Low-Profile Fuse Module for Direct Battery Mounting
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Solution Overview
Problem
Existing pre-fuse boxes in automotive applications are large and require significant space, necessitating strain relief features that increase complexity and cost, and cannot be mounted directly to the battery without flexible conductors, which limits their compactness and integration.
Innovation Solution
A low-profile integrated fuse module with a mounting block, terminal posts, and a fuse plate that can be directly coupled to an automobile battery without flexible conductors, featuring a compact design that allows for overcurrent protection and reduced height, eliminating the need for strain relief features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If existing pre-fuse boxes are mounted adjacent to automobile batteries with flexible conductive leads, then electrical connections are provided, but the arrangement requires a great deal of space within the engine compartment
Solution Approach 1:
The fuse box is merged with the battery terminal structure, integrating the fuse housing, terminal posts, and mounting features into a single compact unit that attaches directly to the battery, eliminating the need for separate flexible leads and reducing overall space requirements
Solution Approach 2:
The fuse box is designed with a low-profile configuration that mounts on top of the battery rather than hanging adjacent to it, utilizing the vertical dimension above the battery to achieve compact integration without extending into the pedestrian protection zone
2Volume of moving object
If pre-fuse box is connected directly to battery terminal, then space is saved, but strain relief features are necessary that increase design complexity
Solution Approach 1:
The mounting block incorporates integrated strain relief features and flexible mounting mechanisms in advance, allowing direct attachment to the battery terminal while accommodating thermal expansion and vibration without requiring additional complex strain relief components
3Shape
If pre-fuse box hangs off the side of battery, then pedestrian protection zone is not extended into, but strain relief features and design complexity increase
Solution Approach 1:
The fuse box is merged with the battery terminal structure, integrating the fuse housing, terminal posts, and mounting features into a single compact unit that attaches directly to the battery, eliminating the need for separate flexible leads and reducing overall space requirements
Solution Approach 2:
The fuse box is designed with a low-profile configuration that mounts on top of the battery rather than hanging adjacent to it, utilizing the vertical dimension above the battery to achieve compact integration without extending into the pedestrian protection zone
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 solution provides a compact, space-saving design that fits within the limited space of an automobile engine compartment, reducing material and design complexity while ensuring effective overcurrent protection without extending into the pedestrian protection zone.
Implementation Method 1
fusible elements connected between the bus bar and the fuse terminals, respectively, and providing overcurrent protection between the battery and the electrical components
Implementation Method 2
fusible elements connected between the bus bar and the fuse terminals, respectively, and providing overcurrent protection between the battery and the electrical components
Data Source
Figure 1
Figure 2a~2c
Figure 3
AI summary
A fuse module including a mounting block formed of an electrically insulating material, the mounting block including a base portion and a wall portion disposed in a perpendicular relationship, the fuse module further including a fuse plate including an electrically conductive bus bar disposed on a bottom of the base portion, a fusible element electrically connected to the bus bar and disposed adjacent a front of the wall portion, and a fuse terminal electrically connected to the fusible element and disposed on a top of the base portion, the fuse module further including an electrically conductive terminal post extending from the top of the base portion and through the fuse terminal for facilitating connection to an electrical component.