Dual-Sided Fuse Block Bus Bar Design
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Solution Overview
Problem
Conventional fuse boxes in motor vehicles occupy a lot of space due to the limited capacity for accommodating increasing numbers of electrical components and wires, necessitating a more compact design to enhance the ratio of fuses to volume.
Innovation Solution
The implementation of a dual series of fuses mounted on opposite sides of a power bar bus, with double studs providing both mechanical fixation and electrical conduction, allowing for twice as many fuses to be integrated within the same volume by crossing the bus bar and ensuring contact between the fuses and the bus bar.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a conventional fuse box with single-sided fuse mounting is used, then the structure is simple and easy to manufacture, but the space utilization is poor and the number of fuses per volume is limited
Solution Approach 1:
The patent transitions from single-sided fuse mounting to dual-sided mounting by utilizing both sides of the bus bar. The conduction means extends through the bus bar to provide electrical contact on both the first side and the second side, effectively doubling the space utilization for fuse accommodation within the same volume.
Solution Approach 2:
The conduction means serves multiple functions: it provides electrical conduction from the bus bar to fuses on the first side, extends through the bus bar to provide conduction to fuses on the second side, and structurally supports the dual-sided mounting configuration. This multi-functionality enables increased fuse capacity without proportionally increasing box volume.
2Quantity of substance
If dual series of fuses are mounted on opposite sides of the bus bar with conduction means crossing through it, then the number of fuses per volume is doubled, but the structural complexity increases
Solution Approach 1:
The patent merges the conduction function with the mounting function by integrating the conduction means into the dual-sided mounting structure. The same conduction means that provides electrical contact also serves as the structural element for mounting fuses on both sides, reducing the need for separate components and simplifying the overall structure despite the increased functionality.
3Quantity of substance
If more fuses are accommodated in the same volume, then the ratio of fuses to volume increases, but the available space for electrical harnesses and components is reduced
Solution Approach 1:
By utilizing the third dimension (both sides of the bus bar) for fuse mounting, the patent increases fuse capacity without expanding the horizontal footprint of the fuse box. This vertical/dual-sided arrangement preserves more horizontal space for electrical harnesses and other components to route through the fuse box interior.
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
This configuration effectively doubles the number of fuses that can be accommodated in the same volume, enhancing the space efficiency of the fuse box while maintaining reliable electrical connections and overcurrent protection.
Implementation Method 1
conduction means are provided intended to ensure the electrical conduction on the one hand between the input leg of each fuse of the first series of fuses and the bus bar and on the other hand between the input leg of each fuse of the second series and the bus bar
Data Source
AI summary
The box (1) has a current supply bus bar (2) supplying current to electric cables or electric wires. Conduction units provide electric conduction between inlet end leg (5) of series of upper fuses (4) and the bar, and inlet end leg (5') of series of lower fuses (4') and the bar. The conduction units are passed through the bar for being extended on both sides of the bar. The conduction units have a series of double studs (20), where each stud is constituted of a central body (21).