Compact high voltage power fuse and methods of manufacture

A method of manufacturing a high voltage power fuse utilizing an assembly frame, the assembly frame having first and second assembly legs, and the high voltage power 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.