Vertical SMD Fuse with Integrated Pass-Through Lead Frame
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Solution Overview
Problem
Conventional surface mount device (SMD) fuses have a large footprint on printed circuit boards and require a separate pass-through terminal for external connections, which complicates installation and increases space usage.
Innovation Solution
A vertically oriented SMD pass-through fuse with an integrated lead frame that includes a bow portion and elongate shank portion, allowing for a smaller footprint and direct pass-through connection without additional terminals, enhancing thermal management and installation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional SMD fuses are used with terminals bent around the fuse body, then the fuse can be electrically connected to PCB contacts, but the footprint on the PCB becomes relatively large
Solution Approach 1:
The patent transitions from a conventional horizontal SMD fuse configuration to a vertical orientation. The fuse body extends vertically from the PCB surface, with the fusible element oriented vertically between terminals. This dimensional change allows the fuse to occupy less horizontal footprint area on the PCB while maintaining electrical connection capability through the vertical terminal arrangement.
2Adaptability or versatility
If conventional SMD fuses are used for pass-through connections, then external electrical components can be connected, but a separate pass-through terminal is required which complicates installation
Solution Approach 1:
The patent integrates the pass-through function directly into the fuse structure by incorporating a lead frame with a shank portion that extends through the fuse body. This merged design eliminates the need for separate pass-through terminals, allowing external electrical components to be connected directly through the fuse while simplifying installation procedures.
Solution Approach 2:
The fuse structure is designed to perform multiple functions: overcurrent protection through the fusible element and pass-through connection for external components through the integrated lead frame. This multi-functional design allows a single component to replace what would traditionally require multiple separate elements, reducing overall system complexity.
3Reliability
If conventional SMD fuses are used, then overcurrent protection is provided, but additional pass-through terminals increase space usage on the PCB
Solution Approach 1:
By orienting the fuse vertically with the fusible element extending vertically between terminals, the patent reduces the horizontal footprint required for overcurrent protection functionality. The vertical orientation allows the protective function to be achieved within a smaller planar area on the PCB.
Solution Approach 2:
The integration of the pass-through lead frame into the fuse body combines the overcurrent protection function with the pass-through connection function in a single compact structure, eliminating the need for additional separate terminals and reducing total space occupation on the PCB.
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 vertical orientation and integrated lead frame reduce the fuse's footprint, eliminate the need for separate pass-through terminals, and improve thermal management by acting as a heat sink, while ensuring robust connections and increased breaking capacity.
Implementation Method 1
improve thermal management by acting as a heat sink
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
A vertical surface mount device pass-through fuse including an electrically insulating fuse body, a fusible element disposed on a first side of the fuse body and extending between first and second terminals, an electrically insulating cap having a domed portion and a flanged portion extending from the domed portion, the domed portion disposed over the fusible element, and the flanged portion affixed to the fuse body, and a conductive lead frame having a bow portion and an elongate shank portion extending from the bow portion, wherein the bow portion is disposed on the cap and is connected to the first terminal, and wherein the shank portion extends away from the fuse body.