Fusible Link Support Member Reduces Battery Electrode Load

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Solution Overview

Problem

Conventional electrical component units apply a full load to the battery electrode, increasing the load on the electrode and posing a challenge in efficiently fixing electrical components.

Innovation Solution

An electrical component unit with a support member that extends orthogonally from the battery, supporting the main electrical component body and power supply terminal, reducing the load on the electrode by distributing it across the support member and terminal fixing portion, and utilizing grooves for guidance during attachment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the electrical component is fixed directly to the battery terminal, then the electrical component can be securely fixed to the battery, but the full load of the electrical component is applied to the electrode, increasing the load on the electrode

Engineering Contradiction:
Improvefixation strengthVSAvoidload on electrode
Core Design Contradiction:
StrengthVSForce

Solution Approach 1:

The invention divides the fixation system into separate functional components: a support member that provides mechanical support and load distribution, and a battery terminal that provides electrical connection. The support member is fixed to the battery body while the electrical component is fixed to the support member, separating the mechanical load-bearing function from the electrical connection function. This segmentation allows the electrode to be relieved of mechanical load while maintaining secure fixation of the electrical component.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The support member acts as an intermediary element between the battery and the electrical component. It transfers the mechanical load from the electrical component to the battery body without requiring the electrode to bear the full load. The support member mediates between the electrical component's need for secure fixation and the electrode's need to avoid excessive mechanical stress, allowing both requirements to be satisfied simultaneously.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Device complexity

If the electrical component is fixed directly to the battery terminal, then the structure is simple, but the load concentration on the electrode increases and fixation reliability decreases

Engineering Contradiction:
Improvestructural complexityVSAvoidfixation reliability
Core Design Contradiction:
Device complexityVSReliability

Solution Approach 1:

The fixation system is segmented into distinct functional modules: the support member for mechanical support and load distribution, and the battery terminal for electrical connection. This segmentation improves fixation reliability by ensuring that each component performs its designated function optimally without being compromised by the other's requirements, despite the increased structural complexity.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The support member extends in an orthogonal direction from the battery terminal, creating a three-dimensional spatial arrangement that separates the load-bearing path from the electrical connection path. This dimensional separation allows the load to be distributed across multiple attachment points on the battery body rather than concentrating force on the electrode, thereby improving fixation reliability while managing structural complexity through spatial optimization.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

3Device complexity

If the electrical component is fixed directly to the battery terminal, then fewer components are needed, but the load distribution is poor and the electrode experiences excessive stress

Engineering Contradiction:
Improvenumber of componentsVSAvoidload distribution
Core Design Contradiction:
Device complexityVSForce

Solution Approach 1:

The system is divided into functionally independent components: the support member dedicated to load distribution and mechanical support, and the battery terminal dedicated to electrical connection. This segmentation enables effective load distribution across the battery body through the support member's multiple attachment points, while the battery terminal maintains its electrical function without bearing excessive mechanical stress, justifying the additional component for improved force distribution.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The support member serves as a mediator that distributes the load from the electrical component across multiple attachment points on the battery body. It intercepts and redistributes the mechanical forces before they reach the electrode, preventing stress concentration. This intermediary function necessitates an additional component but achieves superior load distribution that would be impossible with direct fixation.

Inventive Principle:
Principle #24Intermediary (Mediator)

Data Source

PatentUS9941086B2Electrical component unit, fusible link unit, and fixing structure
Publication Date: 2018.04.10 YAZAKI CORP
  • US9941086B2 patent drawing
  • US9941086B2 patent drawing
  • US9941086B2 patent drawing

AI summary

Provided is a fusible link unit (electrical component unit) including a fusible link (electrical component), a battery terminal fixed to an electrode post (electrode) of a battery, and a support member formed as a different body from the battery terminal and fixed to the battery, the support member supporting the fusible link (electrical component), in which the fusible link (electrical component) includes a main link body (main electrical component body) and a power supply terminal made of conductive metal to be exposed from the main link body (main electrical component body) and electrically connected to the electrode post (electrode) through the battery terminal, and the support member supports the main link body (main electrical component body) such that the main link body extends in an orthogonal direction substantially orthogonal to an installation surface portion.