Battery Cable Circuit Protection Device with Integrated Fuse Mounts
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Solution Overview
Problem
Existing battery cable systems face high manufacturing and assembly costs due to the need for expensive integrated circuits to withstand voltage fluctuations and additional protection devices, which also increase the cost of electric system assembly in vehicles.
Innovation Solution
A battery cable circuit protection device with a terminal base, high-current fuses, and a fuse cover that provides electrical interconnection between the battery and vehicle systems, eliminating intermediary connections and reducing additional hardware, thus controlling voltage fluctuations while maintaining low manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If expensive integrated circuits are used to withstand voltage fluctuations, then circuit reliability is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive, complex integrated circuits with inexpensive fuses that provide equivalent protection. Fuses are simple, disposable components that break the circuit when voltage fluctuations occur, offering reliable protection at a fraction of the cost of voltage-regulating integrated circuits.
Solution Approach 2:
The patent extracts the protection function from complex integrated circuits and implements it through simple fuse-based circuitry. By separating the protection function from the main circuit design, the system achieves reliability without the manufacturing complexity and cost of specialized voltage-regulating components.
2Reliability
If additional protection devices are added to the battery cable system, then circuit protection is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple protection functions into a single integrated battery cable assembly. The fuse mounts, cable connections, and protection circuitry are merged into one unified structure, eliminating the need for separate protection devices and reducing overall system complexity.
Solution Approach 2:
The battery cable assembly performs multiple functions simultaneously: power transmission, circuit protection, and electrical interconnection. The single device serves as both the power delivery mechanism and the protection system, eliminating the need for dedicated protection components.
3Reliability
If additional parts and hardware are used for circuit protection, then protection effectiveness is improved, but assembly cost increases
Solution Approach 1:
The patent integrates protection functionality directly into the battery cable assembly, eliminating the need for separate protection devices. This merging reduces the total number of parts that need to be procured, managed, and assembled, thereby reducing assembly costs while maintaining protection effectiveness.
Data Source
AI summary
A battery cable circuit protection device and circuit for preventing fluctuations in voltage from a supply battery is provided. The device includes a terminal base having a battery cable lug member adapted for mounting to and making an electrical connection with a battery post of the battery. A battery cable mounting structure is fixedly connected to the terminal base for detachably connecting the terminal base to a battery cable. The battery cable supplies a vehicle starter motor with electrical energy. A first fuse mount supported by the terminal base provides electrical interconnection to the battery post. A second fuse mount supported by the terminal base provides electrical energy to vehicle electrical systems other than the vehicle starter motor. The first and second fuse mounts are adapted for detachable a connection to a fuse which provides electrical interconnection between the first and second fuse mounts.