Fuse Housing Interlock for Weld-Free Lid Assembly
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Solution Overview
Problem
The existing fuse manufacturing process is complex due to thermal welding of lid and case members, which increases the number of manufacturing steps and complicates assembly while maintaining breaking performance.
Innovation Solution
A fuse design featuring a case member with projections and a lid member with recesses that securely engage, allowing for easy assembly and maintaining positional alignment, thereby preventing the lid from detaching even under increased air pressure, without the need for welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal welding is used to join the lid member and case member, then the sealing performance and breaking performance are improved, but the manufacturing complexity and number of steps increase
Solution Approach 1:
The patent replaces the thermal welding process with a mechanical engagement system consisting of projections on the case member and corresponding recesses on the lid member. This mechanical interlocking mechanism achieves both secure joining and sealing without requiring thermal welding equipment or processes, thereby reducing manufacturing complexity while maintaining breaking performance.
Solution Approach 2:
The joining mechanism is segmented into discrete engagement elements: multiple projections extending from the case member walls and corresponding recesses in the lid member. This segmentation allows for simplified manufacturing of individual components that can be assembled through straightforward mechanical engagement, eliminating the need for complex thermal welding procedures.
2Reliability
If thermal welding is used to join the lid member and case member, then the sealing performance is improved, but the ease of assembly deteriorates
Solution Approach 1:
The patent substitutes thermal welding with a mechanical projection-and-recess engagement system that enables easy assembly. The projections on the case member fit into corresponding recesses on the lid member, creating a self-aligning, tool-free assembly process that maintains sealing performance without requiring welding operations.
Solution Approach 2:
The engagement structure is designed to be self-aligning and self-securing. The projections and recesses automatically guide the lid member into proper position on the case member during assembly, and the mechanical interlocking provides inherent sealing without requiring additional welding steps or specialized assembly equipment.
3Ease of operation
If the lid member is made detachable to facilitate assembly, then the ease of assembly is improved, but the reliability deteriorates due to potential detachment under air pressure
Solution Approach 1:
The patent incorporates preliminary positioning features in the form of projections and recesses that guide the lid member into correct alignment with the case member before final engagement. This preliminary action ensures proper positioning during assembly while the subsequent mechanical interlocking of projections and recesses provides secure attachment that resists detachment under air pressure.
Solution Approach 2:
The engagement mechanism combines multiple functional elements: mechanical interlocking through projections and recesses, and sealing through contact surfaces. This composite approach provides both easy assembly (through simple mechanical engagement) and high reliability (through secure interlocking that prevents detachment under pressure).
Data Source
AI summary
A fuse includes a case member that has a rectangular parallelepiped shape and has a space, a lid member that closes an upper opening of the case member and closely adheres to the case member, a fuse-element disposed in the space, and a pair of terminals, whose distal ends are exposed to outside, connected to both ends of the fuse-element. The case member includes a plurality of first engaging projections formed on a first side wall, and a plurality of second engaging projections formed on a second side wall. The lid member includes a plurality of first engagement recesses formed in a first contact wall and fitted respectively to the plurality of first engaging projections, and a plurality of second engagement recesses formed in a second contact wall and fitted respectively to the plurality of second engaging projections.