Fuse Unit With Oblong Insertion Hole For Battery Assembly
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Solution Overview
Problem
Conventional fuse units with circular insertion holes and L-shaped resin bodies cannot be assembled to batteries with varying battery post positions, leading to assembly issues due to mismatched dimensions.
Innovation Solution
The fuse unit features an oblong-shaped insertion hole and a tapered abutment portion, allowing the stud bolt to be inserted while ensuring the resin body abuts the battery side surface, accommodating different battery post positions through a sliding tapered surface for proper alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a circular insertion hole is used in the fuse element, then the fuse unit can be manufactured with simple geometry, but it cannot be assembled to batteries with varying battery post positions
Solution Approach 1:
The insertion hole is changed from a circular symmetric shape to an oblong asymmetric shape with a long axis aligned in the abutting direction. This asymmetric geometry allows the stud bolt to be inserted at various angular orientations while maintaining proper alignment between the abutment portion and battery side surface, thereby enabling compatibility with different battery post positions without increasing manufacturing complexity
2Adaptability or versatility
If the resin body is formed in an L-like shape, then the structure is simple and easy to manufacture, but the abutment portion cannot reliably abut on the battery side surface when battery post positions vary
Solution Approach 1:
The abutment portion is designed with a tapered surface that allows dynamic adjustment during assembly. As the fuse unit is pressed onto the battery, the tapered surface enables the abutment portion to slide and self-align with the battery side surface, automatically compensating for variations in battery post positions and ensuring reliable abutment without complicating the L-like overall structure
3Manufacturing precision
If the insertion hole is circular, then manufacturing precision is easier to achieve, but assembly precision deteriorates when batteries have different post positions
Solution Approach 1:
The oblong insertion hole shape provides built-in alignment guidance through its directional geometry. The long axis of the oblong hole naturally aligns with the abutting direction, ensuring that when the stud bolt is inserted, the fuse unit automatically orients itself correctly relative to the battery side surface, thereby maintaining high alignment precision without compromising manufacturing simplicity
Data Source
AI summary
A fuse unit includes: a fuse element with an insertion hole into which a stud bolt inserted, the stud bolt protrudingly provided on a battery terminal fixed to a battery post protrudingly provided on an upper surface of a battery; and a resin body integrally formed with the fuse element by insert molding, and having an abutment portion abutting on a side surface of the battery. For a plurality of batteries each having the battery post at a different arrangement position, the insertion hole of the fuse element is formed in a shape allowing insertion of the stud bolt thereinto in a state where the side surface of the battery and the abutment portion of the resin body abut on each other.