Modular Fuse Terminals Using Ferrule-and-Blade Construction
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Solution Overview
Problem
Existing electrical protection device terminals require significant precision machining, resulting in high material waste and increased production costs, while also requiring large inventories to accommodate various fuse constructions.
Innovation Solution
The electric terminal is formed from multiple components, such as a ferrule and a connector blade, which are hydro-formed, drawn, 3D printed, and/or stamped, reducing material usage and machining requirements. The ferrule has a cup portion with an interior space for the connector blade, which is secured using braze or weld attachments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If terminals are formed by precision machining from solid blocks, then manufacturing precision and structural integrity are improved, but material waste and production costs increase
Solution Approach 1:
The terminal is divided into multiple components: a ferrule (cup-shaped) and a blade (connector portion). These segments are formed separately using less material-intensive processes and then joined together, reducing the need for precision machining of a single solid block while maintaining structural integrity.
Solution Approach 2:
The invention changes the manufacturing parameters and methods from traditional precision machining to alternative forming processes such as hydroforming, drawing, 3D printing, and stamping. These parameter changes enable terminal component formation with significantly reduced material waste while achieving required dimensional precision.
2Adaptability or versatility
If multiple terminal types are maintained for different fuse constructions, then adaptability is improved, but inventory complexity and costs increase
Solution Approach 1:
The modular terminal design with a standardized ferrule and interchangeable blades creates a universal base component that can accommodate different fuse constructions. The ferrule serves multiple functions across different applications, while blade variations provide specific adaptations, reducing overall inventory complexity.
Solution Approach 2:
By segmenting the terminal into a universal ferrule portion and application-specific blade portions, the invention allows the common ferrule to be stocked once and reused across multiple fuse types, while only the variable blade components need to be maintained in inventory for different constructions.
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 and production costs, allows for lighter terminals with reduced material usage, and is adaptable to existing fuse designs without the need for secondary machining, thereby simplifying terminal manufacturing and inventory management.
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
the electrical connector is attached to the ferrule by at least one of a braze or weld
Implementation Method 4
the electrical connector is attached to the ferrule by at least one of a braze or weld
Data Source
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.