Thermal Fuse Pellet Segmentation for Contact Separation
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Solution Overview
Problem
Existing temperature sensitive pellet type thermal fuses face issues with the temperature sensitive material flowing within the metal envelope, preventing effective separation of contacts and reliable current interruption.
Innovation Solution
A temperature sensitive pellet type thermal fuse design featuring a conductive envelope with a temperature sensitive device, a first lead, a second lead, a movable contact, and a strong compression spring, where the temperature sensitive material is housed in a cylindrical case with a lid and push plate, preventing the material from leaking and ensuring reliable contact separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If inorganic temperature sensitive material (such as solder) is used in a cylindrical metal envelope, then the melting point can be controlled, but the material flows in the metal envelope after melting which prevents contact separation
Solution Approach 1:
The patent divides the temperature sensitive material into discrete pellets rather than using a continuous metal envelope filling. This segmentation prevents the material from flowing freely when melted, as each pellet remains contained within its own space, thereby enabling reliable contact separation while maintaining controlled melting characteristics
Solution Approach 2:
The patent introduces a holder as an intermediary component that contains the temperature sensitive pellets. This holder prevents direct contact between the melted material and the movable contact, allowing the material to melt and expand without interfering with the contact separation mechanism, thus resolving the contradiction between temperature control and reliable operation
2Reliability
If temperature sensitive pellets are arranged in contact with the second lead, then the circuit can be broken when temperature rises, but the pellets may flow within the metal envelope preventing effective contact separation
Solution Approach 1:
The temperature sensitive material is segmented into discrete pellets housed in a holder, preventing flow and ensuring that contact separation occurs cleanly without material interference, thereby maintaining both reliability and ease of operation
Solution Approach 2:
The patent extracts the temperature sensitive pellets from direct contact with the movable contact and houses them in a separate holder. This extraction allows the pellets to perform their temperature sensing function independently without interfering with the mechanical contact separation process, resolving the contradiction between circuit breaking reliability and contact separation ease
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 effectively breaks the current flow when the temperature sensitive material melts, preventing overheating and ensuring reliable operation by maintaining the temperature sensitive material within the envelope.
Implementation Method 1
the temperature sensitive material which is housed in the cylindrical case and melts at a predetermined operating temperature
Implementation Method 2
a strong compression spring which is configured to press against the temperature sensitive material so as to bring the movable contact into contact with the fixed contact
Implementation Method 3
a weak compression spring which is housed in the envelope and configured to press the movable contact in the direction of separating the movable contact from the fixed contact
Data Source
AI summary
The temperature sensitive pellet type thermal fuse includes: a conductive envelope having an opening at a first end; a temperature sensitive device housed inside the envelope; a first lead which is installed in the opening of the envelope and has a fixed contact; a second lead connected to a second end of the envelope; a movable contact housed in the envelope; and a weak compression spring housed in the envelope. The temperature sensitive device includes a cylindrical case having an open end which may be arranged at the side of the first lead, a temperature sensitive material housed in the cylindrical case, and a strong compression spring configured to press against the temperature sensitive material.