Explosion-Roof Surge Module with Pivot Disconnect
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Solution Overview
Problem
Conventional surge absorbers in electrical circuits fail to quickly open the circuit during a surge or high temperature, potentially causing explosions or fires due to ineffective isolation of electrical connections, and existing solutions increase production costs and physical volume.
Innovation Solution
An explosion-proof and flameproof pullout safety surge-absorbing module comprising a surge-absorbing unit, a protective component, and a hot melt component, where a flexible recovery component and a function part pivot to disconnect from a partially exposed electrode side when the temperature exceeds the melting point of the hot melt component, creating an open circuit and preventing fragment dispersal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thermal fuse is added to make the circuit open, then protection capability is improved, but the circuit cannot open and break in a short time causing explosion or fire
Solution Approach 1:
The circuit protection function is segmented into two independent components: a thermal fuse for temperature-based protection and a snap action switch for rapid surge-based protection. This segmentation allows each component to specialize in its optimal protection mechanism, with the snap action switch providing immediate circuit opening during surges while the thermal fuse handles sustained overheating conditions.
Solution Approach 2:
A bi-metallic strip serves as an intermediary element that converts thermal energy from surges into mechanical motion. When heated by surge current, the bi-metallic strip bends and triggers the snap action switch, which then rapidly opens the circuit. This intermediary mechanism transforms the slow thermal response into a fast mechanical action, solving the speed limitation of pure thermal fuses.
2Reliability
If a damper is provided between metal spring plate and voltage sensor component, then electrical connection isolation is improved, but production cost increases and physical volume is higher
Solution Approach 1:
The damping function is extracted from a separate component (damper) and integrated into the spring plate itself through a damping layer. This extraction eliminates the need for additional damping components, reducing part count, assembly complexity, and overall device volume while maintaining effective electrical connection isolation during circuit opening.
Solution Approach 2:
The spring plate and damper functions are merged into a single integrated component. The spring plate provides both the mechanical spring function and the damping function through its embedded damping layer, which absorbs impact energy during circuit opening. This merging reduces the number of parts, simplifies assembly, and decreases the overall physical volume of the protective device.
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 module effectively opens the circuit to prevent damage from surges and explosions, while the protective component contains fragments to prevent fire accidents, offering improved safety and cost-effectiveness compared to prior solutions.
Implementation Method 1
when the temperature increases... when the temperature exceeds the melting point of the hot melt component, the function part is pulled by the recovery component to disconnect from the partially exposed electrode side. The hot melt component is melt and kept away from the section between the function part and the partially exposed electrode side.
Implementation Method 2
The recovery component is flexible, of which one terminal is fixed onto the base and the other one is connected to the function part... in the second state, the function part is pulled by the recovery component to disconnect from the partially exposed electrode side.
Data Source
AI summary
An explosion-proof and flameproof pullout safety surge-absorbing module includes a surge-absorbing unit, a protective unit, a function member, and a hot melt component. The unit has a body defining an electrode side. The middle section of electrode side defines a partially exposed electrode side further connected to a first pin. The protective component includes a base and a top cover conjoint to the base. The body is between the base and the top cover. The function member includes a recovery component and a function part. The recovery component is flexible, of which one terminal connects the base and the other terminal connects the function part pivoting onto the base and working in a first state and a second state. In the first state, one terminal of the function part is connected to the partially exposed electrode side; in the second state, the hot melt component is heated and melt.