Compact high voltage power fuse and methods of manufacture

A method of manufacturing a high voltage power fuse utilizing an assembly frame, the frame having first and second assembly legs and the fuse including a housing, a full-range fuse element assembly, and first and second terminal fabrications, the method comprising:

• inserting the housing over the first assembly leg of the assembly frame;
• assembling the first terminal fabrication to the first assembly leg of the assembly frame;
• assembling the second terminal fabrication to the second assembly leg of the assembly frame;
• connecting the full-range fuse element assembly in a gap between the first terminal fabrication and the second terminal fabrication;
• sliding the housing over the connected full-range fuse element assembly;
• securing the housing in position to enclose the full-range fuse element assembly;
• and
• applying a silicated filler material to the assembled housing, full-range fuse element, and first and second terminals to establish a mechanical bond between the silicated filler material and the assembled housing, full-range fuse element, and first and second terminals.

A method of manufacturing a high voltage power fuse comprising:

• connecting a full-range fuse element assembly across a gap between a first terminal fabrication and a second terminal fabrication, the full-range fuse element assembly including first and second metal strip fuse elements defining a plurality of weak spots therein and being connected in parallel to one another, the first metal strip fuse element configured to uniquely respond to a short circuit current condition and the second metal strip element configured to uniquely respond to an overload current condition;
• attaching an arc barrier material to completely surround an entire cross section of portions of each of the first and second metal strip fuse elements in the full-range fuse element assembly adjacent the respective first and second terminal fabrications in order to prevent arcing from reaching the first and second terminal fabrications during the opening of the full-range fuse element assembly at one or more of the plurality of weak spots in each of the first and second metal strip fuse elements, wherein none of the plurality of weak spots in each of the first and second metal strip fuse elements is covered by the arc barrier material;
• enclosing the full-range fuse element assembly and the arc barrier material in a housing after the full-range fuse element is connected and after the arc barrier material is attached;
• introducing a silicated filler material mixture to the housing in order to surround and mechanically bond to exposed surface of the full-range fuse element assembly not covered by the arc barrier material and to a portion of each of the first and second terminal fabrications inside the housing;
• and
• drying the silicated filler material mixture.

A method of manufacturing a high voltage power fuse comprising:

• connecting a full-range fuse element assembly across a gap between a first terminal fabrication and a second terminal fabrication, wherein connecting the full-range fuse element assembly comprises:
• connecting opposing ends of a first metal strip fuse element to respective ones of the first terminal fabrication and the second terminal fabrication, the first metal strip fuse element defining a plurality of weak spots therein, the first metal strip fuse element configured to uniquely respond to a short circuit current condition, and the first metal strip element having an arc barrier material attached thereto and completely surrounding an entire cross section of a portion of the first metal strip fuse element adjacent the respective first and second terminal fabrication and without covering any of the plurality of weak spots in the first metal strip fuse element, the arc barrier material preventing electrical arcing from reaching the first and second terminal fabrications during an opening of the first metal strip fuse element;
• and
• connecting opposing ends of a second metal strip fuse element to respective ones of the first terminal fabrication and the second terminal fabrication and therefore extend in parallel to the first metal strip element between the first terminal fabrication and the second terminal fabrication, the second metal strip fuse element defining a plurality of weak spots therein, the second metal strip fuse element configured to uniquely respond to an overload current condition, and the second metal strip element having an arc barrier material attached thereto and completely surrounding an entire cross section of a portion of the second metal strip fuse element adjacent the respective first and second terminal fabrication without covering any of the plurality of weak spots in the second metal strip fuse element, the arc barrier material preventing electrical arcing from reaching the first and second terminal fabrications during an opening of the second metal strip fuse element;
• enclosing the connected full-range fuse element assembly in a housing;
• introducing a silicated filler material mixture to the housing in order to surround and mechanically bond to exposed surfaces of the full-range fuse element assembly not covered by the arc barrier material and to a portion of each of the first and second terminal fabrications inside the housing;
• and
• drying the silicated filler material mixture.