Fuse End Cap Crimpable Terminal Friction Fit
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Solution Overview
Problem
Existing fuse connection methods, such as soldering and welding, generate excessive heat and are prone to inconsistent conductivity and disconnection, requiring additional components like fuse-holders and occupying valuable circuit space, necessitating a more robust and secure electrical connection mechanism between fuses and conductors.
Innovation Solution
A fuse end cap with a crimpable terminal that securely grips conductors within a cavity, eliminating the need for additional components and avoiding heat-related damage, using a mounting cuff for a friction fit with the fuse body and crimpable terminals to establish a reliable connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering or welding is used to connect wires to fuse ends, then electrical connection is established, but excessive heat is generated that can damage the fuse element
Solution Approach 1:
The patent replaces thermal joining methods (soldering/welding) with a mechanical crimping system. The end cap includes a crimpable terminal that mechanically grips the conductor through deformation, eliminating the need for heat-based joining and preventing thermal damage to the fuse element while maintaining reliable electrical connection.
Solution Approach 2:
The patent combines the fuse holder and electrical connection terminal into a single integrated end cap component. This merging eliminates the need for separate fuse-holders and connection terminals, reducing component count and circuit complexity while providing both mechanical support and electrical connection functions in one element.
2Reliability
If soldering is used to attach wires to fuse ends, then electrical connection is achieved, but manufacturing consistency is poor leading to compromised conductivity and disconnection susceptibility
Solution Approach 1:
The patent replaces the skill-dependent soldering process with a standardized mechanical crimping operation. The crimpable terminal provides consistent gripping force through controlled deformation, eliminating variability associated with manual or automated soldering processes and ensuring uniform electrical conductivity across all connections.
Solution Approach 2:
The patent changes the connection mechanism from thermal parameters (temperature, heating time) to mechanical parameters (crimping force, deformation amount). This parameter transformation enables more precise and consistent control over the connection process, improving manufacturing repeatability and electrical conductivity consistency.
3Reliability
If separate fuse-holders and fuseblocks are used, then fuse connection is secured, but valuable circuit real estate is occupied and circuit complexity increases
Solution Approach 1:
The patent merges the fuse holder and electrical terminal into a single integrated end cap that performs both functions. This consolidation eliminates separate fuse-holders and fuseblocks, reducing the number of components in the circuit while maintaining secure mechanical support and reliable electrical connection for the fuse.
Solution Approach 2:
The end cap is designed as a multi-functional component that simultaneously provides mechanical support for the fuse, electrical connection for the conductor, and structural integration into the circuit board. This universality eliminates the need for multiple specialized components, reducing overall device complexity and space requirements.
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 provides a robust, secure, and efficient electrical connection between fuses and conductors, reducing the risk of damage and complexity, while eliminating the need for separate components like fuse-holders, enhancing wire retention, and simplifying the attachment process.
Implementation Method 1
The mounting cuff may be configured to be mounted to the fuse body by friction fit, for example.
Implementation Method 2
The terminal may be configured to be crimped about the conductor to grip and retain the conductor within the second cavity.
Data Source
AI summary
A fuse end cap for providing an electrical connection between a fuse and an electrical conductor. The fuse end cap may include a mounting cuff defining a first cavity that is adapted to receive a fuse body. The mounting cuff may be configured to be mounted to the fuse body by friction fit, for example. The fuse end cap may further include a terminal defining a second cavity adapted to receive a conductor. The terminal may be configured to be crimped about the conductor to retain the conductor within the second cavity.