Inline Fuse with Integrated Connector Housing
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Solution Overview
Problem
Existing fuses are difficult to install and handle, and their components are not adequately protected, leading to frequent failures due to electrical connection issues and costly replacements, especially in outdoor applications like solar technology where weather and mechanical loads pose challenges.
Innovation Solution
A safety device that integrates a fuse and plug connectors into a common housing with a protective body, using thermoplastic potting material to create a stable and reliable connection, and a heat-shrinkable sealing sleeve for insulation, allowing for easy replacement and enhanced protection against environmental influences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fuse and connector are installed separately, then the installation flexibility is higher, but the handling difficulty increases and components are not adequately protected
Solution Approach 1:
The fuse and connector are integrated into a single common housing, creating a unified assembly that is installed and handled as one unit. This merging eliminates the need for separate installation of multiple components, reducing handling complexity while simultaneously providing comprehensive protection for all internal components through the common housing structure.
2Reliability
If the fuse is placed in a common housing with connectors, then component protection improves, but the device complexity increases
Solution Approach 1:
Multiple components (fuse and connectors) are combined into a single housing structure, which simplifies the overall system architecture by reducing the number of separate parts and assembly steps, despite the increased integration within the housing.
Solution Approach 2:
The common housing serves multiple functions simultaneously: it provides mechanical protection for the fuse and connectors, establishes electrical connections, and enables unified installation. This multi-functionality reduces the need for additional protective structures or mounting mechanisms.
3Reliability
If separate components are used, then the device complexity is lower, but the components fail frequently due to lack of protection
Solution Approach 1:
The common housing provides pre-established mechanical and environmental protection for the fuse and connectors before they are subjected to external stresses. This protective structure is built-in from the outset, preventing damage from weather, mechanical loads, and installation stresses that would otherwise cause frequent failures.
4Ease of repair
If the fuse and connector are integrated, then replacement becomes simpler, but the manufacturing complexity increases
Solution Approach 1:
The fuse and connector are manufactured as a single integrated unit, which simplifies the replacement process by allowing the entire assembly to be replaced as one component. While manufacturing may require additional steps for integration, the modular design enables efficient production through standardized assembly 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 improves the reliability and manageability of components by providing a robust, protected inline fuse connection, ensuring reliable operation in outdoor conditions and simplifying replacement processes, particularly in solar technology applications.
Implementation Method 1
heat-shrinkable sealing sleeve
Implementation Method 2
thermoplastic potting material to create a stable and reliable connection
Data Source
Figure 1~5
Figure 6~8
Figure 9~14
AI summary
Safety device (100) comprising a fuse (2) with a fuse body (8) having two contact ends (4, 6), wherein each contact end (4, 6) is electrically connected to a plug contact (50), and wherein at least one plug contact (50) is electrically connected to a connector (80, 86), and wherein the fuse (2) is completely and the respective connector (80, 86) is at least partially enclosed in a common protective body (112).