Isolated Single Stud Fuse Mounting for Unspecialized Stud Assemblies
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Solution Overview
Problem
Existing single stud fuses are not compatible with assemblies that have unspecialized studs, as the studs in these assemblies do not provide the necessary insulation, rendering the fuses ineffective in protecting circuitry and components.
Innovation Solution
The introduction of an electrically isolated stud with a stud base and shaft, combined with a landing pad assembly that is orbital riveted into the electrical device's housing, allowing for secure and insulated connection of the single stud fuse, ensuring that current flows through the fuse and not the stud, thereby providing effective protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single stud fuse is attached to an assembly with unspecialized studs, then the fuse cannot function correctly to protect circuitry, but adding specialized insulated studs increases device complexity
Solution Approach 1:
The patent introduces a specialized stud assembly that acts as an intermediary between the unspecialized stud in the electrical device and the single stud fuse. This specialized stud includes an electrically isolated stud base with insulating material and a stud shaft, serving as a mediator that enables the fuse to function correctly without requiring modification to the original electrical device studs. The insulating material on the stud base prevents current from flowing through the stud, forcing current to flow through the fuse element as intended.
2Reliability
If a specialized insulated stud is used to ensure current flows through the fuse, then fuse protection is effective, but the assembly requires additional components increasing manufacturing complexity
Solution Approach 1:
The patent combines multiple functions into the specialized stud assembly: the stud base with insulating material, the stud shaft, and the fuse retention features are integrated into a single assembly that can be installed as one unit. The insulating material is integrated into the stud base structure, and the fuse shaft receptacle is formed as part of the stud assembly, reducing the number of separate components and simplifying the manufacturing process despite the increased functional complexity.
3Reliability
If the stud is made electrically isolated with insulating material, then current flows correctly through the fuse, but the stud assembly becomes more complex
Solution Approach 1:
The patent applies electrical isolation only where necessary - specifically on the stud base portion that contacts the electrical device housing, while the stud shaft portion that interfaces with the fuse remains conductive. The insulating material is applied locally to the stud base, providing electrical isolation only at the critical interface with the housing, while maintaining electrical conductivity where needed for fuse operation. This localized approach provides the necessary electrical isolation without unnecessarily complicating the entire stud assembly.
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
This solution enables the single stud fuse to function correctly in assemblies with unspecialized studs by providing a secure, insulated, and torque-resistant connection, enhancing protection against overcurrent and mechanical stress while maintaining a sealed and dust-free environment.
Implementation Method 1
The landing pad, which is part of the single stud fuse assembly, also features a stud base receptacle to which a stud base of an electrically isolated stud, also part of the single stud fuse assembly, is inserted
Data Source
AI summary
An electrical device assembly and method to attach an isolated single stud fuse assembly to an electrical device are disclosed. The electrical device assembly consists of multiple studs, one or more of which is replaced with the isolated single stud fuse. A conductive copper landing zone receives an electrically isolated steel stud. When the landing pad assembly is orbital riveted into a plastic housing of the electrical device, the stud is locked into the housing permanently. Electrical devices such as disconnect switches and power distribution modules, both of which include multiple studs, are good candidates for being adapted with the single stud fuse assembly.