Fuse element assembly and method of fabricating the same

Abstract

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.