Clamped Fuse Module for Fastener-Free Pre-Fuse Box Installation

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Solution Overview

Problem

Existing pre-fuse boxes in automobiles are large and require cumbersome mechanical fasteners for fuse installation and removal, occupying valuable space and increasing installation time.

Innovation Solution

A fuse module with a clamped and unclamped mechanism using pushrods and a busbar structure, allowing for easy insertion and removal of fuses without mechanical fasteners.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional mechanical fasteners (nuts, bolts) are used to secure fuses in pre-fuse boxes, then the fuses can be reliably secured, but the installation and removal of fuses becomes cumbersome and time-consuming

Engineering Contradiction:
Improvefuse securing reliabilityVSAvoidinstallation and removal time
Core Design Contradiction:
ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces conventional mechanical fasteners (nuts, bolts) with a spring-loaded clamp mechanism. The spring element provides automatic clamping force when the fuse is inserted, securing it reliably without requiring threaded fasteners. This substitution eliminates the need for complex mechanical assembly and disassembly operations, thereby reducing installation and removal time while maintaining secure fuse attachment.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The spring-loaded clamp mechanism automatically engages and secures the fuse upon insertion, without requiring manual operation of fasteners. The spring element self-adjusts to apply clamping force, and the fuse can be removed simply by withdrawing it, allowing the clamp to reset. This self-service mechanism eliminates the need for operators to manually tighten or loosen mechanical fasteners, significantly reducing installation and removal time.

Inventive Principle:
Principle #25Self-service

2Reliability

If conventional mechanical fasteners are used in pre-fuse boxes, then secure fuse mounting is achieved, but the overall size of the pre-fuse box increases

Engineering Contradiction:
Improvefuse mounting securityVSAvoidpre-fuse box size
Core Design Contradiction:
ReliabilityVSVolume of moving object

Solution Approach 1:

The patent replaces bulky mechanical fastener systems (nuts, bolts, washers, and associated threading structures) with a compact spring-loaded clamp mechanism. The spring element and clamp can be designed in a space-efficient manner, requiring minimal clearance for operation. This substitution reduces the overall volume required for each fuse mounting location, thereby reducing the total size of the pre-fuse box while maintaining reliable fuse securing.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If conventional mechanical fasteners are used for fuse installation, then secure electrical connections can be made, but the device complexity increases

Engineering Contradiction:
Improveelectrical connection securityVSAvoidfastening mechanism complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical fastener systems with a simpler spring-loaded clamp mechanism. Instead of requiring multiple components (nuts, bolts, washers, threaded holes, alignment features), the spring clamp uses a single actuating element that automatically engages with the fuse. This substitution reduces the number of parts and assembly steps, thereby reducing device complexity while maintaining secure electrical connections through reliable mechanical contact.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The spring-loaded clamp mechanism automatically performs the securing function upon fuse insertion, eliminating the need for manual operation of complex fastening mechanisms. The spring element self-adjusts to apply appropriate clamping force, and the electrical connection is established automatically. This self-service approach simplifies the overall system by eliminating the need for operators to manipulate complex mechanical fasteners, thereby reducing device complexity.

Inventive Principle:
Principle #25Self-service

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Facilitates quick and convenient installation and removal of fuses, reducing space requirements and installation time, while maintaining electrical connections.

Implementation Method 1

a spring element disposed within the housing and having a free end configured to clamp the fuse between the busbar and the terminal

Methodology Applied
Scientific EffectElasticity: Elasticity

Data Source

PatentEP4184547B1Fuse module with clamped fuse installation
Publication Date: 2025.11.05 SUZHOU LITTELFUSE OVS LTD
  • EP4184547B1 patent drawingFigure 1A~1B
  • EP4184547B1 patent drawingFigure 2A~2C
  • EP4184547B1 patent drawingFigure 3A~3B

AI summary

A fuse module including a housing formed of an electrically insulating material, a busbar disposed within the housing adjacent an interior surface of a rear wall of the housing, a terminal extending through a front wall of the housing, the terminal having a fuse coupling portion disposed within the housing adjacent an interior surface of a front wall of the housing and a conductor coupling portion protruding from an exterior surface of the front wall of the housing, and a movable pushrod extending through the rear wall of the housing and having a head portion disposed adjacent a rigid portion of the busbar for moving the rigid portion of the busbar between a retracted position, wherein the rigid portion of the busbar is located near the interior surface of the rear wall, and an extended position wherein the rigid portion of the busbar is located further from the interior surface of the rear wall relative to the retracted position.