Integrally Formed Fuse Box Busbar Terminals
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Solution Overview
Problem
Existing fuse box busbars require more material than necessary, leading to increased space and weight, and lack flexibility in design and connection options.
Innovation Solution
A fuse box busbar with integrally formed terminals that can be connected directly to fuse contacts, allowing for flexible configurations through ultrasonic welding, clinching, or welding, and enabling the use of busbars of varying lengths and shapes with the same tooling, along with a housing that defines busbar cavities for secure assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional busbar designs with separate terminals are used, then connection reliability is improved, but material usage increases leading to more weight and space occupation
Solution Approach 1:
The patent combines separate terminals and busbar into a single integrated component. The integrally formed terminals are directly formed on the busbar body, eliminating the need for separate terminal pieces and their associated fastening hardware. This merging reduces material usage and weight while maintaining reliable electrical connections through the integral structure.
2Ease of manufacture
If fixed busbar designs are used, then manufacturing simplicity is improved, but design flexibility and adaptability are reduced
Solution Approach 1:
The patent enables dynamic adaptability in busbar design by allowing the integrally formed terminals to be configured in various patterns and positions within a single stamping operation. The flexible stamping die can produce different terminal arrangements (number, position, orientation) without requiring different tooling sets, enabling the same manufacturing process to adapt to different design requirements.
Solution Approach 2:
The integrated busbar with integrally formed terminals serves multiple functions: it provides electrical conduction, structural support, and customizable connection points. The single component design can accommodate various terminal configurations to suit different fuse box layouts and electrical requirements, making it a universal solution for multiple applications.
3Productivity
If standard-length busbars are used, then inventory management is improved, but space efficiency and weight are worsened due to unused portions
Solution Approach 1:
The patent enables dynamic length adjustment of busbars through flexible stamping die design. The same tooling can produce busbars of varying lengths by adjusting the stamping position and sequence, allowing precise cutting-to-length without excessive inventory of standard sizes. This reduces wasted material from unused portions while maintaining efficient inventory management through standardized manufacturing processes.
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 solution reduces material usage, saving space and weight while allowing for customizable designs and flexible connections, enabling efficient assembly and reduced material costs.
Implementation Method 1
the busbar has a coined area, and the cable is ultrasonically welded to the busbar at the coined area
Implementation Method 2
the second busbar is mechanically connected to the first busbar, for example, by clinching or welding
Data Source
AI summary
A fuse box has a housing in which a plurality of fuses are received. The housing defines a busbar cavity. A busbar has a plurality of integrally formed terminals, and is received in the busbar cavity of the housing. The housing and the busbar are arranged such that the plurality of integrally formed terminals on the busbar are positioned to directly receive corresponding contacts of the plurality of fuses.