Fusible Link Mounting Structure for Compact Junction Box
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical junction box designs struggle to achieve further size reduction while maintaining versatility, as they often require exclusive cavities for specific types of fusible links, limiting the ability to mount different series fusible links in the same cavity.
Innovation Solution
A fusible link mounting structure that includes n-series fusible links formed by multiple fuse elements in a common housing, monopole fusible links in a single housing, and a cavity designed to accommodate both, with terminals arranged to connect electrically and not interfere with each other, allowing for reduced size and versatile mounting options.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a cavity is designed to accommodate n-series fusible links with multiple fuse elements, then the size of the electrical junction box is reduced, but the cavity becomes limited to exclusive use for n-series fusible links and cannot mount monopole fusible links
Solution Approach 1:
The cavity is designed with universal adaptability to accommodate both n-series fusible links and monopole fusible links. The mounting structure includes adjustable terminal positions and a common housing design that can interface with different fusible link configurations, allowing a single cavity to serve multiple functions and different fusible link types without requiring exclusive design for one type.
Solution Approach 2:
The fusible link is divided into multiple separate fuse elements within a common housing for n-series configurations, while monopole configurations use a single fuse element. The mounting structure accommodates both segmented and non-segmented designs through flexible terminal arrangements and a common housing interface, enabling the same cavity to support different structural configurations.
2Reliability
If monopole fusible links are mounted in separate cavities with partition walls, then electrical connection is ensured, but the pitch in the arranging direction increases and the junction box size increases
Solution Approach 1:
Multiple fuse elements are combined within a single common housing to form an n-series fusible link. This merging approach allows multiple electrical connections to be achieved within a single cavity space that would traditionally require multiple separate cavities with partition walls, thereby reducing the overall pitch in the arranging direction while maintaining reliable electrical connections through the common housing structure.
3Volume of moving object
If n-series fusible links are used to reduce size, then the junction box becomes more compact, but the mounting structure complexity increases due to terminal arrangement requirements
Solution Approach 1:
The mounting structure incorporates adjustable and reconfigurable terminal positions that can adapt to different fusible link configurations. The terminal arrangement is designed to be flexible rather than fixed, allowing the same mounting structure to accommodate both n-series and monopole fusible links by repositioning terminals as needed, thereby reducing overall structural complexity despite the compact design requirements.
Data Source
AI summary
A fusible link mounting structure, comprising a three-series fusible link formed by providing three pieces of fuse elements in series within a single common housing, a cavity having a mounting space formed according to a size of the common housing for the three-series fusible link, a plurality of tabs projected from a bottom of the cavity into the mounting space, and a monopole fusible link formed by providing a piece of fuse element in a single monopole housing, wherein a total length of the mounting space is set to be shorter than a sum of lengths of three-pieces of the monopole housings, and the tabs are arranged corresponding to positions of fuse terminals provided in the three-series fusible link, and also arranged at such positions that a plurality of the terminals do not interfere with the monopole housing, when the monopole fusible link is mounted in the cavity.