Integrated Conductor Fuse Connector Assembly
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Solution Overview
Problem
Existing electrical distribution systems lack an integrated assembly of an electrical conductor, fuse, and connector that is specifically designed for automotive applications, which can efficiently manage electrical energy distribution to multiple devices while providing protection against excessive current.
Innovation Solution
An integrated assembly comprising a flexible metallic conductor body with secured terminals, a conductor housing with support and connector interfaces, a releasable cover, and a fuse connected within the connector interface, along with a connector housing and terminal, forming a comprehensive unit for automotive electrical distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single rigid electrical conductor (bus bar) is used to supply electrical energy to multiple devices, then electrical energy distribution is achieved, but the system lacks flexibility and integration with protective devices
Solution Approach 1:
The patent combines the electrical conductor, fuse, and connector into a single integrated assembly. The conductor body is formed as one piece with the housing, and the fuse is pre-installed within the housing, eliminating the need for separate rigid bus bars and separate fuse installations. This merging provides flexibility while maintaining integration.
Solution Approach 2:
The integrated assembly serves multiple functions simultaneously: the conductor body conducts electrical energy, the housing provides structural support and contains the fuse, the fuse protects against excessive current, and the connector interface enables device connection. This multi-functionality achieves versatility without proportionally increasing complexity.
2Reliability
If separate fuses are connected between the electrical conductor and each electrically-operated device, then protection against excessive current is provided, but the system lacks an integrated structure
Solution Approach 1:
The fuse is integrated within the housing structure itself, forming a unified assembly with the conductor and connector. This eliminates the need for separate fuse installations at each device while maintaining reliable current protection through the pre-installed fuse in the housing.
3Ease of manufacture
If a pre-formed rigid conductor is used, then electrical energy supply is established, but the system lacks ease of installation and flexibility
Solution Approach 1:
The integrated assembly is designed as a modular unit that can be installed as a single component rather than assembling multiple separate parts. The conductor body, housing, fuse, and connector interface are integrated into one installable unit, improving ease of installation while the internal structure maintains necessary stability.
4Adaptability or versatility
If multiple separate components (conductor, fuse, connector) are used, then functionality is achieved, but the system lacks integration and streamlined structure
Solution Approach 1:
The patent merges the conductor body, housing, fuse, and connector interface into a single integrated assembly. This reduces the number of separate components that need to be handled and installed, achieving streamlined integration without sacrificing the necessary functional complexity.
Data Source
AI summary
An integrated assembly of an electrical conductor, a fuse, and a connector includes a conductor body having a conductor terminal secured thereto. A conductor housing includes a support portion engaging the conductor body and a connector interface containing the conductor terminal. The conductor cover is releasably secured to the support portion and covers the conductor body. The fuse is disposed within the connector interface and is connected to the conductor terminal. A connector includes a connector housing that is supported on the connector interface and a connector terminal that is disposed within the connector housing. The connector terminal is connected to the fuse to complete the integrated assembly.