Sealed Inline Fuse Module for Remote Mounting and Easy Replacement
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Solution Overview
Problem
Existing fuse modules in vehicular applications often require direct mounting to an electrical source, lack remote placement options, and fail to provide a fluidically sealed and easily removable fuse solution.
Innovation Solution
A sealed inline fuse module with a fuse holder made of electrically insulating material, featuring integrated electrical cables and a fusible element within a mounting block, allowing for remote placement and easy replacement, while maintaining electrical and fluidic sealing through a bolt and nut mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fuse module is mounted directly to an electrical source, then electrical connection is simplified, but placement flexibility is reduced
Solution Approach 1:
The fuse module is segmented into a separate mounting structure with integrated cables and a separate fuse holder, allowing the module to be placed remotely from the electrical source while maintaining simplified electrical connection through the pre-integrated cable assembly
Solution Approach 2:
The mounting structure serves multiple functions: it provides mechanical support, electrical connection through integrated cables, and fluidic sealing, eliminating the need for separate mounting brackets and connection components
2Object-affected harmful factors
If a fuse module is sealed from the environment, then fluidic protection is improved, but manufacturing complexity increases
Solution Approach 1:
The sealing function is merged with the mounting structure by integrating an O-ring seal directly into the mounting body, eliminating the need for separate sealing components and reducing manufacturing steps while providing comprehensive fluidic protection
Solution Approach 2:
The fuse holder is nested within the sealed mounting structure, with the O-ring seal positioned between the mounting structure and fuse holder to create a fluidically sealed environment without requiring complex external sealing mechanisms
3Ease of repair
If a fuse is permanently installed, then electrical connection reliability is improved, but replaceability is reduced
Solution Approach 1:
The electrical connection is designed with a dynamic bolted joint that allows the fuse to be easily removed and reinstalled, while the connection maintains reliable electrical contact when assembled through the bolt and nut mechanism with integrated sealing
4Ease of manufacture
If integrated cables are used, then installation simplicity is improved, but cable replacement difficulty increases
Solution Approach 1:
The cable assembly is segmented into a removable fuse holder component and a fixed mounting structure with integrated cable terminals, allowing the fuse to be replaced independently while the cables remain permanently installed, providing both installation simplicity and repairability
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
Enables remote placement and easy replacement of fuses, providing effective overcurrent protection and preventing electrical damage by ensuring a fluidically sealed and electrically insulated connection.
Implementation Method 1
Upon the occurrence of an overcurrent condition, a fusible element within the fuse module melts, disintegrates, or otherwise opens to arrest the flow of current
Implementation Method 2
a fuse holder having a main body portion formed of an electrically insulating material
Implementation Method 3
the main body portion defining a hollow interior... providing a fluidically sealed environment
Data Source
AI summary
A fuse holder including a main body portion formed of an electrically insulating material, the main body portion defining a hollow interior and having first and second through holes formed in opposing rear and front walls thereof, respectively, the first and second through holes being aligned with one another, an integrated first electrical cable having a first ring terminal extending into the hollow interior of the main body portion, the first ring terminal disposed on the rear wall and aligned with the first through hole in the rear wall, and an integrated second electrical cable having a second ring terminal extending into the hollow interior of the main body portion, the second ring terminal disposed on the front wall and aligned with the second through hole in the front wall.