Modular Fuse Terminals With Ferrule-Blade Assembly for Low-Scrap Manufacturing
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Solution Overview
Problem
Conventional electrical terminals require significant precision machining, resulting in high material scrap and increased costs, and large inventories are needed to accommodate various fuse constructions, making them costly and inefficient to produce and manage.
Innovation Solution
The electrical terminal is constructed from multiple components, such as a ferrule and a connector blade, which are hydro-formed, drawn, 3D printed, or stamped, and subsequently attached using methods like brazing or welding, reducing material usage and machining requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If terminals are formed by precision machining solid blocks, then manufacturing precision and structural integrity are improved, but material waste and production cost increase
Solution Approach 1:
The terminal is divided into multiple components: a ferrule portion and a blade portion. Each component is formed separately using optimized processes (hydroforming, stamping, or 3D printing) that minimize material waste, then joined together through brazing or welding. This segmentation allows each part to be manufactured efficiently without requiring precision machining of a solid block, thereby reducing material scrap while maintaining dimensional precision.
Solution Approach 2:
The invention changes the manufacturing parameters and methods from traditional precision machining to alternative processes such as hydroforming, stamping, or 3D printing. These parameter changes enable the formation of terminal components with minimal material waste while achieving the required dimensional precision and structural integrity through process optimization rather than subtractive machining.
2Adaptability or versatility
If multiple terminal types are maintained for different fuse constructions, then adaptability is improved, but inventory complexity and cost increase
Solution Approach 1:
By segmenting the terminal into a standardized ferrule portion and a configurable blade portion, the invention allows different blade configurations to be attached to a common ferrule base. This modular approach enables adaptability to various fuse constructions while maintaining a core standardized component, thereby reducing inventory complexity.
Solution Approach 2:
The ferrule portion is designed as a universal component that can accommodate multiple blade configurations and fuse types. This multi-functional design allows a single ferrule type to serve multiple applications, reducing the need for maintaining separate terminal inventories for different fuse constructions while preserving adaptability.
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
This approach reduces material waste, lowers production costs, and allows for adaptable terminal configurations that can meet different application demands without compromising the insulative body, while being compatible with pre-existing fuse designs.
Implementation Method 1
At least some of the components of the terminal are hydro-formed, drawn, 3D printed and/or stamped
Implementation Method 2
the ferrule is formed using a metal drawing process
Implementation Method 3
At least some of the components of the terminal are hydro-formed, drawn, 3D printed and/or stamped
Implementation Method 4
the electrical connector is attached to the ferrule by at least one of a braze or weld
Implementation Method 5
the electrical connector is attached to the ferrule by at least one of a braze or weld
Data Source
Figure 1A~1E
Figure 2A~3C
Figure 4A~4D
AI summary
A terminal for an electrical protection device includes a ferrule having a base and a wall disposed along a periphery of the base, wherein the base extends along a first plane and the wall extends along a direction that is substantially perpendicular to the first plane, whereby the base and the wall form a cup having an interior space. An electrical connector is attached to the ferrule, where the electrical connector extends out from the interior space.