Fabrication of printed fuse

A method of fabricating a power fuse for protecting an electrical load subject to transient load current cycling events in a direct current electrical power system, the method comprising:

• forming a plurality of fusible weak spots on a plurality of planar substrates;
• providing a conductor separately from the plurality of planar substrates and the plurality of weak spots, wherein the conductor includes an elongated strip of metal having no stamped weak spot openings therein and therefore avoiding thermal-mechanical fatigue strain in the conductor when subjected to the transient load current cycling events, the elongated strip of metal includes coplanar connector sections and obliquely extending sections bent out of plane of the coplanar connector sections;
• and
• attaching the coplanar connector sections of the conductor to respective ones of the plurality of weak spots such that the plurality of weak spots are longitudinally spaced apart from one another along the conductor and the plurality of planar substrates are longitudinally spaced apart from one another along the conductor.

A power fuse for protecting an electrical load subject to transient load current cycling events in a direct current electrical power system, the power fuse comprising:

• at least one fuse element assembly comprising:
• one or more substrates;
• one or more fusible weak spots each printed on one of the one or more substrates;
• and
• a conductor separately provided from the one or more substrates and the one or more weak spots, wherein the conductor comprises an elongated strip of metal having no stamped weak spot openings therein and therefore avoiding thermal-mechanical fatigue strain in the conductor when subjected to the transient load current cycling events, the elongated strip of metal further comprising:
• coplanar connector sections that are attached to respective ones of the one or more weak spots;
• and
• obliquely extending sections bent out of plane of the coplanar connector sections,
• wherein the one or more weak spots are longitudinally spaced apart from one another along the conductor, and the one or more substrates are longitudinally spaced apart from one another along the conductor.