Fuse Assembly Simplification via Holding Plate Integration
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Solution Overview
Problem
The existing fuse manufacturing methods for automobile electric circuits are complicated due to the need for intricate assembly processes, including sandwiching the fuse element between two fusible body holders, which increases the number of components and complexity.
Innovation Solution
A fuse manufacturing method that positions the fuse element in a casing with terminal portions protruding, using a holding plate inserted between the casing's peripheral portion and an abutment piece, allowing the cap to cover the holding plate, simplifying assembly and eliminating the need for separate abutment pieces, and forming the terminal portion by folding a single metal plate to reduce resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fuse element is sandwiched between two fusible body holders from above and below, then the fuse element is securely held in the cover body, but the assembling work becomes complicated
Solution Approach 1:
The patent combines the holding function and the abutment function into a single integrated structure. The holding plate is formed as one piece that simultaneously holds the fuse element and abuts against the cover body, eliminating the need for separate fusible body holders above and below. This merging reduces the number of components and simplifies the assembly process while maintaining secure holding of the fuse element.
Solution Approach 2:
The patent extracts the abutment function from the fusible body holders and assigns it to a dedicated abutment piece. This separation allows the holding plate to focus on holding the fuse element while the abutment piece provides the necessary abutment against the cover body, simplifying the overall structure and assembly process.
2Device complexity
If the terminal portion is formed with conventional thickness, then the structure is simple, but the resistance value is high
Solution Approach 1:
The patent reduces the resistance value by changing the cross-sectional area of the terminal portion. By forming the terminal portion with a larger cross-sectional area through folding and superimposition, the electrical resistance is reduced without increasing the overall thickness dimension. This dimensional change in the cross-section allows lower resistance while maintaining structural simplicity.
Solution Approach 2:
The terminal portion is formed by folding and superimposing the fuse element onto itself, creating a composite structure where multiple layers of the same material are stacked. This composite construction increases the effective cross-sectional area for current flow, thereby reducing resistance while keeping the external dimensions compact.
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 method simplifies the assembly process, reduces the number of components, and minimizes contact resistance by integrating the terminal portion's formation within the single metal plate, enhancing workability and reducing resistance values compared to prior art.
Implementation Method 1
when unintended overcurrent flows in the electric circuit, a fusing portion of a fuse element embedded in the fuse fuses due to heat generated by overcurrent
Data Source
AI summary
The present invention provides a fuse manufacturing method and a fuse that facilitate an assembling work of the fuse. Disclosed is a method of manufacturing a fuse including a fuse element including a pair of terminal portions and a fusing portion between the terminal portions, a casing for accommodating the fuse element, and a cap for closing openings at both ends of the casing. In this fuse manufacturing method, the fuse element is positioned in the casing such that the terminal portion of the fuse element protrudes from the opening of the casing, and a holding plate for holding the fuse element is inserted between a peripheral portion of the opening of the casing and an abutment piece provided at the terminal portion of the fuse element. Further, in this method, the opening of the casing is closed by the cap so as to cover the holding plate.