Battery Terminal Fuse Module for Compact Automotive Circuit Protection
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Solution Overview
Problem
Existing pre-fuse boxes in automotive applications are large and require significant space, necessitating a more compact solution for circuit protection in limited engine compartments.
Innovation Solution
A battery terminal fuse module with an integrated mounting structure that directly couples to the automobile battery without flexible conductors, featuring a battery clamp, fuse assembly, and mounting cradle, allowing for compact installation and efficient protection of low to medium-current electrical loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing pre-fuse boxes are used with flexible conductive leads, then electrical connections can be established, but the device occupies excessive space in the engine compartment
Solution Approach 1:
The patent integrates the battery terminal connection, fuse holder, and electrical connection components into a single compact fuse module assembly. This merging eliminates the need for separate flexible conductive leads and reduces the overall space required in the engine compartment while maintaining reliable electrical connections.
Solution Approach 2:
The fuse module serves multiple functions within a single compact unit: it provides battery terminal connection, houses the fuse, establishes electrical connections, and offers circuit protection. This multi-functionality reduces the number of separate components needed and minimizes space occupation.
2Area of stationary object
If compact fuse module design is implemented, then space is saved, but manufacturing complexity increases
Solution Approach 1:
The fuse module is designed as a segmented assembly with distinct functional components (battery clamp, fuse holder, terminal connections) that can be manufactured separately and then assembled. This segmentation allows each component to be optimized for its specific manufacturing process while maintaining the overall compact design.
Solution Approach 2:
The patent employs a nested arrangement where the fuse holder is positioned within the battery clamp structure, and electrical terminals are integrated within the fuse holder. This nesting minimizes the external dimensions of the assembly while keeping manufacturing of individual components relatively simple.
Data Source
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AI summary
A fuse module including an battery clamp, a fuse assembly including a mounting block, a bus bar on a first side of the mounting block in contact with the battery clamp, fuse terminals on a second side of the mounting block connected to the bus bar by fusible elements, and a terminal post extending through one of the fuse terminals for facilitating electrical connection to a first electrical component, the fuse module further including a mounting cradle holding the fuse assembly and the battery clamp, the mounting cradle including a mounting post extending through the battery clamp, the bus bar, the mounting block, and one of the fuse terminals for facilitating connection to a second electrical component and for securing the fuse module components together, wherein the mounting post is surrounded by a tubular sleeve extending between the bus bar and the fuse terminal through which the mounting post extends.