Single Piece Fuse Element for High Breaking Capacity
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Solution Overview
Problem
Existing compact fuses with high breaking capacity are often expensive and prone to reliability issues due to connection failures between the fuse element and terminals, necessitating a low-cost, reliable solution for compact circuit protection applications.
Innovation Solution
A compact high breaking capacity fuse design featuring a single piece fusible element with terminal portions and a fusible element portion disposed within a chamber defined by two insulative layers, where the fusible element is surrounded by air to minimize arc duration and increase breaking capacity, and ceramic elements or coatings are used to enhance reliability and protect against rupture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fuses with separate fuse elements and terminals are used, then connection reliability improves, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the fuse element and terminals into a single integrated component. The fuse element includes integrated terminal portions that are formed as one piece with the fusible element portion, eliminating separate connection interfaces and reducing assembly steps while maintaining reliable electrical connections.
Solution Approach 2:
The single piece fusible element serves multiple functions: it acts as the fusible element, provides terminal connections, and establishes electrical pathways. This multi-functional design eliminates the need for separate terminal components and reduces overall device complexity.
2Volume of moving object
If compact fuse design is implemented, then space utilization improves, but breaking capacity decreases
Solution Approach 1:
The patent utilizes three-dimensional spatial arrangement within the compact housing. The fusible element portion is disposed within a chamber defined by insulative layers, with terminal portions extending to opposite sides, optimizing space utilization while maintaining adequate arc quenching distances for high breaking capacity.
Solution Approach 2:
The fusible element portion is nested within the chamber defined by the insulative layers, with the terminal portions extending through or along the insulative layers. This nested arrangement maximizes the use of available space while maintaining the necessary clearances for high breaking capacity operation.
3Ease of manufacture
If single piece fusible element is used, then manufacturing cost decreases, but connection reliability worsens
Solution Approach 1:
The fuse element is manufactured as a single integrated piece where the terminal portions are formed as one continuous structure with the fusible element portion. This eliminates separate assembly operations and potential connection failure points while reducing manufacturing steps and cost.
Solution Approach 2:
The patent employs specific material compositions and geometric parameters in the single piece fusible element to ensure both manufacturability and reliability. The terminal portions are designed with appropriate dimensions and material properties to provide reliable electrical connections while maintaining cost-effectiveness.
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 design provides a cost-effective, reliable high breaking capacity fuse with reduced arc duration and improved reliability through the use of a single piece fusible element and ceramic enhancements, addressing the limitations of existing fuses.
Implementation Method 1
the fusible element is surrounded by air to minimize arc duration and increase breaking capacity
Data Source
AI summary
A compact, high breaking capacity fuse that includes a top and bottom insulative layer and a single piece fusible element disposed between the top and bottom insulative layer. The top and bottom insulative layers include cavities that are aligned at assembly to form a chamber in which a fusible element portion of the single piece fusible element is disposed. The single piece fusible element additionally includes terminal portions that extend along outer surfaces of the top and bottom insulative layers.