Fusible Link Tri-Fold Connecting Plates
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Solution Overview
Problem
Conventional fusible links have limited flexibility in installation configuration, making them inflexible and space-inefficient as the number of electric circuits on vehicles increases, necessitating a solution that allows for adaptable installation based on available space on the battery side.
Innovation Solution
A fusible link design featuring a metallic fuse element integrated with three resin housings, allowing the connecting plates to be bent for a tri-fold configuration, enabling flexible installation orientations and increased durability through reinforcing plates and a housing lock mechanism to secure positions and prevent vibration-induced fatigue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the fusible link uses a fixed installation configuration, then the structure is simple, but the adaptability to different space requirements is poor
Solution Approach 1:
The connecting plates are designed to be bendable, allowing the fusible link to change its installation configuration dynamically. The housing structure includes positioning protrusions and recesses that guide the bending process while maintaining structural integrity. This enables the fusible link to adapt to different space requirements on the battery side without requiring multiple fixed-configuration units.
2Area of stationary object
If the fusible link is mounted with limited space consideration, then the space utilization improves, but the installation flexibility decreases
Solution Approach 1:
The fusible link utilizes three-dimensional space efficiently by allowing the connecting plates to bend in multiple directions. The housing structure is designed with positioning features that accommodate bending in different planes, enabling the component to adapt to various mounting orientations and save space on the battery side while maintaining installation flexibility.
3Strength
If the connecting plates are made rigid for structural strength, then the durability improves, but the ability to bend for different configurations is lost
Solution Approach 1:
The connecting plates incorporate localized bending sections with reduced thickness or different material properties that allow flexible deformation. These bending sections are positioned at specific locations while the rest of the connecting plates maintain sufficient thickness and strength. The housing structure provides localized support at non-bending areas to maintain overall structural integrity while enabling configurability.
4Adaptability or versatility
If the fusible link allows multiple installation configurations, then the adaptability improves, but the positioning stability may decrease
Solution Approach 1:
The housing structure includes pre-designed positioning protrusions and recesses that guide the connecting plates into stable positions during the bending process. These positioning features are arranged to engage at specific configuration stages, ensuring that once the connecting plates are bent to a desired configuration, the housing locks them in place to maintain positioning stability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design allows for compact, adaptable installation configurations, enhanced durability against vibrations, and reduced space requirements, while maintaining effective current protection by allowing the fusible link to be oriented based on available space, thus addressing the inflexibility and space constraints of conventional designs.
Implementation Method 1
a fusible part configured to conductively couple the connecting plate to an external coupling plate opposing to each other and which is fused if a current with a value equal to or larger than a rated current value flows
Data Source
AI summary
In a fusible link, a fuse element integrally formed with a metallic plate includes a battery coupling plate and two external coupling plates. The battery coupling plate is coupled to a battery terminal. The external coupling plates are coupled through fusible parts to connecting plates extending to both sides of the battery coupling plate. Three resin housings support the fuse element so as to expose the connecting plates among the housings adjacent to each other. The installation configuration of the fuse element can be selected depending on the space on the battery side, thereby achieving increased flexibility of and reduction in the space for the fusible link mounted on the battery.