Protective Element with Integrated Heating Layer for Fast Fuse Activation
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Solution Overview
Problem
The manufacturing process of conventional protective elements is overly complex, requiring a substrate with a concave portion and a heating body covered by a second substrate or insulating member, which complicates the assembly and increases production time.
Innovation Solution
A protective element with a body made of single insulation material, featuring an inner connection layer, a low-melting-point alloy layer electrically connected to the inner connection layer, and a heating layer mounted inside the body, eliminating the need for a concave portion or insulating member, and a fabrication method that stacks substrates with outer and inner connection layers to form a single insulation body with the heating layer encapsulated within.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a concave portion is formed on the substrate and a heating body is disposed on it, then the heating body can be properly positioned, but the manufacturing process becomes complicated and time-consuming
Solution Approach 1:
The patent merges the heating body positioning function directly into the substrate structure by forming the heating body on the substrate surface without requiring a separate concave portion. The substrate integrates both the heating body support and insulation functions, eliminating the need for additional structural components and simplifying the manufacturing process.
Solution Approach 2:
The substrate is designed to perform multiple functions: it serves as the base structure, the heating body support, and the insulation member simultaneously. This multi-functional design eliminates the need for separate insulating members or concave portions, reducing manufacturing steps while maintaining positioning accuracy.
2Reliability
If a second substrate or insulating member is used to cover the heating body, then the heating body is protected, but the manufacturing steps and time are increased
Solution Approach 1:
The patent combines the protection function with the substrate itself by designing the substrate to inherently protect the heating body through its structural design, eliminating the need for a separate second substrate or insulating member. This reduces manufacturing steps while maintaining heating body protection.
Solution Approach 2:
The patent extracts the insulating member and second substrate from the conventional design, removing these unnecessary components. The substrate alone provides both structural support and protection for the heating body, simplifying the overall structure and reducing manufacturing time.
3Adaptability or versatility
If multiple separate components (substrate, insulating member, second substrate) are used, then each component can be optimized independently, but the overall device complexity and assembly difficulty increase
Solution Approach 1:
The patent merges multiple separate components (substrate, insulating member, second substrate) into a single integrated substrate structure. This integration maintains the ability to optimize the substrate design while dramatically simplifying assembly, as fewer components need to be handled and positioned during manufacturing.
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 simplifies the manufacturing process by reducing the number of steps and time required, allowing the heating layer to store heat and fuse the low-melting-point alloy layer more efficiently, thereby protecting the power circuit from overcurrent without the need for a concave portion or insulating member.
Implementation Method 1
When a power loop of the power circuit encounters overcurrent, large current flows through the low-melting-point metal via the electrodes and also flows through the heating body via the through hole and the connection terminal. Then the low-melting-point metal is fused quickly by heating from the heating body
Implementation Method 2
Then the low-melting-point metal is fused quickly by heating from the heating body so that a loop between the electrodes is cut off to protect the power circuit
Data Source
AI summary
A protective element has a body, an inner connection layer, an outer connection layer, a heating layer and a low-melting-point alloy layer. The body is made of a single insulation material. The inner and outer connection layers are formed on two upper and lower surfaces of the body. The low-melting-point alloy layer is formed on the upper surface of the body and is electrically connected to the inner connection layer. The heating layer is mounted inside the body and is electrically connected to the low-melting-point alloy layer by the inner connection layer. The outer connection layer is electrically connected to the low-melting-point alloy layer and the heating layer. The outer connection layer is soldered on a power circuit. When the power circuit encounters overcurrent, the heating layer is heated to fuse the low-melting-point alloy layer faster. Thus, power circuit is cut to protect the power circuit.