovered so that the head-to-tail series connection is possible.