PCB Electrical Tap With Sealed Conductor-Track Overcurrent Protection
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Solution Overview
Problem
Existing power distribution components face challenges in efficiently and cost-effectively protecting against overcurrents and preventing arc faults in electrical taps, which can lead to damage and safety risks, particularly in low-voltage networks with renewable energy fluctuations.
Innovation Solution
An electrical tap with an integrated overcurrent protection device, where the conductor track on a printed circuit board forms the protection mechanism, ensuring hermetic sealing and eliminating the need for separate fuses, thus preventing arcs and allowing for simple and inexpensive manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate electrical fuse is used to protect against overcurrent, then overcurrent protection is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent integrates the overcurrent protection function directly into the conductor track of the printed circuit board. The conductor track is designed with a hermetically sealed section that acts as an integrated fuse, eliminating the need for separate electrical fuse components. This merging of the protection function into the existing conductor structure reduces device complexity while maintaining reliable overcurrent protection.
2Reliability
If a separate electrical fuse is used to protect against overcurrent, then overcurrent protection is achieved, but manufacturing cost increases
Solution Approach 1:
The overcurrent protection function is merged into the conductor track structure of the printed circuit board. The hermetically sealed section of the conductor track serves as an integrated fuse element, eliminating the need for separate fuse components and their associated assembly steps. This integration reduces manufacturing complexity and cost while ensuring reliable overcurrent protection.
3Ease of operation
If exposed current-carrying components are used in electrical taps, then electrical connection is achieved, but arc faults can occur leading to damage and safety risks
Solution Approach 1:
The patent applies hermetic sealing specifically to the conductor track section that forms the overcurrent protection device. This localized hermetic sealing creates a protected environment that prevents arc faults while maintaining electrical connectivity. The sealed section isolates the critical overcurrent protection area from environmental factors that could lead to arcing, thereby eliminating safety risks without compromising electrical connection functionality.
4Adaptability or versatility
If the electrical tap is designed as a separate component, then functionality is achieved, but installation and replacement complexity increases
Solution Approach 1:
The electrical tap functionality is integrated directly into the printed circuit board structure. The conductor track with hermetically sealed overcurrent protection is formed as part of the PCB itself, eliminating the need for separate electrical tap components. This integration simplifies installation and replacement procedures while maintaining all necessary electrical tap functions, including voltage tapping and overcurrent protection.
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 effectively interrupts the electrical circuit during overcurrents, prevents arc faults, and allows for easy replacement of the electrical tap, ensuring continued functionality and safety while reducing manufacturing and installation costs.
Implementation Method 1
at least a section of the conductor track, in particular the entire conductor track, is hermetically sealed
Data Source
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Figure 4~5
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AI summary
The present invention relates to an electrical tap (1) with an overcurrent protection device and an arrangement of a current distribution component and an electrical tap (1). The electrical tap (1) according to the invention comprises a printed circuit board (2), the printed circuit board (2) having an input contact (3) and an output contact (4). The input contact (3) is electrically connectable to a current-carrying component. The printed circuit board (2) has a conductor track (5), wherein the input contact (3) and the output contact (4) are electrically connected to each other by means of the conductor track (5), and at least a section of the conductor track (5) forms the overcurrent protection device. At least this section of the conductor track (5) is hermetically sealed.