Multi-Level Fuse Housing for Compact Power Distribution
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Solution Overview
Problem
Existing utility vehicle power distribution modules are limited by their size and cable entry/exit openings, making it difficult to accommodate both larger and smaller fuses in a compact space and to route battery cables effectively, especially in space-constrained areas with thick, nonflexible cables.
Innovation Solution
A multi-level housing design with fuse connection terminals on multiple levels, allowing for perpendicular installation of fuses and providing multiple cable entry/exit openings on each side to facilitate easier routing and mounting, accommodating a range of fuse sizes from 30 to 500 amps in a smaller footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single-level housing is used for power distribution modules, then the module size is determined by the larger fuse dimensions, but the module cannot accommodate both larger and smaller fuses efficiently in a compact space
Solution Approach 1:
The patent transitions from a single-level housing to a multi-level housing structure with at least a first level and a second level. Each level has fuse connection terminals configured to receive different sizes of fuses. This vertical dimensionality change allows the module to accommodate both larger fuses (e.g., 60-500 amp AMG/MEGA fuses requiring 50mm+ spacing) and smaller fuses (e.g., 30-200 amp AMI/MIDI or ATM/MINI fuses requiring 30mm or less spacing) within a compact footprint, resolving the contradiction between adaptability and module size.
2Ease of operation
If limited cable entry/exit openings are provided on the module, then the module structure is simpler, but it becomes difficult to route thick, nonflexible battery cables into the module, especially in space-constrained areas
Solution Approach 1:
The multi-level housing structure serves multiple functions: it provides structural support for different fuse sizes while simultaneously creating multiple cable entry/exit openings on different sides of the housing. These openings are strategically positioned to facilitate easy routing of thick, nonflexible battery cables from various directions, making the housing universally adaptable to different mounting locations and cable routing requirements without requiring complex external cable management systems.
3Adaptability or versatility
If the module is designed for larger fuses with greater terminal spacing, then larger fuses are accommodated, but smaller fuses cannot be efficiently housed in the same module
Solution Approach 1:
The patent applies local quality by configuring different regions of the multi-level housing with different terminal spacing characteristics. The first level has fuse connection terminals spaced to accommodate larger fuses with greater spacing requirements (50mm or more), while the second level has fuse connection terminals spaced for smaller fuses with tighter spacing requirements (30mm or less). This localized differentiation of terminal spacing within the same housing allows the module to efficiently house both larger and smaller fuses without requiring a uniform design that would waste space.
Data Source
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AI summary
A utility vehicle power distribution module (100) for a plurality of fuses (118, 128) on a first level (108) and a second level (110) of a multi-level housing (102). Each fuse may be installed between a pair of fuse connection terminals (114, 116; 124, 126). One of each pair of fuse connection terminals may be connected to an electrical bus bar (134), and the other of each pair of fuse connection terminals connected to a cable (152) extending through one of a plurality of cable entry and exit openings (150) in an outside wall (140) on a first side and a second side of the multi-level housing.