Fuse operability detection and replaceability in a power electronic system

Abstract

A power electronic device and / or system includes a power electronic circuit, a terminal for electrically coupling to the power electronic circuit, a sealed housing, a fuse disposed outside the sealed housing, and a comparator disposed within the sealed housing. The power electronic circuit is disposed within the sealed housing and electrically accessible through the terminal extending out of the sealed housing. The fuse is electrically coupled to the power electronic circuit and the terminal. The comparator coupled to receive a first current or voltage value from a first test point on a first electrical path through the fuse between the terminal and the power electronic circuit and a second current or voltage value from a second test point on a second electrical path through the fuse between the terminal and the power electronic circuit.

Description

FUSE OPERABILITY DETECTION AND REPLACEABILITY IN A POWERELECTRONIC SYSTEMCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present invention claims the benefit of India Provisional Application Number 202311059267, filed on September 4, 2023, India Provisional Application Number 202411004709, filed on January 23, 2024, and India Provisional Application Number 202411004710, filed on January 23, 2024, all of which are hereby incorporated by reference in their entirety, including any figures, tables, and drawings.BACKGROUND

[0002] Power electronic devices and systems (e.g., inverter, converter, battery, and eHeater devices and systems) often need to be sealed to prevent damage, and keeping these systems sealed is often part of a warranty on the systems themselves. Fuses in these systems are often blown and / or made unusable, requiring replacement of the fuse. However, in order to change the fuse, the sealed portion of these systems must be accessed, potentially resulting in damage and loss of warranty. Therefore, there is a need for a solution that allows a fuse in these systems to be replaced without accessing the sealed portion of these systems. Similarly, there is a need to be able to detect when these fuses fail so that these fuses can be replaced.BRIEF SUMMARY

[0003] A power electronic system (e.g., eHeater, converter, inventor, and / or battery) is provided with a replaceable fuse outside of the sealed portion of the electrical system is provided. Advantageously, the electrical system provides the ability to easily and conveniently change the fuse(s) without having to break the seal of a housing of the power electronic system. Furthermore, a comparator electrically coupled on each side of the replaceable fuse provides the ability to detect the status (e.g., operability) of the replaceable fuse.

[0004] A power electronic device and / or system includes a power electronic circuit, a terminal for electrically coupling to the power electronic circuit, a sealed housing, a fuse disposed outside the sealed housing, and a comparator disposed within the sealed housing. The power electronic circuit is disposed within the sealed housing and electrically accessible through the terminal extending out of the sealed housing. The fuse is electrically coupled to the power electronic circuit and the terminal. The comparator coupled to receive a first current or voltage value from a first test point on a first electrical path through the fuse between theterminal and the power electronic circuit and a second current or voltage value from a second test point on a second electrical path through the fuse between the terminal and the power electronic circuit.

[0005] A method of replacing a fuse in a power electronic system includes detaching an electrical connection from a terminal, removing an overmold feature or at least a portion of the terminal, replacing the fuse, reinserting overmold feature or at least the portion of the terminal, and reattaching the electrical connection to the terminal. The fuse is located outside a sealed housing of the power electronic system;

[0006] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 illustrates a schematic of a mobile application having a DC / DC converter with fuses.

[0008] Figures 2A and 2B illustrate a top cover of a power electronic system having fully enclosed connectors.

[0009] Figures 3A and 3B illustrate terminal assemblies that are designed to receive a fully enclosed connector for a power electronic system.

[0010] Figure 3C illustrates a fully enclosed connector for a power electronic system.

[0011] Figures 4A-4G illustrate cross-sectional views of embodiments of a terminal assembly having a replaceable fuse located outside of a power electronic system that receive fully enclosed connectors.

[0012] Figures 5A-5E illustrate cross-sectional views of embodiments of a terminal assembly having a replaceable fuse located outside of a power electronic system that receive ring connectors.

[0013] Figures 6A and 6B illustrate a top cover of a power electronic system having RD8 connectors.

[0014] Figures 7A-7G illustrate portions of terminal assemblies that are configured to provide power to a power electronic system using RD8 connectors.

[0015] Figures 8A and 8B illustrate cross-sectional views of embodiments of a terminal assembly having a replaceable fuse located outside of a power electronic system that receive RD8 connectors.

[0016] Figure 9 illustrates a process flow diagram describing a method of replacing a fuse in a power electronic system.

[0017] Figures 10A-10C illustrate a comparator that tests a voltage or current on either side of a fuse in a power electronic device and / or system.

[0018] Figure 11 illustrates cross-sectional views of embodiments of a current flow through a terminal assembly and a replaceable fuse located outside of a power electronic system.

[0019] Figure 12 illustrates cross-sectional views of an embodiment of a current flow through a terminal assembly and a replaceable fuse located outside of a power electronic system that receives a fully enclosed connector.

[0020] Figure 13 illustrates cross-sectional views of an embodiment of a current flow through a terminal assembly and a replaceable fuse located outside of a power electronic system that receives a ring connector.

[0021] Figure 14 illustrates cross-sectional views of embodiments of a current flow through a terminal assembly and a replaceable fuse located outside of a power electronic system that receives an RD8 connector.DETAILED DESCRIPTION

[0022] A power electronic system (e.g., eHeater, converter, inventor, and / or battery) is provided with a replaceable fuse outside of the sealed portion of the electrical system is provided. Advantageously, the electrical system provides the ability to easily and conveniently change the fuse(s) without having to break the seal of a housing of the power electronic system. Furthermore, a comparator electrically coupled on each side of the replaceable fuse provides the ability to detect the status (e.g., operability) of the replaceable fuse.

[0023] Although some examples are described herein with respect to a 48V to 12V DC / DC converter, it should be understood that other types of converter, inverter, eHeater, and battery systems can include some or all of the features described herein. Furthermore, some or all of the features described herein may be altered for implementation in a specific type of converter, inverter, eHeater, and / or battery system(s) and still be within the scope of this disclosure.

[0024] Figure 1 illustrates a schematic of a mobile application having a DC / DC converter with fuses. Referring to Figure 1, a schematic 100 of a mobile application includes a starter motor 102, an internal combustion engine 104, a transmission 106, and a motor / generator (M / G) 108 that is supplies energy to a 48V battery 110 and / or directly to a DC / DC converter 112 (e.g., 48V to 12V) having a first fuse 114 on the incoming power side (e.g., the 48V side) and a second fuse 116 on the outgoing power side (e.g., the 12V side). The schematic 100 furtherincludes a 12V batery 118 that is powered via the outgoing power side of the DC / DC converter 112. The 48V batery 110 and / or the M / G 108 supply power to the 48V loads 120 and the 12V batery 118 and / or the outgoing power side of the DC / DC converter 112 supply power to the 12V loads 122. As can be seen, the first fuse 114 and / or the second fuse 116 may each be a point of failure that prevents the 12V loads 122 from being powered. For example, once the 12V batery is dead, it must rely on power coming from the DC / DC converter 112 to recharge. The first fuse 114 and the second fuse 116 are replaceable fuses.

[0025] Figures 2A and 2B illustrate a top cover of a power electronic system having fully enclosed connectors. Figure 2A includes a line from X to X’ that represents a cross-sectional line through a top cover of a top cover 200 of a power electronic device and / or system (e.g., eHeater, converter, inventor, and / or batery system as represented in Figures 4B-4G). Referring to Figures 2A and 2B, a top cover 200 of a DC / DC converter includes one or more terminal assemblies 202, 204. In some cases, there is a power-in terminal assembly 202 and a power- out terminal assembly 204. For example, the power-in terminal assembly 202 includes 48V power coming into a DC / DC converter and the power-out terminal assembly 204 includes 12V power coming out of the DC / DC converter (e.g., as described in Figure 1). In some cases, a ground terminal assembly 206 is included. While the power-in terminal assembly 202 and the power-out terminal assembly 204 illustrate a fully enclosed connector, such as an Aptiv® connector, in some cases, the power-in terminal assembly 202, the power-out terminal assembly 204, and / or the ground terminal assembly 206 are configured to receive a ring terminal connector, a stud connector, an RD8 connector, an RD8 connector on the harness side and / or any other type of connector for coupling wiring to the power-in terminal assembly 202 and the power-out terminal assembly 204.

[0026] Figures 3A and 3B illustrate terminal assemblies that are designed to receive a fully enclosed connector for a power electronic system. Referring to Figures 3A and 3B, a terminal assembly 300 includes a terminal 302 and an overmold feature 304 that is positioned within a stud 306 of an eHeater, converter, inventor, and / or batery. In some cases, the overmold feature 304 is made of non-conductible material.

[0027] Figure 3C illustrates a fully enclosed connector for a power electronic system. Referring to Figure 3C, a fully enclosed connector 310 includes an outer housing 312, a snap lid 314 (e.g., for enclosing the electrical connection to the terminal assembly 300) connected to the outer housing 312 via a hinge 316, an electrical wire 318, a cable gland 320, and a seal 322 that fits between the electrical wire 318 and the cable gland 320 to provide a water-proof enclosure where the electrical wire 318 enters the outer housing 312. The fully enclosed connector 310prevents corrosion, wear and tear, and other deteriorating effects on the electrical connection to the terminal assembly 300 that happen during normal use of the power electronic device and / or system.

[0028] Figures 4A-4G illustrate cross-sectional views of embodiments of a terminal assembly having a replaceable fuse located outside of a power electronic system that receive fully enclosed connectors. Referring to Figures 4A-4G, a terminal assembly 400 of a power electronic device and / or system includes a power electronic circuit 402, a terminal 404 for electrically coupling to the power electronic circuit 402, a sealed housing 406 (or sealed portion), a fuse 408 disposed outside of the sealed housing 406, a stud 410, and, in some cases such as illustrated in Figures 4D and 4E, an overmold feature positioned around at least a portion of the terminal 404 and within the stud 410. The fuse is electrically coupled to the power electronic circuit 402 and the terminal 404. The fuse 408 may be positioned beneath the overmold feature 412 and / or a portion of the terminal 404 and is positioned around at least a portion of the terminal 404. The power electronic circuit 402 is disposed within the sealed housing 406 and electrically accessible through the terminal extending out of the sealed housing 406. The top cover (e.g., as illustrated in Figures 2A and 2B) is separate from the sealed housing 406.

[0029] The terminal 404 includes an exterior terminal 414 for attaching to a fully enclosed connector 416 and an interior terminal 418 coupled to the exterior terminal 414 for attaching to the power electronic circuit 402. In some cases, the interior terminal 418 provides a compression force on the power electronic circuit 402 when attached to the exterior terminal 414. In some cases, the interior terminal 418 provides a compression force on the power electronic circuit 402 when attached to the exterior terminal 414. In some cases, the interior terminal 418 is attached to the exterior terminal 414 via a press fit. In some cases, the interior terminal 418 is attached to the exterior terminal 414 via a nut and bolt configuration. In some cases, the interior terminal 418 includes a longitudinal shaft 420 and an oversized head 422 attached to an end of the longitudinal shaft 420. In some cases, a washer / bolt or only a bolt, as illustrated in Figure 4B, is utilized in lieu of an oversized head 422. In some cases, the overmold feature 412 is positioned around the exterior terminal 414. In some cases, the fuse 408 is positioned beneath the exterior terminal 414.

[0030] In some cases, as illustrated in Figure 4D, the terminal assembly 400 further includes a spring force element 424. In some cases, the fuse 408 is electrically coupled to the terminal 404 by the spring force element 424. In some cases, the terminal assembly 400 further includes a conductive element 426 electrically coupling the fuse 408 to the power electronic circuit 402.

[0031] In some cases, the fuse 408 is inserted and / or snapped into place by fitting around at least a portion of the terminal 404. In some cases, the fuse 408 is a marine-rated battery fuse. In some cases, the terminal assembly 400 further includes an O-ring 428 to provide sufficient pressure to keep the overmold feature 412 and / or fully enclosed connector 416 and / or stud 410 in place during normal usage of the power electronic device and / or system. The O-ring 428 may be positioned between the stud 410 and a connector block 430. In some cases, as illustrated in Figure 4E, the overmold feature 412 includes a snap feature to further prevent corrosion, wear and tear, and other deteriorating effects to the terminal assembly 400 that happen during normal use of the power electronic device and / or system.

[0032] In some cases, the power electronic circuit 402 is a printed circuit board (PCB). A comparator, such as described with respect to Figures 10A-10C) is also disposed within the sealed housing 406. In some cases, the comparator is formed as a part of the power electronic circuit 402.

[0033] The power-in and power-out may be supplied / facilitated via one or more fully enclosed connectors 416 (e.g., one fully enclosed connector 416 for each terminal assembly 400) that electrically couple to the terminal 404.

[0034] Figures 5A-5E illustrate cross-sectional views of embodiments of a terminal assembly having a replaceable fuse located outside of a power electronic system that receive ring connectors. Although Figures 5A-5E illustrate a single terminal assembly, a power electronic device and / or system utilizing ring connectors can include one or more terminal assemblies. In some cases, there is a power-in terminal assembly and a power-out terminal assembly. In some cases, a ground terminal is also included.

[0035] Referring to Figures 5A-5E, a terminal assembly 500 includes a terminal 502 (e.g., a bolt), an overmold feature 504 positioned around at least a portion of the terminal 502 and within a stud 506 of the terminal assembly 500, and a fuse 508 positioned beneath the overmold feature 504 around at least a portion of the terminal 502. In some cases, the terminal 502 is a bolt. In some cases, the fuse 508 can be inserted and / or snapped into place by fitting around at least a portion of the terminal 502. In some cases, the fuse 508 is a marine-rated battery fuse. In some cases, an O-ring 510 is included in the terminal assembly 500 to provide sufficient pressure to keep the overmold feature 504 in place during normal usage of the power electronic device and / or system. The O-ring 510 may be positioned between the stud 506 and a connector block 512 of the terminal assembly 500.

[0036] The terminal assembly 500 further includes a power electronic circuit 514 that is electrically coupled to the terminal assembly 500. In some cases, the power electronic circuit514 is a printed circuit board (PCB). The top cover 200 forms at least a portion of a sealed housing 516 of the DC / DC converter. The terminal 502 of the terminal assembly 500 is electrically coupled to the power electronic circuit 514 and the power electronic circuit 514 is disposed within a sealed housing 516 of the power electronic device and / or system. The terminal assembly 500 is electrically accessible through the terminal 502 extending out of the sealed housing 516. The fuse 508 is disposed outside of the sealed housing 516 and is electrically coupled to the power electronic circuit 514 and the terminal 502. The top cover (e.g., as illustrated in Figures 2A and 2B) is separate from the sealed housing 516.

[0037] A comparator, such as described with respect to Figures 10A-10C) is also disposed within the sealed housing 516. In some cases, the comparator is formed as a part of the power electronic circuit 514.

[0038] The power-in and power-out may be supplied / facilitated via one or more terminal wire connection mechanisms 518 (e.g., one terminal wire connection mechanism for each terminal assembly 500) that electrically couple to the terminal 502. The one or more terminal wire connection mechanisms 518 are secured to the terminal 502 (e.g., securing the electric coupling) via a terminal locking mechanism 520. For example, the terminal 502 is a bolt and the terminal locking mechanism 520 is a nut. In other cases, the terminal locking mechanism 520 can be any other mechanism that can secure the one or more terminal wire connection mechanisms 518 to the terminal 502. While the terminal assembly 500 illustrates a ring terminal connector, in some cases, the terminal assembly 500 is configured to receive a fully enclosed connector, a stud connector, an RD8 connector, an RD8 connector on the harness side and / or any other type of connector for coupling wiring to the terminal assembly 500.

[0039] Figures 6A and 6B illustrate a top cover of a power electronic system having RD8 connectors. Referring to Figures 6A and 6B, a top cover 600 of a power electronic device and / or system includes one or more terminal assemblies 602, 604. In some cases, there is a power-in terminal assembly 602 and a power-out terminal assembly 604. For example, the power-in terminal assembly 602 includes 48V power coming into a DC / DC converter and the power-out terminal assembly 604 includes 12V power coming out of the DC / DC converter. In some cases, a ground terminal assembly 606 is included. While the power-in terminal assembly 602 and the power-out terminal assembly 604 illustrates an RD8 connector, in some cases, the power-in terminal assembly 602, the power-out terminal assembly 604, and / or the ground terminal assembly 606 are configured to receive a ring terminal connector, a stud connector, an RD8 connector on the harness side, and / or a fully enclosed connector (e.g., an Aptiv ® connector).

[0040] Figures 7A-7G illustrate portions of terminal assemblies that are configured to provide power to a power electronic system using RD8 connectors. Referring to Figures 7A- 7G, terminal assemblies include an overmold feature 702, a terminal 704, an RD8 connector 706, and a stud 708. Specifically, an overmold feature 702 is positioned within the stud 708 and around the terminal 704. The RD8 connector 706 fits over and into the terminal 704 on the stud 708. The RD8 connector 706 prevents corrosion, wear and tear, and other deteriorating effects to the terminal assembly that happen during normal use of the power electronic device and / or system.

[0041] Figures 8A and 8B illustrate cross-sectional views of embodiments of a terminal assembly having a replaceable fuse located outside of a power electronic system that receive RD8 connectors. Referring to Figures 8A and 8B, a terminal assembly 800 of a power electronic device and / or system includes a power electronic circuit 802, a terminal 804 for electrically coupling to the power electronic circuit 802, a sealed housing 806, a fuse 808 disposed outside of the sealed housing 806, a stud 810, and an overmold feature 812 positioned around at least a portion of the terminal 804 and within the stud 810. The fuse is electrically coupled to the power electronic circuit 802 and the terminal 804. The fuse 808 may be positioned beneath the overmold feature 812 and / or a portion of the terminal 804 and is positioned around at least a portion of the terminal 804. The power electronic circuit 802 is disposed within the sealed housing 806 and electrically accessible through the terminal 804 extending out of the sealed housing 806. The top cover (e.g., as illustrated in Figures 2A, 2B, 6A and 6B) is separate from the sealed housing 806.

[0042] The terminal 804 includes an exterior terminal 814 for attaching to an RD8 connector 816 and an interior terminal 818 coupled to the exterior terminal 814 for attaching to the power electronic circuit 802. In some cases, the interior terminal 818 provides a compression force on the power electronic circuit 802 when attached to the exterior terminal 814. In some cases, the interior terminal 818 provides a compression force on the power electronic circuit 802 when attached to the exterior terminal 814. In some cases, the interior terminal 818 is attached to the exterior terminal 814 via a press fit. In some cases, the interior terminal 818 is attached to the exterior terminal 814 via a nut and bolt configuration. In some cases, the interior terminal 818 includes a longitudinal shaft 820 attached to a bolt 822 that is secured to the power electronic circuit 802. In some cases, the overmold feature 812 is positioned around the exterior terminal 814. In some cases, the fuse 808 is positioned beneath the exterior terminal 814. In some cases, the terminal assembly 800 further includes a conductive element 826 electrically coupling the fuse 808 to the power electronic circuit 802.

[0043] In some cases, the fuse 808 is inserted and / or snapped into place by fitting around at least a portion of the terminal 804. In some cases, the fuse 808 is a marine-rated battery fuse. In some cases, the terminal assembly 800 further includes an O-ring 828 to provide sufficient pressure to keep the overmold feature 812 and / or RD8 connector 816 and / or stud 810 in place during normal usage of the power electronic device. The O-ring 828 may be positioned between the stud 810 and a connector block 830. In some cases, the overmold feature 812 includes a snap feature to further prevent corrosion, wear and tear, and other deteriorating effects to the terminal assembly 800 that happen during normal use of the power electronic device and / or system. A comparator, such as described with respect to Figures 10A-10C) is also disposed within the sealed housing 806. In some cases, the comparator is formed as a part of the power electronic circuit 802.

[0044] Figure 9 illustrates a process flow diagram describing a method of replacing a fuse in a power electronic system. Referring to Figure 9, a method 900 of replacing a fuse in a power electronic system includes detaching (902) an electrical connection from a terminal, removing (904) an overmold feature or at least a portion of the terminal, replacing (906) the fuse, reinserting (908) the overmold feature or at least the portion of the terminal, and reattaching (910) the electrical connection to the terminal. The fuse is located outside of a sealed housing of the power electronic device and / or system.

[0045] In some cases in which a fully enclosed connector is used, detaching (902) the electrical connection includes removing a fully enclosed connector from an exterior terminal and the removing (904) the overmold feature or at least a portion of the terminal includes removing an exterior terminal of the terminal and removing the overmold feature. In some cases in which a fully enclosed connector is used, reinserting (908) the overmold feature or at least the portion of the terminal includes reinserting the overmold feature and reattaching the exterior terminal of the terminal and reattaching (910) the electrical connection to the terminal includes reattaching the fully enclosed connector to the exterior terminal.

[0046] In some cases, replacing (906) the fuse includes replacing the fuse with a same type of fuse. In some cases, replacing (906) the fuse with a same type of fuse includes positioning the same type of fuse around the interior terminal; that is, the interior terminal is used to facilitate positioning the same type of fuse in the correct position (e.g., beneath the exterior terminal and / or overmold feature and around at least a portion of the interior terminal).

[0047] In some cases, reinserting (908) the overmold feature or at least the portion of the terminal includes “snapping” the overmold feature into place (e.g., around at least a portion of the exterior terminal and within the stud of that corresponding terminal assembly). In somecases, the method 900 further includes, before detaching (902) the fully enclosed connector from the exterior terminal and / or removing (904) the overmold feature and / or at least the portion of the terminal and / or stud, removing an O-ring and, after reinserting (908) the overmold feature and / or at least the portion of the terminal and reattaching (910) the fully enclosed connector to the exterior terminal and / or stud, reinserting the O-ring to provide sufficient pressure to keep the overmold feature in place during normal usage of the power electronic device.

[0048] In some cases in which a ring connector is used, detaching (902) the electrical connection includes removing a terminal locking mechanism and a terminal wire connection mechanism (e.g., a ring connector) from a terminal. In some cases in which a ring connector is used, reattaching (910) the electrical connection to the terminal includes reattaching the terminal wire connection and reattaching the terminal locking mechanism to the terminal.

[0049] In some cases, replacing (906) the fuse includes replacing the fuse with a same type of fuse. In some cases, replacing (906) the fuse with a same type of fuse includes positioning the same type of fuse around the terminal; that is, the terminal is used to facilitate positioning the same type of fuse in the correct position (e.g., beneath the overmold feature around at least a portion of the terminal). In some cases, reinserting (908) the overmold feature or at least the portion of the terminal includes “snapping” the overmold feature into place (e.g., around at least a portion of the terminal and within a stud of that corresponding terminal assembly). In some cases, the method 900 further includes, before removing (904) the overmold feature or at least the portion of the terminal, removing an O-ring and, after reinserting (908) the overmold feature or at least the portion of the terminal, reinserting the O-ring to provide sufficient pressure to keep the overmold feature in place during normal usage of the power electronic device.

[0050] In some cases in which an RD8 connector is used, detaching (902) the electrical connection includes removing an RD8 from an exterior terminal, and the removing (904) the overmold feature or at least a portion of the terminal includes removing an exterior terminal of the terminal and removing the overmold feature. In some cases in which an RD8 connector is used, reinserting (908) the overmold feature or at least the portion of the terminal includes reinserting the overmold feature and reattaching the exterior terminal of the terminal and reattaching (910) the electrical connection to the terminal includes reattaching the the RD8 connector to the exterior terminal.

[0051] In some cases, replacing (906) the fuse includes replacing the fuse with a same type of fuse. In some cases, replacing (906) the fuse with a same type of fuse includes positioningthe same type of fuse around the interior terminal; that is, the interior terminal is used to facilitate positioning the same type of fuse in the correct position (e.g., beneath the exterior terminal and / or overmold feature and around at least a portion of the interior terminal.

[0052] In some cases, reinserting (908) the overmold feature or at least the portion of the terminal includes “snapping” the overmold feature into place around at least a portion of the exterior terminal and within the stud of that corresponding terminal assembly. In some cases, the method 900 further includes, before detaching (902) the RD8 connector and / or removing (904) the overmold feature and / or at least the portion of the terminal and / or stud, removing an O-ring and, after reinserting (908) the overmold feature and / or at least the portion of the terminal and / or reattaching (910) RD8 connector and / or stud, reinserting the O-ring 428 to provide sufficient pressure to keep the overmold feature in place during normal usage of the power electronic device and / or system.

[0053] Figures 10A- 10C illustrate a comparator that tests a voltage or current on either side of a fuse in a power electronic device and / or system. Referring to Figures 10A-10C, a comparator 1000 is electrically coupled to a first test point 1002 and a second test point 1004. The first test point 1002 is in a first electrical path 1006 through a fuse 1008 between a terminal 1010 and a power electronic circuit 1012 and the second test point 1004 is in a second electrical path 1016 through the fuse 1008 between the terminal 1010 and the power electronic circuit 1012. In some cases, the comparator 1000 may be located and / or formed within a power electronic circuit 1012 and / or printed circuit board (PCB).

[0054] The comparator 1000 receives a first current or voltage value from the first test point 1002 on the first electrical path 1006 through the fuse 1008 between the terminal 1010 and the power electronic circuit 1012 and a second current or voltage value from the second test point 1004 in the second electrical path 1016 through the fuse 1008 between the terminal 1010 and the power electronic circuit 1012.

[0055] In some cases, the first test point 1002 is positioned on the first electrical path 1006 on one side of the fuse 1008 and the second test point 1004 is positioned on the second electrical path 1016 on an opposing side of the fuse 1008. In some cases, the first test point 1002 is positioned on the first electrical path 1006 before power reaches the fuse 1008 and the second test point 1004 is positioned on the second electrical path 1016 after power moves through the fuse 1008. The comparator 1000 can determine, based on the first current or voltage value and the second current or voltage value, whether the fuse 1008 is operable. For example, the comparator 1000 may receive the first current or voltage value from the first test point 1002 that is equal to the second current or voltage value from the second test point 1004 anddetermine that the fuse 1008 is operable. As another example, the comparator 1000 may receive the first current or voltage value from the first test point 1002 that is different than the second current or voltage value from the second test point 1004 and determine that the fuse 1008 is not operable. As a specific example, the comparator 1000 may receive a non-zero and / or positive first current or voltage value from the first test point 1002 and a zero second current or voltage value from the second test point 1004 and determine that the fuse 1008 is not operable. In this example, the second current or voltage value from the second test point 1004 is zero.

[0056] In some cases, a fuse operability indicator light (not illustrated) is coupled to receive the determination of whether the fuse 1008 is operable. For example, the fuse operability indicator light may turn on when the received determination is that the fuse 1008 is operable and turn off when the received determination is that the fuse 1008 is not operable. As another example, the fuse operability indicator light may turn a specific color (e.g., green) when the received determination is that the fuse 1008 is operable and turn a different specific color (e.g., red) when the received determination is that the fuse 1008 is not operable. As another example, the fuse operability indicator light may turn off when the received determination is that the fuse 1008 is operable and turn on when the received determination is that the fuse 1008 is not operable. In some cases, the comparator 1000 is used in a DC / DC convertor. In some cases, the comparator 1000 is used in other types of converter, inverter, eHeater, and / or battery systems.

[0057] Figure 11 illustrates cross-sectional views of embodiments of a current flow through a terminal assembly and a replaceable fuse located outside of a power electronic system. The current flow (e.g., as represented by arrows in the first electrical path 1126) is a power-out path for the terminal assembly; however, the current flow would be reversed in the first electrical path 1126 in a power-in path for the terminal assembly. Referring to Figure 11, a terminal assembly 1100 of a power electronic device and / or system includes a terminal 1102 and a fuse 1104. The terminal 1102 can include an exterior terminal 1106 and an interior terminal 1108. The fuse 1104 can be positioned around at least a portion of the interior terminal 1108. In some cases, terminal 1102 is a single piece and / or monolithic.

[0058] In some cases, an overmold feature (not illustrated in this Figure) is positioned around at least a portion of the exterior terminal 1106 and within a stud 1110 of the terminal assembly 1100. In some cases, an O-ring (not illustrated in this Figure) is included in the terminal assembly 1100 to provide sufficient pressure to keep the overmold feature and / or stud 1110 in place during normal usage of the power electronic device and / or system. The O-ringmay be positioned between the stud 1110 and a connector block 1112 of the terminal assembly 1100.

[0059] A power electronic circuit 1114 is electrically coupled to the interior terminal 1108. In some cases, the power electronic circuit 1114 is a printed circuit board (PCB). A portion of a sealed housing 1116 of the power electronic device and / or system is also illustrated. The interior terminal 1108 of the terminal 1102 is electrically coupled to the power electronic circuit 1114 and the power electronic circuit 1114 is disposed within the sealed housing 1116 and is electrically accessible through the exterior terminal 1106 and / or interior terminal 1108 extending out of the sealed housing 1116. The fuse 1104 is disposed outside of the sealed housing 1116 and is electrically coupled to the power electronic circuit 1114 and the exterior terminal 1106 and / or interior terminal 1108. A comparator (e.g., not illustrated but described with respect to Figures 10A-10C) is also disposed within the sealed housing 1116. In some cases, the comparator is formed as a part of the power electronic circuit 1114.

[0060] The power-in and power-out may be supplied / facilitated via a ring terminal connector, a fully enclosed connector, a stud connector, an RD8 connector, an RD8 connector on the harness side and / or any other type of connector for coupling wiring to the terminal assembly 1100.

[0061] The comparator is electrically coupled to a first test point 1118 and a second test point 1120. The first test point 1118 is in a first electrical path 1122 through a fuse 1104 between the terminal 1102 and the power electronic circuit 1114 and the second test point 1120 is in a second electrical path 1124 through the fuse 1104 between the terminal 1102 and the power electronic circuit 1114. In some cases, the comparator may be located and / or formed within the power electronic circuit 1114. In some cases, the comparator is separate from the power electronic circuit 1114.

[0062] As described above with respect to Figures 10A-10C, the comparator receives a first current or voltage value from the first test point 1118 on the first electrical path 1122 through the fuse 1104 between the terminal 1102 and the power electronic circuit 1114 and a second current or voltage value from the second test point 1120 in the second electrical path 1124 through the fuse 1104 between the terminal 1102 and the power electronic circuit 1114.

[0063] In some cases, the comparator is configured to determine, based on the first current or voltage value and the second current or voltage value, whether the fuse 1104 is operable. For example, the comparator may receive the first current or voltage value from the first test point 1118 that is equal to the second current or voltage value from the second test point 1120 and determine that the fuse 1104 is operable. As another example, the comparator may receivethe first current or voltage value from the first test point 1118 that is different than the second current or voltage value from the second test point 1120 and determine that the fuse 1104 is not operable. As a specific example, the comparator may receive a non-zero and / or positive first current or voltage value from the first test point 1118 and a zero second current or voltage value from the second test point 1120 and determine that the fuse 1104 is not operable. In any case, if it is determined that the fuse 1104 is not operable, the fuse 1104 may be replaced via the method 900 described with respect to Figure 9.

[0064] In some cases, a fuse operability indicator light (not illustrated) is couple to receive the determination of whether the fuse 1104 is operable. For example, the fuse operability indicator light may turn on when the received determination is that the fuse 1104 is operable and turn off when the received determination is that the fuse 1104 is not operable. As another example, the fuse operability indicator light may turn a specific color (e.g., green) when the received determination is that the fuse 1104 is operable and turn a different specific color (e.g., red) when the received determination is that the fuse 1104 is not operable. As another example, the fuse operability indicator light may turn off when the received determination is that the fuse 1104 is operable and turn on when the received determination is that the fuse 1104 is not operable. In some cases, the comparator is used in a DC / DC convertor. In some cases, the comparator is used in other types of converter, inverter, eHeater, and / or battery systems.

[0065] Figure 12 illustrates cross-sectional views of an embodiment of a current flow through a terminal assembly and a replaceable fuse located outside of a power electronic system that receives a fully enclosed connector. Referring to Figure 12, a terminal assembly 1200 includes a terminal 1202, a fuse 1204, a conductive element 1206, a power electronic circuit 1208, and a fully enclosed connector 1210. The terminal assembly 1200 further includes an overmold feature (not illustrated in these Figures). The fuse 1204 may be positioned beneath the overmold feature and / or a portion of the terminal 1202 (e.g., an exterior terminal 1212 of the terminal 1202) and is positioned around at least a portion of the terminal 1202 (e.g., an interior terminal 1214 of the terminal 1202). The fuse 1204 is also positioned outside of the sealed housing 1220. The power electronic circuit 1208 is disposed within the sealed housing 1220 and electrically accessible through the terminal 1202 extending out of the sealed housing 1220.

[0066] The terminal assembly 1200 further includes a stud 1216, a connector block 1218, and the sealed housing 1220. In some cases, an O-ring (not illustrated in this Figure) is included in the terminal assembly 1200 to provide sufficient pressure to keep the overmold feature and / or stud 1216 in place during normal usage of the power electronic device and / or system.The O-ring may be positioned between the stud 1216 and the connector block 1218 of the terminal assembly 1200. In some cases, the power electronic circuit 1208 is a printed circuit board (PCB).

[0067] In this embodiment, the current flow (e.g., as represented by arrows in the first electrical path 1222) is a power-out path for the terminal assembly 1200; however, the current flow would be reversed in the first electrical path 1222 in a power-in path for the terminal assembly 1200. A comparator (e.g., not illustrated but described with respect to Figures 10A- 10C) is also disposed within the sealed housing 1220. In some cases, the comparator is formed as a part of the power electronic circuit 1208. The comparator is electrically coupled to a first test point 1224 and a second test point 1226. The first test point 1224 is in the first electrical path 1222 through a fuse 1204 between the terminal 1202 and the power electronic circuit 1208 and the second test point 1226 is in a second electrical path 1228 through the fuse 1204 between the terminal 1202 and the power electronic circuit 1208. In some cases, the comparator may be located and / or formed within the power electronic circuit 1208. In some cases, the comparator is separate from the power electronic circuit 1208. The comparator is configured to determine operability of the fuse 1204 as described above with respect to Figures 10A-10C and Figure 11.

[0068] Figure 13 illustrates cross-sectional views of an embodiment of a current flow through a terminal assembly and a replaceable fuse located outside of a power electronic system that receives a ring connector. Referring to Figure 13, a terminal assembly 1300 includes a terminal 1302, a fuse 1304, a conductive element 1306, a power electronic circuit 1308, and a ring connector 1310. The terminal assembly 1300 further includes an overmold feature 1309. The fuse 1304 may be positioned beneath the overmold feature 1309 and / or a portion of the terminal 1302 and is positioned around at least a portion of the terminal 1302. The fuse 1304 is also positioned outside of the sealed housing 1320. The power electronic circuit 1308 is disposed within the sealed housing 1320 and electrically accessible through the terminal 1302 extending out of the sealed housing 1320. A terminal locking mechanism 1312, such as a nut, is included to secure and / or electrically couple the ring connector 1310 to the terminal 1302.

[0069] The terminal assembly 1300 further includes a stud 1316, a connector block 1318, and the sealed housing 1320. In some cases, an O-ring 1321 is included in the terminal assembly 1300 to provide sufficient pressure to keep the overmold feature 1309 and / or stud 1316 in place during normal usage of the power electronic device and / or system. The O-ring may be positioned between the stud 1316 and the connector block 1318 of the terminalassembly 1300. In some cases, the power electronic circuit 1308 is a printed circuit board (PCB).

[0070] In this embodiment, the current flow (e.g., as represented by arrows in the first electrical path 1322) is a power-out path for the terminal assembly 1300; however, the current flow would be reversed in the first electrical path 1322 in a power-in path for the terminal assembly 1300. A comparator (e.g., not illustrated but described with respect to Figures 10A- 10C) is also disposed within the sealed housing 1320. In some cases, the comparator is formed as a part of the power electronic circuit 1308. The comparator is electrically coupled to a first test point 1324 and a second test point 1326. The first test point 1324 is in the first electrical path 1322 through a fuse 1304 between the terminal 1302 and the power electronic circuit 1308 and the second test point 1326 is in a second electrical path 1328 through the fuse 1304 between the terminal 1302 and the power electronic circuit 1308. In some cases, the comparator may be located and / or formed within the power electronic circuit 1308. In some cases, the comparator is separate from the power electronic circuit 1308. The comparator is configured to determine operability of the fuse 1304 as described above with respect to Figures 10A-10C and Figure 11.

[0071] Figure 14 illustrates cross-sectional views of embodiments of a current flow through a terminal assembly and a replaceable fuse located outside of a power electronic system that receives an RD8 connector. Referring to Figure 14, a terminal assembly 1400 includes a terminal 1402, a fuse 1404, a conductive element 1406, a power electronic circuit 1408, and an RD8 connector 1410. The terminal assembly 1400 further includes an overmold feature 1409. The fuse 1404 may be positioned beneath the overmold feature 1409 and / or a portion of the terminal 1402 (e.g., an exterior terminal 1412 of the terminal 1402) and is positioned around at least a portion of the terminal 1402 (e.g., an interior terminal 1414 of the terminal 1402). The fuse 1404 is also positioned outside of the sealed housing 1420. The power electronic circuit 1408 is disposed within the sealed housing 1420 and electrically accessible through the terminal 1402 extending out of the sealed housing 1420.

[0072] The terminal assembly 1400 further includes a stud 1416, a connector block 1418, and the sealed housing 1420. In some cases, an O-ring 1419 is included in the terminal assembly 1400 to provide sufficient pressure to keep the overmold feature 1409 and / or stud 1416 in place during normal usage of the power electronic device and / or system. The O-ring 1419 may be positioned between the stud 1416 and the connector block 1418 of the terminal assembly 1400. In some cases, the power electronic circuit 1408 is a printed circuit board (PCB).

[0073] In this embodiment, the current flow (e.g., as represented by arrows in the first electrical path 1422) is a power-out path for the terminal assembly 1400; however, the current flow would be reversed in the first electrical path 1422 in a power-in path for the terminal assembly 1400. A comparator (e.g., not illustrated but described with respect to Figures 10A- 10C) is also disposed within the sealed housing 1420. In some cases, the comparator is formed as a part of the power electronic circuit 1408. The comparator is electrically coupled to a first test point 1424 and a second test point 1426. The first test point 1424 is in the first electrical path 1422 through a fuse 1404 between the terminal 1402 and the power electronic circuit 1408 and the second test point 1426 is in a second electrical path 1428 through the fuse 1404 between the terminal 1402 and the power electronic circuit 1408. In some cases, the comparator may be located and / or formed within the power electronic circuit 1408. In some cases, the comparator is separate from the power electronic circuit 1408. The comparator is configured to determine operability of the fuse 1404 as described above with respect to Figures 10A-10C and Figure 11.

[0074] Clause 1. A system, comprising: a power electronic circuit; a terminal for electrically coupling to the power electronic circuit; a sealed housing, wherein the power electronic circuit is disposed within the sealed housing and electrically accessible through the terminal extending out of the sealed housing; a fuse disposed outside the sealed housing, wherein the fuse is electrically coupled to the power electronic circuit and the terminal; and a comparator disposed within the sealed housing, the comparator coupled to receive a first current or voltage value from a first test point on a first electrical path through the fuse between the terminal and the power electronic circuit and a second current or voltage value from a second test point on a second electrical path through the fuse between the terminal and the power electronic circuit.

[0075] Clause 2. The system of clause 1, wherein the comparator is configured to determine, based on the first current or voltage value and the second current or voltage value, whether the fuse is operable.

[0076] Clause 3. The system of clause 1 or 2, further comprising a fuse operability indicator light coupled to receive the determination of whether the fuse is operable.

[0077] Clause 4. The system of any clause 1-3, further comprising a conductive element electrically coupling the fuse to the power electronic circuit.

[0078] Clause 5. The system of any clause 1-4, wherein the system is an converter, inverter, eHeater, or battery.

[0079] Clause 6. The system of any clause 1-5, wherein the terminal comprises: an exterior terminal for attaching to a connector; and an interior terminal coupled to the exterior terminal for attaching to the power electronic circuit.

[0080] Clause 7. The system of any clause 1-6, wherein the interior terminal provides a compression force on the power electronic circuit when attached to the exterior terminal.

[0081] Clause 8. The system of any clause 1-7, wherein the interior terminal is attached to the exterior terminal via a press fit.

[0082] Clause 9. The system of any clause 1-8, wherein the interior terminal comprises a longitudinal shaft and an oversized head attached to an end of the longitudinal shaft.

[0083] Clause 10. The system of any clause 1-9, further comprising an overmold feature positioned around the exterior terminal and above the fuse.

[0084] Clause 11. The system of any clause 1-10, wherein the connector is a ring connector.

[0085] Clause 12. The system of any clause 1-11, wherein the connector is a fully enclosed connector.

[0086] Clause 13. The system of any clause 1-12, wherein the connector is an RD8 connector.

[0087] Clause 14. The system of any clause 1-13, further comprising a spring force element, wherein the fuse is electrically coupled to the terminal via the spring force element.

[0088] Clause 15. A method of replacing a fuse in a power electronic system, comprising: detaching an electrical connection from a terminal; removing an overmold feature or at least a portion of the terminal; replacing the fuse, wherein the fuse is located outside a sealed housing of the power electronic system; reinserting overmold feature or at least the portion of the terminal; and reattaching the electrical connection to the terminal.

[0089] Clause 16. The method of clause 15, wherein removing an overmold feature or at least the portion of the terminal comprises: removing an exterior terminal of the terminal; removing the overmold feature; wherein reinserting overmold feature or at least the portion of the terminal comprises: reinserting the overmold feature; and reattaching the exterior terminal of the terminal.

[0090] Clause 17. The method of clause 15 or 16, further comprising: removing an O-ring before removing the overmold feature or at least the portion of the terminal; and reinserting the O-ring after reinserting the overmold feature or at least the portion of the terminal.

[0091] Clause 18. The method of any clause 15-17, wherein the electrical connection comprises a ring connector.

[0092] Clause 19. The method of any clause 15-18, wherein the electrical connection comprises a fully enclosed connector.

[0093] Clause 20. The method of any clause 15-19, wherein the electrical connection comprises an RD 8 connector.

[0094] Although the subject matter has been described in language specific to structural features and / or acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts described above are disclosed as examples of implementing the claims and other equivalent features and acts are intended to be within the scope of the claims.

Claims

CLAIMSWhat is claimed is:

1. A system, comprising: a power electronic circuit; a terminal for electrically coupling to the power electronic circuit; a sealed housing, wherein the power electronic circuit is disposed within the sealed housing and electrically accessible through the terminal extending out of the sealed housing; a fuse disposed outside the sealed housing, wherein the fuse is electrically coupled to the power electronic circuit and the terminal; and a comparator disposed within the sealed housing, the comparator coupled to receive a first current or voltage value from a first test point on a first electrical path through the fuse between the terminal and the power electronic circuit and a second current or voltage value from a second test point on a second electrical path through the fuse between the terminal and the power electronic circuit.

2. The system of claim 1, wherein the comparator is configured to determine, based on the first current or voltage value and the second current or voltage value, whether the fuse is operable.

3. The system of claim 2, further comprising a fuse operability indicator light coupled to receive the determination of whether the fuse is operable.

4. The system of claim 2, further comprising a conductive element electrically coupling the fuse to the power electronic circuit.

5. The system of claim 1, wherein the system is an converter, inverter, eHeater, or battery.

6. The system of claim 1, wherein the terminal comprises: an exterior terminal for attaching to a connector; and an interior terminal coupled to the exterior terminal for attaching to the power electronic circuit.

7. The system of claim 6. wherein the interior terminal provides a compression force on the power electronic circuit when attached to the exterior terminal.

8. The system of claim 7, wherein the interior terminal is attached to the exterior terminal via a press fit.

9. The system of claim 8, wherein the interior terminal comprises a longitudinal shaft and an oversized head attached to an end of the longitudinal shaft.

10. The system of claim 6, further comprising an overmold feature positioned around the exterior terminal and above the fuse.

11. The system of claim 6, wherein the connector is a ring connector.

12. The system of claim 6, wherein the connector is a fully enclosed connector.

13. The system of claim 6, wherein the connector is an RD8 connector.

14. The system of claim 1, further comprising a spring force element, wherein the fuse is electrically coupled to the terminal via the spring force element.

15. A method of replacing a fuse in a power electronic system, comprising: detaching an electrical connection from a terminal; removing an overmold feature or at least a portion of the terminal; replacing the fuse, wherein the fuse is located outside a sealed housing of the power electronic system; reinserting overmold feature or at least the portion of the terminal; and reattaching the electrical connection to the terminal.

16. The method of claim 15, wherein removing an overmold feature or at least the portion of the terminal comprises: removing an exterior terminal of the terminal; removing the overmold feature;wherein reinserting overmold feature or at least the portion of the terminal comprises: reinserting the overmold feature; and reattaching the exterior terminal of the terminal.

17. The method of claim 15, further comprising: removing an O-ring before removing the overmold feature or at least the portion of the terminal; and reinserting the O-ring after reinserting the overmold feature or at least the portion of the terminal.

18. The method of claim 15, wherein the electrical connection comprises a ring connector.

19. The method of claim 15, wherein the electrical connection comprises a fully enclosed connector.

20. The method of claim 15, wherein the electrical connection comprises an RD8 connector.

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