Modular Fuse Block with Integrated Clearance
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Solution Overview
Problem
Conventional fuse blocks for high-rated fuses are costly and difficult to manufacture due to the need for large, heavy fuse clips and complex assembly processes, which are challenging to scale for higher power applications.
Innovation Solution
A modular fuse block design featuring a nonconductive base with elevated end portions and a recessed middle section, allowing for smaller, lighter fuse clips and simplified assembly, with clearance for larger fuse bodies and easy removal using a fuse puller tool.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional fuse blocks use large, heavy fuse clips to accommodate high-rated fuses, then the fuse block can handle higher power applications, but the manufacturing cost and complexity increase significantly
Solution Approach 1:
The fuse block is divided into a base portion and a separate fuse clip assembly. The fuse clip can be removed and replaced independently, allowing the expensive, complex fuse clip to be manufactured separately and only assembled with the simpler base portion during final assembly. This segmentation reduces overall manufacturing complexity while maintaining high power handling capability.
Solution Approach 2:
The fuse clip is extracted as a separate, removable component from the fuse block assembly. This allows the complex, expensive fuse clip to be manufactured independently using optimized processes, and only integrated with the simpler base portion when needed. The extracted fuse clip can also be easily replaced if damaged, reducing long-term manufacturing costs.
2Strength
If conventional fuse blocks use complex assembly processes to ensure structural integrity, then the fuse block can accommodate high-rated fuses, but the assembly difficulty and time increase
Solution Approach 1:
The fuse block is segmented into a base portion and a fuse clip assembly that can be manufactured separately and assembled through simple insertion. The base portion contains the terminal structures and mounting features, while the fuse clip is a separate component that snaps into place, requiring minimal assembly steps while maintaining structural integrity for high-rated fuses.
Solution Approach 2:
The fuse clip assembly is designed to be self-containing, with the fuse clip retaining the fuse blade and the entire assembly being inserted into the base portion as a unit. This self-service design eliminates the need for complex fastening or alignment procedures during assembly, reducing assembly complexity while ensuring proper structural support for high-power applications.
3Power
If conventional fuse blocks are designed for larger fuse bodies, then they can accommodate high-rated fuses, but the overall size and material usage increase
Solution Approach 1:
The fuse block design utilizes vertical clearance space above the fuse clip rather than increasing horizontal dimensions. The base portion is configured with a cavity that provides vertical clearance for the fuse body, allowing high-rated fuses to be accommodated without proportionally increasing the overall material usage. This dimensional optimization reduces material consumption while maintaining high current rating capability.
Data Source
AI summary
A fuse block assembly includes a nonconductive base formed with pedestal surfaces attachable to terminals from a location above the base, while providing a clearance between the body of a fuse and the middle portion of the base when a fuse is installed.