Fuse for interrupting a voltage and/or current-carrying conductor in case of a thermal fault and method for producing the fuse

• US 9,093,238 B2
• Filed: 02/14/2008
• Issued: 07/28/2015
• Est. Priority Date: 03/26/2007
• Status: Expired due to Fees

• Current Assignee: Robert Bosch GmbH
• Original Assignee: Robert Bosch GmbH
• Inventors: Knab, Norbert, Schulze-Icking-Konert, Georg, Mohr, Thomas, Kotthaus, Stefan, Haberl, Nikolas, Stampfer, Stefan, Mueller, Michael
• Primary Examiner(s): Vortman, Anatoly
• Application Number:
  US12/532,971
• Publication Number:
  US 20100085141A1
• Time in Patent Office: 2,721 Days
• Field of Search: 337/227, 337/152, 337/159, 337/160, 337/180, 337/181, 337/290, 337/158, 337/296, 337/413, 420/561, 420/562, 420/559, 420/577, 296/23, 148/400
• US Class Current: 1/1
• CPC Class Codes: H01H 1/52 Contacts adapted to act as latches
• CPC Class Codes: H01H 2037/768 characterised by the composition of the fusible material
• CPC Class Codes: H01H 37/761 with a fusible element forming part of the switched circuit H01H37/767 takes precedence
• CPC Class Codes: H01H 69/02 Manufacture of fuses
• CPC Class Codes: H01H 85/0418 with ferrule type end contacts
• CPC Class Codes: H01H 85/0458 with ferrule type end contacts
• CPC Class Codes: H01H 85/055 Fusible members
• CPC Class Codes: H01H 85/06 characterised by the fusible material H01H85/11 takes precedence
• CPC Class Codes: H01H 85/143 Electrical contacts; Fastening fusible members to such contacts
• CPC Class Codes: H01H 85/157 Ferrule-end contacts
• CPC Class Codes: H01H 85/165 Casings
• CPC Class Codes: Y10T 29/49107 Fuse making

Abstract

A fuse (10) is proposed for interrupting a voltage and/or current-carrying conductor (12) in case of a thermal fault, having a conductor bar (14) ensuring an electrically conductive connection of the voltage and/or current-carrying conductor during correct operation, said fuse (10) being characterized in that the conductor bar (14) melts upon an increase in temperature above the melting point, and the electrically conductive connection of the voltage and/or current-carrying conductor is interrupted due to inherent surface tension. Also proposed is a method for producing the fuse (10) according to the invention.

Claims

1. A fuse for interrupting an electrical conductor in event of a thermal fault, comprising:

a conductor bar providing an electrically conductive connection of the electrical conductor during correct operation, wherein the conductor bar melts upon an increase in temperature above a melting point and the electrically conductive connection of the electrical conductor is interrupted due to inherent surface tension; and

a retaining element coupled to at least one end of the conductor bar, wherein the retaining element comprises a first part configured as a hollow body having one open side for holding the conductor bar and a second part for connecting the retaining element to the electrical conductor,

wherein the conductor bar is coupled to an interior of the hollow body by a solder joint, wherein a melting point of the solder joint is less than the melting point of the conductor bar and greater than a maximally admissible temperature for correct operation, wherein the maximally admissible temperature is in a range up to 170°

Celsius,

wherein the conductor bar is further directly coupled to the hollow body in a force-fitting manner by a mechanical deformation of the hollow body, and

wherein the hollow body further includes at least one raised portion on an outer circumference that constitutes a point of force application for the mechanical deformation of the hollow body after inserting the conductor bar into the hollow body for holding the conductor bar in the hollow body in a force-fitting manner to directly secure the conductor bar to the hollow body.

2. The fuse of claim 1, wherein the electrical conductor is coupled to a stamped grid, a printed circuit board or the like.

3. The fuse of claim 1, wherein the hollow body further comprises at least one of an additional chamfer and a slot.

4. The fuse of claim 1, wherein the first part and the second part of the retaining element are configured as one piece.

5. The fuse of claim 1, wherein the first part and the second part of the retaining element are one of welded and riveted together.

6. The fuse of claim 1, wherein the second part of the retaining element is configured as one of a bar-like, a wire-like, and a strip-like form.

7. The fuse of claim 1, wherein the second part of the retaining element is angled with respect to a preferred orientation of the conductor bar.

8. The fuse of claim 1, wherein the retaining element is an integral component part of a stamped grid.

9. The fuse of claim 1, wherein the conductor bar comprises of one of a metal, a highly electrically conductive alloy, and a soft solder alloy.

10. The fuse of claim 1, wherein the conductor bar comprises a core that contains an activator medium.

11. The fuse of claim 10, wherein the activator medium is a carboxylic acid.

12. The fuse of claim 10, wherein the core contains a mixture of a carboxylic acid and a resin.

13. The fuse of claim 1, wherein the conductor bar comprises a core that contains a salt of a carboxylic acid.

14. The fuse of claim 1, wherein the conductor bar comprises a flux encasement that contains one of a carboxylic acid and a salt of a carboxylic acid.

15. The fuse of claim 14, wherein the flux encasement comprises a lacquer coating.

16. A method for producing a fuse comprising a retaining element and a conductor bar for interrupting an electrical conductor in event of a thermal fault, the method comprising:

forming the retaining element to include a first and a second part, wherein the second part is formed to connect the retaining element to the electrical conductor, and wherein the first part includes a hollow body with one open side for receiving the conductor bar and at least one raised portion on an outer circumference to be used as a point of force application for mechanical deformation of the hollow body to directly secure the conductor bar to the hollow body in a force fitting manner;

applying a solder to the first part such that at least one of a base and an interior wall of the first part is covered by the solder;

inserting the conductor bar into the open side of the hollow body of the retaining element;

applying a thermal pulse to at least one component selected from a group consisting of the second part of the retaining element, the raised portion of the first part of the retaining element, and the conductor bar, wherein the applied thermal pulse heats the at least one component to a temperature between a melting point of the solder and a melting point of the conductor bar and forms a solder joint between the conductor bar and the retaining element by melting the solder, wherein the melting point of the solder lies beneath that of the conductor bar and above a maximally admissible temperature for correct operation of the fuse, wherein the maximally admissible temperature is in a range up to 170°

Celsius; and

applying a force to the at least one raised portion on the outer circumference of the hollow body to cause the mechanical deformation of the hollow body and to directly secure the conductor bar to the hollow body in a force fitting manner.

17. The method of claim 16, wherein the thermal pulse is impressed by one of a laser and an infrared light in a non-contact manner.

18. The method of claim 16, wherein the act of inserting the conductor bar into the hollow body is performed before the act of applying the thermal pulse.

19. The method of claim 16, further comprising applying an activator onto the conductor bar.

20. The method of claim 19, wherein the act of applying the activator forms a lacquer layer on the conductor bar.

21. The method of claim 16, further comprising checking a connection of the first part and the conductor bar.

22. The method of claim 21, further comprising optically checking the connection.

23. The method of claim 21, further comprising automatically checking the connection.

24. The method of claim 21, further comprising checking the connection with a probe disposed as to be freely displaceable in order to cover a region to be checked in the first part of the retaining element.

25. The method of claim 21, further comprising supplying an operating result for confirming a flawless soldering if a soldering meniscus is detected upon the conductor bar being one of affixed on and inserted into the first part in one of the force-fitting and the positive-locking manner.

26. A fuse for interrupting a voltage-and-current-carrying conductor in the case of a thermal fault, comprising:

a conductor bar which ensures an electrically conductive connection of the voltage-and current-carrying conductor during correct operation,

wherein an increase in temperature above a melting point of the conductor bar causes the conductor bar to melt and interrupts the electrically conductive connection of the voltage-and-current-carrying conductor as a result of its inherent surface tension, and

wherein at least one end of the conductor bar is held by a holding element, which has a first part for holding the conductor bar and a second part for connecting the holding element to the voltage-and-current carrying conductor of a leadframe or a printed circuit board, characterized in that the first part is formed as a hollow body that is open on one side to receive the conductor bar and includes at least one raised portion on an outer circumference of the hollow body used as a point of force application for mechanical deformation of the hollow body to directly secure the conductor bar in a force-fitting manner to the hollow body, and wherein the conductor bar is further secured to an interior of the hollow body by a solder, wherein the melting point of the solder lies below that of the conductor bar and above a maximum temperature for correct operation of the fuse.