Thermal Fuse Installation with Connection Detection
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Solution Overview
Problem
Conventional temperature fuses cannot detect poor contact with a printed circuit board (PCB), leading to potential overheating accidents due to faulty mounting or degradation.
Innovation Solution
An installation structure for a temperature fuse that includes a first and second leg fixed to the PCB, a bent part, a third leg with a conductive member electrically isolated from the PCB, and a sensing part to detect the connection state between the third leg and the conductive member by measuring resistance values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional temperature fuse is mounted to a PCB through soldering, then the temperature fuse can protect circuits from high temperature or overcurrent, but it cannot detect poor contact between the temperature fuse and the PCB
Solution Approach 1:
The temperature fuse is divided into functional segments: first and second legs for circuit protection, a bent part for mechanical mounting, and a third leg specifically for connection detection. This segmentation allows the detection function to be separated from the protection function, enabling independent optimization of each function while maintaining overall system reliability.
Solution Approach 2:
A conductive member is introduced as an intermediary between the third leg and the sensing part. This conductive member facilitates electrical connection for detection purposes while being electrically isolated from the PCB in other aspects, enabling the sensing circuit to detect connection status without interfering with the main protection function.
2Ease of manufacture
If the temperature fuse is electrically mounted to the PCB surface through soldering, then both legs can be conductively soldered to the PCB, but poor contact cannot be recognized
Solution Approach 1:
The third leg is configured to extend from the first or second leg before the soldering process, and the sensing part is pre-positioned to detect connection status. This preliminary arrangement of detection components allows connection state to be monitored during and after mounting, enabling early detection of poor contact before it causes protection failures.
Solution Approach 2:
The sensing part provides real-time feedback about the connection state between the temperature fuse and PCB by measuring electrical continuity through the conductive member. This feedback mechanism enables the system to recognize poor contact conditions and trigger appropriate responses, such as alerting operators or preventing device operation.
3Difficulty of detecting and measuring
If a third leg with conductive member and sensing part is added, then connection state can be detected, but the device complexity increases
Solution Approach 1:
The third leg serves multiple functions: it provides a separate detection pathway, acts as an electrical connection point for the sensing circuit, and maintains mechanical integrity with the fuse body. The conductive member similarly serves both as an electrical connector and as a structural element, reducing the need for separate components and minimizing overall device complexity.
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
Enables the recognition of a normal or abnormal connection state, preventing accidental overheating by ensuring the temperature fuse operates correctly and preventing accidents caused by poor contact.
Implementation Method 1
a sensing part electrically connected to the third leg through the conductive member, and configured to detect whether a connection state between the third leg and the conductive member is normal
Data Source
AI summary
An installation structure of a temperature fuse is disclosed. The temperature fuse includes a first leg fixed to one surface of a printed circuit board (PCB), a bent part formed to be bent several times in an outer direction of the PCB from an end part of the first leg, and a second leg incorporated with the bent part and fixed to one surface of the PCB while being spaced apart from the first leg by a predetermined distance. The installation structure of the temperature fuse includes a third leg formed to extend from any one of the first leg and the second leg, a conductive member electrically connected to the third leg while being electrically isolated from the PCB, and a sensing part electrically connected to the third leg through the conductive member, and configured to detect whether a connection state between the third leg and the conductive member is normal.