Split-Body Fuse Holder With Lead Guide Paths for Dense PCB Layouts
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Solution Overview
Problem
The challenge in power supply unit design is to reduce the number of installation steps and board space footprint for fuses on a printed circuit board (PCB), while maintaining electrical isolation and high power density.
Innovation Solution
A fuse holder assembly comprising two body halves with channels that guide fuse leads, reducing the need for additional installation steps and minimizing board space by aligning leads and maintaining electrical isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fuse installation methods are used with additional isolation steps, then electrical isolation between fuses is maintained, but the number of installation steps increases and board space footprint increases
Solution Approach 1:
The patent combines multiple isolation functions into a single integrated fuse holder structure. The holder simultaneously provides physical containment, electrical isolation between adjacent fuses, and lead guidance, eliminating the need for separate heat shrink tubing and RTV silicone application steps while maintaining complete electrical isolation.
Solution Approach 2:
The fuse holder is designed as a multi-functional component that performs several functions: it holds the fuse body, guides the leads through integrated channels, provides electrical isolation between adjacent fuses, and secures the fuse in place. This universal design replaces multiple separate components and steps with a single integrated solution.
2Reliability
If traditional fuse installation methods with heat shrink tubing and RTV silicone are used, then electrical isolation and physical placement are maintained, but installation time increases
Solution Approach 1:
The fuse holder is pre-designed with integrated isolation barriers and lead guidance channels built into the structure. These isolation features are manufactured in advance as part of the holder itself, eliminating the need for operators to apply heat shrink tubing or RTV silicone during installation, thereby significantly reducing installation time while maintaining complete electrical isolation.
3Area of stationary object
If fuses are placed in tighter arrangements to meet high power density requirements, then board space is reduced, but the risk of unintentional interactions between components increases
Solution Approach 1:
The fuse holder incorporates localized isolation barriers and shielding structures specifically at the interfaces between adjacent fuse cavities. These local quality enhancements provide targeted electrical isolation exactly where needed between closely-spaced fuses, enabling tight board arrangements while preventing unwanted electromagnetic interactions or arcing between adjacent components.
4Reliability
If additional installation steps such as heat shrink tubing and sleeving are applied to each fuse, then electrical isolation is improved, but the device complexity and manufacturing time increase
Solution Approach 1:
The patent merges the functions of heat shrink tubing, lead sleeving, and isolation barriers into a single integrated fuse holder structure. The holder's built-in channels and barriers provide all necessary electrical isolation and lead guidance functions that would otherwise require multiple separate components, simplifying the overall assembly and reducing the number of parts needed.
Data Source
AI summary
A fuse holder comprises first and second body halves. The first body half includes a wall having a fuse cavity, a first channel extending from a first end of the fuse cavity of the first body half, and a second channel extending from a second end of the fuse cavity of the first body half. The second body half includes a wall having a fuse cavity, a third channel extending from a first end of the fuse cavity of the second body half, and a fourth channel extending from a second end of the fuse cavity of the second body half. The first channel and the third channel mate together and form a first fuse lead guide path, and the second channel and the fourth channel mate together and form a second fuse lead guide path.