Fuse Module Wiring Lug Crimping Mechanism
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Solution Overview
Problem
Conventional wiring lugs for fuse modules face issues with heat transfer, electrical resistance, and high torque requirements, which can damage electrical leads, and they often use expensive conductive materials that result in waste and increased manufacturing costs due to the need for hydraulic presses.
Innovation Solution
A wiring lug design featuring a fuse clip with a pressure plate and a box lug that crimps an electrical conductor, using projections for enhanced holding strength and alignment, and formed from a single piece of conductive material to minimize waste and reduce manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screw terminals are used to connect electrical leads, then electrical connections can be established, but high torque is required which may damage the leads
Solution Approach 1:
The patent replaces the screw terminal mechanical system with a crimping system. The box lug with crimping teeth directly crimps the electrical lead without requiring screws, eliminating the high torque requirement while maintaining reliable electrical connection through the crimping action and multiple contact points.
Solution Approach 2:
The box lug incorporates multiple crimping teeth that segment the contact area along the electrical lead. This segmentation distributes the connection force across multiple points, reducing the torque needed at any single point while maintaining overall connection reliability.
2Strength
If conventional conductive materials with spring properties are used in wiring lugs, then fuse securing is achieved, but material cost increases and hydraulic presses are required for manufacturing
Solution Approach 1:
The patent uses standard copper or copper alloy that is easier and cheaper to manufacture than specialized spring-conductive materials. The design achieves sufficient strength through the crimping mechanism and structural features rather than relying on expensive proprietary materials with inherent spring properties.
Solution Approach 2:
The patent extracts the spring function from the conductive material itself and implements it through the mechanical crimping structure. The box lug and pressure plate provide the necessary holding force through their design and assembly rather than requiring the conductive material to have inherent spring properties.
3Reliability
If conventional wiring lugs are used, then electrical leads can be connected, but heat transfer issues and electrical resistance problems occur
Solution Approach 1:
The patent merges the electrical contact function with thermal management by designing the box lug and pressure plate to create extensive contact area with the electrical lead. The crimping teeth and pressure distribution merge electrical connection with heat dissipation, allowing heat to conduct away from the connection point through the large contact area.
Solution Approach 2:
The patent transitions from point-contact electrical connections to area-contact connections through the crimping teeth distributed along the lead. This dimensional change from 0D point contact to 2D area contact simultaneously improves electrical reliability and thermal management by distributing both current and heat across a larger area.
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 design provides secure electrical connections with reduced torque requirements, improved heat dissipation, and cost-effective production by minimizing material waste and eliminating the need for hydraulic presses.
Implementation Method 1
A box lug moves with respect to the pressure plate to crimp the conductor between an interior of the box lug and the pressure plate
Implementation Method 2
One or more projections formed in the pressure plate can increase a holding strength of the wiring lug on the conductor
Data Source
AI summary
A method of manufacturing a fuse module includes forming a fuse clip member from a single, substantially planar piece of electrically conductive material to include a pressure plate, and assembling the pressure plate with a box lug and a securing member, wherein operating the securing member causes the box lug to move relative to the pressure plate.