A sub-structure element support system is disclosed. The sub-structure element support system includes a novel molded structure designed to support an electrical element, such as a fuse. The molded structure is a protective and insulative sleeve for the electrical element and reduces forces on the electrical element during free-fall and operation conditions. The molded structure also facilitates automation during manufacturing and reduces cost.

An arc flash mitigation system includes a main circuit protector such as a high amperage overcurrent protection fuse, and an arc flash mitigation network connected in parallel to the main circuit protector. The arc flash mitigation network includes at least one semiconductor switch operable to provide a shunt current path to a low amperage arc mitigation fuse for a faster response time to certain circuit conditions than the main circuit protector otherwise provides. The semiconductor switch may be a silicon controller rectifier operatively responsive to a voltage drop across the main circuit protector in use.

A sub-structure element support system is disclosed. The sub-structure element support system includes a novel molded structure designed to support an electrical element, such as a fuse. The molded structure is a protective and insulative sleeve for the electrical element and reduces forces on the electrical element during free-fall and operation conditions. The molded structure also facilitates automation during manufacturing and reduces cost.

A high-voltage direct-current thermal fuse includes one or more fusible components each having two fusible alloy support arms, a fluxing agent, a fusing cavity, two pins, and an insulation block. Two fusible alloy support arms are arranged opposite, and the fusible component is U-shaped. The fusible component and the fluxing agent are sealed within the fusing cavity. The two pins are respectively connected to the two fusible alloy support arms. The insulation block is arranged between the two fusible alloy support arms and separates the two pins. A volume ratio of the fluxing agent to the fusing cavity is approximately 50% or less, preferably, 10%-50%. The number of the one or more fusible components is at least two, and the at least two fusible components are arranged separately. The thermal fuse can avoid the burst and quickly cut off the current, which provides effective thermal protection for a circuit.

A power fuse includes a housing, first and second conductive terminals extending from the housing, and at least one fatigue resistant fuse element assembly connected between the first and second terminals. The fuse element assembly includes at least a first conductive plate and a second conductive plate respectively connecting the first and second conductive terminals, and a plurality of separately provided wire bonded weak spots interconnecting the first conductive plate and the second conductive plate.

A power fuse includes a housing, first and second conductive terminals extending from the housing, and at least one fatigue resistant fuse element assembly connected between the first and second terminals. The fuse element assembly includes at least a first conductive plate and a second conductive plate respectively connecting the first and second conductive terminals, and a plurality of separately provided wire bonded weak spots interconnecting the first conductive plate and the second conductive plate.

The present disclosure provides a fuse for protecting a 48V battery system of an electric vehicle, which includes a shell and a fuse element arranged in the shell, wherein the fuse element includes a fusing portion, and a first heating portion and a second heating portion which are connected to two sides of the fusing portion, respectively and the fusing portion has a width greater than that of the first heating portion and the second heating portion, the fusing portion includes at least one hole which partitions the fusing portion into constricted portions each having a width less than that of the first heating portion or the second heating portion, and the fusing portion, the first heating portion and the second heating portion are formed integrally.

A method for fabricating an electronic fuse includes forming a recess within a film material to define opposed contact segments and a central fuse segment interconnecting the contact segments and altering the material of the central fuse segment of the film material to increase electrical resistance characteristics of the central fuse segment. The central fuse segment may include defects such as voids created by directing a laser at the central fuse segment as a component of a laser annealing process. Alternatively, and or additionally, the central fuse segment may include dopants implementing via an ion implantation process to increase resistance characteristics of the central fuse segment.

The present disclosure provides a conductive connection structure, a multifunctional high-voltage connector and a battery product, the conductive connection structure comprises: a main body portion; and two conductive connection portions. The main body portion comprises: a tube body having openings; and a conductive fusing body. The conductive connection portion has: a first contact segment connected to the conductive fusing body and sealing a corresponding opening; a second contact segment; and a transitional connection segment. It is not necessary to additionally provide the package plate, thereby making the structure of the conductive connection structure simple and the volume of the conductive connection structure small, reducing the assembling steps, and improving the space utilization of the multifunctional high-voltage connector. When the upper cover and the pedestal are assembled, the second contact segment is directly inserted into the corresponding mating terminal, thereby further reducing the connection resistance in the high-voltage circuit.

A method for fabricating an electronic fuse includes forming a recess within a film material to define opposed contact segments and a central fuse segment interconnecting the contact segments and altering the material of the central fuse segment of the film material to increase electrical resistance characteristics of the central fuse segment. The central fuse segment may include defects such as voids created by directing a laser at the central fuse segment as a component of a laser annealing process. Alternatively, and or additionally, the central fuse segment may include dopants implementing via an ion implantation process to increase resistance characteristics of the central fuse segment.