Junction Connector Assembly with Integrated Fuse and Branching Circuit
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Solution Overview
Problem
In-line fused connectors require disassembly of the fuse subassembly and release of matching terminals for fuse replacement, making the process difficult and prone to damage, and lack a separate circuit for power branching, limiting connection possibilities.
Innovation Solution
A junction connector assembly integrated with a fuse, featuring an inner housing with spaced bus bars, a fuse that connects these bars, and a design allowing for fuse replacement without releasing the matching terminal, along with a circuit for power branching and connection to other units, including a fuse cover and outer cover for easy operation and safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fuse is assembled to the fuse subassembly and coupled to the outside housing, then the fuse can be protected and organized, but the fuse replacement becomes difficult and requires disassembly of the fuse subassembly and release of matching terminals
Solution Approach 1:
The fuse assembly is segmented into a fuse holder and a fuse body. The fuse holder remains permanently installed in the connector housing, while only the fuse body needs to be removed and replaced. This segmentation allows the protective structure to remain intact while simplifying the replacement operation to merely extracting and inserting the fuse body.
Solution Approach 2:
The fuse body is extracted as a separate replaceable component from the fuse holder. The matching terminal is released from the fuse holder but remains in the connector, allowing the fuse body to be independently removed and replaced without affecting the terminal connection structure.
2Ease of repair
If the matching terminal is released and the fuse subassembly is disassembled for fuse replacement, then the fuse can be replaced, but the matching terminal may be damaged or deformed
Solution Approach 1:
The fuse body is extracted as a separate replaceable component from the fuse holder. The matching terminal is released from the fuse holder but remains in the connector, allowing the fuse body to be independently removed and replaced without affecting the terminal connection structure.
Solution Approach 2:
The fuse holder is pre-assembled with the matching terminal in a nested configuration. This preliminary arrangement ensures that when the fuse body is removed, the terminal remains protected within the fuse holder structure, preventing damage during the replacement operation.
3Device complexity
If no separate circuit is provided in the connector, then the connector structure remains simple, but power branching and connection with other units becomes impossible
Solution Approach 1:
The connector is designed with multi-functional capabilities by integrating a junction box structure that provides both the original connector function and additional power branching circuits. The housing contains multiple terminal options that can accommodate different connection configurations, allowing the same connector to serve multiple purposes without requiring separate dedicated circuits.
Data Source
AI summary
A junction connector assembly integrated with a fuse may include an inner housing having a 1-1-th bus bar, a 1-2-th bus bar, and a second bus bar disposed therein to be spaced apart from one another and a first opening portion formed on one side surface to protrude first terminal portions of the 1-1-th bus bar and the 1-2-th bus bar; and a fuse configured to electrically connect the 1-1-th bus bar and the 1-2-th bus bar to each other, the fuse being inserted and fixed into the first opening portion.