Single-Piece Copper Fuse Tabs for Low-Heat Multi-Connection Assembly
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Solution Overview
Problem
Existing automotive fuses with two-part connection ends made of copper alloy exhibit suboptimal electrical performance and lack flexibility, requiring separate fuse designs for different connection types such as screwing, soldering, and female contact connections.
Innovation Solution
A fuse design featuring electrically conductive tabs formed from crushed portions of one-piece pure copper parts, allowing for direct welding, screw fixation, or female contact insertion, providing a common reusable base with multiple connection options.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two-part connection ends made of copper alloy are used, then the fuse can be manufactured with standard materials, but the electrical performance is suboptimal and heating exceeds acceptable levels
Solution Approach 1:
The material composition parameter is changed from copper alloy to pure copper, which has superior electrical conductivity and lower resistive heating, directly resolving the contradiction between acceptable heating levels and electrical performance
Solution Approach 2:
The base and tab are merged into a single integral piece rather than being separate welded components, eliminating the weld joint that creates electrical resistance and excessive heating, thereby improving reliability while reducing temperature
2Adaptability or versatility
If separate fuse designs are created for each connection type (screwing, soldering, female contact), then each application can be optimized, but the device complexity and manufacturing variety increase
Solution Approach 1:
The tab is designed with a crushed/flattened cross-section that serves multiple functions: it can be welded directly, pierced for screw fixation, or inserted into female contacts. This single design achieves adaptability across different connection types without increasing device complexity
Solution Approach 2:
The tab's cross-section is segmented into multiple zones with different properties: the flattened body provides surface area for welding, while the structure allows piercing for mechanical fastening, enabling one component to fulfill multiple connection roles
3Reliability
If integral single-piece parts made of pure copper are used, then electrical performance improves, but the manufacturing process becomes more complex
Solution Approach 1:
The tab portion of the integral piece is pre-formed with a crushed or flattened cross-section during the casting or drawing process, so that subsequent manufacturing steps (welding, piercing, or insertion) can proceed easily without requiring additional complex forming operations
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 solution enhances electrical performance by maintaining lower heat levels and offers flexibility by enabling a single fuse design to accommodate various connection types, improving usability and efficiency in automotive applications.
Implementation Method 1
at least one of the electrically conductive legs made in one piece with a base consists of a tab formed from a crushed portion of the single-piece part
Data Source
Figure 1a~4c
AI summary
The invention relates to a fuse for a motor vehicle electrical circuit. The fuse comprises at least one single-piece connection end (5) provided with a tongue (9), said tongue (9) being formed by crushing a crimping portion, for example consisting of an, optionally hollow, cylinder. The invention also relates to a method for producing the fuse and to a method for mounting same.