Inline High-Current Fuse Holder With Reinforced Blade Contact
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Solution Overview
Problem
Existing inline fuse holders lack an effective mechanism for securely connecting high current fuses in electrical systems, particularly in applications like solar photovoltaic systems, where reliable overcurrent protection is crucial.
Innovation Solution
An inline fuse holder assembly that includes conductive end caps and contact elements with a base member, where the end caps are crimped to securely trap conductors and the contact elements are designed to increase contact force with the fuse blade, enhancing the electrical connection without additional fasteners or solder, and a cover that engages the contact elements to further secure the fuse in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional compression nut and two-piece holder body are used, then assembly is simple, but contact force and electrical connection reliability are insufficient for high current applications
Solution Approach 1:
The patent merges the holder body and cover into a single integrated unitary structure, eliminating the need for separate compression nuts and multiple parts. This integration maintains structural simplicity while providing enhanced contact force and reliable electrical connection for high current applications through the monolithic design's inherent structural integrity.
Solution Approach 2:
The patent segments the electrical connection function into distinct contact elements within the unitary holder, allowing optimized contact geometry and force distribution. The segmented contact surfaces and internal structure enable high current carrying capacity while maintaining overall structural simplicity.
2Strength
If additional fasteners or solder are used to secure fuse, then connection strength increases, but device complexity and assembly steps increase
Solution Approach 1:
The unitary holder structure provides self-service by incorporating integrated contact elements and securing mechanisms that automatically engage with the fuse blade upon insertion. The design eliminates the need for additional fasteners or soldering operations, as the holder's own structure provides both electrical connection and mechanical securing through its monolithic construction and internal geometry.
3Reliability
If contact force between fuse blade and terminals is increased, then electrical connection reliability improves, but manufacturing precision requirements increase
Solution Approach 1:
The patent optimizes contact force by changing the geometric parameters of the contact elements within the unitary holder, such as contact surface area, angle, and positioning. These parameter optimizations enable high reliable electrical connection with standard manufacturing tolerances, avoiding the need for excessive precision while ensuring sufficient contact force for high current applications.
Data Source
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AI summary
Provided herein are approaches for securing an electrical protection device (e.g., a fuse). In one approach, an apparatus includes a conductor and a terminal coupling the conductor to the fuse, wherein the terminal includes an end cap having a cavity for receiving and securing the conductor, and a set of contact elements extending from a base member. The base member may be coupled to the end cap, and a body of the fuse may be coupled to the base member. In some approaches, a fuse blade of the fuse is disposed between the set of contact elements. In some approaches, the apparatus further includes a cover adjacent the terminal, wherein the cover is configured to engage the contact elements to increase a contact force and electrical connection between the set of contact elements and the fuse blade.