High voltage, reinforced in-line fuse assembly, systems, and methods of manufacture

Patent metadata

Field	Value
Publication number	US-10553386-B2
Application number	US-201314081331-A
Country	US
Kind code	B2
Filing date	Nov 15, 2013
Priority date	Nov 15, 2013
Publication date	Feb 4, 2020
Grant date	Feb 4, 2020

Abstract

Fuse assemblies, systems and methods of manufacture include reinforcement materials and arc absorbent materials to provide overcurrent protection for 1500 VDC power systems without enlarging the body of the fuse.

First claim

What is claimed is:

1. A compact high voltage electrical fuse assembly for a high voltage, direct current electrical power distribution system, the compact high voltage electrical fuse assembly comprising:
an in-line electrical fuse assembly comprising:
an electrical fuse designed to provide a predetermined direct current voltage rating, the electrical fuse comprising:
a cylindrical fuse body having first and second ends opposing one another;
a first ferrule terminal coupled to the first end of the cylindrical fuse body;
a second ferrule terminal coupled to the second end of the cylindrical fuse body;
a fuse element establishing a circuit path inside the cylindrical fuse body between the first ferrule terminal and the second ferrule terminal;

a first in-line wire crimp terminal coupled to an exterior of the first ferrule terminal;
a second in-line wire crimp terminal coupled to an exterior of the second ferrule terminal; and

a structural reinforcement material applied to and conforming with an exterior shape of the in-line electrical fuse assembly, the structural reinforcement material being sufficient to contain arc flash energy and prevent release of arc flash energy when the fuse element opens under a direct current load at a voltage 50% greater than the predetermined direct current voltage rating, and the structural reinforcement material:
entirely covering and structurally reinforcing an exterior of the cylindrical fuse body;
entirely covering and structurally reinforcing any exposed exterior of each of the first and second ferrule terminals that are not already covered by the first or second in-line wire crimp terminal; and
incompletely covering and structurally reinforcing only a minor portion of an exterior of each respective one of the first and second in-line wire crimp terminals.

2. The compact high voltage electrical fuse assembly of claim 1 , wherein the electrical fuse is provided in a 10×38 mm fuse package.

3. The compact high voltage electrical fuse assembly of claim 1 , wherein the predetermined direct current voltage rating of the electrical fuse is about 1000 VDC.

4. The compact high voltage electrical fuse assembly of claim 1 , wherein the cylindrical fuse body is fabricated from ceramic.

5. The compact high voltage electrical fuse assembly of claim 1 , further comprising an arc absorbing material extending in surface contact with the reinforcement material, in surface contact with the cylindrical fuse body, and in surface contact with a portion of each of the first ferrule terminal and the second ferrule terminal;
wherein the structural reinforcement material covers the arc absorbing material.

6. The compact high voltage electrical fuse assembly of claim 5 , wherein the arc absorbing material is one of silicone or resinous fluorine-containing polymer material tape.

7. The compact high voltage electrical fuse assembly of claim 1 , wherein the structural reinforcement material is applied as a sleeve of heat shrink material.

8. The compact high voltage electrical fuse assembly of claim 7 , wherein the heat shrink material is adhered to the in-line electrical fuse assembly.

9. The compact high voltage electrical fuse assembly of claim 7 , further comprising a label applied to an exterior of the structural reinforcement material, the label being color coded to identify a compatible fuse accessory.

10. The compact high voltage electrical fuse assembly of claim 9 , wherein the compatible fuse accessory is a fuse holder or a wiring harness.

11. A method of manufacturing a compact high voltage electrical fuse assembly including an electrical fuse having a predetermined direct current voltage rating and including a cylindrical fuse body having opposing ends, a fuse element extending interior to the cylindrical fuse body, and first and second ferrule terminal elements on the respective opposing ends of the cylindrical fuse body and establishing a circuit path through the fuse element, the method comprising:
attaching first and second in-line wire crimp connectors to the respective first and second ferrule terminal elements; and
entirely covering an exterior of the cylindrical fuse body and any exterior portion of the first and second ferrule terminal elements that are not covered by the first or second in-line wire crimp connectors with a structural reinforcement material conforming to the shape of the cylindrical fuse body and the first and second ferrule terminal elements, while incompletely covering exterior portions of the first and second in-line wire crimp connectors with the structural reinforcement material conforming to the shape of the portions of the first and second in-line wire crimp connectors;
whereby the compact high voltage electrical fuse reinforcement material contains arc energy when the fuse element opens to break the circuit path under a direct current electrical load at a voltage 50% greater than the predetermined direct current voltage rating of the electrical fuse.

12. The method of claim 11 , wherein the predetermined direct current voltage rating is about 1000 VDC.

13. The method of claim 11 , wherein attaching the first and second in-line wire crimp connectors comprises friction fitting the first and second in-line wire crimp connectors to the respective first and second ferrule terminal elements of the electrical fuse.

14. The method of claim 11 , wherein the cylindrical fuse body of the electrical fuse is fabricated from ceramic.

15. The method of claim 11 , further comprising extending an arc absorbing material between the structural reinforcement material and the cylindrical fuse body, between the structural reinforcement material and a portion of the first and second ferrule terminal elements, and between the structural reinforcement material and portions of the first and second in-line wire crimp connectors.

16. The method of claim 15 , wherein extending the arc absorbing material comprises extending one of silicone or resinous fluorine-containing polymer material tape.

17. The method of claim 11 , wherein covering the body and a portion of the first and second ferrule terminal elements with the structural reinforcement material while incompletely covering portions of the first and second in-line wire crimp connectors with the structural reinforcement material comprises applying a heat shrink material.

18. The method of claim 17 , wherein applying the heat shrink material comprises applying an adhesive heat shrink material.

19. The method of claim 18 , further comprising applying a color coding to the structural reinforcement material.

20. The method of claim 19 , further comprising providing a fuse accessory, and color coding the fuse accessory to match the color coding of the structural reinforcement material.

21. The method of claim 11 , wherein the electrical fuse has a current rating of 1 to 20 Amps.

22. The compact high voltage electrical fuse assembly of claim 1 , wherein the electrical fuse has a current rating of 1 to 20 Amps.

23. A compact in-line electrical fuse assembly for a 1500 VDC power system, the in-line fuse assembly comprising:
an electrical fuse having a voltage rating of 1000 VDC , the electrical fuse comprising:
a cylindrical fuse body having first and second ends opposing one another;
a first ferrule terminal coupled to the first end of the cylindrical fuse body;
a second ferrule terminal coupled to the second end of the cylindrical fuse body;
a fuse element establishing

Assignees

• Eaton Intelligent Power Ltd

Inventors

• Von Zur Muehlen Patrick A
• Henricks Michael C

Classifications

• H01H85/34

  Distinguishing marks, e.g. colour coding · CPC title

• H01H85/157

  Ferrule-end contacts · CPC title

• H01H85/43

  Means for exhausting or absorbing gases liberated by fusing arc, or for ventilating excess pressure generated by heating · CPC title

• H01H69/02

  Manufacture of fuses · CPC title

• Y10T29/49107

  Fuse making · CPC title