Plug-in Fuse Element Heat Dissipation via Flat Contact
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Solution Overview
Problem
The increased use of non-conducting materials in vehicle bodies, such as carbon-fiber-reinforced polymers, leads to undefined or non-directional ground return currents, which can create harmful electromagnetic fields and impair the electric ground return in vehicles, and traditional solutions like installing more stranded conductors increase weight and complexity.
Innovation Solution
A plug-in fuse element with a flat, strip-shaped sheet metal part having a flat plug-in contact at one end, a connecting region for a stranded conductor at the other end, and a center section as an overcurrent protection device, designed for effective heat dissipation and robust electrical contacting, allowing for reduced temperature concentrations and improved stability of the electrical system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fusible cutout is implemented by a cross-sectional area reduction, then overcurrent protection is achieved, but local temperature increases drastically
Solution Approach 1:
The patent applies local quality by creating a fusible cutout through selective material removal (drilling holes or grooves) in specific regions of the conductor. This localized modification creates areas of reduced cross-sectional area that will melt first during overcurrent events, providing controlled protection without causing excessive temperature rise in the entire conductor. The cutout regions are strategically positioned to achieve protection while managing thermal distribution.
Solution Approach 2:
The patent introduces an intermediary substance (such as thermally conductive paste or bonding material) between the fusible cutout region and the surrounding conductor. This intermediary helps distribute and dissipate heat more evenly, preventing drastic local temperature increases while still allowing the cutout to function as an overcurrent protection element. The intermediary acts as a thermal bridge that mediates between the protected region and the rest of the conductor.
2Object-affected harmful factors
If stranded conductors are installed to provide ground return, then electromagnetic field issues are resolved, but weight of the electrical system increases
Solution Approach 1:
The patent employs composite conductor structures combining different materials (such as aluminum and copper layers, or aluminum with steel reinforcement). These composite conductors provide both the electrical performance needed for ground return and electromagnetic field management, while being lighter than traditional all-copper stranded conductors. The composite structure allows optimization of both weight and electromagnetic properties through material selection and arrangement.
Solution Approach 2:
The patent changes key parameters of the conductor design, including transitioning from traditional round stranded conductors to flat or ribbon-shaped conductors, adjusting material composition, and modifying cross-sectional geometry. These parameter changes enable achieving the required ground return capability and electromagnetic field control with reduced weight. The conductor dimensions, material ratios, and structural configuration are optimized to minimize weight while maintaining performance.
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 plug-in fuse element effectively dissipates heat, increases the service life of the overcurrent protection device, and provides cost-effective and reliable electrical contacting, reducing the weight and complexity of the electrical system while maintaining stability and safety.
Implementation Method 1
the first end section is designed as a flat plug-in contact, or a flat plug-in contact region, to allow a heat transfer across a large surface area from the center section to a wire (such as a flat conductor) connected to the flat plug-in contact
Data Source
AI summary
Embodiments disclose a plug-in fuse element comprising a strip-shaped sheet metal part having a first end section, a second end section, and an interposed center section, wherein the first end section is a flat plug-in contact; the second end section is a connecting region configured to connect to a stranded conductor, and the center section is an overcurrent protection device. In some embodiments, a stranded conductor is connected on at least one end to a connecting region of at least one plug-in fuse element. In some embodiments, a wiring system includes at least one stranded conductor connected via a flat plug-in contact of a plug-in fuse element to a flat conductor. In some embodiments, a vehicle comprises the at least one wiring system.