Tuning Fork Fuse Terminal for High Current Capacity
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Solution Overview
Problem
The current design of fuse terminals in automotive applications, such as cartridge fuses, is limited by the current-carrying capacity and requires significant space and increased costs when multiple fuses are connected, with potential points of failure due to the limited contact points.
Innovation Solution
The use of a system with a first and second tuning fork terminal end, where the first prong and second prong extend from a joined end to form a first gap, and the third and fourth prong extend from a joined end to form a second gap, configured to be substantially perpendicular, allowing for increased contact points and flexible prongs to maintain the terminals in place with spring forces, reducing heat and resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple fuses are connected to increase current-carrying capacity, then the current capacity is improved, but the space occupied and cost increase
Solution Approach 1:
The patent combines multiple terminal contacts into a single integrated tuning fork terminal structure. The tuning fork terminal has multiple prongs (first, second, third, and fourth prongs) that simultaneously contact multiple corresponding prongs on the circuit board, merging what would traditionally require multiple separate fuse connections into one unified component. This allows the single terminal to carry higher current equivalent to multiple fuses while occupying less space.
Solution Approach 2:
The patent utilizes three-dimensional spatial arrangement by extending prongs in different directions and planes. The tuning fork terminal structure arranges prongs spatially to contact multiple points on the circuit board simultaneously, effectively using dimensional space to increase contact points without proportionally increasing the footprint area on the circuit board.
2Power
If multiple fuses are connected to increase current-carrying capacity, then the current capacity is improved, but the number of parts and cost increase
Solution Approach 1:
The patent merges multiple fuse terminal functions into a single integrated tuning fork terminal component. Instead of requiring multiple separate fuse units each with their own terminals, the invention provides one terminal structure with multiple prongs that performs the function of multiple terminals, thereby reducing the number of parts and assembly steps while maintaining equivalent or enhanced current-carrying capacity.
3Device complexity
If traditional terminal contacts are used, then the structure is simple, but the number of contact points is limited and heat generation increases
Solution Approach 1:
The patent segments the terminal contact into multiple prongs (first, second, third, and fourth prongs) that make contact at different locations on the circuit board. This segmentation distributes the current flow across multiple contact points, reducing the current density and heat generation at any single point while maintaining structural simplicity through the unified tuning fork design.
Solution Approach 2:
The patent adds spatial dimensionality to the contact arrangement by extending prongs in different directions and planes, allowing multiple contact points to be achieved without significantly increasing the overall structural complexity. The prongs are arranged to contact the circuit board at multiple locations simultaneously, distributing heat generation across a larger area.
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 configuration increases the number of electrical contact points, reduces heat generation, and allows for higher current carrying capacity while minimizing space and cost, with staggered contact points reducing initial engagement force and stress.
Implementation Method 1
The first prong and the second prong may be flexible to deflect away from each other such that the first gap is enlarged for receiving the second tuning fork terminal
Implementation Method 2
A first spring force may maintain the second tuning fork terminal in the first gap between the first and second prongs
Implementation Method 3
The distal ends of the first and second prongs may be configured to contact the second end of the second tuning fork
Data Source
AI summary
A system for increasing terminal electrical contact may include a first tuning fork terminal extendable on a first plane, and may include a first prong and a second prong both extending from a joined first end to respective distal ends and may form a first gap therebetween. The system may further include a second tuning fork terminal extendable on a second plane and may include a third prong and a fourth prong both extending from a joined second end to respective distal ends and may form a second gap therebetween. The first plane and the second plane may be substantially perpendicular. The distal ends of the first and second prongs may be configured to contact the second end of the second tuning fork, and the distal ends of the third and fourth prongs may be configured to contact the first end of the first tuning fork.