Molded Fuse Support Sleeve for Automation and Impact Protection
Solution Overview
Problem
Existing fuse assembly methods are time-consuming and prone to damage during manufacturing, lacking adequate support for the fuse element until the final stage of assembly, and require multiple manual operations.
Innovation Solution
A molded structure with integrated copper terminals and ribs provides a supportive sleeve for the fuse element, facilitating automation and reducing forces during free-fall and operation, made from non-conductive materials like plastic or ceramic to support the fuse element from initial manufacture to final placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional fuse assembly methods are used, then manual operations can be performed, but the assembly process is time-consuming and productivity is low
Solution Approach 1:
The molded structure is prepared in advance with pre-formed cavities, ribs, and terminal mounting positions. The fuse element is pre-positioned within the molded structure during molding, eliminating the need for manual positioning and assembly operations later. This preliminary preparation of the support structure enables automated assembly processes and significantly reduces assembly time.
2Manufacturing precision
If fuse element is left unsupported during manufacturing, then material usage is reduced, but the fuse element is prone to damage and manufacturing precision decreases
Solution Approach 1:
The molded structure incorporates localized support features including ribs positioned at specific intervals along the fuse element, cavities that precisely accommodate the fuse element diameter, and terminal mounting positions at exact locations. These localized structural qualities provide targeted support where needed while maintaining simplicity elsewhere in the design.
3Ease of manufacture
If multiple separate components are used for fuse support, then ease of manufacture is improved, but device complexity increases and assembly time increases
Solution Approach 1:
The patent combines multiple functions into a single molded structure: support for the fuse element, positioning features, terminal mounting structure, and protective enclosure are all integrated into one piece. This merging of functions reduces the number of separate components from multiple parts to a single molded structure, simplifying assembly while maintaining manufacturing ease through molding processes.
Data Source
AI summary
A sub-structure element support system is disclosed. The sub-structure element support system includes a novel molded structure designed to support an electrical element, such as a fuse. The molded structure is a protective and insulative sleeve for the electrical element and reduces forces on the electrical element during free-fall and operation conditions. The molded structure also facilitates automation during manufacturing and reduces cost.