Direct-Connect Fuse Unit With Bent Terminal For Compact Battery Mounting
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Solution Overview
Problem
Conventional direct-connect fuse units for battery terminals face challenges in compact design due to their flat, plate-like conducting hardware, which increases footprint and limits the arrangement in limited spaces, and the integral casing restricts the structure of output terminal sections and attachment of electrical components.
Innovation Solution
The design incorporates a bent connecting terminal on the conducting hardware to project from the casing surface, allowing for an electrical component housing that can be separately fitted, enabling the mounting of various components without increasing the fuse unit's size, and utilizes a rectangular housing with elastic engaging projections for stable attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the conducting hardware is made flat plate-like for integral molding with casing, then manufacturing is simplified, but the footprint and size of the fuse unit increases
Solution Approach 1:
The connecting terminal is bent in the plate thickness direction (vertical dimension) to project from the surface of the casing, transforming a 2D flat layout into a 3D structure. This allows electrical components to be mounted in the vertical direction rather than spreading horizontally, thereby reducing the footprint while maintaining manufacturing simplicity through integral molding
2Adaptability or versatility
If multiple output side terminal sections and fusing sections are provided on the conducting hardware, then functionality is improved, but the fuse unit size increases
Solution Approach 1:
By bending the connecting terminal in the plate thickness direction to project vertically from the casing surface, the design enables multiple electrical components to be stacked or arranged in the vertical dimension. This allows enhanced functionality with multiple output terminal sections without increasing the horizontal footprint or overall volume of the fuse unit
3Ease of manufacture
If the casing is molded integrally with the conducting hardware, then manufacturing is simplified, but the output side terminal section structure is limited
Solution Approach 1:
The bent connecting terminal that projects vertically from the casing surface creates additional structural complexity and versatility in the output side terminal section. This 3D configuration allows for various electrical component mounting arrangements while maintaining the manufacturing advantage of integral molding of the casing and conducting hardware
Data Source
AI summary
An object of the present invention is to provide a direct-connect fuse unit for a battery terminal that can restrain from being upsized and can mount various kinds of electrical components. A conducting hardware is integrally provided with a connecting terminal. The connecting terminal is bent in a plate thickness direction of the conductive hardware to project from a surface of a casing. An electrical component housing contains and holds an external electrical component connected to the connecting terminal. The electrical component housing is separated from the casing and is adapted to be fitted in the casing.