U.S. patent number 3,654,696 [Application Number 05/006,674] was granted by the patent office on 1972-04-11 for method for manufacturing electric fuses.
Invention is credited to Bernard Wechsler, Roger Wechsler.
United States Patent |
3,654,696 |
Wechsler , et al. |
April 11, 1972 |
METHOD FOR MANUFACTURING ELECTRIC FUSES
Abstract
Method for manufacturing a fuse comprising, prior to fixing the
responsive element of the fuse to the two strips for connecting the
element to the electric circuit, fixing the two strips at a fixed
distance apart in a case of insulating material. The responsive
element is thereafter soldered to the two strips and the interior
of the case is closed off and filled with powdered material. The
case is then finally closed. Various embodiments of the fuse
obtained are disclosed.
Inventors: |
Wechsler; Bernard (93
Montreuil, FR), Wechsler; Roger (93 Montreuil,
FR) |
Family
ID: |
21722044 |
Appl.
No.: |
05/006,674 |
Filed: |
January 29, 1970 |
Current U.S.
Class: |
29/623; 337/186;
337/231; 337/246 |
Current CPC
Class: |
H01H
69/02 (20130101); Y10T 29/49107 (20150115) |
Current International
Class: |
H01H
69/00 (20060101); H01H 69/02 (20060101); H01h
069/02 () |
Field of
Search: |
;337/231,233,246,251,252,186 ;29/623 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Campbell; John F.
Assistant Examiner: DiPalma; Victor A.
Claims
We claim:
1. A method for manufacturing electric fuses comprising a
responsive element connected to strips which serve to connect the
responsive element to an exterior electric circuit to be protected,
said method comprising mounting said strips on responsive opposite
walls of an open case of insulating material so that the strips are
held in position, each strip extending on both sides of its
respective wall in a direction substantially perpendicular to the
latter, whereby the spacing between the strips inside said case is
fixed, then metallurgically bonding said responsive element to
respective parts of said strips inside said case, placing a cover
on said case, said cover having a filling aperture, filling the
interior of said case with a powdered material through said
aperture and blocking said cover on said case while stopping up
said aperture.
2. A method for manufacturing electric fuses comprising a
responsive element connected to strips which serve to connect the
responsive element to an exterior electric circuit to be protected,
said method comprising mounting said strips on respective opposite
walls of an open case of insulating material so that the strips are
held in position, each strip extending on both sides of its
respective wall in a direction substantially perpendicular to the
latter, whereby the spacing between the strips inside said case is
fixed, then soldering or otherwise welding said responsive element
to respective parts of said strips inside said case, placing a
cover on said case, said cover having a filling aperture, filling
the interior of said case with a powdered material through said
aperture and blocking said cover on said case while stopping up
said aperture by moulding under high pressure in a mould an
insulating material which covers said case and said cover, said
moulding including injecting under high pressure in said mould an
amount of insulating material whose volume is slightly greater than
the space available in said mould after introduction of said case
and said cover therein, so as to deform said cover and said case
and thereby compressing said powdered material.
3. A method as claimed in claim 1, said case and said cover being
of a thermosetting plastic material.
4. A method as claimed in claim 2, wherein said insulating material
introduced in said mould is a thermoplastic material.
5. A method as claimed in claim 1, wherein said powdered material
is fine sand.
6. A method for manufacturing electric fuses comprising a
responsive element connected to strips which serve to connect the
responsive element to an exterior electric circuit to be protected,
said method comprising moulding tow identical shells of insulating
material forming respectively an open case and a cover for said
case, providing a hole in the shell forming said cover, mounting
said strips on respective opposite walls of said shell forming said
case so that the strips are held in position, each strip extending
on both sides of its respective wall in a direction substantially
perpendicular to the latter, whereby the spacing between the strips
inside said shell forming said case is fixed, then soldering or
otherwise welding said responsive element to respective parts of
said strips inside said case, applying said shell forming said
cover onto said shell forming said case, filling the interior of
said shells with a powdered material through said hole and blocking
said shells one on the other by moulding a layer of insulating
material around the whole of said shells.
7. A method for manufacturing electric fuses comprising a
responsive element connected to strips which serve to connect the
responsive element to an exterior electric circuit to be protected,
said method comprising moulding an open box of insulating material
and fixing said strips in opposite walls of said box in the course
of said moulding, each strip extending through its corresponding
wall in a direction substantially perpendicular to the latter so
that said strips have a fixed spacing therebetween, then
metallurgically bonding said responsive element to the parts of
said strips inside said box, filling the interior of said box with
powdered material, closing off said interior with a yieldable
closing member and moulding in a mould a cover on said box over
said closing member by injecting in said mould moulding material
under pressure.
8. A method as claimed in claim 7, wherein said box comprises walls
and edge portions on said walls, said edge portions having a
dove-tail cross section and being embedded in said cover during
moulding of the latter.
9. A method for manufacturing electric fuses comprising a
responsive element connected to strips which serve to connect the
responsive element to an exterior electric circuit to be protected,
said method comprising moulding an open box of insulating material
and fixing said strips in opposite walls of said box in the course
of said moulding, each strip extending through its corresponding
wall in a direction substantially perpendicular to the latter so
that said strips have a fixed spacing therebetween, then soldering
or otherwise welding said responsive element to the parts of said
strips inside said box, filling the interior of said box with
powdered material, and closing said box by sliding a cover on
dove-tail section edge portions provided on two opposite walls of
said box.
Description
The present invention relates to the manufacture of electric fuses
having a high cut-off or break power of the type comprising a
sensitive or responsive element in the form of wires or a metal
strip embedded in a powdered mass, the assembly being enclosed in a
housing of insulating material. The sensitive element is
electrically connected to two blades or strips projecting from the
body of the fuse and serving to place the assembly on a base or
wiring panel or the like provided with tongs which ensure the
connection with the circuit controlled by the fuse.
Up to the present time, difficulties have been met with in the
manufacture of these fuses owing to the very poor stiffness of the
sensitive elements which are not only very thin but provided with
calibration orifices to afford a carefully predetermined cut-off
value. These orifices result in zones of smaller cross section
which still further increase the risk of damage to the sensitive
elements by the deformation which could easily occur during
handling in the course of manufacture and particularly when the
elements are fixed to the strips which have a mass distinctly
greater than the elements.
The object of the invention is to avoid all these risks of damage
to the sensitive or responsive elements.
The invention provides a method for manufacturing electric fuses
comprising, prior to fixing the responsive element of the fuse to
the strips which serve to connect it to the exterior electric
circuit to be protected, placing said strips in a case of
insulating material so as to impart to the strips a fixed spacing
therebetween in said shell, soldering or otherwise welding said
responsive element to said strips, closing off the interior of said
case, filling said case with a powdered material and closing said
case.
Owing to these features of the invention, the responsive element is
mounted on the strips only after they have been given a fixed
distance apart and prevented from moving relative to each other, so
that deformations of the responsive element are avoided.
According to one embodiment of the invention, the closing
operations comprise moulding under high pressure an insulating
material which covers at least a part of the case by injecting in
the mould employed an amount of insulating material whose volume is
slightly greater than the space available in the mould after
introduction of the case.
This particular feature of the invention enables a very high
compression of the powdered mass to be achieved by a small inward
deformation of at least a part of said case, this compression being
essential in order to avoid formation of arcs in the fuse upon
cutoff.
Another object of the invention is to provide a fuse obtained by
the method defined hereinbefore, said fuse comprising a case and
two strips adapted to connect the fuse to an exterior circuit, a
responsive element located inside said case and fixed to said
strips, a powdered material filling said case, means for holding
said strips at a fixed distance apart during all the manufacturing
stages of said fuse, and means for closing said case .
Further features and advantages of the invention will be apparent
from the ensuing description with reference to the accompanying
drawings.
In the drawings:
FIG. 1 is an exploded perspective view of two half-cases provided
with strips and a sheet element constituting the sensitive or
responsive element, the assembly constituting an intermediate
product of the method according to the invention;
FIG. 2 is a perspective view of one of the half-cases shown in FIG.
1, the strips and responsive element having been removed;
FIG. 3 is an exploded and perspective view of one of the strips of
the fuse with its strip support;
FIG. 4 shows a closing stage of the method according to the
invention;
FIG. 5 is a perspective view of the finished fuse;
FIG. 6 is a perspective view of a modification of the strip
support;
FIGS. 7-10 are sectional views and FIG. 11 a perspective view of
intermediate products obtained after various manufacturing stages
of a modification of the method according to the invention, and
FIG. 12 is a perspective view of a modification of the fuse
according to the invention.
According to the embodiment shown in FIGS. 1-5, two identical
half-cases 1 are first manufactured, these half-cases constituting
after assembly a rectangular-sided housing having rounded corners.
The half-cases are of an insulating material, such as a
thermosetting plastics material. Their transverse or end walls are
combined with integral flanges 2 each of which forms a cavity 3 in
which can be closely embedded a support 4 for fixing a blade or
strip 5 to the case.
FIG. 3 shows a blade or strip 5 and its support 4. It can be seen
that the strip has the shape of a blade slotted at 6 for mechanical
and electrical connection to the electric system of which the fuse
subsequently forms part. The opposite end of the strip has two
lateral recesses 7.
The strip support 4 preferably of metal comprises a body 8 in one
piece with a roughly T-shaped tab 9. One of the branches 10 of the
T-shaped tab defines with an edge of the body 8 a recess for
receiving the strip 5, the distance between the bottoms of the
recess 7 being adjusted to the distance between the edge of the
branch 10 and said edge of the body 8. The strip is thus maintained
in lateral position. It is maintained in transverse position owing
to the cooperation therewith of notches 11 respectively provided in
the lateral walls of each half-case 1 and in the flanges 2.
Each strip support 4 is provided with four small projecting
portions 12 each of which terminates in two fastening points 13.
The projecting portions are respectively embedded in aligned
rectangular slots 14 provided in the bottom of each cavity 3.
The strip support and the strip itself are of metal, such as
copper, covered with a layer of tin or other metal.
The component parts described up till now having been manufactured
in the conventional manner, they are assembled by introducing the
strips in their support 4 and embedding thereafter the latter in
their cavities 3 provided for this purpose in the half-cases 1.
A number of half-cases being thus provided with strips, a sensitive
or responsive element 15 is then fixed in each of them by soldering
or welding the ends of the element to the inner ends of the strips
at 16 as shown in FIG. 1.
The strips 5 are prevented from moving longitudinally relative to
each other, since they are trapped by their support 4 in the
half-case. Thus, there is absolutely no risk of damage to the
responsive element 15 by bending during handling and the precision
of its calibration is in no way affected. A half-case with its
strips and its responsive element can therefore be easily stored
and handled with no risk.
After the soldering operation, the assemblies thus obtained are
enclosed in the identical half-cases the centering of which is
facilitated owing to provision of tabs 17 on the longitudinal walls
of each half-case.
The assembled cases 10 (FIG. 4) are thereafter rendered rigid by
deforming the fastening points 13.
The following operation of the manufacturing method comprises
filling the assembled case 18 with a powdered material, for example
fine sand, adapted to stifle the arcs which might occur when the
fuse operates and the responsive element is severed by the Joule
effect. The filling can be carried out through an aperture 19
previously provided in each half-case when moulding the latter. The
sand is tamped by subjecting the case to vibrations.
FIG. 4 shows the following stage in the method according to the
invention. In this stage, the finished case 18 filled with sand is
placed in a mould 20 in which are provided passages 21 for the
strips 5. The case is suitably centered in the mould 20 owing to a
series of studs 22 and ribs 23 (FIGS. 1 and 4) which are moulded on
each half-case 1.
An appropriate material, such as a thermoplastic or thermosetting
material, is introduced under high pressure in the mould 20. This
material forms, after stripping from the mould, an outer case 24
which covers the case 18. This moulding serves two purposes :
1. The outer case 24 renders the fuse tamperproof and improves its
rigidity.
2. Owing to the high moulding pressure, the inner case is
compressed and even slightly deformed and this results in an
additional tamping of the powdered material inside the fuse. The
pressure results in the introduction of a volume of material
slightly greater than the space available before application of
pressure in the mould 20.
FIG. 5 shows a finished fuse obtained by the method described
hereinbefore. It can be seen that the fuse is provided with a
conventional indicator or telltale element 25 which indicates when
the fuse has cut-off the circuit and is inserted between the tabs
26 forming part of the strip supports 4. The fuse can also be
provided with a plate showing its cut-off value or some other
indication.
FIG. 6 shows another embodiment of a strip support 4.sup.a. The
body 8.sup.a of this support is in one piece with two parallel tabs
9.sup.a which define an oblong opening 27 in which the strip is
lodged after a slight deformation of one of the tabs 9.sup.a, as
indicated by the dotted line 28 in FIG. 6. Similar to the support 4
shown in FIG. 3, the support 4.sup.a has four projecting portions
12.sup.a and a tab 26.sup.a provided for fixing an indicator or
telltale element 25 which indicates when the fuse has cut-off the
circuit.
In the modification of the method according to the invention shown
in FIGS. 7-11, the starting component is a case 29 having the shape
of an open box or housing in which are introduced subsequent to the
moulding thereof, two strips 30 and two supports 31. The upper
edges of the walls of the case are provided with edge portions 32
having a dove-tail cross section moulded thereon.
With the strips 30 thus trapped in the case 29, a sensitive or
responsive element 33 is soldered to their inner ends (FIG. 9). It
will be observed that the responsive element therefore cannot be
damaged by bending after assembly with the strips.
With the case filled with a powdered material and closed with a
thin plug or screen 34, it is introduced in a mould in which a
cover 35 is formed. The latter is rigidly secured to the case,
after stripping from the mould, owing to the dove-tail edge
portions 32. The entire moulding is carried out under pressure, the
excess material introduced in the mould resulting in a tamping of
the powdered material consequent to a slight deformation of the
screen 34.
FIG. 11 shows the finished fuse. It can be seen that an indicator
or telltale element 36 can be engaged in a groove 37 provided in
the case 29. The telltale element is clamped between two tabs 38
respectively forming part of the strip supports 31.
A modification of the fuse in which the final moulding has not been
carried out is shown in FIG. 12. In this fuse, the case 39
comprises an edge portion having a dove-tail section only on the
edge portions of two opposite walls and a cover 40 is slidable on
these edge portions. Tapped holes 41 enable the cover 40 to be
secured to the case 39 by means of screws (not shown). If desired,
this fuse can be re-armed after having performed its cutting-off
function by replacing the melted responsive element by another
element and filling the case once again with a powdered
material.
Although specific embodiments of the invention have been described,
many modifications and changes may be made therein without
departing from the scope of the invention.
* * * * *