Compact Fuse Unit Reducing Battery Post Load
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Solution Overview
Problem
Conventional fuse units directly mounted on battery posts are oversized, leading to increased protrusion and space requirements, and apply a high load on the battery post due to their cantilevered fixation and positioning of fusion and energizing terminals.
Innovation Solution
A compact fuse unit design where the power-feeding terminal is positioned between the energizing terminal and the fusion portion, with the fusion portion arranged over the battery post, and the energizing terminal is inwardly folded from a vertical plate part, reducing the overall dimensions and center of gravity distance from the battery post.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fusion portions are arranged on the opposite side ends of the power-feeding terminal and the energizing terminals are arranged on end portions of the fusion portions, then the electrical connection function is achieved, but the fuse unit becomes oversized and protrudes greatly from the battery side surface
Solution Approach 1:
The patent transitions from a linear arrangement of terminals and fusion portions to a three-dimensional configuration where the power-feeding terminal is positioned between the energizing terminal and fusion portion. This spatial reorganization in multiple dimensions reduces the overall length and allows compact integration while maintaining electrical connectivity through the bus bar structure.
Solution Approach 2:
The energizing terminal is folded inward from the vertical plate part, creating a nested configuration where components are arranged within the spatial envelope of others. This nesting approach minimizes the external dimensions of the fuse unit while preserving all necessary electrical connection points and fusion portions.
2Reliability
If the fusion portions and energizing terminals are arranged on opposite side ends of the power-feeding terminal, then the electrical circuit configuration is complete, but the width dimension of the fuse unit becomes wide
Solution Approach 1:
The patent employs three-dimensional arrangement where the power-feeding terminal is positioned between the energizing terminal and fusion portion in space, rather than arranging all components in a single plane. This vertical and depth-based arrangement reduces the width footprint while completing the circuit configuration through the bus bar's spatial structure.
Solution Approach 2:
The asymmetric positioning of the power-feeding terminal between the other two terminals creates an unbalanced but compact layout. This asymmetric arrangement optimizes space utilization by placing components at different spatial locations rather than symmetrically on opposite sides, thereby reducing the overall width dimension.
3Ease of manufacture
If the fuse unit is fixed to the battery post in a cantilevered manner, then the installation is simplified, but the bending moment and load on the battery post increase due to the center of gravity being distant from the battery post
Solution Approach 1:
The patent positions the power-feeding terminal between the energizing terminal and fusion portion in three-dimensional space, with the fusion portion arranged over the battery post. This vertical arrangement above the battery post brings the center of gravity closer to the mounting point, reducing the lever arm and consequently the bending moment on the battery post while maintaining cantilevered installation simplicity.
Data Source
AI summary
A fuse unit includes a feeding terminal, an energizing terminal and a fusion portion. The feeding terminal is fixed to a battery post to receive power from a battery. The fusion portion electrically connects the feeding terminal and the energizing terminal, and is arranged over the battery post. The feeding terminal is positioned between the energizing terminal and the fusion portion.