Integrated Fuse Disconnect Switch with Insulator
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing circuit protection systems face challenges with high current fuses requiring additional holders, wires, and connections, leading to increased size, cost, and complexity, and are prone to short circuits due to direct electrical contact between the ring terminal and post, which complicates installation and reliability.
Innovation Solution
A mechanical disconnect switch integrated with a fuse assembly featuring a post arrangement and a glass mat washer insulator to prevent short circuits and allow secure torque application, eliminating unnecessary components and ensuring correct electrical paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high current fuses are positioned close to relays and battery disconnect switches, then circuit protection is improved, but size, cost and complexity increase due to additional holders, wires and connections
Solution Approach 1:
The patent combines the fuse and disconnect switch into a single integrated assembly, eliminating the need for separate holders, wires and connections. The fuse is positioned directly within the disconnect switch housing, creating a unified component that provides both circuit protection and disconnect functionality without requiring additional mounting hardware or wiring.
Solution Approach 2:
The integrated assembly performs multiple functions simultaneously: the fuse provides overcurrent protection while the disconnect switch provides circuit isolation capability. This multi-functional design consolidates what would traditionally require separate components into a single unit, reducing overall system complexity.
2Ease of operation
If direct electrical contact is made between ring terminal and post, then electrical connection is simplified, but short circuits occur compromising reliability
Solution Approach 1:
The patent introduces an insulator as an intermediary component between the ring terminal and the post. This insulator provides the necessary electrical isolation to prevent short circuits while still allowing mechanical mounting and secure connection. The insulator mediates between the need for electrical connection and the need for short circuit prevention.
3Ease of manufacture
If fuse is integrated directly into disconnect switch, then installation is simplified and cost is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The patent incorporates the insulator and fuse positioning features into the disconnect switch housing during the molding process. By pre-forming the insulator integration and post positioning features in the initial manufacturing step, the design eliminates the need for separate assembly operations, thereby reducing overall manufacturing complexity despite the integrated nature of the components.
Data Source
Figure 1A~1B
Figure 2A
Figure 2B
AI summary
A circuit protection assembly (CPA) is disposed between a source of power and a circuit to be protected. The CPA comprises a mounting block having a bore extending therethrough and a recess cavity on a first surface of the mounting block. A post having a first end is disposed within the recess cavity and a body portion extends through the bore. The body portion configured to receive a terminal and the second end configured to receive a securing mechanism. A fuse having a centrally disposed aperture is configured to receive the body portion of the post and to receive the terminal for connection to a circuit to be protected. An insulator disposed on the terminal and disposed beneath the securing mechanism. The insulator configured to isolate the post from the terminal and the fuse while allowing the securing mechanism to apply an amount of torque.