Fuse Unit with Dual Bolt and Connector Interfaces

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Solution Overview

Problem

Conventional fuse units require multiple types to accommodate both bolting and connector connections, leading to increased costs due to the need for different busbar and insulating resin designs and molds.

Innovation Solution

A fuse unit with both bolt and connector connection portions integrated into a single busbar, where the bolt connection is facilitated by a stud bolt with an insulating resin fixation, and the connector connection is a tab terminal surrounded by resin, allowing for both connection types without requiring multiple fuse unit designs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a conventional fuse unit is designed for only one connection type (bolting or connector), then the design is simple and cost-effective, but it cannot accommodate both connection types and requires multiple product variants

Engineering Contradiction:

Improveconnection type compatibilityVSAvoidbusbar and insulating resin design complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The busbar is designed with dual functionality: it includes both a bolt connection portion (with through-hole) and a connector connection portion (with tab terminal). This allows a single fuse unit design to accommodate both bolting and connector connections, eliminating the need for multiple product variants and reducing overall system complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The busbar is segmented into distinct functional regions: a bolt connection portion for traditional bolting applications, a connector connection portion for plug-and-play connections, and a fusible portion. This segmentation allows each region to be optimized for its specific connection type while maintaining a unified overall structure

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If multiple types of fuse units are prepared to meet different connection needs, then both bolting and connector connections can be supported, but the total cost increases due to multiple molds and designs

Engineering Contradiction:

Improveconnection type compatibilityVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

A single busbar design incorporates both bolt and connector connection capabilities, allowing one mold and one design to produce fuse units that serve multiple connection purposes. This eliminates the need for separate molds and designs for different connection types, directly reducing manufacturing costs

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The bolt connection portion and connector connection portion are merged into a single integrated busbar structure. This consolidation allows both connection types to be produced using the same manufacturing process and mold, eliminating the need for multiple product lines and reducing overall manufacturing complexity and cost

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS8821190B2Fuse unit

Publication Date: 2014.09.02 YAZAKI CORP

AI summary

A fuse unit includes a first connection part to which power is fed and a second connection part to be connected with a mating terminal. The second connection part includes a bolt connection portion to which the mating terminal is connected by a bolt and a connecter connection portion to which the mating terminal is connected by a connector.