Double-Molded Fuse Joint for Wire Harness Safety
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Solution Overview
Problem
Existing wire harnesses with in-line fuses have a high number of connection points, which increases the likelihood of electrical and mechanical failures, and expose weak areas that can lead to massive harness failure before the fuse activates.
Innovation Solution
A double-molded fuse joint is integrated into the wire harness, where an in-line fuse is undermolded and overmolded, reducing the number of connection points by integrating the fuse with the middle portion of a wire segment, thereby enhancing safety and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If in-line fuses are integrated into wire harnesses, then safety is improved, but the number of connection points increases
Solution Approach 1:
The patent combines the fuse and connector into a single integrated component called a fuse joint. This merging eliminates the need for separate connection points for the fuse and connector, reducing the total number of connection points from four to three or two, while maintaining the safety benefits of in-line fusing.
Solution Approach 2:
The fuse joint performs multiple functions simultaneously: it provides fuse protection, creates electrical connections, and serves as a structural joint. This multi-functionality consolidates what would traditionally require separate components, thereby reducing the number of connection points while improving reliability.
2Reliability
If in-line fuses are integrated into wire harnesses, then safety is improved, but weak exposed wire areas are created
Solution Approach 1:
By merging the fuse with the connector housing to create an integrated fuse joint, the patent eliminates the exposed wire section that exists between separate in-line fuses and connectors. The wire is directly connected to the fuse joint without exposed sections, removing the vulnerability to short circuits while maintaining safety protection.
Solution Approach 2:
The fuse joint acts as an intermediary component that directly connects the wire to the fuse without requiring exposed wire sections. This intermediary structure eliminates the weak area between the fuse and connector, providing both mechanical support and electrical connection while preventing short circuits.
3Reliability
If the number of connection points is reduced, then reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent employs a double-molding process that changes the manufacturing parameters by integrating multiple components in a single manufacturing operation. The first molding creates the fuse housing and electrical contacts, while the second molding adds the connector housing and structural elements, resulting in an integrated fuse joint that reduces assembly steps despite the complex molding process.
Solution Approach 2:
The double-molding process performs preliminary actions by pre-integrating the fuse and connector into a single assembled unit during manufacturing. This preliminary integration eliminates the need for separate assembly operations, reducing the number of connection points and potential failure points while the manufacturing complexity is managed through optimized molding sequences.
Data Source
AI summary
A novel fuse joint may be incorporated into a wire harness for use in solar energy installations. The novel fuse joint interfaces an in-line fuse with the middle portion of a wire segment at one end of the fuse, and with a wire end at the other end of the fuse. In this manner the number of connection points required to achieve in-line fuse functionality is decreased, thereby improving safety and conductivity over conventional in-line fuses. The fuse is undermolded, and the undermold is overmolded in situ, thereby yielding a double molded fuse joint. The novel fuse joint may be incorporated into a wire harness with conventional in-line fuses.