FUSE ELEMENT ASSEMBLY AND METHOD OF FABRICATING THE SAME
A fuse element assembly has been disclosed. The fuse element assembly includes a fuse element having a pair of side edges and at least one weak spot between the side edges. The fuse element assembly also includes an arc-quenching material attached locally to the fuse element adjacent the weak spot.
1 . A fuse element assembly comprising:
a fuse element having a pair of side edges and at least one weak spot between the side edges; and
an arc-quenching material attached locally to the fuse element adjacent the weak spot.
2 . The fuse element assembly of claim 1 , wherein the arc-quenching material wraps around at least one of the side edges.
3 . The fuse element assembly of claim 2 , wherein the arc-quenching material completely encapsulates the fuse element in a plane extending between the side edges.
4 . The fuse element assembly of claim 1 , wherein each of the side edges has an indented segment near the weak spot.
5 . The fuse element assembly of claim 1 , wherein the fuse element has a fold extending between the side edges adjacent the weak spot, the fold covered in the arc-quenching material.
6 . The fuse element assembly of claim 1 , further comprising a support structure coupled to the fuse element beneath the arc-quenching material.
7 . The fuse element assembly of claim 1 , wherein the fuse element comprises a pair of wings bent upwardly at the side edges, each wing having an upper edge covered in the arc-quenching material.
8 . A method of fabricating a fuse element assembly, said method comprising:
forming a fuse element having a pair of side edges and at least one weak spot between the side edges; and
locally attaching n arc-quenching material to the fuse element adjacent the weak spot.
9 . The method of claim 8 , further comprising wrapping the arc-quenching material around at least one of the side edges.
10 . The method of claim 9 , further comprising encapsulating the fuse element in the material in a plane extending between the side edges by at least one of:
dispensing the material at the side edges; and
dipping the side edges in a reservoir of the material after attaching a removable mask to the fuse element.
11 . The method of claim 8 , further comprising forming an indented segment along each side edge near the weak spot.
12 . The method of claim 8 , further comprising:
folding the fuse element between the side edges and adjacent the weak spot; and
covering the fold in the arc-quenching material.
13 . The method of claim 8 , further comprising:
coupling a support structure to the fuse element; and
applying the arc-quenching material to the fuse element atop of the support structure.
14 . The method of claim 8 , further comprising:
bending a pair of wings upwardly at the side edges of the fuse element; and
covering an upper edge of each wing with the arc-quenching material.
15 . A fuse comprising:
a housing;
a pair of terminals coupled to the housing;
an arc-quenching matrix contained within the housing; and
a fuse element assembly embedded in the matrix and extending between the terminals within the housing, the fuse element assembly comprising:
a fuse element having a pair of side edges and at least one weak spot between the side edges; and
an arc-quenching material attached locally to the fuse element adjacent the weak spot.
16 . The fuse of claim 15 , wherein fuse is a high-voltage, direct current (DC) fuse.
17 . The fuse of claim 16 , wherein the fuse has a voltage rating of at least 500VDC.
18 . The fuse of claim 17 , wherein the housing is compact such that the fuse is made for use in a power system of an electric vehicle (EV).
19 . The fuse of claim 15 , wherein the arc-quenching material wraps around at least one of the side edges.
20 . The fuse of claim 19 , wherein the arc-quenching material completely encapsulates the fuse element in a plane extending between the side edges.