Aluminum alloy miniature cartridge fuses

A high-capacity miniature cartridge fuse comprising:

• a cylindrical housing having opposing first and second ends:
• a fusible element positioned inside the cylindrical housing and including opposing first and second ends:
• and
• first and second deep-drawn ferrules fabricated from aluminum alloy, the aluminum alloy first and second deep-drawn ferrules fabricated to withstand pressure generated inside the cylindrical housing as a result of arcing and to stay in place after temperature or pressure changes caused by at least one of i) current or ii) arcing during short circuit events, wherein the first and second deep-drawn ferrules are respectively attached to the first and second ends of the cylindrical housing and electrically connected to the respective first and second ends of the fusible element, the aluminum alloy being plated with nickel, each of the first and second deep-drawn ferrules comprising:
• a side wall surrounding the first or second end of the cylindrical housing;
• and
• an end wall extending from the side wall and closing the first or second end of the cylindrical housing, wherein the end wall includes a boss extending toward an interior of the cylindrical housing and defining an interior surface of the end wall,
• wherein the side wall and the end wall define an interior receptacle that is sized to receive the first or second end of the cylindrical housing,
• wherein the fusible element comprises a fusible wire having a first end and a second end, wherein the first end of the fusible wire is configured to be in contact with the boss of the first ferrule, and wherein the second end of the fusible wire is configured to not be in contact with the boss of the second ferrule, and
• wherein electrical resistance of the fuse is adjusted based on a specification of opening time of the fuse.

A high-capacity miniature cartridge fuse comprising:

• a housing having opposing first and second ends;
• a fusible element positioned inside the housing;
• first and second ferrules, wherein the first and second ferrules are electrically connected to the fusible element, each of the first and second ferrules comprising:
• a side wall;
• and
• an end wall extending from the side wall and closing the first or second end of the housing, wherein the end wall includes a boss extending toward an interior of the housing and defining an interior surface of the end wall;
• a first eyelet extending adjacent the respective interior surface of the end wall associated with the first ferrule, and a second eyelet extending adjacent the respective interior surface of the end wall associated with the second ferrule;
• and
• a fusible paste,
• wherein the fusible element comprises a fusible wire having a first end and a second end, wherein the first end of the fusible wire is configured to be in contact with the boss of the first ferrule, and wherein the second end of the fusible wire is configured to not be in contact with the boss of the second ferrule, and
• wherein the second end of the fusible wire extends through the second eyelet and held between the second eyelet and the end wall associated with the second ferrule, the fusible paste positioned between the second eyelet and the end wall associated with the second ferrule and welding the second end of the fusible wire to the second eyelet and the second ferrule.