Fuse module
The fuse module design addresses the need for improved mechanical strength and flexibility by using reinforced terminals and customizable housings, ensuring robust circuit protection and adaptability in automotive applications.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- LITTELFUSE INC
- Filing Date
- 2025-11-14
- Publication Date
- 2026-05-27
AI Technical Summary
Existing fuse modules in automotive applications require improved mechanical strength and flexibility to withstand pressure and weight while maintaining a low profile and providing robust circuit protection.
A fuse module design featuring a fuse element enclosed by two housings, with mechanically reinforced terminals and a customizable second housing that can be overmolded to secure to a fuse box, allowing for various orientations and materials to adapt to different environments.
The design provides enhanced mechanical robustness and flexibility, ensuring effective protection against over-current conditions while occupying minimal space and adapting to diverse applications.
Smart Images
Figure 2026087513000001_ABST
Abstract
Description
Technical Field
[0001] [Cross - Reference to Related Applications] This application claims the benefit of priority to U.S. Provisional Application No. 63 / 720,974, titled "FUSE MODULE," filed on November 15, 2024, under 35 U.S.C. § 119, the disclosure of which is hereby incorporated by reference in its entirety.
[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 Art
[0003] A fuse module can be implemented in automotive applications. In a typical implementation, the fuse module is attached to a power source (e.g., a battery) and electrically connected in series between the source and the connected load. When an over - current condition occurs, the fuse element within the fuse module melts, decomposes, or otherwise opens to stop the current flow through the fuse module. Thereby, the fuse module prevents or mitigates electrical damage to the source and / or the connected load that would otherwise occur if the over - current condition were allowed to persist.
[0004] In some applications, it is essential to make the fuse module mechanically strong and robust to protect the fuse module and the environment in which it is placed and withstand the pressure and weight applied thereto. Also, the fuse module must have flexibility in design to be suitable for different applications and environments. Therefore, there is a continuing and ongoing need for an improved fuse module.
Summary of the Invention
[0005] This summary is provided to introduce, in a simplified form, the selection of concepts that will be further explained below in the detailed description. This summary is not intended to identify any important or essential features of the claimed subject matter, nor is it intended to assist in determining the scope of the claimed subject matter.
[0006] In some embodiments, the fuse module may include a fuse element positioned between a first terminal and a second terminal, a first housing surrounding the fuse element, and a second housing overmolded on the first housing. The first terminal may extend outward from the first and second housings and be mechanically reinforced, and the second terminal may extend outward from the first and second housings and be mechanically reinforced.
[0007] In some embodiments, the first housing may include an upper and lower section that can be mechanically fitted together.
[0008] In some embodiments, the first housing may include an internal volume, and the cutting element may be located within that internal volume.
[0009] In some embodiments, the first housing may include at least one exhaust channel.
[0010] In some embodiments, the exterior of the second housing may include one or more lateral features for securing the second housing to the fuse box.
[0011] In some embodiments, the second terminal can be bent 180° so as to overlap itself, forming the first and second layers of the second terminal.
[0012] In some embodiments, the first and second layers may include holes for receiving a mechanical fastener to lock the first and second layers together.
[0013] In some embodiments, the second housing can be overmolded over the holes and mechanical fasteners.
[0014] In some embodiments, the second terminal may include a first layer adjacent to the cutting element and a second layer bonded to the first layer.
[0015] In some embodiments, the second housing can be overmolded over 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 can hold the first housing during an overmolding process for forming the second housing, and any 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 for manufacturing a fuse module may include the steps of mechanically securing a first housing around a fuse-cutting element positioned between a first terminal and a second terminal, and overmolding a second housing onto the first housing. The first terminal may be mechanically reinforced extending outwards from the first and second housings, and the second terminal may be mechanically reinforced extending outwards from the first and second housings.
[0018] In some embodiments, the method may further include the step of ultrasonically welding, snap-fitting, heat-staking, or press-fitting the upper and lower parts of the first housing together.
[0019] In some embodiments, the first housing may include an internal volume and at least one exhaust channel, and the cutting element may be located within the internal volume.
[0020] In some embodiments, the method may include the step of overmolding a second housing having one or more lateral features for securing the second housing to a fuse box.
[0021] In some embodiments, the method may include the step of bending the second terminal by 180° so that it overlaps itself, thereby forming the first and second layers of the second terminal.
[0022] In some embodiments, the method may include the step of overmolding a second housing onto holes and mechanical fasteners located within the first and second layers to lock the first and second layers together.
[0023] In some embodiments, the method may include the steps of bonding a second layer of a second terminal to a first layer of a second terminal adjacent to a cutting 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 a step during the overmolding process of holding the first housing with one or more mold inserts to form a 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 may be readily apparent to those skilled in the art from the following figures, description, and claims. [Brief explanation of the drawing]
[0027] To facilitate the easy identification of the discussion of any particular element or operation, one or more of the leading digits in the reference numbers refer to the figure number in which that element is first introduced.
[0028] [Figure 1] A exploded view showing a fuse module according to the disclosed embodiment.
[0029] [Figure 2] A exploded view showing a part of a fuse module according to the disclosed embodiment.
[0030] [Figure 3A] A perspective view showing a fuse module according to the disclosed embodiment.
[0031] [Figure 3B] A perspective view showing a fuse module according to the disclosed embodiment.
[0032] [Figure 4A] A perspective view showing a fuse module according to the disclosed embodiment.
[0033] [Figure 4B] A perspective view showing a fuse module according to the disclosed embodiment.
[0034] [Figure 4C] A perspective view showing a fuse module according to the disclosed embodiment.
[0035] [Figure 5A] A top view or bottom view showing a fuse module according to the disclosed embodiment.
[0036] [Figure 5B] A side view showing a fuse module according to the disclosed embodiment.
[0037] [Figure 6]This flowchart shows a method for manufacturing a fuse module according to the disclosed embodiments. [Modes for carrying out the invention]
[0038] Exemplary embodiments of the fuse module described herein will be described more fully below with reference to the accompanying drawings. However, the fuse module may be implemented in many different ways and should not be construed as being limited to the embodiments described herein. Rather, these embodiments are provided so that the disclosure conveys specific exemplary forms of the fuse module to those skilled in the art.
[0039] According to the disclosed embodiments, the fuse module may have a low profile, thereby occupying minimal space, and in some embodiments, the fuse module may provide time-delay circuit protection. In some embodiments, the fuse module may be free-hanging, and in some embodiments, the fuse module may be fixed within a fuse box.
[0040] The fuse modules disclosed herein may have a voltage rating required for the application in which the fuse module is used. In particular, in some embodiments, the voltage rating may be 32V or 70V. Similarly, the fuse modules may have an ampere rating required for the application in which the fuse module is used. In particular, in some embodiments, the ampere rating may be 100 to 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 fuse element enclosed by two housings to be mechanically robust and sturdy, thereby protecting the fuse module and the environment in which it is placed, while also withstanding the pressure and weight applied to it. In this regard, Figures 1 and 2 are exploded views showing a fuse module 100 according to the disclosed embodiments. Figures 3A and 3B are perspective views showing a fully assembled fuse module 100, and Figures 4A and 4B are perspective views showing a fully assembled fuse module 100 with alternative terminals.
[0043] In particular, as shown in Figures 1 and 2, the fuse module 100 may include a fuse element 102 positioned between a first terminal 104 and a second terminal 106, a first housing 108 (inner housing) surrounding the fuse element 102, and a second housing 110 (outer housing) overmolded on top of the first housing 108. Both the first terminal 104 and the second terminal 106 may extend outside the first housing 108 and the second housing 110 and be mechanically reinforced. In particular, as 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] In the embodiments shown in Figures 1 and 2, the first terminal 104 may be bent so as to fold over it around the second housing 110, thereby providing mechanical reinforcement and support to the first terminal 104. Thus, the first terminal 104 may be positioned on the upper or lower surface of the second housing 110 in a plane parallel to but different from the cutting element 102. Conversely, the second terminal 106 or a portion thereof may be linear so as to extend outward from the second housing 110 in the same plane as the cutting element 102. However, the embodiments disclosed herein are not limited in this respect. Instead, the first terminal 104 and the second terminal 106 may be positioned in any orientation known and understood by those skilled in the art with respect to the cutting element 102 and the second housing 110.
[0045] For example, both the first terminal 104 and the second terminal 106 may be bent so as to fold over them around the second housing 110, with the first terminal 104 located on the upper surface of the second housing 110 and the second terminal 106 located on the lower surface of the second housing 110. Alternatively, either the first terminal 104 or the second terminal 106 may be bent so as to fold over them around the second housing 110 and positioned on the side of the second housing perpendicular to the fuse element 102. Alternatively, both the first terminal 104 and the second terminal 106 may be linear so as to extend outward from the second housing 110 in the same plane as the fuse element 102. In any embodiment, the first terminal 104 and the second terminal 106 may be oriented to conform to all electrical and physical requirements of the environment in which the fuse module 100 is placed, while being mechanically reinforced as disclosed herein.
[0046] In particular, as shown in Figures 1, 2, 3A, 4A, and 4B, the first terminal 104 can accept bolts 112, such as M6 or M8 clinch bolts, into its opening 132 in order to electrically connect the first terminal 104 to a power source or electrical load, directly or indirectly, for example, via a busbar, cable, or similar. Similarly, although not shown in Figures 1 and 2, it should be understood that the opening 134a of the second terminal 106 can also accept bolts or other mechanical fasteners, directly or indirectly, for example, via a busbar, cable, or similar, in order to electrically connect the second terminal 106 to a power source or electrical load. Regardless of the various configurations of the electrical connections of the first terminal 104 and the second terminal 106, it should be understood that if the first terminal 104 is electrically connected to a power source, the second terminal 106 can be connected to an electrical load. However, if the first terminal 104 is electrically connected to an electrical load, the second terminal 106 may be electrically connected to a power source.
[0047] In some embodiments, the first housing 108 may include an upper part 114 and a lower part 116 that can be mechanically fitted together. For example, in some embodiments, the upper part 114 may be joined to the lower part 116 by ultrasonic welding, snap fitting, heat staking, or press fitting. 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 cutting element 102 may be placed within the internal volume 118. For example, the upper part 114 and the lower part 116 can form the internal volume 118 when mechanically fitted together.
[0049] In some embodiments, the first housing 108 may include one or more exhaust channels 120. In Figures 1 and 2, two of the exhaust channels 120 are shown on the upper surface of the upper part 114 of the first housing 108, but it should be understood that the embodiments disclosed herein are not limited to this. Alternatively, one, two, or any number of the multiple exhaust channels 120 may be formed and placed in any location on the first housing 108 as is desirable for applications in which fuse modules are used.
[0050] In particular, as shown in Figures 3A, 3B, and 4A, 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 a dovetail, wedge, rib, or the like on its exterior.
[0051] Some embodiments of the second terminal 106 can be double-layered to provide mechanical reinforcement and support to the second terminal 106 and further increase the flexibility in the design of the fuse module 100, for example, when adapting to different applications and environments. Different double-layer designs for the second terminal 106 are envisioned.
[0052] For example, as best shown in Figures 1, 2, 3A, and 3B, in some embodiments, the second terminal 106 can be bent 180° so as to overlap itself, forming the first layer 122a and the second layer 124a of the second terminal 106. In these embodiments, the first layer 122a and the second layer 124a may include a hole 126 for receiving a mechanical fastener and locking the first layer 122a and the second layer 124a together. In some embodiments, the second housing 110 can be overmolded over the hole 126 and the mechanical fastener.
[0053] However, as best shown in Figures 4A, 4B, 4C, and 5A, in some embodiments the second terminal 106 may include first layers 122b, 122c adjacent to the cutting element 102, and second layers 124b, 124c bonded to the first layers 122b, 122c. For example, in some embodiments the second layers 124b, 124c may be bonded to the first layers 122b, 122c via clinching, laser welding, adhesive bonding, soldering, or the like. In this regard, Figure 4C shows a mechanical fastener 404 clinching the first layers 122b and 2 layers 124b of the second terminal 106 together. However, it should be understood that the embodiments disclosed herein are not limited to this. Instead, the first layers 122b, 122c and the second layers 124b, 124c may be connected to each other in any way known and understood by those skilled in the art.
[0054] As best shown in Figure 4C, in some embodiments, the second housing 110 can be overmolded over at least a portion of the connection between the first layer 122b and the second layer 124a of the second terminal 106, including, for example, a 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, 124c of the second terminal 106 are flexible and can be varied based on the application in which the fuse module is deployed. In this regard, the second terminal 106 is customizable. For example, as shown in Figure 4A, the second layer 124b of the second terminal 106 may include one 90° bend in a portion of its body that extends outside the second housing 110 and beyond the first layer 122b of the second terminal 106. Alternatively, as shown in Figure 4B, the second layer 124c of the second terminal 106 may include two 90° bends in a portion of its body that extends outside the second housing 110 and beyond 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. Instead, the second layers 124b, 124c of the second terminal 106 may include one or more bends at any angle known and understood to those skilled in the art.
[0056] In some embodiments, the second terminal 106 can also be customized in terms of material composition. For example, the second terminal 106 may include copper, brass, bronze, or other materials desirable for applications where a fuse module is used.
[0057] Although the fuse module 100 is shown and described herein as having a double-layered second terminal 106, 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 positioned 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 on the first housing 108 such that both the first terminal 104 and the second terminal 106 extend outside the first housing 108 and the second housing 110. In these embodiments, a single layer of the second terminal 106 can provide sufficient mechanical reinforcement and support for the application in which the fuse module 100 is used.
[0058] As described above, the second housing 110 can be overmolded on top of the first housing 108. During the overmolding process to form the second housing 110, one or more mold inserts can hold the first housing 108, and in some embodiments, the mold inserts can prevent the first housing 108 from collapsing during the overmolding process. Furthermore, in some embodiments, the mold inserts can partially or completely cover the exhaust channel 120 to prevent molten plastic from entering the first housing 108 during the overmolding process.
[0059] During the overmolding process, a first insert of the mold insert can hold the first housing 108 at its top or bottom, and a second insert of the mold insert can hold the first housing 108 at its side. Thus, as best shown in Figures 1 and 5A, the second housing 110 may include a first opening 128 at its top or bottom, formed by the first insert of the mold insert, which holds the first housing 108 during the overmolding of the second housing 110. Similarly, as best shown in Figures 1, 4A, 4B, and 5B, the second housing 110 may include a second opening 130 at its side, formed by the second insert of the mold insert, which holds the first housing 108 during the overmolding of the second housing 110. As best shown in Figures 4A and 4B, a portion of the first housing 108 held by the mold insert during the overmolding process may remain exposed, for example, through the second opening 130, even after the overmolding process is complete.
[0060] While 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 will be known and understood to 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 is a flowchart showing a method 600 for manufacturing a fuse module according to the disclosed embodiment. It should be understood that method 600 may be used to manufacture fuse module 100 and / or other fuse modules that fall within the spirit and scope of the disclosed embodiment.
[0062] As shown, method 600 may include the step of mechanically securing the first housing around a cutting element positioned between the first and second terminals in 602. For example, in some embodiments, the upper part of the first housing may be attached to the lower part of the first housing by ultrasonic welding, snap fitting, heat staking, or press fitting, and in some embodiments, the first and second terminals may extend outside the first housing.
[0063] Method 600 also includes a step in 604 of mechanically reinforcing the first and second terminals. For example, the first terminal may be bent so as to fold over it around the second housing. In addition or alternatively, the second terminal may be bent 180° so as to overlap itself to form the first and second layers of the second terminal, or the second layer of the second terminal may be bonded to the first layer of the second terminal adjacent to the cutting element. In any embodiment, after the mechanical reinforcement of the first and second terminals, Method 600 may include a step in 606 of holding the first housing in one or more mold inserts during the overmolding process.
[0064] Finally, method 600 may include the step of overmolding the second housing onto the first housing in 608. For example, in some embodiments, the second housing may be overmolded with one or more lateral features for securing the second housing to the fuse box. In some embodiments, the first and second terminals may extend outside the second housing.
[0065] If the second terminal is bent 180° so as to overlap itself, forming the first and second layers of the second terminal, the second housing can be overmolded over the holes and mechanical fasteners located in the first and second layers. However, if the second layer of the second terminal is joined to the first layer of the second terminal so that the first and second layers are locked together, the second housing can be overmolded over at least part of the connection between the first and second layers.
[0066] When used herein, elements or steps listed in the singular and beginning with the word "a" or "an" should not be understood as excluding multiple elements or steps unless such exclusions are explicitly listed. Furthermore, references to “one embodiment” in this disclosure are not intended to be construed as excluding the existence of additional embodiments that also incorporate the listed features.
[0067] While this disclosure refers to specific embodiments, multiple modifications, alterations, and changes are possible to the embodiments described without departing from the spirit and scope of this disclosure as defined in the appended claims. Therefore, this disclosure is not limited to the embodiments described, and is intended to encompass the entire scope defined by the following claims and their equivalents.
Claims
1. A cutting element positioned between the first and second terminals; A first housing surrounding the aforementioned cutting element; A second housing overmolded on the first housing. Equipped with, Here, 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 and second housings and is mechanically reinforced. Fuse module.
2. The fuse module according to claim 1, wherein the first housing includes an upper and lower portion that are mechanically fitted together.
3. The fuse module according to claim 1 or 2, wherein the first housing includes an internal volume and the fuse element is disposed within the internal volume.
4. The fuse module according to claim 1 or 2, wherein the first housing includes at least one exhaust channel.
5. The fuse module according to claim 1 or 2, wherein the exterior of the second housing includes one or more lateral features for securing the second housing to a fuse box.
6. The fuse module according to claim 1 or 2, wherein the second terminal is bent 180° so as to overlap itself, forming the first and second layers of the second terminal.
7. The fuse module according to claim 6, wherein the first layer and the second layer include holes for receiving a mechanical fastener for locking the first layer and the second layer 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 or 2, wherein the second terminal includes a first layer adjacent to the fuse element and a second layer bonded 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 or 2, wherein the second housing includes one or more openings formed by one or more mold inserts that hold the first housing during an overmolding process for forming the second housing, and 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. The steps include mechanically fixing the first housing around the cutting element positioned between the first and second terminals, and The process includes the step of overmolding a second housing onto the first housing, Here, 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 and second housings and is mechanically reinforced. How to manufacture a fuse module.
13. The method according to claim 12, further comprising the step of ultrasonically welding, snap-fitting, heat-staking, or press-fitting the upper and lower parts of the first housing together.
14. The method according to claim 12 or 13, wherein the first housing includes an internal volume and at least one exhaust channel, and the cutting element is disposed within the internal volume.
15. The method according to claim 12 or 13, further comprising the step of overmolding the second housing having one or more lateral features for securing the second housing to a fuse box.
16. The method according to claim 12 or 13, further comprising the step of bending the second terminal by 180° so as to overlap it with itself, thereby forming the first and second layers of the second terminal.
17. The method according to claim 16, further comprising the step of overmolding the second housing onto holes and mechanical fasteners disposed in the first and second layers to lock the first and second layers together.
18. The step of joining the second layer of the second terminal to the first layer of the second terminal adjacent to the cutting element; and The step of overmolding the second housing over at least a portion of the connection between the first layer and the second layer. The method according to claim 12 or 13, further comprising:
19. The method according to claim 12 or 13, further comprising holding the first housing with one or more mold inserts during the overmolding process 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 a portion of the first housing held by the one or more mold inserts during the overmolding process remains exposed after the overmolding process.