Offset Tuning Fork Fuse Terminals for High Current
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In automotive applications, cartridge fuses with side-by-side terminals face challenges such as reduced prong width, susceptibility to deformation, and increased cost and complexity due to the need for isolation, which limits their ability to handle high currents effectively.
Innovation Solution
The design incorporates offset tuning fork terminals with prongs of constant width, forming gaps that can expand to accommodate blades, maintained by spring forces, and connected via a fusible link, allowing for increased clearance and reduced interference, thus enabling higher current handling without additional structural elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If side-by-side terminals are used, then the fuse can contact the circuit board, but the prong width is reduced and strength is lowered
Solution Approach 1:
The patent transitions from a two-dimensional side-by-side terminal arrangement to a three-dimensional offset configuration. The first and second tuning fork terminals are positioned at different longitudinal positions along the fuse body, with curvatures that offset them from each other. This spatial reorganization allows each terminal to have sufficient prong width and strength while maintaining circuit board contact capability.
2Reliability
If wider prongs are used to increase cross-sectional area, then resistance is improved, but the terminals interfere with each other and require isolation structures
Solution Approach 1:
By offsetting the terminals along the longitudinal axis and using curvatures to position them in different spatial planes, the patent eliminates the need for isolation walls or partitions in the housing. Each terminal operates in its own spatial zone, allowing wider prongs for better conductivity without interference between terminals.
Solution Approach 2:
The fuse body is segmented into distinct zones along its length, with the first tuning fork terminal located at a first longitudinal position and the second tuning fork terminal at a second longitudinal position. This segmentation allows each terminal to be optimized independently for electrical conductivity without requiring complex isolation structures.
3Reliability
If isolation walls are added to separate terminals, then terminal interference is prevented, but cost and complexity increase
Solution Approach 1:
Instead of using isolation walls that extend across the housing, the patent uses longitudinal offset positioning and curvatures to separate terminals in the longitudinal dimension. This approach achieves terminal isolation without requiring additional housing features, reducing manufacturing cost and complexity.
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 design enhances the strength and reliability of terminal contacts, reduces the risk of deformation, and simplifies the fuse housing, allowing for effective high-current applications without the need for additional isolation features, while maintaining electrical conductivity.
Implementation Method 1
The first curvature of the first end and the second curvature of the second end may offset the respective first and second tuning fork terminals from each other along the second axis
Implementation Method 2
The first prong and the second prong may be flexible to deflect away from each other and outward from the first gap such that at least a portion of the first gap is enlarged for receiving the blade
Implementation Method 3
A first spring force may maintain the blade in the first gap between the first and second prongs
Implementation Method 4
A fusible link may connect the first end of the first tuning fork to the second end of the second tuning fork
Data Source
AI summary
An electrical terminal contact may include a first tuning fork terminal extendable along a first axis, and may include a first prong and a second prong both extending from a joined first end to respective distal ends. The first end may have a first curvature transitioning to extend along a second axis substantially perpendicular to the first and second prongs. A second tuning fork terminal may be extendable along the first axis, and a third prong and a fourth prong may both extend from a joined second end to respective distal ends. The second end may have a second curvature transitioning to extend along the second axis substantially perpendicular to the third and fourth prongs. The first curvature of the first end and the second curvature of the second end may offset the respective first and second tuning fork terminals from each other along the second axis.