Fuse module
The fuse module design, supported by a double-layer structure and mold inserts, solves the problem of insufficient mechanical strength and flexibility of existing fuse modules in automotive applications, achieving efficient power and load protection, and a low-profile, space-saving design suitable for different environments.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- LITTELFUSE INC
- Filing Date
- 2025-11-17
- Publication Date
- 2026-05-15
AI Technical Summary
Existing fuse modules are difficult to meet the requirements of high mechanical strength, high flexibility, and adaptability to different environments in automotive applications, and their performance in protecting the power supply and load under overcurrent conditions is not good.
The fuse module features a dual-layer structure, including a first housing and a second housing molded over it. The first and second terminals extend and are mechanically reinforced. The second terminal is bent 180° to form a double layer to increase mechanical support. A ventilation channel is designed for heat dissipation, and the housing shape is maintained by a mold insert to ensure stable connection and protection.
This fuse module achieves a small footprint while providing high mechanical strength and flexibility to adapt to different application environments, effectively protecting the power supply and load and preventing overcurrent damage.
Smart Images
Figure CN122051091A_ABST
Abstract
Description
Cross-reference to related applications
[0001] This application claims priority to U.S. Provisional Application Serial No. 63 / 720,974 entitled “FUSE MODULE”, filed November 15, 2024, pursuant to 35 USC §119, the disclosure of which is incorporated herein by reference in its entirety. Technical Field
[0002] This disclosure generally relates to circuit protection devices. More specifically, this disclosure relates to a low-profile integrated fuse module suitable for automotive battery applications. Background Technology
[0003] Fuse modules can be implemented in automotive applications. In a typical implementation, the fuse module is mounted to a power source (e.g., a battery) and connected in series between the power source and the connected load. In the event of an overcurrent condition, the fusible element within the fuse module melts, disintegrates, or otherwise disconnects to prevent current from flowing through the fuse module. Thus, the fuse module prevents or mitigates electrical damage to the power source and / or the connected load that would otherwise have resulted in power source failure if the overcurrent condition had been allowed to persist.
[0004] In some applications, fuse modules must be mechanically strong and robust to protect the fuse module and its surrounding environment, and to withstand applied pressure and weight. Fuse modules must also be designed with flexibility to suit different applications and environments. Therefore, the need for improved fuse modules is continuous. Summary of the Invention
[0005] This brief overview is provided to present, in a simplified form, the selection of concepts further described in the detailed embodiments below. This brief overview is not intended to identify key or essential features of the claimed subject matter, nor is it intended to help determine the scope of the claimed subject matter.
[0006] In some embodiments, the fuse module may include a fusible element disposed between a first terminal and a second terminal, a first housing surrounding the fusible element, and a second housing molded over the first housing. The first terminal may extend to the outside of the first and second housings and be mechanically reinforced, and the second terminal may extend to the outside of the first and second housings and be mechanically reinforced.
[0007] In some embodiments, the first housing may include a top and a bottom that can be mechanically fitted together.
[0008] In some embodiments, the first housing may include an internal volume, and a fusible element may be disposed within the internal volume.
[0009] In some embodiments, the first housing may include at least one ventilation channel.
[0010] In some embodiments, the exterior of the second housing may include one or more side features for securing the second housing to the fuse box.
[0011] In some embodiments, the second terminal may be bent 180° to overlap itself and create a first layer and a second layer of the second terminal.
[0012] In some embodiments, the first and second layers may include holes for receiving mechanical fasteners to lock the first and second layers together.
[0013] In some embodiments, the second housing may be molded over the hole and the mechanical fastener.
[0014] In some embodiments, the second terminal may include a first layer adjacent to the fusible element and a second layer attached to the first layer.
[0015] In some embodiments, the second housing may cover at least a portion of the connection between the first and second layers.
[0016] In some embodiments, the second housing may include one or more openings formed by one or more mold inserts that may hold the first housing during the overmolding process to form the second housing, and a portion of the first housing held by the one or more mold inserts during the overmolding process may remain exposed after the overmolding process.
[0017] In some embodiments, a method of manufacturing a fuse module may include mechanically securing a first housing around a fusible element disposed between a first terminal and a second terminal, and overmolding a second housing over the first housing. The first terminal may extend to the outside of the first and second housings and be mechanically reinforced, and the second terminal may extend to the outside of the first and second housings and be mechanically reinforced.
[0018] In some embodiments, the method may further include ultrasonically welding, snap-fitting, thermally riveting, or press-fitting the top and bottom of the first housing together.
[0019] In some embodiments, the first housing may include an internal volume and at least one ventilation channel, and the fusible element may be disposed within the internal volume.
[0020] In some embodiments, the method may include molding a second housing with one or more side features to secure the second housing to a fuse box.
[0021] In some embodiments, the method may include bending the second terminal 180° to overlap itself and create a first layer and a second layer of the second terminal.
[0022] In some embodiments, the method may include molding a second housing over holes provided in the first and second layers and mechanical fasteners provided therein to lock the first and second layers together.
[0023] In some embodiments, the method may include attaching a second layer of the second terminal to a first layer of the second terminal adjacent to the fusible element, and overmolding a second housing over at least a portion of the connection between the first and second layers.
[0024] In some embodiments, the method may include holding the first housing with one or more mold inserts during an overmolding process to form the second housing.
[0025] In some embodiments, the second housing may include one or more openings formed by one or more mold inserts, and a portion of the first housing held by one or more mold inserts during the overmolding process may remain exposed after the overmolding process.
[0026] Other technical features will be apparent to those skilled in the art from the following figures, description and claims. Attached Figure Description
[0027] When it is for the purpose of easy identification of any particular element or action being discussed, one or more of the most significant digits in the figure references refer to the figure references that first introduced that element.
[0028] Figure 1 This is an exploded view showing a fuse module according to a disclosed embodiment.
[0029] Figure 2 This is an exploded view showing a portion of a fuse module according to a disclosed embodiment.
[0030] Figure 3A This is a perspective view showing a fuse module according to a disclosed embodiment.
[0031] Figure 3B This is a perspective view showing a fuse module according to a disclosed embodiment.
[0032] Figure 4A This is a perspective view showing a fuse module according to a disclosed embodiment.
[0033] Figure 4B This is a perspective view showing a fuse module according to a disclosed embodiment.
[0034] Figure 4C This is a ghosted view showing a fuse module according to a disclosed embodiment.
[0035] Figure 5A This is a top view or bottom view showing a fuse module according to the disclosed embodiments.
[0036] Figure 5B This is a side view showing a fuse module according to a disclosed embodiment.
[0037] Figure 6 This is a flowchart illustrating a method for manufacturing a fuse module according to a disclosed embodiment. Detailed Implementation
[0038] Exemplary embodiments of the fuse module according to the present disclosure will now be described more fully below with reference to the accompanying drawings. However, the fuse module may be implemented in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will convey certain exemplary aspects of the fuse module to those skilled in the art.
[0039] According to the disclosed embodiments, the fuse module can have a low profile, thereby occupying minimal space, and in some embodiments, the fuse module can provide time-delay circuit protection. In some embodiments, the fuse module can be freely suspended, and in some embodiments, the fuse module can be fixed inside a fuse box.
[0040] The fuse module disclosed herein may have a rated voltage depending on the application in which it is used. Specifically, in some embodiments, the rated voltage may be 32V or 70V. Similarly, the fuse module may have a rated ampere capacity depending on the application in which it is used. Specifically, in some embodiments, the rated ampere capacity may be 100-600A.
[0041] In some embodiments, the fuse module may include a reverse polarity fuse, and in some embodiments, the fuse module may be used in automotive applications. However, the embodiments disclosed herein are not limited in this respect.
[0042] According to the disclosed embodiments, the fuse module may include a fusible element surrounded by two housings to provide high mechanical strength and robustness, thereby protecting the fuse module and the environment in which it is located, while also withstanding the pressure and weight applied thereto. In this regard, Figure 1 and Figure 2 This is an exploded view showing a fuse module 100 according to a disclosed embodiment. Figure 3A and Figure 3BThis is a perspective view showing the fully assembled fuse module 100, and Figure 4A and Figure 4B This is a perspective view showing a fuse module 100 fully assembled with replacement terminals.
[0043] like Figure 1 and Figure 2 As shown, specifically, the fuse module 100 may include a fusible element 102 disposed between a first terminal 104 and a second terminal 106, a first housing 108 (inner housing) surrounding the fusible element 102, and a second housing 110 (outer housing) overmolded above the first housing 108. Both the first terminal 104 and the second terminal 106 may extend to the outside of the first housing 108 and the second housing 110 and be mechanically reinforced. In particular, and as will be described herein, in some embodiments, the first terminal 104 and / or the second terminal 106 may be mechanically reinforced by the second housing 110, and in some embodiments, the first terminal 104 and / or the second terminal 106 may be mechanically reinforced by the terminals themselves (including their layers).
[0044] exist Figure 1 and Figure 2 In the illustrated embodiment, the first terminal 104 can be bent to fold around and onto the second housing 110, which can provide mechanical reinforcement and support to the first terminal 104. Thus, the first terminal 104 can be disposed on the top or bottom of the second housing 110, parallel to the fusible element 102 but in a different plane from the fusible element 102. Conversely, the second terminal 106, or a portion thereof, can be straight to extend to the outside of the second housing 110 in the same plane as the fusible element 102. However, the embodiments disclosed herein are not limited in this respect. Rather, the first terminal 104 and the second terminal 106 can be disposed in any orientation relative to the fusible element 102 and the second housing 110, as is known and understood by those skilled in the art.
[0045] For example, both the first terminal 104 and the second terminal 106 can be bent to fold around and onto the second housing 110, with the first terminal 104 on the top of the second housing 110 and the second terminal 106 on the bottom of the second housing 110. Alternatively, either the first terminal 104 or the second terminal 106 can be bent to fold around and onto the second housing 110 and positioned on a side of the second housing perpendicular to the fusible element 102. Alternatively, both the first terminal 104 and the second terminal 106 can be straight, extending into the outside of the second housing 110 in the same plane as the fusible element 102. In any embodiment, the first terminal 104 and the second terminal 106 can be oriented to meet all the electrical and physical requirements of the environment in which the fuse module 100 is located, while being mechanically reinforced as disclosed herein.
[0046] In particular, such as Figure 1 , Figure 2 , Figure 3A , Figure 4A and Figure 4B As shown, the first terminal 104 can receive a bolt 112, such as an M6 or M8 clinched bolt, in its hole 132 for electrically connecting the first terminal 104 directly or indirectly to a power source or electrical load, for example via a busbar, cable, or the like. Similarly, although in Figure 1 and Figure 2 Not shown, but it should be understood that the aperture 134a of the second terminal 106 can also receive bolts or other mechanical fasteners for directly or indirectly connecting the second terminal 106 to a power source or electrical load, for example via a busbar, cable, or the like. Although the electrical connection of the first terminal 104 and the second terminal 106 can be configured in various ways, it should be understood that when the first terminal 104 is electrically connected to a power source, the second terminal 106 can be connected to an electrical load. However, when the first terminal 104 is electrically connected to an electrical load, the second terminal 106 can be electrically connected to a power source.
[0047] In some embodiments, the first housing 108 may include a top 114 and a bottom 116 that can be mechanically fitted together. For example, in some embodiments, the top 114 may be ultrasonically welded, snap-fitted, heat-riveted, or press-fitted to the bottom 116. In some embodiments, the first housing 108 may be symmetrical, and in some embodiments, the first housing 108 may be asymmetrical.
[0048] In some embodiments, the first housing 108 may include an internal volume 118, and the fusible element 102 may be disposed within the internal volume 118. For example, the top 114 and the bottom 116 may form the internal volume 118 when mechanically fitted together.
[0049] In some embodiments, the first housing 108 may include one or more ventilation channels 120. Although in Figure 1 and Figure 2 In this embodiment, two of the ventilation channels 120 are shown on the top of the top portion 114 of the first housing 108; however, it should be understood that the embodiments disclosed herein are not limited in this respect. Rather, one, two, or any number of ventilation channels 120 may be formed and located anywhere on the first housing 108, as desired in applications using fuse modules.
[0050] like Figure 3A , Figure 3B and Figure 4A As shown, specifically, in some embodiments, the exterior of the second housing 110 may include one or more side features 302, 304 for securing the second housing 110 to the fuse box. For example, the second housing 110 may include dovetail joints, wedges, ribs, or similar structures on its exterior.
[0051] Some embodiments of the second terminal 106 may be double-layered to provide mechanical reinforcement and support to the second terminal 106 and to increase flexibility in the design of the fuse module 100, such as in adapting to different applications and environments. Different double-layered designs for the second terminal 106 are conceivable.
[0052] For example, such as Figure 1 , Figure 2 , Figure 3A and Figure 3B As shown, in some embodiments, the second terminal 106 can be bent 180° to overlap itself and create a first layer 122a and a second layer 124a of the second terminal 106. In these embodiments, the first layer 122a and the second layer 124a may include holes 126 for receiving mechanical fasteners to lock the first layer 122a and the second layer 124a together. In some embodiments, the second housing 110 may be molded over the holes 126 and the mechanical fasteners.
[0053] However, as Figure 4A , Figure 4B , Figure 4C and Figure 5A As is best seen in some embodiments, the second terminal 106 may include a first layer 122b, 122c adjacent to the fusible element 102 and a second layer 124b, 124c attached to the first layer 122b, 122c. For example, in some embodiments, the second layer 124b, 124c may be attached to the first layer 122b, 122c via riveting, laser welding, adhesive bonding, soldering, or similar methods. In this regard, Figure 4CA mechanical fastener 404 is shown that rivets the first layer 122b and the second layer 124b together to the second terminal 106. However, it should be understood that the embodiments disclosed herein are not limited in this respect. Rather, the first layers 122b, 122c and the second layers 124b, 124c can be connected to each other in any manner known and understood by those skilled in the art.
[0054] like Figure 4C As is best seen in some embodiments, the second housing 110 may cover at least a portion of the connection molded between the first layer 122b and the second layer 124a of the second terminal 106, including, for example, above the mechanical fastener 404. Thus, the connection between the first layers 122b, 122c and the second layers 124b, 124c of the second terminal 106 can be integrated within the second housing 110.
[0055] The shape and orientation of the second layers 124b and 124c of the second terminal 106 can be flexible and vary depending on the application deploying the fuse module. In this respect, the second terminal 106 can be customized. For example, as... Figure 4A As shown, the second layer 124b of the second terminal 106 may include a 90° bend in the portion extending to the outside of the second housing 110 and passing through the first layer 122b of the second terminal 106. Alternatively, and as... Figure 4B As shown, the second layer 124c of the second terminal 106 may include two 90° bends in the portion extending to the outside of the second housing 110 and passing through the first layer 122c of the second terminal 106. However, it should be understood that the embodiments disclosed herein are not limited in this respect. Rather, the second layers 124b, 124c of the second terminal 106 may include one or more bends of any degree, as known and understood by those skilled in the art.
[0056] In some embodiments, the second terminal 106 may also be customized in terms of material composition. For example, the second terminal 106 may include copper, brass, bronze, or any other material desired for an application in which a fuse module is used.
[0057] While a fuse module 100 is shown and described herein, wherein the second terminal 106 is double-layered, the embodiments disclosed herein are not limited thereto and may include a second terminal 106 having a single layer. For example, in some embodiments, the fuse module 100 may include a fusible element 102 disposed between the first terminal 104 and the second terminal 106, a first housing 108 surrounding the fusible element 102, and a second housing 110 overmolded over the first housing 108, wherein both the first terminal 104 and the second terminal 106 extend to the exterior of the first housing 108 and the second housing 110. In these embodiments, a single layer of the second terminal 106 may provide sufficient mechanical reinforcement and support for applications using the fuse module 100.
[0058] As described above, the second housing 110 may be overmolded over the first housing 108. During the overmolding process of forming the second housing 110, one or more mold inserts may hold the first housing 108, and in some embodiments, the mold inserts may prevent the first housing 108 from collapsing during the overmolding process. Furthermore, in some embodiments, the mold inserts may partially or completely cover the ventilation channel 120 to prevent molten plastic from entering the first housing 108 during the overmolding process.
[0059] During the overmolding process, the first mold insert in the mold insert can hold the first housing 108 on its top or bottom, and the second mold insert in the mold insert can hold the first housing 108 on its side. Therefore, and as... Figure 1 and Figure 5A As best seen, the second housing 110 may include a first opening 128 on its top or bottom, the first opening 128 being formed by a first mold insert that holds the first housing 108 in a mold insert during the overmolding of the second housing 110. Similarly and as Figure 1 , Figure 4A , Figure 4B and Figure 5B As best seen in the middle, the second housing 110 may include a second opening 130 on its side, the second opening 130 being formed by a second mold insert that holds the first housing 108 in a mold insert during the overmolding of the second housing 110. (As in...) Figure 4A and Figure 4B Ideally, a portion of the first housing 108, which is held by the mold insert during the overmolding process, can remain exposed, for example, via the second opening 130, even after the overmolding process is completed.
[0060] Although the fuse module 100 is shown and described herein as having two openings 128, 130 in the second housing 110, the embodiments disclosed herein are not limited thereto and may include any number of openings formed by any number of mold inserts during the overmolding process, as is known and understood by those skilled in the art. For example, in some embodiments, a single mold insert may hold the first housing 108 during the overmolding process, thereby forming a single opening in the second housing 110. Alternatively, any number of multiple mold inserts may hold the first housing 108 during the overmolding process, thereby forming a corresponding number of openings in the second housing 110.
[0061] Figure 6 This is a flowchart illustrating a method 600 for manufacturing a fuse module according to a disclosed embodiment. It should be understood that method 600 can be used to manufacture fuse module 100 and / or other fuse modules falling within the spirit and scope of the disclosed embodiments.
[0062] As seen, method 600 may include mechanically securing a first housing around a fusible element disposed between a first terminal and a second terminal, as in 602. For example, in some embodiments, the top of the first housing may be ultrasonically welded, snap-fitted, thermally riveted, or press-fitted to the bottom of the first housing, and in some embodiments, the first and second terminals may extend to the outside of the first housing.
[0063] Method 600 may further include mechanically reinforcing the first and second terminals, as in 604. For example, the first terminal may be bent to fold around and onto the second housing. Additionally or alternatively, the second terminal may be bent 180° to overlap itself and create a first and second layer of the second terminal, or the second layer of the second terminal may be attached to the first layer of the second terminal adjacent to the fusible element. In any embodiment, after mechanically reinforcing the first and second terminals, method 600 may include holding the first housing with one or more mold inserts during an overmolding process, as in 606.
[0064] Finally, method 600 may include overmolding a second housing over the first housing, as in 608. For example, in some embodiments, the second housing may be overmolded with one or more side features for securing the second housing to the fuse box. In some embodiments, the first and second terminals may extend to the outside of the second housing.
[0065] When the second terminal is bent 180° to overlap itself and create a first layer and a second layer of the second terminal, the second housing may cover the holes formed in the first and second layers and the mechanical fasteners formed therein. However, when the second layer of the second terminal is attached to the first layer of the second terminal to lock the first and second layers together, the second housing may cover at least a portion of the connection between the first and second layers.
[0066] As used herein, an element or step described in the singular and beginning with the word "a" or "an" should be understood to not exclude multiple elements or steps unless such exclusion is explicitly stated. Furthermore, references to "one embodiment" in this disclosure are not intended to be construed as excluding the existence of additional embodiments also incorporated into the described features.
[0067] While this disclosure references certain embodiments, many modifications, alterations, and variations of the described embodiments are possible without departing from the spirit and scope of this disclosure as defined by the appended claims. Therefore, this disclosure is intended to be limited to the described embodiments, but rather to have the full scope defined by the language of the appended claims and their equivalents.
Claims
1. A fuse module, comprising: A fusible element disposed between a first terminal and a second terminal; A first housing surrounds the fusible element; as well as A second housing is molded over the first housing. The first terminal extends to the outside of the first and second housings and is mechanically reinforced. The second terminal extends to the outside of the first housing and the second housing and is mechanically reinforced.
2. The fuse module according to claim 1, wherein, The first housing includes a top and a bottom that fit together mechanically.
3. The fuse module according to claim 1, wherein, The first housing includes an internal volume, and the fusible element is disposed within the internal volume.
4. The fuse module according to claim 1, wherein, The first housing includes at least one ventilation channel.
5. The fuse module according to claim 1, wherein, The exterior of the second housing includes one or more side features for securing the second housing to the fuse box.
6. The fuse module according to claim 1, wherein, The second terminal is bent 180° to overlap itself and create a first layer and a second layer of the second terminal.
7. The fuse module according to claim 6, wherein, The first and second layers include holes for receiving mechanical fasteners to lock the first and second layers together.
8. The fuse module according to claim 7, wherein, The second housing is overmolded over the hole and the mechanical fastener.
9. The fuse module according to claim 1, wherein, The second terminal includes a first layer adjacent to the fusible element and a second layer attached to the first layer.
10. The fuse module according to claim 9, wherein, The second housing is overmolded over at least a portion of the connection between the first layer and the second layer.
11. The fuse module according to claim 1, wherein, The second housing includes one or more openings formed by one or more mold inserts, which hold the first housing during the overmolding process to form the second housing, and wherein a portion of the first housing held by the one or more mold inserts during the overmolding process remains exposed after the overmolding process.
12. A method for manufacturing a fuse module, the method comprising: The first housing is mechanically secured around the fusible element disposed between the first terminal and the second terminal; and The second shell is molded over the first shell. The first terminal extends to the outside of the first and second housings and is mechanically reinforced. The second terminal extends to the outside of the first housing and the second housing and is mechanically reinforced.
13. The method of claim 12, further comprising: The top and bottom of the first housing are ultrasonically welded, snap-fitted, heat-riveted, or press-fitted together.
14. The method according to claim 12, wherein, The first housing includes an internal volume and at least one ventilation channel, wherein the fusible element is disposed within the internal volume.
15. The method of claim 12, further comprising: The second housing is molded by covering it with one or more side features for securing the second housing to the fuse box.
16. The method of claim 12, further comprising: The second terminal is bent 180° to overlap itself and create a first layer and a second layer of the second terminal.
17. The method of claim 16, further comprising: The second housing is overmolded over the holes provided in the first and second layers and the mechanical fasteners provided therein, to lock the first and second layers together.
18. The method of claim 12, further comprising: The second layer of the second terminal is attached to the first layer of the second terminal adjacent to the fusible element; and The second housing is overmolded over at least a portion of the connection between the first layer and the second layer.
19. The method of claim 12, further comprising: During the overmolding process, the first housing is held in place by one or more mold inserts to form the second housing.
20. The method according to claim 19, wherein, The second housing includes one or more openings formed by the one or more mold inserts, and wherein a portion of the first housing, which is held by the one or more mold inserts during the overmolding process, remains exposed after the overmolding process.