Integrated Fuse Unit Busbar Connector for Vehicle Power Distribution
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Solution Overview
Problem
Existing fuse units for motor vehicles require complex connections and separate components for power distribution and disconnection, making them cumbersome for assembly and disassembly, especially during long immobilization or transport times.
Innovation Solution
A fuse unit with an electrically conductive busbar that serves both as a current distributor and a direct plug, allowing for easy connection and disconnection with laminated contacts and integrated fusible links, enabling quick disconnection of power-consuming components without additional connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate connector parts and busbars are used for power distribution, then reliable electrical connection is achieved, but device complexity and assembly difficulty increase
Solution Approach 1:
The patent combines the busbar and connector parts into a single integrated fuse unit. The fuse unit includes a housing with built-in connector parts that directly interface with the busbar, eliminating the need for separate connection components. This integration reduces device complexity while maintaining reliable electrical connection through the unified structure.
Solution Approach 2:
The fuse unit serves multiple functions within a single component: it provides power distribution through the busbar, electrical connection through integrated connector parts, and circuit protection through fusible elements. This multi-functionality reduces the number of separate components needed while ensuring reliable electrical connections.
2Reliability
If multiple separate connections are used for power-consuming components, then individual fuse protection is achieved, but assembly and disassembly time increase
Solution Approach 1:
The fuse unit is segmented into multiple independent connection points, each with its own fusible element, allowing individual protection for different power-consuming components. Each connection can be independently accessed and serviced, enabling quick assembly and disassembly of individual components while maintaining their respective fuse protections.
Solution Approach 2:
Multiple individually protected connections are merged into a single removable fuse unit assembly. This allows the entire unit with all its individually protected connections to be installed or removed as one piece, significantly reducing assembly and disassembly time compared to handling each connection separately.
3Reliability
If complex connection structures are used for power distribution, then reliable current supply is ensured, but ease of operation during immobilization decreases
Solution Approach 1:
The busbar connection and connector parts are merged into an integrated fuse unit that can be quickly connected or disconnected as a single assembly. This integration maintains reliable current supply through the robust busbar connection while dramatically improving ease of operation during vehicle immobilization or transport, as the entire unit can be quickly removed without complex disconnection procedures.
4Adaptability or versatility
If separate connector parts are used, then adaptability to different components is achieved, but manufacturing complexity increases
Solution Approach 1:
The connector parts are merged into the housing structure of the fuse unit, creating a unified component that is easier to manufacture as a single piece or pre-assembled unit. This integration maintains adaptability to different power-consuming components through standardized connection interfaces while reducing manufacturing complexity compared to producing and assembling multiple separate connector parts.
Data Source
AI summary
A fuse unit for use in e.g. motor vehicles, includes an electrically conductive busbar and a plurality of connections for individual power consuming components which are connected to the busbar directly or by way of interposed fusible links so as to be electrically conductive. The busbar has a contact blade adapted to plug into a mating connector of a power supply without the interposition of a further connection between them.