EP2489057A1 - Method of assembling fuse end cap - Google Patents

Method of assembling fuse end cap

Info

Publication number
EP2489057A1
EP2489057A1 EP10771809A EP10771809A EP2489057A1 EP 2489057 A1 EP2489057 A1 EP 2489057A1 EP 10771809 A EP10771809 A EP 10771809A EP 10771809 A EP10771809 A EP 10771809A EP 2489057 A1 EP2489057 A1 EP 2489057A1
Authority
EP
European Patent Office
Prior art keywords
end cap
fuse
cavity
adhesive
fuse body
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP10771809A
Other languages
German (de)
French (fr)
Other versions
EP2489057B1 (en
Inventor
Dean Bruce
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Cooper Technologies Co
Original Assignee
Cooper Technologies Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Cooper Technologies Co filed Critical Cooper Technologies Co
Priority to PL10771809T priority Critical patent/PL2489057T3/en
Priority to SI201030507T priority patent/SI2489057T1/en
Publication of EP2489057A1 publication Critical patent/EP2489057A1/en
Application granted granted Critical
Publication of EP2489057B1 publication Critical patent/EP2489057B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H85/00—Protective devices in which the current flows through a part of fusible material and this current is interrupted by displacement of the fusible material when this current becomes excessive
    • H01H85/02—Details
    • H01H85/04—Fuses, i.e. expendable parts of the protective device, e.g. cartridges
    • H01H85/05—Component parts thereof
    • H01H85/143—Electrical contacts; Fastening fusible members to such contacts
    • H01H85/157—Ferrule-end contacts
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H69/00—Apparatus or processes for the manufacture of emergency protective devices
    • H01H69/02—Manufacture of fuses
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H85/00—Protective devices in which the current flows through a part of fusible material and this current is interrupted by displacement of the fusible material when this current becomes excessive
    • H01H85/02—Details
    • H01H85/04—Fuses, i.e. expendable parts of the protective device, e.g. cartridges
    • H01H85/041—Fuses, i.e. expendable parts of the protective device, e.g. cartridges characterised by the type
    • H01H85/044—General constructions or structure of low voltage fuses, i.e. below 1000 V, or of fuses where the applicable voltage is not specified
    • H01H85/045—General constructions or structure of low voltage fuses, i.e. below 1000 V, or of fuses where the applicable voltage is not specified cartridge type
    • H01H85/0458—General constructions or structure of low voltage fuses, i.e. below 1000 V, or of fuses where the applicable voltage is not specified cartridge type with ferrule type end contacts

Definitions

  • the present invention relates to an electrical fuse. More particularly, the invention relates to a method of assembling and adhering an end cap onto an electrical fuse to provide either or both of a mechanical connection and a hermetic seal between the end cap and a body of the fuse.
  • a fuse assembled according to the present invention may be used in a situation in which it is immersed in hot oil.
  • Electrical fuses are used extensively in electrical transformers. Increasingly, electrical transformers are assembled such that both the windings of the transformer and a fuse mounted to the transformer are immersed in oil. When the transformer is energised, electrical resistance can cause significant heating of the windings and thus the oil and the fuse are also heated. Depending upon the operating conditions, a fuse mounted in such a transformer may be exposed to temperatures from -35°C to 125°C, coupled with variations in ambient pressure of plus or minus 100 to 200 mbar.
  • An example of a fuse used in such a way comprises a hollow ceramic body which contains fuse elements, surrounded with fine grains of silica quartz.
  • a cylindrical end cap is assembled over an end of a cylindrical fuse body.
  • an adhesive is applied by injection into the open end of the cylindrical end cap to occupy a space between the wall of the end cap and an outer wall of the fuse body.
  • Adhesives used to adhere an end cap onto a fuse body may have a high viscosity, which can mean that the adhesive will not flow freely into the cavity. The adhesive is therefore generally applied under pressure.
  • Providing an adhesive material through an opening in the end cap into the cavity allows a more direct and consistent application of the adhesive into the cavity. Further, when the adhesive material is provided through an opening in the end cap into the cavity, the more direct provision into the cavity gives a more reliable distribution of the adhesive within the cavity and the need to apply excess adhesive is reduced. Therefore, the amount of waste adhesive may also be reduced.
  • a second opening may be provided in the end cap, over the cavity, to allow air to escape from the cavity as adhesive is provided through the first opening, to the cavity. Allowing air to escape from the cavity as adhesive is injected can improve the reliability of the distribution of the adhesive in the cavity and thus improves the reliability of the hermetic seal created by the adhesive.
  • the second opening may be located on an opposite side of the end cap to the first opening. This allows adhesive to fill the cavity from one side of the end cap and progress through the cavity toward the opposite side of the end cap, expelling air from the second opening in the process.
  • Adhesive maybe provided through both of the first and the second openings. In the event that adhesive injected through the first opening does not sufficiently fill the whole cavity, then adhesive injected through the second opening can fill any spaces left after injection through the first opening is complete.
  • Adhesive may be provided through the second opening after adhesive is provided through the first opening. This can allow adhesive to be provided through each of the first and second openings using a single apparatus for providing adhesive. This may also allow a majority of the air in the cavity to be expelled by injection through the first opening, whilst subsequent injection through the second opening ensures a more even distribution of adhesive on each side of the end cap.
  • the cavity may be formed between the side wall of the fuse body and the end cap. Provision of adhesive into a cavity formed between a side wall of the fuse body and the end cap allows a large surface area of adhesion, which is subject primarily to sh earing forces rather than peeling or longitudinal stress. This can improve the effectiveness of the adhesive in resisting forces created by the internal pressure of the fuse.
  • the cavity may comprise a recess provided in the fuse body. Including a recess in the fuse body in the cavity can allow the adhesive to flow into the recess and thus improve the mechanical engagement of the adhesive and the end cap with the fuse body.
  • the recess may comprise a groove provided on an outer surface of the fuse body.
  • the provision of a groove may allow an improved resistance to forces acting in a direction lateral to the groove, without the need to fill as large a volume as in the case that the recess were of the same dimension in both latitudinal and longitudinal directions.
  • the recess may extend around the fuse body in a direction perpendicular to the axis of the fuse body. This allows an improved mechanical bond between the adhesive and the fuse body, which is particularly resistant to forces along the axis of the fuse body.
  • the groove may circumnavigate the fuse body. This may allow adhesive to flow right around the fuse body, allowing a single opening to permit provision of adhesive to the entirety of a recess circumnavigating the fuse body.
  • a groove or recess which circumnavigates the fuse body can give a bond of improved strength.
  • the method according to the present invention may further comprise the step of providing an inner end cap on the fuse body, the inner end cap having a larger diameter than the fuse body, to form an end wall of the cavity.
  • the method according to the present invention may further comprise the step of providing a shoulder on an outer surface of the fuse body to form an end wall of the cavity. This allows the cavity to be provided with an end wall without the need for additional components.
  • the method may further comprise the steps of:
  • the reduced radius end section having a smaller outer radius than a main section of the fuse body to create a shoulder forming an end wall of the cavity
  • the inner end cap on the reduced radius end section, the inner end cap having an outer radius greater than the radius of the reduced radius end section such that the cavity is created between the main section and the inner end cap. This allows the creation of a cavity for receiving the adhesive without the need for additional components to create end walls to the cavity.
  • the seal may be any one of an o-ring seal, a band, a grommet, a rubber seal, or other sealing means.
  • the seal may be positioned to prevent adhesive exiting the cavity between the fuse body and the end cap. This ensures that adhesive applied through the opening flows into and around the cavity rather than exiting the cavity between the fuse body and the end cap.
  • the seal may provide an end wall of the cavity. This allows the creation of an end wall for the cavity, without the need for additional features on the fuse body, or other additional components.
  • the method according to the present invention may further comprise the step of providing a protrusion or indentation in the inner profile of the end cap, located over the cavity when the end cap is assembled onto the fuse, such that adhesive in the cavity contacts the protrusion or indentation. This may improve the mechanical and hermetic bond between the adhesive and the end cap.
  • the method may further comprise the step of deforming an edge of the end cap towards its interior to provide a protrusion toward the interior of the end cap. This can further improve the mechanical bond and hermetic seal of the adhesive to the end cap.
  • the method may further comprise the step of curing the adhesive at an elevated temperature after injecting it into the cavity.
  • the method may further comprise the step of preheating the fuse body prior to providing the adhesive. This can elevate the temperature of the adhesive once in the cavity to reduce its viscosity and cause it to flow better around the cavity. Heating the fuse body can also cause any air within the fuse body to expand, thus expelling some of the air from the fuse body prior to forming the hermetic seal with the adhesive.
  • the method may further comprise the step of vibrating the fuse after injecting the resin into the void. This may cause the resin to flow more evenly throughout the cavity after it has been provided into the cavity.
  • a first end of a fuse assembly comprising a fuse body and an end cap is preheated
  • the fuse is then temperature stressed in an oven.
  • the present invention further provides an electrical fuse assembly, comprising:
  • a fuse end cap comprising:
  • a side wall section extending from the end wall section; at least one opening through the side wall section, located over a cavity between the fuse body and the end cap.
  • the electrical fuse assembly may further comprise an adhesive disposed in the cavity.
  • the adhesive may be a resin.
  • the electrical fuse assembly may further comprise a seal disposed between the fuse body and the end cap to prevent adhesive exiting the space between the end cap and the fuse body.
  • the present invention further provides a fuse end cap comprising:
  • the fuse end cap may further comprise a protrusion or an indentation in the inner profile of the side wall section for improving adherence on adhesive to the end cap.
  • the fuse end cap may further comprise a second opening through the side wall section.
  • Figure 1 shows a known method of injecting adhesive into a fuse end cap assembly
  • Figure 2 shows an example of fuse assembly according to the present invention
  • Figure 3 shows a section of a fuse body
  • Figure 4 shows a fuse sub-assembly in accordance with the present invention
  • Figure 5 shows a fuse end cap assembly according to the present invention
  • Figure 6 shows an alternative configuration of a fuse assembly in accordance with the present invention
  • Figure 7 shows a further alternative configuration of a fuse assembly according to the present invention.
  • Figure 8 shows a further alternative arrangement according to the present invention.
  • Figure 9 shows a further alternative arrangement according to the present invention.
  • Figure 10 a further alternative arrangement to an end cap assembly according to the present invention.
  • Figure 1 1 shows an end cap assembly according to the present invention.
  • Figure 12 shows an alternative arrangement of an end cap assembly according to the present invention.
  • Figure 1 illustrates the known method of adhering an end cap to a fuse body described above.
  • the figure shows a section of a fuse body 1 and end cap 1 1 assembled in a similar way to those shown in Figure 2.
  • Dashed line 12 represents a cut out of the fuse body and end cap equivalent to dashed line 2A shown in Figure 2.
  • adhesive 13 is provided under pressure from a syringe 14 in this particular example. Any other means of providing adhesive, under pressure or otherwise, may also be used in the present invention.
  • Adhesive 13 flows into a space 15 between an end cap 1 1 and fuse body 1 in the direction of arrow 16. If an adhesive of relatively high viscosity is used, adhesive may tend to build up in the gap between the end cap and fuse body 1. The adhesive may be able to flow out of the gap toward area 17 more easily than it can flow in the direction of arrow 16. To ensure, as far as is possible, that sufficient adhesive has descended in the direction of arrow 16, an excess of adhesive is provided under pressure and adhesive will therefore exit the gap and create unwanted adhesive in areas such as that indicated by numeral 17. As discussed above, excess adhesive in these areas must be removed and this results in significant waste.
  • Figure 2 shows a fuse end cap assembly 2 in accordance with the present invention.
  • End cap 21 is assembled on fuse body 1.
  • Optional inner end cap 22 and optional washer 23 have been assembled on to the fuse body.
  • a cavity 24, between the end cap and the fuse body is provided for receiving adhesive.
  • Adhesive may be provided to the cavity via a first opening 25 and/or optional second opening 26 in the end cap.
  • Optional o-ring seal 27 is shown, positioned to prevent adhesive exiting cavity 24 through the gap between the fuse end cap and the fuse body.
  • Further optional protrusions 28 and indentations 29 are shown on the inner wall of the end cap.
  • Optional curl 29a may also be provided to improve mechanical engagement of the end cap with the fuse body.
  • Dashed circles 2A and 2B represent cut-out sections of the figure referred to in other figures.
  • Figure 3 shows a section of fuse body 1 upon which an optional portion of reduced diameter 31 has been provided, such that a shoulder 32 appears on the outer surface of the fuse body.
  • the shoulder shown comprises a smooth radius extending out to a sharp corner 33.
  • a shoulder may be understood to be any change in diameter or radius on the outer surface of the fuse body.
  • Figure 4 shows a sub-assembly of fuse body 1 , having optional shoulder 32.
  • Optional inner end cap 22 is shown assembled on to the end of fuse body 1 and may be held in place by an interference fit or any other suitable means of fixation.
  • Optional seal 41 is shown pre-assembled onto fuse body 1.
  • Figure 5 shows the subassembly shown in Figure 4, with the addition of fuse end cap 51 , assembled onto fuse body 1 and optional inner end cap 22.
  • a cavity 52 is created between the outer wall of fuse body 1 and an inner wall of end cap 51.
  • Seal 41 is shown, in this particular example providing an end wall to cavity 52.
  • End cap 51 may further comprise optional flared portion 56. Flared portion 56 may ease assembly of the end cap onto fuse body 1. Where seal 41 is present, flared portion 56 may act to ease the placement of end cap 51 over seal 41.
  • An opening 53 through end cap 51 is shown for providing adhesive into cavity 52. Opening 53 is shown in this particular example located toward the end 55 of the cavity nearest the open end 54 of the fuse end cap 51 .
  • Opening 53 could be located at any position over the cavity, however it can be advantageous to have the opening located away from inner end cap 41 , toward the end of cavity 52 nearest the open end of the end cap 51 . This is because it will create the greatest distance between inner end cap 41 and opening 53.
  • the seal between the adhesive and the end cap 51 will be created over a distance starting at a point toward the open end of the fuse body 1 where adhesive first contacts end cap 51 , i.e. generally at inner end cap 41.
  • the seal ends where the adhesive stops, toward the opposite end of cavity 52.
  • opening 53 interrupts the seal between the adhesive and the end cap. This may create a potential weakness in the seal and therefore placing the opening 53 at a point toward reduces the potential weakness in the seal which may be introduced by opening 53.
  • Figure 6 shows a similar assembly to that shown in Figure 5, however a recess 61 has been provided in the fuse body 1.
  • adhesive When adhesive is provided through opening 62 into cavity 52, the adhesive will now flow into recess 61.
  • the resultant advantage is that, when cured, the adhesive achieves an improved mechanical engagement and hermetic seal with fuse body 1.
  • Figure 7 shows a further alternative configuration of fuse body 1.
  • Cavity 52 is now delimited by protrusions 71 and 72 provided on the outer surface of the fuse body.
  • the protrusions here are shown with a square profile, however, any protrusion extending away from outer surface 74 of the fuse body towards end cap 51 would perform similar function.
  • adhesive provided through opening 73 when cured, can provide an improved mechanical and hermetic seal between end cap 51 and fuse body 1.
  • seal 41 may also be provided between an outer surface of protrusion 71 and the end cap 51.
  • inner end cap 22 provides a first end wall to cavity 52.
  • a shoulder 81 is provided to form a second end wall to cavity 52.
  • seal 41 acts to prevent adhesive provided through opening 82 exiting through the open end 83 of the end cap.
  • the provision of shoulder 81 results in a smaller gap between surface 84 of fuse body 1 and the end cap and therefore seal 41 does not need to seal the entire depth of cavity 52 from surface 85 of fuse body 1 to surface 86 of end cap 51. Therefore a smaller sized seal may be used.
  • Figure 9 shows alternative features which may act to improve the mechanical and hermetic seal between end cap 51 and fuse body 1.
  • Protrusions 91 and indentations 92 are shown on inner surface 93 of end cap 51.
  • Features 91 and 92 may be used either separately or in combination and each may act to improve the mechanical and hermetic seal once adhesive is injected into cavity 52 via opening 94.
  • An alternative means of improving the adhesive with the inner wall of the end cup may be to provide knurling on the inner wall.
  • Curled section 95 may be formed on the open end of the side wall of end cap 51. Feature 95 can maintain seal 41 in position and also further improve the mechanical engagement of end cap 51 with fuse body 1.
  • Figure 10 shows a further alternative arrangement which may improve the mechanical and hermetic seal between fuse body 1 and end cap 51.
  • An indentation 101 is created in the outer surface of end cap 51 , resulting in a protrusion into cavity 52, which may optionally be provided with recess 61.
  • Feature 101 may be created by a spinning operation on the end cap after assembling the end cap onto fuse body 1. The feature may be created before assembly onto the fuse body, as shown in Figure 9. However where recess 61 is provided and indentation 101 is of sufficient depth to protrude into recess 61 , then the mechanical and hermetic seal between fuse end cap 51 and fuse body 1 , once adhesive is provided into cavity 52 via opening 102 may be further improved.
  • Figure 1 1 shows the arrangement of Figure 9, where cavity 52 has been filled with adhesive via opening 94.
  • Figure 12 shows a further alternative arrangement wherein a recess 121 has been provided in outer surface 122 of fuse body 1 to improve the mechanical and hermetic seal between end cap 51 and fuse body 1.
  • Recess 121 is shown having a curved profile, however, this recess could take any form, such as the right-angled form shown in Figure 6, or any other form of indentation in the outer surface of the fuse body.
  • the recess or indentation 121 in the fuse body may extend all or a part of the way around the fuse body and may form a groove extending around the fuse body. Any of these configurations may provide improved adherence of the adhesive to the fuse body.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Fuses (AREA)

Abstract

A method of assembling an electrical fuse as described, in which a fuse body (1) is provided, an end cap (21) is provided on an end of a fuse body such that a cavity (15) is created between the fuse body and the end cap, the fuse end cap has at least one opening located over the cavity and an adhesive material (13) is provided through the opening in the end cap into the cavity to adhere the end cap to the fuse. Alternative forms of the cavity into which the adhesive is provided are described. An electrical fuse assembly is also described, comprising a fuse body having an outer surface, and a fuse end cap, comprising an end wall section, a side wall section extending from the end wall section, at least one opening through the side wall section, located over a cavity between the fuse body and the end cap. A fuse end cap is also described, comprising an end wall section, a side wall section extending from the end wall section, and at least one opening through the side wall section.

Description

METHOD OF ASSEMBLING FUSE END CAP
The present invention relates to an electrical fuse. More particularly, the invention relates to a method of assembling and adhering an end cap onto an electrical fuse to provide either or both of a mechanical connection and a hermetic seal between the end cap and a body of the fuse. A fuse assembled according to the present invention may be used in a situation in which it is immersed in hot oil.
Electrical fuses are used extensively in electrical transformers. Increasingly, electrical transformers are assembled such that both the windings of the transformer and a fuse mounted to the transformer are immersed in oil. When the transformer is energised, electrical resistance can cause significant heating of the windings and thus the oil and the fuse are also heated. Depending upon the operating conditions, a fuse mounted in such a transformer may be exposed to temperatures from -35°C to 125°C, coupled with variations in ambient pressure of plus or minus 100 to 200 mbar. An example of a fuse used in such a way comprises a hollow ceramic body which contains fuse elements, surrounded with fine grains of silica quartz. Air inevitably occupies the spaces between the grains of silica quartz and thus variations in temperature can create high variations in pressure within the fuse where the fuse is hermetically sealed. Fuses used in this situation need to be hermetically sealed to avoid the egress of air and the ingress of oil into the fuse. Further, it is essential that no water is present in the oil when the transformer is assembled and therefore the transformer windi ng and fuse assembly is heated to high temperatures, in excess of 125°C, before the transformer is filled with oil.
Due to the large variations in temperature and therefore internal pressure, it is important that a strong mechanical engagement, combined with a hermetic seal, is provided between an end cap of the fuse and the fuse body to which the end cap is assembled.
In a known method of assembly of an end cap onto a fuse for use under hot oil, a cylindrical end cap is assembled over an end of a cylindrical fuse body. To create a hermetic seal between the end cap and the fuse body, an adhesive is applied by injection into the open end of the cylindrical end cap to occupy a space between the wall of the end cap and an outer wall of the fuse body. A significant degree of skill and experience is required by a manual operator applying an adhesive in this way. If an insufficient amount of adhesive is applied, then an insufficient hermetic seal will be created. Adhesives used to adhere an end cap onto a fuse body may have a high viscosity, which can mean that the adhesive will not flow freely into the cavity. The adhesive is therefore generally applied under pressure. In order to ensure that sufficient adhesive occupies the space between the end cap and the outer wall of the fuse body, an excess of adhesive is generally applied and then any excess adhesive remaining outside the end cap and fuse body assembly is removed. This can result in a significant degree of waste of adhesive. The amount of adhesive wasted can reach up to between 50% and 100% of the volume of adhesive remaining within the assembly and usefully adhering the end cap to the fuse body. Due to inconsistencies in both operator technique and variations in resistance to the flow of the adhesive into the space between the end cap and the fuse body, significant variations in the quality of the hermetic seal achieved can occur and significant numbers of failures during stress testing of the seal can be found. When a failed seal is identified, it cannot be repaired and thus the fuse must be scrapped, resulting in wasted production time and materials.
Accordingly, there exists a need for an improved method of assembling an electrical fuse.
According to the present invention there is provided a method of assembling an electrical fuse, comprising the steps of:
providing a fuse body;
providing an end cap on an end of the fuse body such that a cavity is created between the fuse and the end cap, the fuse end cap having at least one opening located over the cavity;
providing an adhesive material, through the opening in the end cap, into the cavity to adhere the end cap to the fuse.
Providing an adhesive material through an opening in the end cap into the cavity allows a more direct and consistent application of the adhesive into the cavity. Further, when the adhesive material is provided through an opening in the end cap into the cavity, the more direct provision into the cavity gives a more reliable distribution of the adhesive within the cavity and the need to apply excess adhesive is reduced. Therefore, the amount of waste adhesive may also be reduced.
A second opening may be provided in the end cap, over the cavity, to allow air to escape from the cavity as adhesive is provided through the first opening, to the cavity. Allowing air to escape from the cavity as adhesive is injected can improve the reliability of the distribution of the adhesive in the cavity and thus improves the reliability of the hermetic seal created by the adhesive.
The second opening may be located on an opposite side of the end cap to the first opening. This allows adhesive to fill the cavity from one side of the end cap and progress through the cavity toward the opposite side of the end cap, expelling air from the second opening in the process.
Adhesive maybe provided through both of the first and the second openings. In the event that adhesive injected through the first opening does not sufficiently fill the whole cavity, then adhesive injected through the second opening can fill any spaces left after injection through the first opening is complete.
Adhesive may be provided through the second opening after adhesive is provided through the first opening. This can allow adhesive to be provided through each of the first and second openings using a single apparatus for providing adhesive. This may also allow a majority of the air in the cavity to be expelled by injection through the first opening, whilst subsequent injection through the second opening ensures a more even distribution of adhesive on each side of the end cap.
The cavity may be formed between the side wall of the fuse body and the end cap. Provision of adhesive into a cavity formed between a side wall of the fuse body and the end cap allows a large surface area of adhesion, which is subject primarily to sh earing forces rather than peeling or longitudinal stress. This can improve the effectiveness of the adhesive in resisting forces created by the internal pressure of the fuse.
The cavity may be formed between a side wall of the fuse body and a side wall of the end cap. This also allows a greater area of adhesion to the end cap and submits the adhesive bond with the end cap to shearing rather than peeling or longitudinal stresses. The adhesive may be provided through an opening through a side wall of the end cap. Provision through an opening in the side wall of the end cap can allow more direct and reliable provision of the adhesive into the cavity, which ultimately provides a more consistent and reliable mechanical bond and hermetic seal. The adhesive may be injected through the opening in the end cap. Injection of the adhesive under pressure through the opening in a side wall of the end cap allows more direct provision of the adhesive into the cavity and can reduce the amount of excess adhesive that needs to be applied, thus reducing the amount of adhesive wasted during the application process.
The cavity may comprise a recess provided in the fuse body. Including a recess in the fuse body in the cavity can allow the adhesive to flow into the recess and thus improve the mechanical engagement of the adhesive and the end cap with the fuse body.
The recess may comprise a groove provided on an outer surface of the fuse body. The provision of a groove may allow an improved resistance to forces acting in a direction lateral to the groove, without the need to fill as large a volume as in the case that the recess were of the same dimension in both latitudinal and longitudinal directions.
The recess may extend around the fuse body in a direction perpendicular to the axis of the fuse body. This allows an improved mechanical bond between the adhesive and the fuse body, which is particularly resistant to forces along the axis of the fuse body.
The groove may circumnavigate the fuse body. This may allow adhesive to flow right around the fuse body, allowing a single opening to permit provision of adhesive to the entirety of a recess circumnavigating the fuse body. A groove or recess which circumnavigates the fuse body can give a bond of improved strength.
The method according to the present invention may further comprise the step of providing an inner end cap on the fuse body, the inner end cap having a larger diameter than the fuse body, to form an end wall of the cavity.
This allows a cavity of the desired dimensions to be formed between the end cap and the fuse body, without the need for the provision of any specific features on the outer surface of the fuse body. This can reduce the time and cost of the manufacturing and assembly processes.
The method according to the present invention may further comprise the step of providing a shoulder on an outer surface of the fuse body to form an end wall of the cavity. This allows the cavity to be provided with an end wall without the need for additional components.
The method may further comprise the steps of:
providing a reduced radius end section to the fuse body, the reduced radius end section having a smaller outer radius than a main section of the fuse body to create a shoulder forming an end wall of the cavity;
providing an inner end cap on the reduced radius end section, the inner end cap having an outer radius greater than the radius of the reduced radius end section such that the cavity is created between the main section and the inner end cap. This allows the creation of a cavity for receiving the adhesive without the need for additional components to create end walls to the cavity.
The method according to the present invention may further comprise the step of providing a seal between the fuse body and the end cap. This seal can act to prevent adhesive from escaping through a gap between the fuse body and the end cap to ensure that adhesive provided through the opening flows into and around the cavity, rather than exiting the cavity through the gap between the fuse body and the open end of the end cap.
The seal may be any one of an o-ring seal, a band, a grommet, a rubber seal, or other sealing means.
The seal may be positioned to prevent adhesive exiting the cavity between the fuse body and the end cap. This ensures that adhesive applied through the opening flows into and around the cavity rather than exiting the cavity between the fuse body and the end cap.
The seal may provide an end wall of the cavity. This allows the creation of an end wall for the cavity, without the need for additional features on the fuse body, or other additional components.
The method according to the present invention may further comprise the step of providing a protrusion or indentation in the inner profile of the end cap, located over the cavity when the end cap is assembled onto the fuse, such that adhesive in the cavity contacts the protrusion or indentation. This may improve the mechanical and hermetic bond between the adhesive and the end cap.
The method may further comprise the step of deforming an edge of the end cap towards its interior to provide a protrusion toward the interior of the end cap. This can further improve the mechanical bond and hermetic seal of the adhesive to the end cap.
The method may further comprise the step of curing the adhesive at an elevated temperature after injecting it into the cavity.
The method may further comprise the step of preheating the fuse body prior to providing the adhesive. This can elevate the temperature of the adhesive once in the cavity to reduce its viscosity and cause it to flow better around the cavity. Heating the fuse body can also cause any air within the fuse body to expand, thus expelling some of the air from the fuse body prior to forming the hermetic seal with the adhesive.
The method may further comprise the step of vibrating the fuse after injecting the resin into the void. This may cause the resin to flow more evenly throughout the cavity after it has been provided into the cavity.
In a known method of assembling a fuse, the following steps may be carried out:
a first end of a fuse assembly comprising a fuse body and an end cap is preheated;
adhesive applied to the first end according to a known method;
the adhesive cured;
a second end, assembled with an end cap of the fuse assembly is preheated;
adhesive is applied to the second end;
the second end is cured; and
the fuse is then temperature stressed in an oven.
The method of the invention, when applied to a fuse assembly having a fuse body and 2 end caps, may further comprise the steps of:
preheating the fuse body and end caps in an oven;
providing adhesive to first and second ends of the fuse in accordance with the method of the present invention; curing the adhesive in an oven;
stressing the fuse assembly in an oven at an elevated temperature.
These method steps provide a reduced process time as compared to a known method described above:
The present invention further provides an electrical fuse assembly, comprising:
a fuse body having an outer surface;
a fuse end cap comprising:
an end wall section;
a side wall section extending from the end wall section; at least one opening through the side wall section, located over a cavity between the fuse body and the end cap.
The electrical fuse assembly may further comprise an adhesive disposed in the cavity.
The adhesive may be a resin.
The electrical fuse assembly may further comprise a seal disposed between the fuse body and the end cap to prevent adhesive exiting the space between the end cap and the fuse body.
The present invention further provides a fuse end cap comprising:
an end wall section;
a side wall section extending from the end wall section;
at least one opening through the side wall section.
The fuse end cap may further comprise a protrusion or an indentation in the inner profile of the side wall section for improving adherence on adhesive to the end cap.
The fuse end cap may further comprise a second opening through the side wall section.
The present invention will now be described with reference to the following figures in which:
Figure 1 shows a known method of injecting adhesive into a fuse end cap assembly;
Figure 2 shows an example of fuse assembly according to the present invention; Figure 3 shows a section of a fuse body;
Figure 4 shows a fuse sub-assembly in accordance with the present invention;
Figure 5 shows a fuse end cap assembly according to the present invention;
Figure 6 shows an alternative configuration of a fuse assembly in accordance with the present invention;
Figure 7 shows a further alternative configuration of a fuse assembly according to the present invention;
Figure 8 shows a further alternative arrangement according to the present invention;
Figure 9 shows a further alternative arrangement according to the present invention;
Figure 10 a further alternative arrangement to an end cap assembly according to the present invention;
Figure 1 1 shows an end cap assembly according to the present invention; and
Figure 12 shows an alternative arrangement of an end cap assembly according to the present invention.
Figure 1 illustrates the known method of adhering an end cap to a fuse body described above. The figure shows a section of a fuse body 1 and end cap 1 1 assembled in a similar way to those shown in Figure 2. Dashed line 12 represents a cut out of the fuse body and end cap equivalent to dashed line 2A shown in Figure 2.
In Figure 1 , adhesive 13 is provided under pressure from a syringe 14 in this particular example. Any other means of providing adhesive, under pressure or otherwise, may also be used in the present invention. Adhesive 13 flows into a space 15 between an end cap 1 1 and fuse body 1 in the direction of arrow 16. If an adhesive of relatively high viscosity is used, adhesive may tend to build up in the gap between the end cap and fuse body 1. The adhesive may be able to flow out of the gap toward area 17 more easily than it can flow in the direction of arrow 16. To ensure, as far as is possible, that sufficient adhesive has descended in the direction of arrow 16, an excess of adhesive is provided under pressure and adhesive will therefore exit the gap and create unwanted adhesive in areas such as that indicated by numeral 17. As discussed above, excess adhesive in these areas must be removed and this results in significant waste.
Figure 2 shows a fuse end cap assembly 2 in accordance with the present invention. End cap 21 is assembled on fuse body 1. Optional inner end cap 22 and optional washer 23 have been assembled on to the fuse body. A cavity 24, between the end cap and the fuse body is provided for receiving adhesive. Adhesive may be provided to the cavity via a first opening 25 and/or optional second opening 26 in the end cap. Optional o-ring seal 27 is shown, positioned to prevent adhesive exiting cavity 24 through the gap between the fuse end cap and the fuse body. Further optional protrusions 28 and indentations 29 are shown on the inner wall of the end cap. Optional curl 29a may also be provided to improve mechanical engagement of the end cap with the fuse body. Dashed circles 2A and 2B represent cut-out sections of the figure referred to in other figures.
Figure 3 shows a section of fuse body 1 upon which an optional portion of reduced diameter 31 has been provided, such that a shoulder 32 appears on the outer surface of the fuse body. The shoulder shown comprises a smooth radius extending out to a sharp corner 33. However, a shoulder may be understood to be any change in diameter or radius on the outer surface of the fuse body.
Figure 4 shows a sub-assembly of fuse body 1 , having optional shoulder 32. Optional inner end cap 22 is shown assembled on to the end of fuse body 1 and may be held in place by an interference fit or any other suitable means of fixation. Optional seal 41 is shown pre-assembled onto fuse body 1.
Figure 5 shows the subassembly shown in Figure 4, with the addition of fuse end cap 51 , assembled onto fuse body 1 and optional inner end cap 22. A cavity 52 is created between the outer wall of fuse body 1 and an inner wall of end cap 51. Seal 41 is shown, in this particular example providing an end wall to cavity 52. End cap 51 may further comprise optional flared portion 56. Flared portion 56 may ease assembly of the end cap onto fuse body 1. Where seal 41 is present, flared portion 56 may act to ease the placement of end cap 51 over seal 41. An opening 53 through end cap 51 is shown for providing adhesive into cavity 52. Opening 53 is shown in this particular example located toward the end 55 of the cavity nearest the open end 54 of the fuse end cap 51 . Opening 53 could be located at any position over the cavity, however it can be advantageous to have the opening located away from inner end cap 41 , toward the end of cavity 52 nearest the open end of the end cap 51 . This is because it will create the greatest distance between inner end cap 41 and opening 53. The seal between the adhesive and the end cap 51 will be created over a distance starting at a point toward the open end of the fuse body 1 where adhesive first contacts end cap 51 , i.e. generally at inner end cap 41. The seal ends where the adhesive stops, toward the opposite end of cavity 52. However, there exists a shorter sealed distance where opening 53 interrupts the seal between the adhesive and the end cap. This may create a potential weakness in the seal and therefore placing the opening 53 at a point toward reduces the potential weakness in the seal which may be introduced by opening 53.
Figure 6 shows a similar assembly to that shown in Figure 5, however a recess 61 has been provided in the fuse body 1. When adhesive is provided through opening 62 into cavity 52, the adhesive will now flow into recess 61. The resultant advantage is that, when cured, the adhesive achieves an improved mechanical engagement and hermetic seal with fuse body 1.
Figure 7 shows a further alternative configuration of fuse body 1. Cavity 52 is now delimited by protrusions 71 and 72 provided on the outer surface of the fuse body. The protrusions here are shown with a square profile, however, any protrusion extending away from outer surface 74 of the fuse body towards end cap 51 would perform similar function. With this arrangement, adhesive provided through opening 73, when cured, can provide an improved mechanical and hermetic seal between end cap 51 and fuse body 1. In addition to being provided in the position shown, seal 41 may also be provided between an outer surface of protrusion 71 and the end cap 51.
A further alternative arrangement is shown in Figure 8. In this arrangement, inner end cap 22 provides a first end wall to cavity 52. A shoulder 81 is provided to form a second end wall to cavity 52. Although a right angled shoulder is shown here, any change in diameter of the fuse body may suitably perform the function of an end wall to cavity 52. The shoulder 81 , in combination with seal 41 acts to prevent adhesive provided through opening 82 exiting through the open end 83 of the end cap. The provision of shoulder 81 , in this particular case, results in a smaller gap between surface 84 of fuse body 1 and the end cap and therefore seal 41 does not need to seal the entire depth of cavity 52 from surface 85 of fuse body 1 to surface 86 of end cap 51. Therefore a smaller sized seal may be used.
Figure 9 shows alternative features which may act to improve the mechanical and hermetic seal between end cap 51 and fuse body 1. Protrusions 91 and indentations 92 are shown on inner surface 93 of end cap 51. Features 91 and 92 may be used either separately or in combination and each may act to improve the mechanical and hermetic seal once adhesive is injected into cavity 52 via opening 94. An alternative means of improving the adhesive with the inner wall of the end cup may be to provide knurling on the inner wall.
Curled section 95 may be formed on the open end of the side wall of end cap 51. Feature 95 can maintain seal 41 in position and also further improve the mechanical engagement of end cap 51 with fuse body 1.
Figure 10 shows a further alternative arrangement which may improve the mechanical and hermetic seal between fuse body 1 and end cap 51. An indentation 101 is created in the outer surface of end cap 51 , resulting in a protrusion into cavity 52, which may optionally be provided with recess 61. Feature 101 may be created by a spinning operation on the end cap after assembling the end cap onto fuse body 1. The feature may be created before assembly onto the fuse body, as shown in Figure 9. However where recess 61 is provided and indentation 101 is of sufficient depth to protrude into recess 61 , then the mechanical and hermetic seal between fuse end cap 51 and fuse body 1 , once adhesive is provided into cavity 52 via opening 102 may be further improved.
Figure 1 1 shows the arrangement of Figure 9, where cavity 52 has been filled with adhesive via opening 94.
Figure 12 shows a further alternative arrangement wherein a recess 121 has been provided in outer surface 122 of fuse body 1 to improve the mechanical and hermetic seal between end cap 51 and fuse body 1. Recess 121 is shown having a curved profile, however, this recess could take any form, such as the right-angled form shown in Figure 6, or any other form of indentation in the outer surface of the fuse body. The recess or indentation 121 in the fuse body may extend all or a part of the way around the fuse body and may form a groove extending around the fuse body. Any of these configurations may provide improved adherence of the adhesive to the fuse body.

Claims

1 A method of assembling an electrical fuse, comprising the steps of:
providing a fuse body;
providing an end cap on an end of the fuse body such that a cavity is created between the fuse body and the end cap, the fuse end cap having at least one opening located over the cavity;
providing an adhesive material, through the opening in the end cap, into the cavity to adhere the end cap to the fuse.
2. The method according to claim 1 , wherein a second opening is provided in the end cap, over the cavity, to allow air to escape from the cavity as adhesive is provided through the first opening.
3. The method according to claim 2, wherein the second opening is located on an opposite side of the end cap to the first opening.
4. The method according to claim 3, wherein adhesive is provided through the first and second openings.
5. The method according to claim 4, wherein adhesive is provided through the second opening after adhesive is provided through the first opening.
6. The method according to any one of the preceding claims, wherein the cavity is formed between a side wall of the fuse body and the end cap.
7. The method according to any one of the preceding claims, wherein the cavity is formed between a side wall of the fuse body and a side wall of the end cap.
The method according to any one of the preceding claims, wherein the adhesive is provided through an opening through a side wall of the end cap.
The method according to any one of the preceding claims, wherein the adhesive is injected through the opening.
The method according to any one of the preceding claims wherein the cavity comprises a recess provided in the fuse body.
The method according to claim 8, wherein the recess comprises a groove provided on an outer surface of the fuse body.
The method according to claim 8, wherein the recess extends around the fuse body in a direction perpendicular to the axis of the fuse body.
The method according to claim 11 , wherein the groove circumnavigates the fuse body.
The method according to any one of the preceding claims, further comprising the step of:
providing an inner end cap on the fuse body, the inner end cap having a larger diameter than the fuse body, to form an end wall of the cavity.
The method according to any one of the preceding claims, further comprising the step of:
providing a shoulder on an outer surface of the fuse body to form an end wall of the cavity.
The method according to any one of the preceding claims, further comprising the steps of: providing a reduced radius end section to the fuse body, the reduced radius end section having a smaller outer radius than a main section of the fuse body create a shoulder form ing an end wall of the cavity;
providing an inner end cap on the reduced radius end section, the inner end cap having an outer radius greater than the radius of the reduced radius end section such that the cavity is created between the main section and the inner end cap.
The method according to any one of the preceding claims, further comprising the step of providing a seal between the fuse body and the end cap.
The method according to claim 17, wherein the seal is any one of an o- ring seal, a band, a grommet, a rubber seal, or other sealing means.
The method according to claim 17 or claim 18, wherein the seal is positioned to prevent adhesive exiting the cavity between the fuse body and the end cap.
The method according to any one of claims 16 to 19, wherein the seal provides an end wall of the cavity.
The method according to any one of the preceding claims, further comprising the step of providing a protrusion or an indentation in the inner profile of the end cap, located over the cavity when the end cap is assembled onto the fuse, such that adhesive in the cavity contacts the protrusion or indentation.
22. The method according to any one of the preceding claims, further comprising the step of deforming an edge of the end cap toward its interior to provide a protrusion toward the interior of the end cap.
The method according to any one of the preceding claims, further comprising the step of curing the resin at an elevated temperature after injecting it into the cavity.
The method according to any one of the preceding claims, further comprising the step of pre-heating the fuse body prior to providing the adhesive.
25. The method according to any one of the preceding claims, further comprising the step of vibrating the fuse after injecting the resin into the cavity.
The method according to any one of the preceding claims, further comprising the steps of:
preheating the fuse body and end caps in an oven; providing adhesive to first and second ends of the fuse in accordance with the method of claim 1 ;
curing the adhesive in an oven;
stressing the fuse assembly in an oven at an elevated temperature.
An electrical fuse assembly, comprising:
a fuse body having an outer surface;
a fuse end cap comprising:
an end wall section;
a side wall section extending from the end wall section; at least one opening through the side wall section, located over a cavity between the fuse body and the end cap.
An electrical fuse assembly according to claim 27, further comprising an adhesive disposed in the cavity.
29. An electrical fuse assembly according to claim 28, wherein the adhesive is a resin.
30. An electrical fuse assembly according to any of claims 27 to 29, further comprising a seal disposed between the fuse body and the end cap to prevent adhesive exiting the space between the end cap and the fuse body.
31. A fuse end cap comprising:
an end wall section;
a side wall section extending from the end wall section;
at least one opening through the side wall section.
32. A fuse end cap according to claim 31 , further comprising a protrusion or an indentation in the inner profile of the side wall section for improving the adherence of an adhesive to the end cap.
33. A fuse end cap according to claim 31 or claim 32, further comprising a second opening through the side wall section.
EP10771809.0A 2009-10-12 2010-10-12 Method of assembling fuse end cap Active EP2489057B1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
PL10771809T PL2489057T3 (en) 2009-10-12 2010-10-12 Method of assembling fuse end cap
SI201030507T SI2489057T1 (en) 2009-10-12 2010-10-12 Method of assembling fuse end cap

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GBGB0917808.8A GB0917808D0 (en) 2009-10-12 2009-10-12 Method of assembling fuse end cap
PCT/GB2010/051710 WO2011045591A1 (en) 2009-10-12 2010-10-12 Method of assembling fuse end cap

Publications (2)

Publication Number Publication Date
EP2489057A1 true EP2489057A1 (en) 2012-08-22
EP2489057B1 EP2489057B1 (en) 2013-11-20

Family

ID=41402869

Family Applications (1)

Application Number Title Priority Date Filing Date
EP10771809.0A Active EP2489057B1 (en) 2009-10-12 2010-10-12 Method of assembling fuse end cap

Country Status (6)

Country Link
EP (1) EP2489057B1 (en)
CN (1) CN102612729B (en)
GB (1) GB0917808D0 (en)
PL (1) PL2489057T3 (en)
SI (1) SI2489057T1 (en)
WO (1) WO2011045591A1 (en)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
BR112014018754A8 (en) 2012-07-20 2017-07-11 Ningbo Yinzhou Yonglin Electron Electrical Equipment Co Ltd AUTOMOTIVE RELAY WITH INSULATING CHARACTER WITH A SAFETY DEVICE

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4274073A (en) * 1976-12-30 1981-06-16 Westinghouse Electric Corp. Submersible fuse
US4562420A (en) 1984-04-13 1985-12-31 Littelfuse, Inc. Time delay fuse
JPH11185595A (en) * 1997-12-18 1999-07-09 Asahi Denki Seisakusho:Kk How to join cylindrical fuse links
CN2419681Y (en) * 2000-04-26 2001-02-14 西安熔断器制造公司 High voltage current limiting fuse for protecting oil immersed transformer
US20050168315A1 (en) * 2004-01-30 2005-08-04 Russel Brown High capacity fuse and arc resistant end caps therefor

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See references of WO2011045591A1 *

Also Published As

Publication number Publication date
EP2489057B1 (en) 2013-11-20
SI2489057T1 (en) 2014-05-30
CN102612729B (en) 2016-08-31
WO2011045591A1 (en) 2011-04-21
CN102612729A (en) 2012-07-25
GB0917808D0 (en) 2009-11-25
PL2489057T3 (en) 2014-06-30

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