EP0826228A1 - Fusible femelle pour voitures - Google Patents

Fusible femelle pour voitures

Info

Publication number
EP0826228A1
EP0826228A1 EP96907205A EP96907205A EP0826228A1 EP 0826228 A1 EP0826228 A1 EP 0826228A1 EP 96907205 A EP96907205 A EP 96907205A EP 96907205 A EP96907205 A EP 96907205A EP 0826228 A1 EP0826228 A1 EP 0826228A1
Authority
EP
European Patent Office
Prior art keywords
fuse
link
thermal
clips
blocks
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP96907205A
Other languages
German (de)
English (en)
Inventor
Terence John Evans
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Cooper Industries LLC
Original Assignee
Cooper Industries LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US08/407,356 external-priority patent/US5631619A/en
Application filed by Cooper Industries LLC filed Critical Cooper Industries LLC
Publication of EP0826228A1 publication Critical patent/EP0826228A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H69/00—Apparatus or processes for the manufacture of emergency protective devices
    • H01H69/02—Manufacture of fuses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H85/00—Protective devices in which the current flows through a part of fusible material and this current is interrupted by displacement of the fusible material when this current becomes excessive
    • H01H85/02—Details
    • H01H85/04—Fuses, i.e. expendable parts of the protective device, e.g. cartridges
    • H01H85/041—Fuses, i.e. expendable parts of the protective device, e.g. cartridges characterised by the type
    • H01H85/0411—Miniature fuses
    • H01H85/0415—Miniature fuses cartridge type
    • H01H85/0417—Miniature fuses cartridge type with parallel side contacts
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H85/00—Protective devices in which the current flows through a part of fusible material and this current is interrupted by displacement of the fusible material when this current becomes excessive
    • H01H85/0039—Means for influencing the rupture process of the fusible element
    • H01H85/0047—Heating means
    • H01H85/0056—Heat conducting or heat absorbing means associated with the fusible member, e.g. for providing time delay
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H85/00—Protective devices in which the current flows through a part of fusible material and this current is interrupted by displacement of the fusible material when this current becomes excessive
    • H01H85/02—Details
    • H01H85/04—Fuses, i.e. expendable parts of the protective device, e.g. cartridges
    • H01H85/05—Component parts thereof
    • H01H85/055—Fusible members
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H85/00—Protective devices in which the current flows through a part of fusible material and this current is interrupted by displacement of the fusible material when this current becomes excessive
    • H01H85/02—Details
    • H01H85/04—Fuses, i.e. expendable parts of the protective device, e.g. cartridges
    • H01H85/05—Component parts thereof
    • H01H85/055—Fusible members
    • H01H85/06—Fusible members characterised by the fusible material

Definitions

  • This invention relates to fuses in general, and in particular to a female fuse with a fuse clip insert molded into a one piece fuse link and thermal block, and still more particularly to methods of producing the one piece fuse link.
  • a bus bar includes blade type connectors for connecting to male bladed type fuses.
  • a double female clip is required which connects to the blade on the bus bar at one end and the blade from the blade type fuse at the other end.
  • the fuses plug into fuse blocks which have metal, spring clips.
  • prior art fuses are physically large.
  • One prior art fuse is 29 millimeters long and approximately nine millimeters wide.
  • prior art fuses typically have an overall height of approximately 34 millimeters. This causes the fuses of the prior art to have substantial size.
  • the double female spring clip between the bus bar and the fuse blades is an additional component that adds cost, increases the size of the product, and requires additional labor to assemble. Further, the double female spring clip must be manually installed which adds more expense.
  • the double female spring clips are the weakest part of the assembly and are relatively expensive compared to their size and function since their only purpose is to connect the two male blades together.
  • the fuse link of prior art fuses is typically made of a continuous strip of zinc which is stamped and then bent into shape.
  • Zinc has a melting temperature of approximately 440°C.
  • the present invention incorporates a fuse clip which is insert molded into a thermal block.
  • the thermal block and fuse link are injection molded in a one piece unit.
  • a female fuse incorporating this invention is smaller in size, operates cooler, and does not require soldering or welding of the parts.
  • One objective of the present invention is to eliminate the need for a double female spring clip which extends between the bus bar and the fuse blades.
  • the female fuse of the present invention has a length approximately one-half that of prior art fuses with very little increase in width. Further, the fuse of the present invention has a reduced height as compared to prior art fuses and thus has a substantial reduction in volume. This permits the use of a smaller PDB (power distribution block) and eliminates the double female clip along with the labor to install it.
  • PDB power distribution block
  • the female fuse of the present invention utilizes a fuse link and thermal blocks which have low melting temperatures thus minimizing the generation of heat which will damage the surrounding insulating housing which is made of plastic.
  • High melting temperature metals of the prior art raise the temperature of the surrounding physical environment of the fuse link thereby causing the plastic housing to deform or melt.
  • the housing may be made of lower temperature plastics which have a lower cost .
  • Figure 1 is a plan view of a fuse element sub-assembly according to the present invention.
  • Figure 2 is a plan view from the right side of the f se element sub-assembly shown in Figure 1.
  • Figure 3 is a sectional view, partially in phantom, of a female fuse according to the present invention.
  • Figure 4 is a perspective view, partially exploded, of a fuse according to the present invention.
  • Figure 5 is a sectional view of an alternative embodiment of the female fuse of the present invention.
  • Figure 6 is a section view at plane 6-6 shown in Figure 5.
  • female fuse 10 is referred to in general by reference numeral 10.
  • the major components of female fuse 10 are element assembly 28 and housing 40, best shown in Figures 3 and 4.
  • the element assembly 28 is comprised of a pair of female fuse clips 30, 31, thermal blocks 24, 25, and fuse link 20.
  • the fuse clips 30, 31 are made from a copper alloy such as tin-bronze, red brass, or ceramic bearing copper alloys. In the preferred embodiment, fuse clips 30, 31 are stamped out of sheet material and formed to shape.
  • Fuse link 20 and thermal blocks 24, 25 are injection molded as a one piece unit.
  • Fuse link 20 includes a hole or weak spot 36 which determines, in part, the fuse rating for the fuse 10.
  • Fuse clips 30, 31 are encapsulated into each thermal block 24, 25, respectively, during the casting and molding process, hereinafter described in further detail.
  • the base 33 of the clips 30, 31 includes aperture (s) 34 for receiving the molten metal forming thermal blocks 24, 25 thereby locking the clips 30, 31 to blocks 24, 25, respectively.
  • the size of the thermal blocks 24, 25 is determined by the size of the fuse clips 30, 31 since the fuse clips 30, 31 must be embedded in blocks 24, 25.
  • the thermal blocks 24, 25 are substantially the same size for fuses of all ratings.
  • the rating of fuse 10 is determined by the configuration of the fuse link 20.
  • the fuse link 20 is a generally flat strip of metal having a U-shaped cross section extending between clips 30, 31.
  • the rating of the fuse 10 is determined by the over all length, width, and thickness of fuse link 20 together with the particular metal being used for fuse link 20.
  • the weak spot 36 and the material are used to adjust the rating for a particular f se.
  • Element assembly 28 is enclosed in an insulating housing 40 made of material such as plastic.
  • the plastic is polypropylene which includes a talc fill.
  • Housing 40 serves as a heat absorber.
  • the plastic housing 40 may be injection molded and then assembled around the assembly 28 or constructed by other methods known in the art.
  • Ears 32 on female clips 30, 31 hold fuse assembly 28 into housing 40 by fitting grooves 42 found in the housing 40. In the preferred embodiment, grooves 42 are molded into the housing 40.
  • the metal used for injection molding fuse link 20 and thermal block 24 is a low melting temperature metal such as tin-silver, lead-antimony, tin-antimony, or other alloys and pure metals with melt or transition temperatures lower than 300 degrees C.
  • the various alloys of the female fuse of the present invention have a melting temperature of less than 300°C and preferably the present invention utilizes alloys that have a melting temperature in the range of 220-250°C.
  • the alloys used are eutectic. For example, a tin/lead
  • (60/40) alloy has a range of approximately 15°C where the metal is both solid and liquid.
  • the eutectic alloys of the present invention do not have a transition range such that the material of the fuse link 20 does not have a state of liquid and solid where it has no mechanical strength.
  • Using a metal for fuse link 20 and thermal blocks 24, 25 having low melting temperatures provides certain advantages. Using low melting temperature alloys and metals lowers the amount of heat generated so as not to damage the surrounding insulating housing 40 made of plastic. Higher melting temperature metals raise the temperature of the surrounding physical environment of the fuse link thereby causing the plastic housing to deform or melt. Copper, for example, melts at approximately 1,083°C requiring that expensive plastics be used for prior art housing so as to have a high heat deflection to withstand such a high temperature. All fuse parts that are in contact with the prior art fuse link and terminal assembly will get very hot causing deterioration. By using low melting temperature metals as in the present invention, the insulating housing 40 may be made of lower temperature plastics having a lower cost . The lower temperature plastics are the result of being able to use low melting temperature metals for fuse link 20 and thermal blocks 24, 25.
  • Thermal blocks 24, 25 serve as a heat sink for fuse link 20 absorbing the heat which is generated by the clips 30, 31 on one side and the fuse link 20 on the other side.
  • the thermal blocks 24, 25 absorb heat from clips 30, 31 and from link 20 on both sides.
  • the function of the thermal blocks 24, 25 is to provide a delay between the initiation of the generation of heat and the melting of fuse link 20 at weak spot 36. As heat is generated, heat is transferred to the thermal blocks 24, 25 which act as heat absorbers. Upon the continued generation of heat, the temperature of the entire assembly is raised until the melting temperature of the material of fuse link 20 is reached at weak spot 36.
  • Female fuse 50 includes an element assembly 60 and a housing 70.
  • the element assembly 60 includes a pair of female fuse clips 62, 64, thermal blocks 66, 68, and fuse link 80.
  • Fuse link 80 and thermal blocks 66, 68 are injection molded as a one piece unit, as hereinafter described in further detail.
  • Fuse clips 62, 64 are encapsulated into each thermal block 66, 68, respectively, during the molding process.
  • Fuse link 80 includes a weak spot 82.
  • fuse link 80 extends in an axial direction away from fuse clips 62, 64. Although this extends the longitudinal length of housing 70, it also locates fuse link 80 further away from the heat generated by clips 62, 64. By projecting fuse link 80 away from fuse clips 62, 64, the life of fuse link 80 is extended.
  • the housing 70 includes a pair of slots 84, 86 for receiving the blades from a bus bar.
  • the end walls 88, 90 of housing 70 include longitudinal slots 92, 94 for receiving projecting ears 96, 98 on clips 62, 64.
  • the lower end of housing 70 is open at 100.
  • the element assemblies 28, 60 may be produced by various molding processes which make it easy to manufacture fuses with different ratings.
  • the size and shape of the mold can be changed to change the size of the thermal block or fuse link, and the composition of the metal alloy can be changed. Any of these actions will change the rating of the fuse.
  • the fuse 10 of the present invention is preferably produced using an insert injection molding process. Injection molding is well known in the art of injecting plastic. However, in the present invention the injection molding process is used for the injection of metal at low temperatures.
  • the same type of molds used for producing fuse 10 are used for producing plastic product by injection molding. In the present process, the fuse clip is stamped, placed into the mold cavity and the molten metal for the fuse link and thermal blocks are shot into the mold cavity around the clips.
  • the insert injection molding process includes a gating process when the metal is injected into the cavity of the mold.
  • the gate is an aperture in the mold which allows the molten metal to enter the mold cavity.
  • a cylinder is charged with air and the air pressure forces the metal into the mold cavity.
  • the tolerances tend to be tighter for metal injection molding than for plastic injection molding since liquid metals will flow into smaller dimensions than plastics.
  • the clips 30, 31 are fitted into the mold and project through an aperture in the mold.
  • the mold is kept at a temperature approximately 20°C below the transition temperature of the link alloy. The clips fit closely within the aperture of the mold so that the metal forced into the mold cavity cannot flow through the apertures between the clips and mold.
  • the above described injection process can be modified by making the fuse links separately and not molding the fuse links into the fuse clips 30, 31.
  • low melting temperature alloys are relatively malleable and could be put into a cavity and formed in a punch press. They also could be fed into a punch press or could be stamped into shape by a coining type operation. It would then be necessary to affix the fuse clips 30, 31 to the thermal blocks 24, 25. This could be done by heating the fuse clip and forcing it into thermal blocks 24, 25 allowing the metal of the thermal blocks to flow around it. The fuse clip must not be kept at an elevated temperature for too long a period since this would cause the clip to anneal.
  • One disadvantage to this modified injection process is that it requires the secondary operation of affixing the fuse clips to the thermal blocks.
  • fuse 10 Another technique for producing fuse 10 is that of compression molding. This technique is also used in the plastic industry. In producing the fuse 10 using a compression molding process, the clips 30, 31 are inserted into the compression mold and then the metal is placed into the cavity of the mold. The mold and thus the cavity is then closed forcing any excess metal out of the cavity. One draw back to this process is that the clip does not have an adequate opportunity to bond with the metal as the metal is merely pressed around the clip.
  • fuse 10 Another technique for producing fuse 10 is investment casting. To avoid an extended cooling down period for the mold, which would be a very slow process, one part of the mold is heated and the other part of the mold is cooled. The liquid eutectic metal is then poured into the mold with the clips 30, 31 already in position. The mold is then closed. Heat is then removed from that portion of the mold holding the liquid metal allowing the liquid metal to cool and solidify. One draw back to this process is that the clip in the cooled portion of the mold does not have an adequate opportunity to bond with the metal. One side of the mold is at a temperature above the liquid temperature of the metal and the other side of the mold is at the liquid temperature of the metal.
  • the transfer insert pressing process is similar to that of the injection molding process.
  • the clips 30, 31 are inserted into the mold and the mold is closed.
  • the upper portion of the mold includes an aperture.
  • the liquid metal is placed in the cavity and a ram is pushed into the aperture to force the metal into the mold cavity.
  • the transfer insert pressing process is preferred when the metal is relatively thick and viscous.
  • the injection process merely uses a screw which is rotated to force the metal through the gate. In the transfer insert pressing process, a much larger force may be applied to the ram and thus the metal, to force the metal into the mold cavity.
  • the mold of the transfer insert pressing process can also be kept at a temperature below the transition temperature of the metal .
  • One of the draw backs of the transfer pressing process is that upon forcing the molten metal into the mold cavity, the mold is cold causing the metal to tend to set up and solidify before it interacts with the clips 30, 31.
  • the sintered powdered metal process has the advantage in that the products produced in the mold are very near their final shape.
  • This process includes placing a metal powder into the mold cavity and closing the mold under pressure.
  • Compatible metals are required to be used for the sintered powdered metal process.
  • Wax binders may be added to the metal powder to hold the metal powder together upon closing and pressing the mold. The wax binders can then be burned off by placing the fuse in an oven and heating it to just below the melting temperature of the metal . More pressure may then be applied to the fuse to make it near its final shape. Typically, the fuse would have some flash around its outside edges. However, the contours would be very close to its final shape.
  • a certain surface finish will be required because the surface has imperfections caused by the application of pressure.
  • the sintered powdered metal process there is a three piece mold. Two halves of the mold are disposed around the clips 30, 31 and with the mold open at the top. The ends of the clips 30, 31 project up inside the mold cavity.
  • the metal powder for the thermal blocks 24, 25 would be inserted in the mold cavity first and tamped into place.
  • the powered metal is then placed into the mold cavity and a tamping tool is used to cause the powdered metal to fill the lower portion of the mold cavity.
  • the tamping tool is typically a piston on the end of a hydraulic ram which is used to apply pressure to the powdered metal in the mold cavity.
  • the third piece of the mold is then used to close the mold.
  • the third piece of the mold has a movable part in the middle which can be used to apply pressure to the powdered metal while it is in the oven.
  • one preferred embodiment would include thermal blocks of copper and fuse links of one of the tin-alloys.
  • the heat processing of copper powdered metal and a tin-alloy powdered metal is complex because the tin-alloy tends to melt at a much lower temperature than the copper and thus the tin-alloy tends to diffuse into the copper powder.
  • One of the advantages of the powdered metal process is that different metal powders may be mixed together to form the fuse link 20 and thermal blocks 24, 25. This will allow the fuse link 20 to be made of one metal and the thermal blocks 24, 25 to be made of another metal with the thermal blocks 24, 25 being made of a metal having a very high heat capacity. The metals are joined because of the pressure on the mold. This process, however, would not be inexpensive. While a preferred embodiment of the invention has been shown and described, modifications thereof can be made by one skilled in the art without departing from the spirit of the invention.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Materials Engineering (AREA)
  • Fuses (AREA)

Abstract

L'invention porte sur un fusible femelle (10) comportant une liaison fusible d'une pièce (20) et des blocs thermiques (24) moulés autour des pinces (30) du fusible. L'élément fusible (20), les blocs thermiques (24) et les pinces (30) étant renfermés dans un logement isolant. L'élément fusible (20) et les blocs thermiques (24) qui peuvent être fabriqués selon différentes techniques le seront de préférence par moulage par injection en une seule pièce. Le fusible ainsi obtenu est de taille moindre et fonctionne à une température plus basse que les fusibles actuels.
EP96907205A 1995-03-20 1996-03-14 Fusible femelle pour voitures Withdrawn EP0826228A1 (fr)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
US602626 1990-10-24
US08/407,356 US5631619A (en) 1995-03-20 1995-03-20 Female automotive fuse having fuse clips electrically connected to conductive thermal blocks
US407356 1995-03-20
US60262696A 1996-02-16 1996-02-16
PCT/US1996/003609 WO1996029721A1 (fr) 1995-03-20 1996-03-14 Fusible femelle pour voitures

Publications (1)

Publication Number Publication Date
EP0826228A1 true EP0826228A1 (fr) 1998-03-04

Family

ID=27019852

Family Applications (1)

Application Number Title Priority Date Filing Date
EP96907205A Withdrawn EP0826228A1 (fr) 1995-03-20 1996-03-14 Fusible femelle pour voitures

Country Status (6)

Country Link
EP (1) EP0826228A1 (fr)
JP (1) JPH11503864A (fr)
KR (1) KR19980703154A (fr)
AU (1) AU5094596A (fr)
BR (1) BR9607786A (fr)
WO (1) WO1996029721A1 (fr)

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6326878B1 (en) * 2000-02-01 2001-12-04 Shih-Tsung Liang Fuse holder
US6558198B2 (en) * 2000-11-30 2003-05-06 Autonetworks Technologies, Ltd. Fuse device and fuse device connecting structure
KR102819127B1 (ko) 2020-03-31 2025-06-12 주식회사 엘지에너지솔루션 이종금속으로 이루어진 hv 버스 바 및 이의 제조 방법
KR102773242B1 (ko) * 2020-04-07 2025-02-27 주식회사 엘지에너지솔루션 이종금속으로 이루어진 전극 리드 및 이의 제조 방법
EP4481936A1 (fr) 2023-06-20 2024-12-25 Röchling Automotive SE Système de contact de cellule et procédé de fabrication

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA1169898A (fr) * 1980-04-28 1984-06-26 Pacific Engineering Co., Ltd. Fusible
US4398785A (en) * 1981-09-28 1983-08-16 Essex Group, Inc. Electrical connector and method of making same
US4635023A (en) * 1985-05-22 1987-01-06 Littelfuse, Inc. Fuse assembly having a non-sagging suspended fuse link
CA1264791A (fr) * 1987-03-20 1990-01-23 Vojislav Narancic Fusible ayant un corps extincteur d'arc en ceramique rigide non poreuse et methode de fabrication de ce fusible
US5391337A (en) * 1991-06-24 1995-02-21 Ford Motor Company Method for making evaporative casting patterns
FR2686828A1 (fr) * 1992-01-30 1993-08-06 Vetrotex France Sa Procede d'obtention d'un produit composite par moulage.

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See references of WO9629721A1 *

Also Published As

Publication number Publication date
WO1996029721A1 (fr) 1996-09-26
AU5094596A (en) 1996-10-08
JPH11503864A (ja) 1999-03-30
KR19980703154A (ko) 1998-10-15
BR9607786A (pt) 1998-07-07

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