Thermal Fuse Cooling Interface Using Curable Heat-Conducting Paste
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Solution Overview
Problem
Conventional thermal fuses in electric vehicles face challenges with reduced lifetime at high currents, leading to large and expensive designs, and existing cooling methods like air and water cooling are inefficient, while pyro fuses are costly and require complex circuits.
Innovation Solution
A method involving a curable liquid or paste is used to form a heat-conducting material between the thermal fuse and a cooling element, adapting to the fuse's surface irregularities and providing efficient cooling, with optional fillers for improved conductivity and insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thermal fuse is used to protect against electrical faults, then electrical safety is improved, but the fuse lifetime is reduced when operating at very high currents
Solution Approach 1:
The patent applies periodic action by implementing a cooling system that periodically removes heat from the fuse body during operation. The cooling element actively cycles to maintain the fuse body temperature below critical levels, allowing the fuse to operate continuously at high currents without degradation, thus extending fuse lifetime while maintaining electrical safety.
Solution Approach 2:
The patent introduces a cooling element as an intermediary between the fuse body and the thermal environment. This cooling element acts as a heat transfer mediator, conducting heat away from the fuse body through thermal contact, thereby protecting the fuse from excessive temperature exposure and extending its operational lifetime at high currents.
2Reliability
If a thermal fuse with very high current rating is used to protect against electrical faults, then electrical safety is improved, but the fuse becomes very large and expensive
Solution Approach 1:
By implementing periodic cooling action, the fuse body can be designed with smaller dimensions since it doesn't need to accommodate excessive heat buildup. The cooling system allows compact fuse design while maintaining the ability to handle very high currents safely, thus reducing fuse size and associated costs.
Solution Approach 2:
The cooling element serves as a thermal intermediary that enables the fuse body to be compact. By actively managing heat transfer, the cooling system allows the use of smaller fuse body dimensions while still providing protection against very high currents, thereby reducing fuse size and expense.
3Temperature
If air cooling is used to cool the fuse body, then cooling is provided, but cooling efficiency is insufficient and fuse lifetime is not adequately extended
Solution Approach 1:
The patent replaces air cooling with a solid cooling element that makes direct thermal contact with the fuse body. This solid intermediary provides much more efficient heat conduction compared to air, significantly improving cooling efficiency and enabling adequate extension of fuse lifetime at high currents.
Solution Approach 2:
The patent replaces the mechanical air cooling system with a direct solid-to-solid thermal contact system. The cooling element with thermal contact to the fuse body provides superior heat transfer efficiency compared to air convection, thereby improving cooling efficiency and extending fuse operational lifetime.
4Temperature
If water cooling of the fuse tabs is used, then some cooling effect is provided, but the cooling effect is limited since most heat is transferred to the fuse body
Solution Approach 1:
The patent introduces a cooling element as a thermal intermediary that contacts the fuse body directly. This intermediary provides a dedicated heat transfer path from the fuse body to the cooling system, significantly improving cooling efficiency compared to water cooling the tabs, which only cools a small portion of the heat-generating area.
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 method enhances fuse lifetime and cooling efficiency, maintaining performance near rated current levels without increasing size or cost, while preventing short-circuits.
Implementation Method 1
the curable liquid or paste, at least when cured and solidified, forms a heat conducting material... provides for a good heat-conducting contact between the cooling element and the fuse body
Implementation Method 2
a cooling element configured to cool the thermal fuse... significantly better than if cooling only the connection tabs or using air cooling
Data Source
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AI summary
The invention concerns a method for providing a fuse cooling arrangement (1), wherein the arrangement comprises a thermal fuse (2) having a fuse body (3) and further having first and second connection tabs (4, 5) configured for connection of the thermal fuse (2) electrically to other components (6, 7), wherein the fuse cooling arrangement (1) comprises a cooling element (8) configured to cool the thermal fuse (2), the method comprising: providing a frame (9) at the cooling element (8); supplying a curable liquid or paste (10) into the frame (9) and positioning at least a part of the fuse body (3) into the frame (9) so that the curable liquid or paste (10) comes in contact with both the cooling element (8) and the fuse body (3), wherein the curable liquid or paste (10), at least when cured and solidified, forms a heat conducting material: and allowing the curable liquid or paste (10) to cure and solidify.