Notched Surface-Mount Fuse Body for Flat Endcap Alignment
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Solution Overview
Problem
Conventional surface mount fuses often have skewed endcaps due to interference from the fusible element, leading to suboptimal affixation and electrical connection on printed circuit boards.
Innovation Solution
A surface mount fuse design featuring a tubular fuse body with notches on its end faces to accommodate the fusible element, allowing endcaps to abut flatly without interference, ensuring parallel and coplanar alignment with the PCB.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fusible element extends over the end face of the fuse body, then the fusible element can be properly positioned and secured, but the endcap becomes skewed and out of parallel with the PCB
Solution Approach 1:
The end face of the fuse body is segmented into multiple notches that divide the surface into distinct zones. The fusible element is positioned within specific notches while other notches remain clear, allowing the endcap to abut the end face without interference from the fusible element, thereby achieving both proper fusible element positioning and flat endcap alignment
Solution Approach 2:
Different regions of the end face are given different functions through the notch pattern. Specific local areas (notches) accommodate the fusible element while other local areas provide flat abutment surfaces for the endcap. This local differentiation allows the fusible element to be secured in specific notches while the endcap contacts only the flat portions, resolving the contradiction between fusible element positioning and endcap alignment
2Area of stationary object
If the endcap is designed to cover the entire end face, then complete coverage and protection is achieved, but the endcap cannot abut flatly due to fusible element interference
Solution Approach 1:
The end face is segmented into multiple notches that create distinct zones. The fusible element is confined to specific notches, allowing the endcap to cover the entire end face while abutting flatly on the portions between notches. This segmentation enables complete coverage without sacrificing installation quality
Solution Approach 2:
The notches act as intermediaries that separate the fusible element from the endcap contact area. By providing designated notches for the fusible element, the design allows the endcap to maintain full coverage while the notches mediate the spatial conflict, enabling the endcap to abut flatly without direct contact with the fusible element
Data Source
AI summary
A fuse including a fuse body having first and second end faces at opposing first and second longitudinal ends thereof, each of the first and second end faces having at least one notch formed therein, a fusible element extending through the fuse body and having a first end bent over the first end face and disposed within the at least one notch in the first end face and a second end bent over the second end face and disposed within the at least one notch in the second end face, and a first endcap disposed on the first longitudinal end of the fuse body and a second endcap disposed on the second longitudinal end of the fuse body, wherein the first and second endcaps flatly abut the first and second end faces without interference from the fusible element.