Composite Fuse Layout for Compact EMI-Shielded Connection Boxes
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Solution Overview
Problem
Conventional electrical connection boxes for vehicles, particularly those with high-voltage circuits, require a metal housing to counter electromagnetic noise, leading to a challenge in reducing their size.
Innovation Solution
A fuse design with a columnar main body and fixing tabs arranged in a three-dimensional configuration, allowing multiple fuses to be packed densely, combined with a composite fuse and bus bar arrangement that uses a negative-side bus bar as a noise shield, reducing the overall size of the electrical connection box.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a metal housing is used to counter electromagnetic noise in high-voltage electrical connection boxes, then electromagnetic noise suppression is improved, but the size of the electrical connection box increases
Solution Approach 1:
The patent implements nesting by placing the positive-side bus bar inside the negative-side bus bar, creating a compact concentric arrangement. This nested configuration allows the noise shield function to be achieved without requiring additional external space, as the shielding structure is integrated within the existing bus bar assembly rather than adding external housing thickness.
Solution Approach 2:
The patent transitions from a conventional planar arrangement of bus bars to a three-dimensional concentric configuration where the positive-side bus bar is positioned inside the negative-side bus bar. This spatial reorganization in multiple dimensions achieves effective electromagnetic shielding while minimizing the overall external dimensions of the electrical connection box.
2Ease of manufacture
If conventional fuse arrangements are used, then ease of manufacture is maintained, but the size of the electrical connection box cannot be reduced
Solution Approach 1:
The patent merges multiple fuses into a single composite fuse unit where multiple fuse elements are arranged concentrically and electrically connected in parallel. This consolidation reduces the number of separate fuse components and mounting locations required, thereby reducing the overall space needed in the electrical connection box while maintaining manufacturing feasibility through standardized assembly processes.
Solution Approach 2:
The composite fuse structure employs nesting by arranging multiple fuse elements concentrically, with inner fuses positioned within the structure of outer fuses. This nested configuration maximizes space utilization within the available volume while maintaining ease of assembly through a unified mounting structure that accommodates all fuse elements simultaneously.
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
The proposed design enables a significant reduction in the size of the electrical connection box while effectively suppressing electromagnetic noise, enhancing its integration in vehicles.
Implementation Method 1
the main body portion is configured to melt when a current of a predetermined value or more flows between the male tab and the fixing tab
Implementation Method 2
a negative-side bus bar that is accommodated in the housing and is formed so as to surround the positive-side bus bar
Data Source
AI summary
A fuse includes a first connection portion, a second connection portion, and a fixing portion connected to the leading end of the second connection portion. The fixing portion includes a fixing hole passing therethrough along a fixing axis extending in a first direction. The fixing portion has a plurality of fixing pieces arranged side by side in a circumferential direction centered on the fixing axis. Each fixing piece is formed in an arc shape centered on the fixing axis. The fixing portion has a level difference at each predetermined angle in the circumferential direction due to the plurality of fixing pieces being arranged so as to be shifted with respect to each other in the first direction, and is formed into an open annular shape that has a first annular end and a second annular end are spaced apart from each other at a predetermined interval.