Printed Circuit Board Fuse Assembly with Permanent Base and Replaceable Element
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Solution Overview
Problem
Existing plug-in blade type fuses for electrical circuits are costly to install and produce, and require frequent replacement, which can be inefficient.
Innovation Solution
A fuse assembly comprising a primary fuse with terminals that attach permanently to a printed circuit board via shoulder sections, allowing for easy replacement with a secondary fuse using receiving tip sections that provide electrical connection and structural support, reducing the need for frequent replacement and installation costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If plug-in blade type fuses are used, then ease of replacement is improved, but installation cost and production cost increase
Solution Approach 1:
The fuse assembly is divided into two distinct segments: a permanent base unit that remains mounted on the printed circuit board, and a replaceable fuse element that can be easily swapped. This segmentation allows the expensive permanent mounting infrastructure to be reused while only the inexpensive fuse element needs replacement, resolving the contradiction between ease of replacement and manufacturing cost.
Solution Approach 2:
The base unit acts as an intermediary between the printed circuit board and the replaceable fuse element. It provides the permanent electrical connection and mounting structure, while allowing temporary fuse elements to be inserted and removed. This intermediary structure enables easy replacement without requiring permanent modification of the circuit board or expensive reusable fuse holders.
2Ease of repair
If plug-in blade type fuses are used, then ease of replacement is improved, but frequency of replacement increases
Solution Approach 1:
By segmenting the fuse system into a permanent base and replaceable element, the design enables rapid replacement without tooling or complex procedures. The replaceable fuse element can be quickly swapped during maintenance windows, reducing the overall frequency of replacements needed compared to more complex fuse systems.
Solution Approach 2:
The fuse assembly is designed to be self-servicing through its simple insert-removed mechanism. The base unit automatically maintains electrical connections and the replaceable element is designed for tool-free replacement, enabling maintenance personnel to quickly replace fuses during routine maintenance without requiring specialized tools or procedures, thereby reducing replacement frequency.
3Ease of manufacture
If permanent attachment to printed circuit board is implemented, then installation cost is reduced, but ease of replacement is worsened
Solution Approach 1:
The permanent attachment is applied only to the base unit, which contains the mounting structure and electrical connections to the printed circuit board. The fuse element itself remains separate and replaceable. This selective permanent attachment reduces installation costs for the mounting infrastructure while preserving ease of replacement for the fuse element.
Solution Approach 2:
The base unit serves as an intermediary that provides permanent mounting to the printed circuit board while accommodating temporary fuse elements. This intermediary structure resolves the contradiction by making the mounting infrastructure permanent and cost-effective while keeping the fuse element replaceable and easy to swap.
Data Source
AI summary
A primary electrical fuse is attached to a printed circuit board. The primary electrical fuse comprises a first and second terminal, a fusible element disposed between the first and second terminals electrically linking the first terminal and the second terminal, and receiving tip sections located on the first and second terminals that receive a replacement electrical fuse to electrically connect the first and second terminals with a replacement fusible element.