Patent Publication Number: US-9892880-B2

Title: Insert for fuse housing

Description:
RELATED APPLICATIONS 
     This application is a continuation-in-part of U.S. patent application Ser. No. 14/716,268, filed May 20, 2015, which claims priority to U.S. provisional patent application No. 62/001,924, filed May 22, 2014, each of which is incorporated by reference herein in its entirety. 
    
    
     FIELD OF THE DISCLOSURE 
     This disclosure relates generally to the fuses and particularly to inserts for use in a fuse housing. 
     BACKGROUND OF THE DISCLOSURE 
     Fuses are commonly used as circuit protection devices. A fuse can provide electrical connections between sources of electrical power and circuit components to be protected. One type of fuse includes a fusible element disposed within a hollow fuse body. Conductive terminals may be connected to different ends of the fusible element through the fuse body to provide a means of connecting the fuse between a source of power and a circuit component. 
     Upon the occurrence of a specified fault condition in a circuit, such as an overcurrent condition, the fusible element of a fuse may melt or otherwise separate to interrupt current flow in the circuit path. Portions of the circuit are thereby electrically isolated and damage to such portions may be prevented or at least mitigated. 
     As a fuse element melts, material of the element vaporizes and can deposit inside the fuse housing. This can lead to a low resistance current path between the fuse terminals. Said differently, even when the fuse element has melted and/or separated, the fuse terminals may still be electrically connected via a low resistance through the deposits of the vaporized fuse element on the inside of the fuse housing. These low resistance electrical paths are often referred to as “carbon bridges.” As will be appreciated, carbon bridges can allow leakage current to flow between the fuse terminals. As such, when a carbon bridge forms, the fuse does not provide enough insulation resistance to protect the circuit components. Furthermore, as circuit voltage increases, so does the chance or occurrence of carbon bridges. In particular, owing to the high energetic light arc occurring when high voltage fuse elements vaporize, the occurrence of carbon bridges also tends to increase. 
     As will be appreciated, carbon bridges, and particularly the resulting leakage current, can damage circuit components intended to be protected by the melting of the fuse element. Accordingly, having a high insulation resistance in a fuse after melting of the fuse element is useful. In particular, some standards exist specifying insulation resistance to be greater than a specific value (e.g., &gt;1 MΩ after melting at 70V, or the like) in order for the fuse to be compliant with the standard. 
     BRIEF SUMMARY 
     In one embodiment, a fuse includes a housing having a cavity, a fuse element disposed within the cavity, a plurality of terminals extending out of the housing and electrically connected to the fuse element, and an insert disposed in the cavity, the insert including a pin extending through an opening of the housing. 
     In another embodiment, a method of forming a fuse includes providing a fuse structure comprising a fuse element and a first terminal and a second terminal connected to the fuse element, providing a first housing part and a second housing part, providing an insert about the fuse element and between the first housing part and the second housing part, wherein the insert includes a pin extending through an opening of one or more of the first housing part and the second housing part, and coupling the first housing part to the second housing part, wherein the first housing part and the second housing part define a cavity retaining the insert therein. 
     In yet another embodiment, a fuse includes a housing having a cavity, a fuse element disposed within the cavity, a plurality of terminals extending out of the housing and electrically connected to the fuse element, and a silicone insert disposed in the cavity, the insert including a first cavity and a second cavity separated by a separating wall. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       By way of example, specific embodiments of the disclosed device will now be described, with reference to the accompanying drawings, where: 
         FIG. 1  is a block diagram of a fuse according to embodiments of the present disclosure; 
         FIG. 2  is a perspective view of an example portion of a housing of the fuse of  FIG. 1  according to embodiments of the present disclosure; 
         FIG. 3  is an image of an example porous material of the fuse of  FIG. 1  according to embodiments of the present disclosure; 
         FIG. 4  is an exploded perspective view of an example of the fuse of  FIG. 1  according to embodiments of the present disclosure; 
         FIGS. 5 a -5 b    are cut-away views of an example of the fuse of  FIG. 1  before and after the fuse element melts according to embodiments of the present disclosure; 
         FIG. 6  is an image of an example of the fuse of  FIG. 1  according to embodiments of the present disclosure; 
         FIG. 7  is an image of an example of the fuse of  FIG. 1  according to embodiments of the present disclosure; 
         FIG. 8A  is a block diagram of another embodiment of a fuse shown in a side view as in  FIG. 1 ; 
         FIG. 8B  is a block diagram of the fuse of  FIG. 8A  in top plan view, with a top piece of porous material removed for clarity; 
         FIG. 9  an exploded perspective view of an example fuse structure according to embodiments of the present disclosure; 
         FIG. 10A  is a top perspective view of an insert for use with a fuse according to embodiments of the present disclosure; 
         FIG. 10B  is a bottom perspective view of the insert of  FIG. 10A  according to embodiments of the present disclosure; 
         FIG. 11A  is a top perspective view of the insert within a housing according to embodiments of the present disclosure; 
         FIG. 11B  is a bottom perspective view of the insert within the housing of  FIG. 11A  according to embodiments of the present disclosure; 
         FIG. 12A  is a top view of the fuse structure of  FIG. 9  according to embodiments of the present disclosure; 
         FIG. 12B  is a perspective view of the fuse structure of  FIG. 12A  according to embodiments of the present disclosure; 
         FIG. 13  is an exploded perspective view of an example fuse structure according to embodiments of the present disclosure; and 
         FIG. 14  is a perspective view of the fuse of  FIG. 14 , with a portion of the insert removed for clarity. 
         FIG. 15A  is a top perspective view of an insert for use with a fuse according to embodiments of the present disclosure; 
         FIG. 15B  is a bottom perspective view of the insert of  FIG. 15A  according to embodiments of the present disclosure; 
         FIG. 16A  is a top perspective view of the insert within a housing according to embodiments of the present disclosure; 
         FIG. 16B  is a bottom perspective view of the insert within the housing of  FIG. 16A  according to embodiments of the present disclosure; 
     
    
    
     DETAILED DESCRIPTION 
     In general, the present disclosure provides a fuse having a housing disposed around a fuse element. The fuse further includes a porous material (e.g., silicone foam, or the like) disposed in the housing adjacent to the fuse element. During vaporization of the fuse element, portions of the vaporized fuse element may be captured in the pores of the porous material to prevent formation of carbon bridges. More specifically, the vaporized portions of the fuse element may be lodged in the pores of the porous material and thereby prevented from settling on the inside of the fuse housing and forming carbon bridges. As such, fuses according to the present disclosure may be provided having high insulation resistance (e.g., &gt;1 MΩ at 70V for a 48V fuse, or the like) after melting of the fuse element. The example insulation resistance value given above is for purposes of clarity and completeness and is not intended to be limiting. 
       FIG. 1  is a block diagram of a fuse  100  according to embodiments of the present disclosure. As depicted, the fuse  100  includes a housing  10 , a conductor  20  and porous material  30 . In general, the conductor  20  may be made from a variety of conductive materials (e.g., copper, tin, silver, zinc, aluminum, alloys including such materials, or some combination of these). Furthermore, the conductor includes a terminal  21  and a terminal  23 . The terminals  21 ,  23  are configured to electrically connect the fuse to a source of power (not shown) and a circuit component to be protected (not shown). The terminals  21 ,  23  are electrically connected by a fuse element  22 . In some examples, the terminals  21 ,  23  and the fuse element  22  may be made from the same material. In some examples, the terminals  21 ,  23  and the fuse element  22  may be made from different materials. Furthermore, various techniques exist for forming the conductor  20  and/or the terminals  21 ,  23  and the fuse element  22  (e.g., stamping, cutting, or the like). Furthermore, in the example where the terminals  21 ,  23  and the fuse element  22  are formed separately, the fuse element  22  and terminals  21 ,  23  can be joined using a variety of techniques (e.g., soldering, welding, or the like). 
     The porous material  30  may be a variety of porous materials configured to “catch” or “retain” portions of the fuse element  22  when the fuse element  22  vaporizes due to an overcurrent and/or overvoltage condition. In some examples, the porous material  30  may be silicone foam. In another example, the porous material  30  may be pumice. In some examples, the porous material  30  may be selected based on a variety of factors. For example, the porous material  30  may be selected based on the temperature resistance of the material. In particular, a high temperature resistance material may be useful to resist damage due to exposure to heat generated by the fuse element during normal operation and well as when the element melts. For example, the expected life span of the fuse and the temperature resistance of the material may be used to ensure the porous material  30  does not age prematurely. Additionally, the porous material  30  may be selected based on the flexibility of the material, such as, to allow the material to act as a damper and/or reduce emissions (e.g., vaporized material pushed out of the fuse housing). 
     In various embodiments, and as shown in particular in  FIGS. 3, 4, 6, and 7  to follow, the porous material  30  may have an open pore structure, meaning at least some pores of porous material  30  are disposed on an outer surface(s) of the porous material. In particular, at least some pores may be disposed on the outer surface  132  of a piece of porous material  30  facing the fuse element  22 . In this manner, the porous material  30  may present open pores directly facing the fuse element  22 . As further detailed below, the porous material  30  may be disposed adjacent the fuse element  22 , may be in contact with the fuse element  22 , or may be spaced apart from the fuse element  22 . In these different configurations pores of the porous material  30  facing the fuse element  22  or proximate the fuse element  22  may receive and retain vaporized or melted portions of the fuse element  22 . In various embodiments, the porous material  30  may be disposed as an insert or inlay within a housing of a fuse or may be molded within a housing of the fuse. 
     In particular, the porous material  30  is configured to provide a large surface area to catch or retain the vaporized portions of the fuse element  22 . Said differently, due to the pores (refer to  FIG. 3 ) of the porous material  30 , a large surface area relative to the inside surface of the housing  10  or the volume of the fuse element  22  is provided. In other words, the surface area of the porous material  30  may be larger than the surface area of the inside surface of the housing  10 . As such, vaporized portions of the fuse element  22  may enter pores of the porous material  30  and may be distributed over the large surface area provided by the porous material  30  to increase the insulation resistance of the fuse  100  after melting of the fuse element  22 . More specifically, the larger surface area of the porous material  30  provides a significantly larger area for vaporized portions of the fuse element  22  to be distributed and disposed. As such, the occurrence of carbon bridges may be reduced. 
     As depicted, the housing  10  includes a cavity  11  where the fuse element  22  and the porous material  30  are disposed. The terminals  21 ,  23  extend through the housing and are electrically connected to the fuse element  22 . In general, the housing  10  may be made from a variety of materials (e.g., plastic, composite, epoxy, or the like). In some examples, the housing  10  may be formed around the conductor  20  and the porous material  30 . In some examples, the housing  10  may be multi-part (e.g., refer to  FIGS. 2, 4 ) and the fuse  100  can be assembled by connecting the housing parts once the conductor  20  and the porous material  30  are placed in the cavity  11 . 
     During normal operation, current flows from terminal  21  to terminal  23  through the fuse element  22  (or vice versa). During an abnormal condition, when the fuse element  22  melts, an arc is generated and the fuse element  22  is vaporized. The porous material  30  may be configured and/or selected to flex and or absorb some of the pressure created during the melting of the fuse element  22 . More specifically, as the arc burns and vaporizes the fuse element  22 , pressure within the housing  10  increases. Known fuses may be prone to rupture due to such pressure. In accordance with various embodiments of the disclosure, a flexible porous material may provide for the absorption of some of the pressure created when the arc burns to reduce and/or prevent rupture of the housing  10  due to the melting of the fuse element  22 . In some examples, as stated above, silicone foam may be used as the porous material  30 . In particular, silicone foam may provide for the porous material  30  not to degrade during the expected life span of the fuse  100 . In other words, the porous material  30  may retain sufficient flexible properties and open pores to absorb and catch vaporized material from the fuse element  22  to prevent or reduce carbon bridges. An additional advantage of silicone foam is because the silicone foam may contain little or no carbon, wherein even in the event the silicone foam decomposes during a fuse event, carbon material is not formed from the foam. 
     As described above, the housing  10  may be multiple parts, where the multiple parts are assembled to form the fuse  100 .  FIG. 2  illustrates an example of a top (or bottom) portion of the housing  10 , referred to as housing  10   a . As depicted, the housing  10   a  includes a cavity  11 , where porous material  30  may be disposed. Furthermore, the housing  10   a  includes recessed portions  12 . The recessed portions  12  may be configured to allow the terminals  21 ,  23  to pass through the housing  10  when the housing  10  is assembled. More specifically, when the housing  10   a  is assembled with another housing  10   a  (refer to  FIG. 4 ) the recessed portions  12  may allow the terminals  21 ,  23  to extend out of the housing  10  to facilitate electrical connection of the fuse  100  to a power source and circuit component. 
     At least one housing  10   a  may include an alignment component configured to couple to another housing  10   a . In particular, the housing  10   a  may also include alignment portions  13 . As can be seen, the alignment portions  13  are configured to align with one another (e.g., when the housing  10   a  is assembled with another housing  10   a ). The alignment portions  13  may be configured to snap together, and or provide space for epoxy, or the like to be used to secure the housing  10  once assembled. In some examples, the alignment portions  13  may be posts and holes (e.g., as depicted in  FIG. 2 ). In other examples, the alignment portions may be rectangular or polygonal shaped protrusions with corresponding slots or receiving holes. 
       FIG. 3  illustrates an example of porous material  30  according to an embodiment of the present disclosure. The porous material  30  includes pores  31 . As described above, the pores  31  are configured to increase the surface area available to catch vaporized material of the fuse element  22 . In particular, the pores  31  are configured to catch the vaporized material and prevent the material from passing through the porous material and from being disposed on inner surface (inside surface) of the fuse housing, i.e., the housing  10 , where the vaporized material if disposed on the inside surface could lead to a carbon bridge being formed and reduced insulation resistance once the fuse element  22  has melted. Said differently, the pores  31  are configured to trap and or retain the vaporized particles (e.g., refer to  FIG. 5 b   ) of the fuse element  22  in the event the fuse element  22  melts. 
       FIG. 4  illustrates an exploded view of the fuse  100  according to embodiments of the present disclosure. As depicted, the fuse  100  includes housing  10   a , porous material  30 , and conductor  20 . The conductor  20  includes the terminals  21 ,  23  and the fuse element  22 . In some examples, the terminal  21  and terminal  23  may have a connection hole  25 . The connection hole  25  may be configured to physically and electrically connect the fuse  100  to a source of power and circuit component. For example, the holes  25  may be configured so the fuse  100  can be secured to a bolt or post. Furthermore, the conductor  20  may have alignment holes  24 . The alignment holes  24  may be configured to align with the alignment portions  13  of the housings  10   a  as the fuse  100  is assembled. The alignment holes  24  and alignment portions  13  can then retain the housing  10  over the fuse element  22  once the fuse  100  is assembled. Additionally, the alignment portions  13 , when passed through the alignment holes  24  may form a structure retaining the porous material  30  centered over the fuse element  22 . This may assist in ensuring substantially all or as much as desired of the vaporized material from the fuse element  22  is caught in the pores  31  (refer to  FIG. 3 ) when the fuse element  22  melts. 
     In some examples, the porous material  30  may be disposed so the porous material is touching the fuse element  22 . With other examples, the porous material  30  may be disposed so a space (e.g., refer to  FIGS. 1 and 7 ) exists between the terminals  21 ,  23  and the porous material  30 . More specifically, a space exists between the terminals  21 ,  23  and the porous material  30  so a carbon bridge is unlikely to build up and provide a low resistance path between terminals  21 ,  23 . With some examples, a space between terminals  21 ,  23  and the porous material  30  may exist, while the porous material  30  is close to or even touches the fuse element  22 . 
     With some examples, the porous material  30  may be configured to cool the arc during melting of the fuse element, in addition to catching vaporized material. Accordingly, the fuse  100 , in addition to providing higher insulation resistance, may provide quicker arc extinction than conventional fuses. 
       FIGS. 5 a -5 b    illustrate a cut-away view of an example fuse, fuse  100 , before and after the fuse element melts. In particular,  FIG. 5 a    illustrates the fuse  100  before the fuse element  22  has melted while  FIG. 5 b    illustrates the fuse  100 ′ once the fuse element  22  has melted. As depicted, the porous material  30  is disposed in the cavity  11  of the housing  10  above and below the fuse element  22 . Furthermore, the porous material  30  is centered about the fuse element  22 . Terminals  21 ,  23  extend out from the housing  10  and provide a path for current to flow through the fuse element  22 . 
     Once an overcurrent and/or overvoltage condition occurs, the fuse element  22  melts and vaporizes as described above. The porous material  30  catches the vaporized material  40  of the fuse element  22 . In particular, the vaporized material  40  is lodged in the pores  31  of the porous material  30  and is thereby substantially prevented from depositing on the inside surface of the housing  10 . Accordingly, the path for current to flow between the terminals  21 ,  23  is interrupted and a high (e.g., &gt;1 MΩ for a 70V fuse, or the like) insulation resistance is provided. 
     In various embodiments, the porous material  30  is provide with a pore structure capturing vaporized material  40  in a manner reducing the likelihood of formation of a continuous electrically conductive path between the terminal  21  and terminal  23  after a fusing event. The porous material  30  may have a pore size distribution adapted to contain solidified particles (referred to as the vaporized material  40 ) formed after solidification of melted or vaporized portions of the fuse element  22 . For example, the pore size of porous material  30  may range from several micrometers to several millimeters, such as between between five micrometers and five millimeters. Additionally, the porous material  30  may have a surface area five times greater than the surface area of the inside of housing  10 , or ten times greater, or one hundred times greater. For a given amount of vaporized material  40 , this structure of porous material  30  provides a much larger surface area to condense upon without forming a continuous layer or bridge of conductive material, as compared to a fuse formed without the porous material  30 . 
       FIG. 6  is an image of an example fuse, fuse  100 , according to embodiments of the present disclosure. As depicted, terminals  21 ,  23  are connected to the fuse element  22  and extend out of the housing  10   a . The alignment holes  24  are fit over the alignment portions  13  of the housing  10   a  and are configured to receive the alignment portions  13  (not shown) of another housing  10   a  (also not shown) to be assembled on the housing  10   a . Furthermore, the porous material  30  is depicted disposed below the fuse element  22  and retained in position (e.g., substantially centered over the fuse element  22 ) by the alignment portions  13 . In some examples, another piece of porous material  30  (not shown for clarity of illustration) may be disposed above the fuse element  22  and retained in position opposite the porous material  30  shown in  FIG. 6 . 
       FIG. 7  is an image of an example fuse, fuse  100 , according to embodiments of the present disclosure. As depicted, the terminals  21 ,  23  are connected to the fuse element  22  and extend out of the housing  10   a . The porous material  30  is inserted into the cavity  11  of the housing  10   a  between ribs  15 . As depicted, the ribs  15  are positioned on either side of the porous material  30 . In general, the ribs  15  may have any of a variety of shapes (e.g., ribs as shown, circular posts, or the like). The ribs  15  may be configured to support the porous material  30  during assembly (e.g., retain the material in the cavity  11 ) as well as support the porous material  30  after assembly and during use. In particular, where the porous material  30  is a flexible material, the porous material  30  may be sized slightly larger than the distance between the ribs. As such, when the material is inserted between the ribs, the material may be biased to push against the ribs and thereby be retained in the cavity. With some example, the porous material  30  may be spaced away from the terminals  21 ,  23  to prevent a carbon bridge from forming on the surface of the porous material  30  itself and providing a low resistance path between the terminals  21 ,  23 . 
     In some examples, the housing  10   a  may have ribs forming a rectangular box or bed. The rectangular bed may be sized slightly smaller than the porous material  30 , such as when the porous material is in an uncompressed state before assembly in the fuse  100 . The porous material  30  can be compressed and inserted into the rectangular bed. Due to the characteristic of the porous material  30 , during assembly in the fuse  100 , the porous material may be biased to expand against the rectangular bed and thereby be retained in the rectangular bed during assembly and use. 
       FIG. 8A  is a block diagram of another embodiment of fuse  100  shown in a side view as in  FIG. 1 .  FIG. 8B  is a block diagram of fuse  100  of  FIG. 8A  in top plan view, with a top piece of porous material  30  removed for clarity. In this embodiment, the fuse  100  may be similar to the embodiment of fuse  100  of  FIG. 1 , with a difference being the porous material  30  includes a hole  45 . The hole  45  may be disposed facing the fuse element  22  and in particular a middle region where melting and or vaporization may take place during a fusing event. According to various embodiments, providing a depression, cavity, or hole within a porous material may be useful to increase capture of vaporized or melted material. In the embodiment of  FIG. 8A , the hole  45  may extend through the thickness of porous material  30 . In other embodiment, a depression may extend partially through the thickness of porous material  30 . The embodiments are not limited in this context. The shape of the hole  45  may be circular, square, rectangular, or other convenient shape. In various embodiments, the diameter or other lateral dimension of the hole  45  may be 2 mm to 10 mm. An advantage of the embodiment of  FIGS. 8A and 8B  is because a depression or hole may be reproducibly located at a target location near where melting or vaporization of a fuse element  22  may take place. Thus, in addition to material captured by pores of the porous material  30 , material is likely captured within hole  45  during a fusing event. 
     Turning now to  FIGS. 9-12B , a fuse insert according to another exemplary embodiment will be described in greater detail. As shown, a fuse  200  includes a housing  210  having a cavity  214  formed therein, and a fuse element  216  disposed within the cavity  214 . The fuse  200  further includes a plurality of terminals  218 A-B extending out of the housing  210  and electrically connected to the fuse element  216 . The fuse  200  further includes an insert  220  disposed within the cavity  214 . As shown, the plurality of terminals  218 A-B includes first and second terminals, wherein the insert  220  is spaced apart/between the first and second terminals  218 A-B. 
     In one embodiment, the insert  220  is a silicone material, as the insert  220  is in direct touch with the melting fuse element  216 , which becomes hot (e.g., 170° C. and higher) during overload conditions. As further shown, the insert  220  includes a pin  224  configured to extend through an opening  228  formed through the housing  210 . During assembly, the pin  224  is inserted through the opening  228  in one or both portions of the housing  210 , and serves as a visual indicator that the insert  220  is contained within the fuse  200 . 
     In some embodiments, the pin  224  may include an orifice  227  formed therein as a pressure release feature. For example, during an arcing event, high pressure is built up inside the housing  210  and/or insert  220 . In the case where the pressure exceeds the capability of the housing  210  and/or insert  220 , the orifice  227  is formed in the silicone that enables venting of the inner cavity to prevent the housing  210  from being damaged. In some embodiments, the orifice  327  may be pre-formed through the pin  324 , e.g., as a narrow channel that is closed in a normal state, expanding as pressure increases. In other embodiments, the orifice  327  is not preformed and, instead, is formed by virtue of the pin  324  rupturing as it expands through the opening  328  of the housing  310 . The pin  324  may be dimensioned, e.g., with a particular sidewall thickness, to ensure that failure occurs at an intended pressure level. 
     As best shown in  FIGS. 9 and 12B , the insert  220  includes a first section  220 -A (e.g., a top half) and a second section  220 -B (e.g., a bottom half) coupleable to one another to encase the fuse element  216  therebetween. As shown, the insert  220  is disposed above and below the fuse element  216 , while the housing  210  is configured to center the insert  220  about the fuse element  216 . During use, as best shown in  FIG. 12B , the fuse element  216  is clamped between the first and second sections  220 A-B of the insert  220 . More specifically, the fuse element  216  is coupled between silicone inlays of the insert  220  in an area of tin pearl (tin pearl not shown in view). The first and second sections  210 A-B of the housing  210  may be coupled together by welding, adhesive, or by rivets  222 , for example, as shown in  FIG. 9 . 
     Furthermore, each of the first and second sections  220 A-B of the insert includes a set of sidewalls  230 A-B and a set of end walls  232 A-B coupled to the set of sidewalls  230 A-B. In this embodiment, the insert  220  further includes a separating wall  240  extending between the set of end walls  232 A-B, for example, in a central portion of the insert  220 . In some embodiments, the separating wall  240  includes one or more buttresses  248  extending perpendicularly therefrom, to provide additional support to the separating wall  240 . As arranged, the separating wall  240 , together with the end walls  232  and sidewalls  230 , define a first cavity  242  and a second cavity  244  within the insert  220 . It will be appreciated, in other embodiments, that any number of separating walls and cavities (e.g., 2-5 cavities) may be formed within the insert  220 . The fuse element  216  is disposed within the insert  220 , such that the fuse element  216  is disposed between the set of sidewalls  230 A-B. 
     Advantageously, the fuse insert  220  separates the inside of the housing into multiple independent cavities  242 ,  244 , which interrupts the conductive paths from one terminal  218 -A to the other terminal  218 -B after fuse opening (e.g., melting of the fuse element  216 ). Furthermore, the fuse insert  220  helps to extinguish the appearing arc during fuse opening, and to lower the amount of vaporized material. In other words, in the moment when the fuse opens, the silicone closes the gap around the fuse element  216  and the arc is interrupted. The closed gap and the fact that less copper material is vaporized results in an increase of the open state resistance. 
     Turning now to  FIGS. 13-16B , a fuse insert according to another exemplary embodiment will be described in greater detail. As shown, a fuse  300  includes a housing  310  having a cavity  314  formed therein, and a fuse element  316  disposed within the cavity  314 . The fuse  300  further includes a plurality of terminals  318 A-B extending out of the housing  310  and electrically connected to the fuse element  316 . The fuse  300  further includes an insert  320  disposed within the cavity  314 . As shown, the plurality of terminals  318 A-B includes first and second terminals, wherein the insert  320  is spaced apart/between the first and second terminals  318 A-B. 
     In one embodiment, the insert  320  is a silicone material in direct touch with the melting fuse element  316 , which becomes hot (e.g., 170° C. and higher) during overload conditions. As further shown, the insert  320  includes a pin  324  configured to extend through an opening  328  formed through the housing  310 . During assembly, the pin  324  is inserted through the opening  328  in one or both portions of the housing  310 , and serves as a visual indicator that the insert  320  is contained within the fuse  300 . 
     Similar to above, the pin  324  may include an orifice  327  formed therein as a pressure release feature. The orifice  327  may be pre-formed through the pin  324 , e.g., as a narrow channel that is closed in a normal state, expanding as pressure increases. In other embodiments, the orifice  327  is not preformed and, instead, is formed by virtue of the pin  324  rupturing as it expands through the opening  328  of the housing  310 . The pin  324  may be dimensioned, e.g., with a particular sidewall thickness, to ensure that failure occurs at an intended pressure level. 
     As best shown in  FIGS. 13 and 14 , the insert  320  includes a first section  320 -A (e.g., a top half) and a second section  320 -B (e.g., a bottom half) coupleable to one another to encase the fuse element  316  within a cavity  326 . As shown, the insert  320  is disposed above and below the fuse element  316 , while the housing  310  is configured to center the insert  320  about the fuse element  316 . The first and second sections  310 A-B of the housing  310  may be coupled together by welding, adhesive, or a set of mating male/female members  322 . 
     During use, the fuse element  316  is clamped between the first and second sections  320 A-B of the insert  320 . More specifically, the fuse element  316  is coupled between silicone inlays of the insert  320  in an area of tin pearl (tin pearl not shown). That is, the tin pearl is positioned in a central area of the fuse element  316 , e.g., directly in the center of the cavity  326  formed by the insert  320 . 
     Furthermore, each of the first and second sections  320 A-B of the insert  320  includes a set of sidewalls  330 A-B and a set of end walls  332 A-B coupled to the set of sidewalls  330 A-B, and defining the cavity  326 . Although not shown, one or more separating walls may be included within the insert  320 . Furthermore, although termed “sidewalls” and “end walls,” it will be appreciated that the set of sidewalls  330 A-B and the set of end walls  332 A-B may themselves be considered separating walls defining, e.g., one or more additional cavities  329 A-B ( FIG. 16B ) formed within the housing  310 . 
     The fuse element  316  is disposed within the cavity  326  of the insert  320 , such that the fuse element  316  is disposed between the set of sidewalls  330 A-B and the set of end walls  332 A-B. During use, in the moment where the fuse element  316  opens, the silicone of the insert  320  closes the gap left by the melted fuse element  316 , and the arc is interrupted. The closed gap and the fact that less copper material is vaporized results in a significant increase of the open state resistance. Also a significant amount of vaporized material will stay in the inside of both silicone inlays, for example, within the cavity  326 . 
     As used herein, references to “an embodiment,” “an implementation,” “an example,” and/or equivalents is not intended to be interpreted as excluding the existence of additional embodiments also incorporating the recited features. 
     While the present disclosure has been made with reference to certain embodiments, numerous modifications, alterations and changes to the described embodiments are possible without departing from the sphere and scope of the present embodiments, as defined in the appended claim(s). Accordingly, the present disclosure is not to be limited to the described embodiments, but rather has the full scope defined by the language of the following claims, and equivalents thereof.