Fuse Assembly Clip Retaining Fastener
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Solution Overview
Problem
Traditional large amperage electrical fuses require handling of loose nuts and washers during installation, leading to risks of foreign object damage and potential heating issues due to voltage drop, particularly in aerospace applications.
Innovation Solution
A fuse assembly with a bus bar fuse and a clip that surrounds a portion of the fuse leg, featuring a fastener passing through angled through-holes and a slotted opening, allowing for secure retention and controlled assembly of fasteners, reducing the risk of lost hardware and assembly errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fuse installation methods are used with loose nuts and washers, then the fuse can be assembled, but there is a risk of losing hardware and foreign object damage
Solution Approach 1:
The patent combines the fuse body, clip, and fastener into an integrated assembly where the fastener is permanently retained within the clip structure. The clip acts as a carrier that holds the fastener in place, merging multiple components into a single assembly unit that cannot be disassembled into loose hardware pieces.
Solution Approach 2:
The clip serves as an intermediary component between the fuse body and the fastener. It provides a structured interface that captures and retains the fastener, preventing it from becoming a loose object while still allowing the fastener to perform its function of securing the fuse to the mounting base.
2Reliability
If loose washers are used during installation, then the fuse can be secured, but washers may slip under the fuse bus bar ends causing higher heating due to voltage drop
Solution Approach 1:
The patent eliminates separate washers by integrating their function into the clip structure. The clip provides a built-in bearing surface against the mounting base, combining the washer's load distribution function with the fastener retention function in a single component.
Solution Approach 2:
The patent removes the washer component entirely from the assembly, extracting its function and incorporating it directly into the clip design. This eliminates the risk of washers becoming loose or misplaced while maintaining the necessary electrical and mechanical connection properties.
3Reliability
If multiple loose hardware components are handled during installation, then the fuse can be assembled, but foreign object damage threats increase particularly in aerospace applications
Solution Approach 1:
The patent segments the assembly into two distinct parts: a pre-assembled fuse-clip-fastener unit and the mounting base. This segmentation allows the hardware components to be manufactured and pre-assembled in a controlled environment, then installed as a single unit, eliminating the risk of loose hardware during field installation.
Solution Approach 2:
The fastener is preliminarily captured and retained within the clip structure during manufacturing, before the actual installation takes place. This preliminary action ensures that no loose hardware needs to be handled during the installation process, as everything is already in its final position.
Data Source
Figure 1~3
AI summary
A fuse assembly includes a bus bar fuse 106 and a clip 110. The bus bar fuse has a leg 108 with a slotted opening 112. The clip 110 surrounds a portion of the leg 108. The clip 110 includes a first side 114 having a threaded through-hole 116 and a second side 118 extending from the first side 114 at an angle with respect to the first side 114. A third side 120 extends from the second side 118 at an angle with respect to the second side 118. The third side 120 includes a through-hole 122. The threaded through-hole of the clip 110 provides for captivation of the fastener 124 within the clip 110 when mounting the fuse assembly to the fuse mounting block assembly.