U.S. patent number 3,845,439 [Application Number 05/180,786] was granted by the patent office on 1974-10-29 for method of manufacturing fuses.
This patent grant is currently assigned to Olvis Smeltzekeringen Fabriek N.V.. Invention is credited to Gerardus J. Deelman.
United States Patent |
3,845,439 |
Deelman |
October 29, 1974 |
METHOD OF MANUFACTURING FUSES
Abstract
A method of manufacturing fuses in which a core wire composed of
a non-conductive fibrous material is provided with a layer of
thermosetting material. The thermosetting layer is set by heating,
so that the core wire is rigidified. The core wire is subsequently
wound with a very thin metal wire. The wound core is then cut into
segments of predetermined dimensions. The segments are mounted in
suitable containers, so that fuses are obtained.
Inventors: |
Deelman; Gerardus J.
(Eindhoven, NL) |
Assignee: |
Olvis Smeltzekeringen Fabriek
N.V. (Utrecht, NL)
|
Family
ID: |
26644579 |
Appl.
No.: |
05/180,786 |
Filed: |
September 15, 1971 |
Foreign Application Priority Data
|
|
|
|
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Sep 15, 1970 [NL] |
|
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7013620 |
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Current U.S.
Class: |
337/291; 337/159;
337/295 |
Current CPC
Class: |
H01H
69/02 (20130101); H01H 85/055 (20130101); Y10T
29/49107 (20150115); Y10T 29/49798 (20150115); Y10T
29/49885 (20150115); Y10T 29/49982 (20150115) |
Current International
Class: |
H01H
69/02 (20060101); H01H 85/00 (20060101); H01H
69/00 (20060101); H01H 85/055 (20060101); H01h
085/04 () |
Field of
Search: |
;337/290,291,295,159 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Primary Examiner: Miller; J. D.
Assistant Examiner: Bell; Fred E.
Attorney, Agent or Firm: Cushman, Darby & Cushman
Claims
1. A fuse for use at current values of one ampere and less
comprising a tubular insulating casing, conductive terminal means
mounted on each end of said casing and a fuse element mounted in
said casing between said conductive terminal means, said fuse
element including an electrically non-conductive, heat-insulating
and heat-resistive wire core of fibres rigidified with set
thermosetting material, wherein at least one current
2. A fuse according to claim 1 wherein said fine wire is silver
having a
3. A fuse according to claim 1 wherein said fine wire is tin having
a
4. A fuse according to claim 1 wherein said fine wire is silver
having a
5. A fuse according to claim 1 wherein said fine wire is tin having
a
6. A low-current value fuse comprising a casing; spaced-apart
conductive terminal means mounted on the casing; and a fuse element
mounted in the casing between the conductive terminal means, said
fuse element including an elongated rigid core which is
electrically non-conductive, heat-insulating and heat-resistive,
said core being an extremely thin wire made of fibres having
diameters of the order of 5-10 microns, said wire being rendered
rigid by the presence of heat-set thermosetting material in contact
with said fibres, said fuse element further including at least
one
7. A fuse according to claim 6 wherein said fine wire is silver
having a
8. A fuse according to claim 6 wherein said fine wire is tin having
a
9. A fuse according to claim 6 wherein said fine wire is silver
having a
10. A fuse according to claim 6 wherein said fine wire is tin
having a
11. A fuse according to claim 6 wherein said core consists of a
fibre material chosen from the group consisting of glass fibres,
quartz fibres
12. A fuse according to claim 1 wherein the number of windings per
length unit of the very thin metal wire around the core in the
centre of the element is larger than at the ends, so that during
operation the greatest
13. A fuse according to claim 6 wherein the number of windings per
length unit of the very thin metal wire around the core in the
centre of the element is larger than at the ends, so that during
operation the greatest heat development occurs in the centre of the
element.
Description
The invention relates to a method of manufacturing fuses,
particularly fuses for use at low current values, as well as to
fuses manufactured by this method.
Modern electronic engineering has an increasing demand for high
quality fuses for low current values, for instance for the
protection of transistorized equipment. The most generally used
type of fuse comprises a container tube in which a highly
conductive fusible wire is stretched between two conductive
terminals. These conventional fuses, however, have a number of
drawbacks.
Since from the point of view of manufacture and use it is desirable
to impart specific uniform dimensions to the fuses, the length of
the fusible wire is substantially fixed. The current protection
range of a conductive wire is known to be determined by parameters,
such as the dimater, resistivity, length and melting point of the
wire. In the case of a specific choice of material the current
protection range is determined only by the diameter of the wire,
since its length is substantially fixed. As only wires with a
limited number of different diameters are commercially available,
it is hardly possible to manufacture fuses for arbitrary current
protection ranges.
Another drawback is that owing to the temperature increase due to
the current flow the fusible wire will expand and sag. This sagging
has an unfavourable effect on the fusing characteristic.
In general for a well defined current protection it is preferred to
use a wire of a metal having a well defined melting point, which
metal at elevated temperature is substatially inert to
environmental affects. Such a material is e.g. silver. However,
silver is less suitable for low current values, since these low
current values require such a small diameter that the wire is
substantially unmanageable. The relation between diameter and
length of the wire should be such that the wire becomes too slack
and tends to sag, which renders the fuse unreliable to a large
extent. Moreover, the manufacture of fuses with very thin silver
wires is practically impossible, since in mounting the silver wire
in the container tube the wire tends to dissolve in the tin of the
mounting places. Therefore, up to now fuses with silver wire have
not been used in the case of current values less than 1A.
In practice the drawbacks linked up with silver are avoided by
using metals of higher resistivity, so that wires of larger
diameter can be used. A frequently used metal is e.g. nickel.
However, these materials are not inert and upon use increasingly
show corrosion effects when heated, as a result of which the
material properties and, consequently, the melting point are no
longer well defined, which reduces the reliability.
A possible solution for the above difficulties would be to replace
the stretched wire by a winding disposed around an insulating core.
In this manner the core can serve as a support so as to prevent
sagging, which makes it possible to use the so desired silver wire
even when very small diameters are required. However, the heat
dissipating properties of such a core affect during use the heat
properties of the winding. In order to meet this objection the core
should be a good heat insulator and should be so thin that its heat
dissipation can substantially be neglected. Suitable core materials
are, for instance, extremely thin wire of glass or quartz fibres or
a similar material. However, since these wires should have a very
small diameter in the order of 5-10 microns, they are highly
pliable and flexible, which makes it hardly possible to wind such
wires with extremely fine metal wire, as during the winding process
the lateral forces on the fibre material due to the winding
operation may easily cause wire rupture.
It is an object of the invention to give a solution for the above
problem by providing a method with which it is possible to dispose
a wire winding of silver or any other desired material of extremely
small diamter (in the order of 20-30 microns) around an extremely
thin wire of fibre material. The method according to the invention
is characterized in that a very thin wire of electrically
non-conductive, heat-insulating and heat-resistive fibre material,
which is provided with a thin layer of thermosetting material, is
set or rigidified by heating, the set wire is wound with extremely
thin metal wire, the wound wire is cut in defined segments and the
segments are mounted in suitable containers.
By using the thermosetting effect of the coating on the fibre wire,
the invention makes it possible to wind extremely thin cores, the
heat dissipating properties of which are negligible, with
micro-wire for obtaining a well defined fuse for low current
values. The fuse manufactured by this method is characterized in
that the current conductor consists of extremely fine wire having a
well defined melting point and the core consists of set fibre
material of such a thickness that its heat dissipating property is
negligible. To this end the core material is preferably composed of
glass fibre wire or quartz fibre wire, the thickness of the
composing fibres being in the order of 5-10 microns. It is also
possible to use fibres of synthetic material capable of standing
high temperatures.
The fibres or fibre bundles may include in longitudinal direction
metal wires or straps, which form an integral part with the core
owing to the winding. The conductive function takes place owing to
the winding material either or not in co-operation with the metal
wires present possibly in longitudinal direction of the fibres.
When applying the fuses according to the invention for higher
current intensities it is preferable to pass part of the current
through such metal wires and the remaining part of the current
through the winding wires.
As observed in the above, the conductor material to be wound
preferably consists of silver wire having a diameter in the order
of 20-30 microns. If desired, a plurality of parallel metal wires
can be used as a conductive winding.
Furthermore, owing to the increased mechanical solidity of the
extremely thin fibre core, it has become possible to use other
desired materials as current conductors. For example, a fine tin
wire having a diameter in the order of 0.2-0.4 mm can be used as
conductor material. Because of the high mechanical weakness of tin
it was impossible to use tin in the conventional fuses for low
current values.
By varying the number of windings it is possible to change the
current protection range while using only one type of wire, so that
the small number of different diameters commercially available
forms no longer an impediment.
By varying the winding pattern it is possible to manufacture fuses
of different characteristics, ranging from very fast to very slow
fuses.
For instance in case of continuous production, it is possible to
impart to the winding of metal wire a variable pitch in each fuse
element in such a manner that each time the greatest heat
development takes place in the centre of each element when in
use.
By a suitable choice of winding wires and fibre core it has
appeared to be possible to adjust the fusing characteristic over a
very large range of nominal current intensities, from very low to
very high values, while the same shape is retained. Both very fast
and very slow-reacting fuses can be manufactured by means of the
method according to the invention.
The above construction furthermore reduces the so-called critical
length of the fuse element considerably. Thus it is possible to
construct fuses with a very compact construction. Such a
compactness is particularly important for panels having a printed
circuitry. Thus, for instance, a fuse was constructed for 80 mA
having a length of 3 mm by means of the method according to the
invention.
Finally it has appeared that the switch-off power of a wound fuse
is much better than that of a fuse having a straight fusible
wire.
The advantages of the method and of the fuse according to the
invention will be explained in greater detail with reference to the
drawings.
FIG. 1 is a schematic side elevational view of a device suitable
for winding a fibrous core yarn with metal wire.
FIG. 2 is a schematic representation in side elevational view of a
device suitable for using the method according to the
invention.
FIGS. 3-5 are representations in cross-section of fuses
manufactured by means of the method according to the invention.
FIG. 1 shows a device which can be applied for the process of
winding a conductive wire around a core formed by a glass fibre
yarn. A spool 1 with mounting 2 having a brake device contains a
supply of glass fibre yarn 4. The yarn is wound under tensile
stress on spool 6. The spool 6 is driven by a motor 7 in such a way
that the yarn passes through the winding device 8 at constant
speed. The winding head 8 contains a supply bobbin 11 with the
conductive metal wire 12. The hollow shaft 9 is rotated by a motor
(not shown) coupled through a V-belt with wheel 10 in such a manner
that the wheel 10 rotates at constant speed. The metal wire 12 is
passed to the front side of the shaft 9 via a small guiding wheel
14, which is mounted on an arm located on the front side 13 of the
bobbin 11. The metal wire is thus progressively wound around the
glass fibre yarn. Depending on the speed adjustments of the yarn
and the winding head the glass fibre yarn is thus provided with a
winding of metal wire with a constant pitch.
The device described in the light of FIG. 1 can be applied
conveniently for carrying out the method according to the
invention. Reference is made in this connection to FIG. 2, in which
drawing the same reference numerals show the same parts as in FIG.
1. From the spool 1 the glass fibre yarn is unwound under tensile
stress and is passed between the rubber rolls 15 and 16, which are
driven by a motor not shown. The rolls 15 and 16 contact each other
and are urged against each other under such a pressure that the
fibre yarn is unwound from the spool 1 without slippage owing to
the effect of the roller. The glass fibre yarn 4 coming from the
spool 1 is provided with a thermosetting material layer. Between
the spool 1 and the rolls 15 and 16 the yarn 4 is passed through a
heating device, which heating device comprises a bored material
block 17. A heating wire 18 is wound around the block 17. The
heating wire 18 is connected to the terminals 19 and 20 of a
suitable power supply not shown. If the fibre yarn 4 passes through
the bore in the heated block 17, the thermosetting layer on the
fibre yarn is set, so that a rigidified fibre core leaves the
heating device. Subsequently the core is passed through the winding
device 8 and is wound with a metal wire in the manner described
above. The wound core is afterwards passed through a cutting device
and is cut into segments by means of the blade 22 of the cutting
device on the die 21. By effecting the cutting operation with
certain intervals, segments of predetermined length are cut. The
segments can subsequently be mounted in suitable containers to
provide the fuses according to the invention.
It will be clear that an expert can contrive himself suitable ways
to mount the segments in containers. Thus, for example, it is
possible to apply at specific positions of the wound yarn an amount
of solder prior to the cutting operation, in such a manner that
after the suitably carried out cutting operation segments with
soldered ends are obtained. It is also possible to mount a sealing
wafer for a tubular insulating casing for the fuse to be
manufactured at the end of the wound yarn 5 before cutting. After
cutting it is only necessary to attach a casing to the sealing
wafer and a different sealing wafer at the other end of the casing
and of the yarn segment to complete the fuse. Automation of these
methods can be effected conveniently by an expert.
Furthermore it will be clear that the above description of a device
for applying the method according to the invention should by no
means be considered limitative, but was only given by way of
illustration. Other embodiments of such a device also come within
the framework of the invention.
An example of fuses constructed in accordance with the invention is
given in FIG. 3, in which 31 is a ferrule cemented to a cylindrical
tube made of glass or any other suitable material and in whose axis
the fuse element made of set or rigidified quartz fibres 34 with
its conductive winding 33 is positioned by means of the eyelets 35.
A solder alloy forms the conductive connection between the winding
34 of said fuse element and the ferrules 31.
Another suitable form that may be chosen in accordance with the
invention is indicated in FIG. 4, in which a cylindrical tube 42
made from percelain or any other suitable material is provided with
end caps 41 made from copper or brass. The ends of the fuse
elements with the conductive winding 44 around a set quartz fibre
core 43 are bent around the edges of tube 42 in such a manner that
the fuse element is in a diagonal position.
Another advantageous construction is given by way of exemple in
FIG. 5. In accordance with the invention the fuse element is made
of winding 54 with a concentration of its windings 56 in the middle
of the element around a glass fibre core 53. The concentration of
the windings in the centre reduces the heat dissipation in the fuse
in a favourable way. The construction of the cylindrical tube 52
and end caps 51 is analogous to that of FIG. 4.
* * * * *