Power Supply Fuse for Overcurrent Protection
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Solution Overview
Problem
Conventional power supply control devices risk short-circuits between the battery and output terminal due to continuous current flow when the switch malfunctions, leading to potential overheating and resin melting, which can cause contact between conductors and result in overcurrent issues.
Innovation Solution
Incorporating a fuse portion between the switch control portion and the output terminal that breaks when a predetermined current is exceeded, along with strategically positioned conductors and substrates with gaps to minimize contact between battery and output conductors, and using multiple fuse elements in parallel to ensure continuous power supply.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a thin conducting wire with large resistance is used to supply power to the switch control portion, then the device complexity is reduced, but overcurrent may flow through the wire when a short-circuit forms between the positive electrode and output terminal
Solution Approach 1:
The patent introduces a fuse portion as an intermediary protective element in the power supply path to the switch control portion. This fuse acts as a mediator that prevents overcurrent from reaching the thin conducting wire, thereby protecting the system while allowing the use of simpler conductor configurations.
Solution Approach 2:
The fuse portion is positioned upstream in the power supply path, performing preliminary protection before current reaches the switch control portion and thin conducting wires. This preliminary action prevents overcurrent conditions from developing in the first place, rather than reacting to them afterward.
2Reliability
If the switch is disposed on the output substrate and kept in the on state due to malfunction, then continuous current flows through the switch, but the resin melts before the fuse breaks, causing contact between battery conductor and output conductor
Solution Approach 1:
The fuse portion serves as an intermediary protective element that interrupts excessive current flow before it can generate enough heat to melt the resin. By positioning the fuse in the power supply path to the switch control portion, it acts as a thermal buffer that protects the resin from overheating.
Solution Approach 2:
The fuse portion provides beforehand cushioning against thermal damage by being positioned to limit current flow that could cause resin melting. This protective measure is in place before any malfunction occurs, cushioning the system against potential thermal runaway.
3Reliability
If multiple fuse elements are connected in parallel, then continuous power supply is maintained even if one fuse element becomes defective, but the device complexity increases
Solution Approach 1:
The fuse portion is segmented into multiple fuse elements connected in parallel. This segmentation allows the system to maintain functionality even if one segment fails, as the other segments continue to provide protection and allow current flow. The segmentation distributes the protective function across multiple independent elements.
Solution Approach 2:
Each fuse element within the parallel configuration has the same protective function, but their collective arrangement provides enhanced reliability. The local quality of each individual fuse element remains simple, while the overall system gains improved fault tolerance through the parallel configuration.
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
This configuration significantly reduces the likelihood of short-circuits between the battery and output terminal, preventing overcurrent flow and maintaining power supply even if one fuse element becomes defective, while allowing for a smaller conductor size with lower resistance.
Implementation Method 1
If a current that is greater than or equal to a given current flows to the fuse, the fuse breaks.
Data Source
AI summary
In a power supply control device, a microcomputer controls the supply of power from a battery to loads via a battery conductor by individually switching on and off switches. While power is being supplied from the battery to the microcomputer, current flows from the positive electrode of the battery to a battery terminal, the battery conductor, a diode, a resistor, a regulator, the microcomputer, an intermediate conductor, a fuse portion, a GND conductor, and a GND terminal in this order. If a current greater than or equal to a predetermined current flows to the fuse portion, the fuse portion breaks.