Master Fuse Module Integrating Multiple Fuses into Single Assembly
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Solution Overview
Problem
Conventional fuse assemblies for automobiles are complex, expensive, and difficult to assemble due to their multi-part housings and numerous components, which complicates the integration of multiple fuses into a single, efficient assembly.
Innovation Solution
A master fuse module comprising a base housing, a fuse assembly with multiple fuses, and a cover, where the fuse assembly is formed from a conductive material with a planar design and connected to the base housing using connectors, allowing for easier assembly and integration of multiple fuses into a single unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional multi-part fuse assemblies are used, then reliable overcurrent protection is provided, but manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The patent combines multiple fuse elements, terminals, and housing components into a single integrated master fuse assembly. The housing contains multiple fuse holders with fuse elements, all connected to common terminals within one unified structure, eliminating the need for separate fuse assemblies and reducing overall system complexity while maintaining reliable overcurrent protection for multiple circuits.
Solution Approach 2:
The master fuse assembly serves multiple functions within a single device: it provides overcurrent protection for multiple electrical circuits simultaneously, houses multiple fuse elements with different ratings, provides common electrical connections through shared terminals, and offers a unified mounting interface for the battery. This multi-functional design replaces what would traditionally require several separate fuse assemblies.
2Reliability
If multiple separate fuse assemblies are used, then individual fuse protection is achieved, but manufacturing cost and assembly time increase
Solution Approach 1:
The patent integrates multiple fuse assemblies into one master assembly where multiple fuse holders are contained within a single housing structure. This allows all fuses to be installed, replaced, or serviced as one unit rather than handling multiple separate assemblies, significantly improving assembly speed and productivity while maintaining individual circuit protection through each fuse element.
Solution Approach 2:
The master fuse assembly is pre-configured during manufacturing with multiple fuse holders, terminals, and housing components already integrated together. This preliminary assembly of multiple fuses into a single unit eliminates the need for on-site assembly of individual fuse assemblies, reducing installation time and improving productivity during vehicle assembly or maintenance operations.
3Reliability
If traditional multi-component fuse assemblies are used, then adequate protection is provided, but material cost and assembly complexity increase
Solution Approach 1:
The patent consolidates multiple separate components (housings, terminals, fuse holders) into a single integrated master fuse assembly. This merging of components reduces the total number of parts that need to be manufactured, inventoried, and assembled, thereby lowering material costs and simplifying the manufacturing process while still providing adequate fused connection protection for multiple circuits.
Solution Approach 2:
The master fuse assembly provides multiple functions within a single manufactured unit: it protects multiple circuits with different current ratings, provides common electrical connections, offers a unified mounting interface, and enables single-unit replacement. This multi-functionality eliminates the need to manufacture and stock multiple separate fuse assemblies, reducing overall manufacturing complexity and cost.
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 master fuse module simplifies assembly, reduces component costs, and provides a cost-effective, efficient solution for providing fused connections to automobile components by integrating multiple fuses into a single assembly that is easier to package and mount on a battery.
Implementation Method 1
A fuse element is in electrical communication between the first and second portions and provides overcurrent protection by melting when subjected to a predetermined current
Data Source
AI summary
A master fuse module includes a base housing configured to be disposed on a battery, a fuse assembly connected to the base housing, and a cover disposed on the base housing. The fuse assembly includes a first generally planar portion including a first terminal, a second generally planar portion disposed generally perpendicular to the first generally planar portion, a plurality of second terminals, and a plurality of fuses. Each fuse includes a first portion in electrical communication with the first terminal and a second portion in electrical communication with one of the plurality of second terminals. A fuse element is in electrical communication between the first and second portions and provides overcurrent protection by melting when subjected to a predetermined current. A plurality of connectors connects the fuse assembly to the base housing.