Integrated Fuse Module for Compact Automotive Battery Mounting
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Solution Overview
Problem
Existing pre-fuse boxes in automotive applications are large and occupy valuable space in the engine compartment due to their configuration with flexible conductive leads, which is inefficient for compact designs.
Innovation Solution
An integrated fuse module with a compact design that mounts directly to the automobile battery without flexible conductors, featuring a mounting block, terminal post, fuse plate, and cover, allowing for overcurrent protection with a fusible element, and can be assembled by folding the fuse plate around the mounting block for a space-saving form factor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If flexible conductive leads are used to connect pre-fuse boxes to battery terminals, then electrical connections can be established, but the device occupies excessive space in the engine compartment
Solution Approach 1:
The patent merges the pre-fuse box housing, mounting structure, and electrical connections into a single integrated unit that mounts directly to the battery terminal. This eliminates the need for separate flexible conductive leads and reduces the overall volume occupied in the engine compartment while maintaining electrical connection functionality.
Solution Approach 2:
The fuse module is nested directly onto the battery terminal structure, with the housing containing the fuse carrier and electrical components within a compact form factor. This nesting approach minimizes the space required compared to external connections with flexible leads.
2Ease of manufacture
If conventional pre-fuse box configuration is used with flexible leads, then electrical connections are established, but material usage and manufacturing complexity increase
Solution Approach 1:
The patent combines multiple components (housing, mounting structure, electrical connections) into a single integrated pre-fuse box unit. This reduces the number of separate parts that need to be manufactured and assembled, simplifying the manufacturing process and reducing material usage compared to conventional configurations with separate flexible leads.
3Volume of moving object
If compact design is implemented by integrating fuse module directly to battery, then space is saved, but device complexity increases
Solution Approach 1:
The patent segments the integrated fuse module into distinct functional components: a housing, a fuse carrier with blade fuses, a mounting structure with contact arms, and a cover. This segmentation allows for simplified manufacturing and assembly of each component while achieving a compact integrated form factor when assembled together.
Solution Approach 2:
The fuse carrier is nested within the housing, and the entire assembly mounts directly to the battery terminal. This nested structure achieves compactness while keeping individual components relatively simple in design and manufacture.
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 integrated fuse module provides effective overcurrent protection in a compact form, reducing space and material usage compared to conventional pre-fuse boxes, while protecting against ambient factors and electrical arcing.
Implementation Method 1
a fusible element providing overcurrent protection in a compact form
Implementation Method 2
an arc suppressor containing an arc generated by the fusible element
Data Source
Figure 1
Figure 2a~2b
Figure 3~4a
AI summary
A fuse module including a mounting block formed of an electrically insulating material, a fuse plate including a fusible element disposed on a bottom surface of the mounting block, an input terminal electrically connected to the fusible element and extending along rear and top surfaces of the mounting block, and a fuse terminal electrically connected to the fusible element and extending from a front surface of the mounting block, the fuse module further including an electrically conductive terminal post extending from the top surface of the mounting block through the fuse terminal for facilitating connection to an electrical component.