Printed Ceramic Fuse Weak Spots for Arc Energy and Fatigue
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Solution Overview
Problem
High voltage, direct current power systems in electric vehicles pose challenges for fuse manufacturers due to the need for smaller, lighter fuses that can handle severe arc energy and cyclic current loads without premature failure, as existing fuses are large, heavy, and costly, and suffer from thermal-mechanical fatigue.
Innovation Solution
The development of printed fuse elements on ceramic substrates with additive manufacturing, where weak spots are formed directly onto the substrate via printing processes, avoiding micro tears and mechanical strain, and incorporating arc extinguishing fillers to manage arc energy effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fuse manufacturing methods are used, then fuse strength and reliability are maintained, but fuse size and weight increase
Solution Approach 1:
The patent replaces traditional mechanical stamping and punching processes with a printing process to form weak spots in the fuse element. This substitution eliminates mechanical strain and micro-tears associated with conventional methods, enabling smaller, lighter fuse construction while maintaining or improving reliability through a gentler manufacturing process that avoids premature failure from manufacturing defects
Solution Approach 2:
The patent changes the manufacturing parameters from mechanical force-based processes to deposition-based printing processes. By controlling the printing parameters (such as layer thickness, material composition, and deposition patterns), the fuse element can be created with precise weak spot locations and characteristics, achieving reduced size and weight while ensuring reliable operation under various electrical conditions
2Weight of stationary object
If fuse size is reduced, then weight and space requirements are improved, but arc energy management becomes more difficult
Solution Approach 1:
The patent applies local quality by incorporating arc extinguishing fillers specifically at the weak spot locations within the compact fuse structure. This localized approach to arc management allows the small fuse to effectively contain and extinguish arcs at the critical failure points without requiring the entire fuse body to be large, thus managing arc energy effectively while maintaining reduced size and weight
Solution Approach 2:
The arc extinguishing fillers act as intermediaries between the arc energy and the fuse structure. These fillers are positioned at the weak spots to intercept and extinguish arcs, protecting the surrounding components from arc damage. This intermediary approach enables compact fuse design by providing targeted arc management without requiring additional space
3Manufacturing precision
If mechanical stamping is used to create weak spots, then manufacturing precision is achieved, but thermal-mechanical fatigue increases
Solution Approach 1:
The patent replaces mechanical stamping with a printing process to create weak spots. This substitution eliminates the thermal-mechanical fatigue caused by repeated mechanical deformation during stamping, while still achieving precise weak spot formation through controlled material deposition. The printing process creates weak spots without introducing manufacturing defects that would lead to premature failure under cyclic electrical loads
4Reliability
If traditional fuse design is used, then circuit protection function is ensured, but device complexity increases
Solution Approach 1:
The patent merges multiple functions into the fuse element structure itself. The printing process integrates weak spot formation, arc extinguishing filler placement, and electrical connection creation into a single manufacturing step. This consolidation reduces device complexity by eliminating separate components and assembly steps while ensuring the circuit protection function is maintained through the printed fuse element's inherent design
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 approach results in fuses with improved reliability, reduced size, and weight, while maintaining effective circuit protection performance, avoiding nuisance operations and extending the service life by mitigating thermal-mechanical fatigue and arc energy containment issues.
Implementation Method 1
improved reliability, reduced size, and weight, while maintaining effective circuit protection performance, avoiding nuisance operations and extending the service life by mitigating thermal-mechanical fatigue
Implementation Method 2
incorporating arc extinguishing fillers to manage arc energy effectively
Data Source
AI summary
A printed fuse fabrication is provided. The printed fuse includes a low thermal conductivity ceramic substrate and a fusible element printed on the substrate. The fusible element printed on the substrate includes a series of portions of reduced printed thickness, defining weak spots for fusible operation of the fusible element, respectively separated by portions of increased printed thickness.