Encapsulated Fuse Box Assembly for Space-Saving Fuse Replacement
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Solution Overview
Problem
Existing fuse boxes require significant space for replacement, making them unsuitable for environments with limited space, as the entire unit must be replaced when a fuse blows, rather than allowing individual fuse replacement.
Innovation Solution
A fuse box design where the busbar and fuses are manufactured from a single sheet of conductive material, with the blown fuse remaining encapsulated within a plastic overmoulded layer, allowing for individual fuse replacement without replacing the entire busbar, and enabling a modular assembly for optimized dimensions and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the busbar and fuses are manufactured as a single integrated unit, then manufacturing cost is reduced and structural integrity is improved, but the entire fuse box must be replaced when a fuse blows, increasing maintenance cost and downtime
Solution Approach 1:
The fuse box is segmented into modular units, each containing a busbar and fuse assembly. The housing is divided into multiple compartments that can independently accommodate individual fuse units. This segmentation allows a blown fuse to be replaced without affecting other fuses or the busbar structure, resolving the contradiction by enabling easy maintenance while preserving manufacturing efficiency.
2Reliability
If the entire fuse box is replaced when a fuse blows, then reliability is ensured, but space requirements increase and maintenance time is lost
Solution Approach 1:
The fuse box is designed with pre-configured mounting positions and connection points for individual fuse units. Each fuse has dedicated terminals and mounting structures already in place, allowing for quick replacement without requiring reconfiguration or complex assembly steps. This preliminary preparation enables rapid maintenance while ensuring reliable connections, reducing both maintenance time and preserving system reliability.
3Ease of operation
If standard fuses are used with adequate spacing for replacement, then ease of maintenance is improved, but the fuse box dimensions increase, making it unsuitable for space-limited environments
Solution Approach 1:
The fuse units are designed to nest within the housing structure, with each fuse positioned in a dedicated compartment that utilizes the available space efficiently. The busbar and fuse assemblies are compactly arranged, and the housing walls are optimized to provide minimal necessary clearance for maintenance operations. This nesting approach allows standard fuses to be used with adequate spacing while minimizing overall dimensions, enabling the fuse box to fit in space-limited environments while maintaining ease of maintenance.
Data Source
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AI summary
The invention concerns a fuse box, comprising a busbar (6) and at least one fuse (8) connected to the busbar, each fuse including two opposite end portions (8A, 8B) and a central portion (82), at least the central portion of each fuse and a section of the busbar being encapsulated in a plastic coating layer. The central portion (82) includes a part (84) of reduced cross-section. The two end portions (8A, 8B) include two respective electrical connectors (81 A, 81 B), and at least the two electrical connectors (81 A, 81 B) of each fuse (8) are not encapsulated in the plastic coating layer, so that a new fuse (12) can be connected between the two electrical connectors (81A, 81B) in replacement of a blown fuse (8).