Surface Mount Fuse Molded Terminal Integration
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Solution Overview
Problem
The market for surface mount fuses is highly competitive, requiring manufacturers to minimize production costs while maintaining effective circuit protection.
Innovation Solution
A low-cost surface mount fuse design featuring a molded fuse body with recessed shoulders and a cover that secures terminals, along with a fusible element connected to these terminals, which melts to interrupt current flow upon fault conditions, and a manufacturing method involving injection molding and bonding techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional surface mount fuse designs are used, then circuit protection function is achieved, but production cost is high
Solution Approach 1:
The terminal and the fuse body are merged into a single molded component, eliminating separate assembly steps and reducing production cost while maintaining the structural integrity needed for reliable circuit protection
Solution Approach 2:
The molded terminal-fuse body combination serves multiple functions: it provides electrical connection, mechanical support, and structural housing in a single component, reducing overall device complexity and manufacturing cost
2Reliability
If terminals are bent around the fuse body to secure the cover, then secure connection is achieved, but manufacturing complexity increases
Solution Approach 1:
The terminal is pre-formed with bends during the molding process itself, rather than requiring post-assembly bending operations. This preliminary action secures the cover while simplifying the overall manufacturing process by combining multiple steps into one
3Reliability
If a recessed shoulder is added to the fuse body, then the cover is securely positioned, but molding complexity increases
Solution Approach 1:
The fuse body is segmented into distinct functional zones: the main body, the recessed shoulder for cover positioning, and the terminal integration area. This segmentation allows each zone to be optimized independently while being formed in a single molding process
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 and manufacturing method enable cost-effective production of surface mount fuses that provide reliable circuit protection by ensuring secure connections and efficient current interruption.
Implementation Method 1
the fusible element melts or otherwise separates to interrupt the flow of electrical current
Data Source
AI summary
A surface mount fuse including a fuse body having a base including a floor and a plurality of adjoining sidewalls defining an interior cavity, wherein top edges of the sidewalls define a recessed shoulder bordering the interior cavity, and a cover including a main body disposed on the recessed shoulder and enclosing the interior cavity, first and second terminals extending through opposing sidewalls of the base, the first and second terminals extending around the opposing sidewalls and the cover and disposed in abutment therewith to secure the cover to the base, and a fusible element extending through the interior cavity and connected to the first and second terminals.