Electric Vehicle Fuse With Overhanging Contact Blade

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Solution Overview

Problem

Conventional fuses used in electric vehicles are inadequate due to limited mounting space, exposure to shocks, vibrations, high temperatures, and fluctuating current loads, which they cannot effectively handle.

Innovation Solution

A fuse design featuring a bushing with a through-hole cavity, a fuse body, and contact blades with overhanging sections that allow for direct sealing and flexible mounting, eliminating the need for an end cover and enabling easy insertion into various components, along with an arc extinguishing medium layer for improved breaking capacity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional fuses are used in electric vehicles, then short-circuit protection function is provided, but they cannot adapt to limited mounting space and harsh environmental conditions (shocks, vibrations, high temperature, high humidity)

Engineering Contradiction:

Improveprotection function under harsh conditionsVSAvoidadaptability to different mounting methods and environments

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The fuse is divided into modular components: a bushing with through-hole cavity, a fuse body, and contact blades with overhanging sections. This segmentation allows each component to be optimized independently for specific functions while adapting to different mounting configurations and environmental conditions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The contact blade is designed with multiple functional sections: a first section for sealing contact with the bushing end surface, an overhanging arm section for structural support, and a second section extending perpendicular to the longitudinal direction for insertion into various mounting interfaces. This multi-functional design enables the fuse to adapt to different mounting methods while maintaining reliable protection function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If conventional fuses are used, then protection function is achieved, but mounting space requirements are not met due to need for end covers and complex structure

Engineering Contradiction:

Improveprotection functionVSAvoidmounting space

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The contact blade integrates multiple functions that were previously separate components: the sealing function (first section covering the through-hole cavity), the structural support function (overhanging arm section), and the mounting interface function (second section for insertion). This merging eliminates the need for separate end covers and reduces overall mounting space.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The contact blade extends in multiple dimensions: the first section covers the end surface in the longitudinal direction, the overhanging arm section provides structural support, and the second section extends perpendicular to the longitudinal direction for insertion into mounting interfaces. This multi-dimensional configuration optimizes space utilization by arranging functional sections in different spatial orientations rather than requiring additional components in the same space.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Reliability

If conventional fuses are used, then basic protection is provided, but they cannot handle fluctuating current loads and high temperature environments effectively

Engineering Contradiction:

Improveprotection under fluctuating loadsVSAvoidhigh temperature and humidity environment

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The bushing is designed with a through-hole cavity that provides localized cooling channels for the fuse body, and the contact blades are positioned to optimize heat dissipation paths. This local quality enhancement allows the fuse to handle high temperature environments and fluctuating current loads more effectively by managing thermal conditions at critical locations.

Inventive Principle:

Principle #3Local quality

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 design provides reliable short-circuit and overload protection in electric vehicles by adapting to different mounting methods and environmental conditions, ensuring effective operation under high stress.

Implementation Method 1

an arc extinguishing medium layer for improved breaking capacity

Methodology Applied

Scientific EffectArc extinguishing: Electric Arc

Data Source

PatentUS11183353B2Fuses, vehicle circuit for electric vehicle and electric vehicle

Publication Date: 2021.11.23 COOPER XIAN FUSE

AI summary

The present utility model relates to a fuse, a vehicle circuit for an electric vehicle, and an electric vehicle. The fuse has a longitudinal direction and a transverse direction, and includes: a bushing, having a through-hole cavity extending in the longitudinal direction and for accommodating quartz sand and two end surfaces in the longitudinal direction; a fuse body, accommodated in the through-hole cavity; and two contact blades, positioned at two ends of the through-hole cavity and conductively joined to the fuse body. At least one of the contact blades comprises a first section coming into direct sealing contact with one of the end surfaces of the bushing by covering the through-hole cavity, and an overhanging arm section extending from the first section. The overhanging arm section includes a second section extending, in a direction perpendicular to the longitudinal direction, out of the bushing.