Modular Fuse Holder with Integrated Rejection Features
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Solution Overview
Problem
Conventional fuse holders face manufacturing difficulties due to complex assembly processes and high costs associated with fuse clips, particularly when incorporating rejection features, which often require multiple types of clips and increase the risk of human error during manual assembly.
Innovation Solution
A modular fuse holder design featuring a two-piece base assembly with integrated fuse rejection features and connection terminals, where the fuse clips and connection terminals are integrally formed and supported by slots in the base, eliminating the need for external fasteners and allowing for automated assembly, and using identically constructed fuse clips on both sides to reduce inventory and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional fuse holders use separately provided mechanical fasteners to attach fuse clips and connection terminals to the base, then the assembly process becomes complex and costly, but the structural stability is maintained
Solution Approach 1:
The fuse clips and connection terminals are integrally formed as a single piece with the base assembly, eliminating the need for separate mechanical fasteners. This merging of components simplifies the assembly process while maintaining structural integrity through the integral design.
Solution Approach 2:
The mechanical fasteners are completely removed from the design. By extracting this unnecessary component, the patent achieves simpler assembly without compromising structural stability, as the integral design provides inherent structural strength.
2Reliability
If multiple types of fuse clips are used to incorporate rejection features, then fuse compatibility control is improved, but manufacturing costs and inventory complexity increase
Solution Approach 1:
The rejection features are integrated directly into the base assembly structure rather than being separate components. This allows the base to work with a single type of fuse clip while still providing compatibility control, reducing inventory complexity.
Solution Approach 2:
The base assembly incorporates localized geometric features (rejection features) that provide compatibility control at specific locations. These features are designed into the base structure itself, allowing simple fuse clips to work with the base while maintaining reliable fuse compatibility control.
3Ease of operation
If manual assembly methods are used for fuse holder construction, then assembly flexibility is maintained, but productivity and manufacturing efficiency decrease
Solution Approach 1:
The fuse holder is divided into modular components (base assembly and fuse clips/terminals) that can be manufactured separately and then easily assembled. The integral design of each module allows for automated manufacturing, while the modular nature enables flexible assembly processes.
Solution Approach 2:
The fuse clips and connection terminals are pre-formed as integral parts of the base assembly through molding or other automated forming processes. This preliminary action enables subsequent automated assembly operations, significantly improving manufacturing efficiency while maintaining flexibility.
Data Source
AI summary
A fuse holder includes a two piece base assembly allowing assembly and attachment of fuse clips and terminals without separately provided, external fasteners such as screws. Fuse rejection features may be built-in to the base assembly adjacent one of the fuse clips.