Electrical Unit Fuse Assembly Integration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electrical units used in vehicles often require additional cables and wiring harnesses, and existing configurations can be cumbersome for external connections, necessitating a solution that minimizes these challenges.
Innovation Solution
An electrical unit design featuring a first and second housing member with a fuse assembly disposed between them, including a bus bar and high-current fuses, and a circuit board assembly with electrical terminals, configured to receive wiring harnesses and connectors, with a method of assembly that integrates the components to minimize external connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical units use separate pre-fuse assemblies with additional cables and wiring harnesses, then current protection functionality is achieved, but device complexity and external connection requirements increase
Solution Approach 1:
The patent combines the fuse assembly and electrical connectors into a single integrated housing unit. The fuse assembly is disposed within the housing and electrically connected to terminals that receive connectors, eliminating the need for separate pre-fuse assemblies and reducing external wiring complexity while maintaining current protection functionality.
2Adaptability or versatility
If electrical units are configured for external connections with wiring harnesses, then connectivity functionality is achieved, but ease of operation deteriorates due to cumbersome external connections
Solution Approach 1:
The electrical connectors are integrated within the housing, with connector receptacles disposed inside the housing and electrically connected to the fuse assembly. This internal integration allows connectivity functionality while eliminating cumbersome external wiring harness connections, improving ease of operation.
Solution Approach 2:
The housing unit serves multiple functions simultaneously: it provides current protection through the fuse assembly, electrical connectivity through integrated connector receptacles, and structural protection. This multi-functionality reduces the need for separate external components and simplifies installation.
3Device complexity
If fuse assembly is disposed between housing members, then compact integration is achieved, but manufacturing precision requirements increase
Solution Approach 1:
The housing is divided into first and second housing members that can be separately manufactured and then assembled. The fuse assembly is disposed between these housing members, allowing each component to be manufactured independently with standard tolerances and then joined together, reducing overall manufacturing precision requirements while achieving compact integration.
Data Source
AI summary
An electrical unit includes a first housing member, a second housing member, and a fuse assembly connected to the first housing member. The first housing member and the second housing member may provide a chamber to receive at least one electrical connector such that the fuse assembly is disposed at least partially between the first housing member and the at least one electrical connector. The first housing member may be configured to retain said at least one electrical connector. The fuse assembly may include a plurality of fuses having current capacities of at least 80 amps. The fuse assembly may include a bus bar and a plurality of fuses fixed to the bus bar. Each of said at least one electrical connector may include a plurality apertures or recesses disposed in a plurality of rows and a plurality of columns.