Abstract:
The present invention provides a fuse block having a plurality of fuse connections. The fuse connections include an array of embedded terminals that contact the initially provided fuse elements. When one of the fuse elements opens, an operator remakes the open connection by inserting an external replacement fuse. The fuse connections therefore eliminate the need to initially provide separate external fuses. In an embodiment, the terminals include fork shaped projections that receive one of the terminals of the replacement fuse, which also eliminates the need for additional female inserts commonly found in automobile fuse blocks. The fuse block is simple, wherein a plurality of same may be provided in an automobile to cut down on long lengths of wire running from load devices to a traditional, single centrally located fuse block.

Description:
BACKGROUND OF THE INVENTION 
   The present invention relates to the field of electrical protection. More particularly, the present invention relates to fuse connections. 
   Current fuse blocks and junction boxes for automobiles are complicated. Referring to  FIG. 1 , a prior art junction box  10  is illustrated. The prior art junction box includes a number of primary components, such as the prior art fuse block  12 , a cover  14  and a lower housing  16 . The prior art fuse block  12  includes an upper press-fit layer  18  that mates with a lower press-fit layer  20 . The upper and lower press-fit layers  18  and  20  mate with an upper housing  22 . The upper housing  22  mates with the upper press-fit layer  18  and the lower press-fit layer  20 , which collectively mate with the lower housing  16 . The cover  14  mates with the upper housing  22 . 
   Prior art fuse block  12  includes a number of electrical devices  24 . For example, the electrical devices  24  can include JCASE® fuses and MINI® fuses provided by the assignee of this invention, mini and micro relays, and solid state relays. The fuses can be blade fuses. 
   The fuses  26  individually insert into a pair of female inserts  28 , which are illustrated as being connected to the upper press-fit layer  18 . The upper housing  22  defines apertures, wherein the female inserts  28  extend through the apertures so that an operator may place a fuse  26 , either initially or after an open fuse condition, into the pair of female inserts  28 . The female inserts  28  connect to the upper press-fit layer  18  by press-fitting over a terminal  30 , which itself mechanically or press-fits into the upper press-fit layer  18 . 
   Referring to  FIG. 2 , a prior art terminal  30  is illustrated in phantom line. The prior art terminal  30  includes a projection  32  that extends from the upper press-fit layer  18 , through the lower press-fit layer  20  and through the lower housing  16 . The prior art terminal  30  also includes a projection  34  that extends a lesser distance in the same direction as the projection  32 . The lower press-fit layer defines apertures that slide over and around the projections  32  and  34 . 
   The prior art terminal  30  also fits into the upper press-fit layer  18 . An upwardly extending projection  38  fits through apertures defined by the upper press-fit layer  18 . Similar to the downwardly extending projections  32  and  34 , the upward projection  38  extends further than a second projection  36 . The projection  38  extends upwardly and outwardly from the upper press-fit layer  18  and engages the female insert  28 . 
   It should therefore be appreciated that the prior art fuse block  12  of the prior art junction box  10  includes a multitude of components that must press-fit together. The prior art requires separate female inserts  28 , which are unwanted due to cost, complexity and weight. Further, because the assembly of the prior art fuse block  12  of the prior art junction box  10  is relatively complicated, automobile manufacturers have tended to provide only one junction box  10  per vehicle. This creates a condition wherein the load wires that run from the various electrical devices have to run all the way to the single junction box  10  regardless of the position of the load device in the vehicle. Extended lengths of load wires create weight, cost and the potential for short circuits. 
   A need therefore exists to provide a simplified automobile fuse block and junction box employing same. 
   SUMMARY OF THE INVENTION 
   In one aspect, the present provides a fuse block. The fuse block includes a plurality of fuse connections. The fuse connections initially eliminate the need to provide separate external fuses. When one of the fuse connections opens, an operator remakes the open connection by inserting an external replacement fuse. In one embodiment, the fuse elements are separate from the fuse body. In such a case, the fuse elements can be any type of material and shape used for conventional fuses. In one embodiment, the fuse element is spiral wound, which provides a time delay characteristic to the operation of the fuse block. 
   In another embodiment, the fuse elements are of a “thin-film” type or surface mounted. Here, the fuse elements can be surface mounted onto a separate substrate that defines apertures or slots, which enable the substrate and surface mount fuses to slide over and electrically connect to the terminals. The surface mount element can be provided having a multitude of separate parallel strands, which provide a higher current carrying characteristic to the operation of the fuse block. 
   The fuse block includes a body. The body is made of an insulative material, such as plastic. The body in an embodiment is one piece but in alternative embodiments has a plurality of pieces that fit, for example, snap-fit or bolt together. Multiple terminals fix to the body. In an embodiment, multiple terminals are molded into a plastic body. The terminals can have one or more apertures that allow the plastic in a liquid state to flow through the apertures to provide a sturdy mount. 
   The body of the fuse block connects to a number of other pieces. For example, a module is provided to which a multitude of wires connect. One use for the fuse block of the present invention is in automobiles. The wires that connect to the modules can therefore be automobile wires that extend to any type of electrical component found in an automobile. The wires can also run to other modules of other fuse blocks. 
   The module snap-fits and/or bolts to the body of the fuse block. The module makes electrical contact between the multitude of wires and a like number of terminals imbedded within the body. The terminals therefore, in an embodiment, extend from two opposing sides of the body. The terminals extend from one side and electrically mate with the fuse elements. The terminals extend from the opposing side of the body and electrically couple to the wires of the plug in module. 
   The fuse elements electrically connect to at least two of the terminals to create at least one fuse connection. The fuse block includes many fuse connections and therefore many pairs of fuse-linked terminals. The fuse block includes sets or rows of terminals, wherein terminals from adjacent sets or rows are connected by fuse elements. In an embodiment, the terminals of one of the rows electrically connect to a power line, for example, the common power line. In this manner, one set or row of terminals electrically connects to the common supply line, while the fuse linked set or row electrically connects to various different loads within, for example, an automobile. 
   In an embodiment, the side of the terminal extending from the body of the fuse block that electrically connects to the fuse element also provides for the receipt of a terminal from an external replacement fuse. That is, when the initially provided fuse element opens, the operator corrects the fault by inserting a standard fuse, for example, a standard automotive fuse. 
   The body of the fuse block also connects to a number of protective parts. A protective member mounts a distance away from the body, between the fuse element mounting portion of the terminals and the replacement fuse insertion portion of the terminals. The protective member defines a plurality of apertures that fit over and around the terminals and over and around a plurality of mounts that project from the body. The member fixes to the mounts, for example, through a staking process. The protective member covers the fuse elements and enables a person to safely mount replacement fuses to the second portions of the terminals. In an embodiment, the protective member is translucent or transparent so that an operator can see which fuse element has opened. 
   The body of the fuse block also mates with and attaches to a protective cover. The protective cover, unlike the protective member, fits completely over the terminals. 
   The fuse block can be arranged electrically in a plurality of different ways. First, the terminals inside the body of the fuse block can include the fuse elements but not include the power connections or “bussing” as it is commonly called. When the terminals molded into the body do provide the bussing, it can be done in a plurality of ways. In one example, the body includes a plurality of sets or rows of terminals, wherein adjacent terminals of the sets or rows are connected together by a fuse element. Here, one of the rows can be bussed or electrically connected to a power supply line, such as the common line. With this embodiment, each different pair of rows of fuses can have a differently rated fuse element. 
   In another embodiment, sets of three terminals of three adjacent sets or rows of terminals are connected together with at least one fuse element. The bussing occurs by electrically connecting the terminals of one of the rows to a power supply line. In an embodiment, the terminals of the central row are bussed together to provide power to the terminals, through one or more fuse elements, in the two outer rows. If the fuse opens between the middle fuse and one of the outer fuses, a fuse link still exists between the middle fuse and the other adjacent terminal. 
   The bussing in one embodiment is provided by inserting or molding a strip of physically and electrically connected terminals into the fuse body instead of separate terminals. One way to manufacture the terminals is to make such a strip of the terminals and then separate them into individual terminals. For the bussed rows, however, the strip is left in tact and is sized so that the terminals are spaced properly apart. 
   In another aspect of the present invention, a terminal for a fuse block is provided. The terminal includes a first portion that extends from a side of the fuse block and contacts a fuse element. A second portion of the terminal extends from the same side of the fuse block as the first portion. The second portion receives a terminal of a separately mounted replacement fuse. 
   The terminal in an embodiment is of a “tuning fork” variety, wherein a plurality of projections extend from the fuse block. This type of terminal creates a notch or groove that accepts the terminal of a male replacement fuse, such as a blade fuse, for example a MINI®fuse. A first portion of the terminal contacts the fuse element. When the fuse element is a separate fuse element, such as a spiral wound fuse element, the first portion includes a first groove defined by a middle projection and an outer projection. When the fuse element is of a surface mount variety, the first portion of the terminal includes the middle section of the fuse element that electrically contacts the surface mount element. 
   A second portion of the terminal, which receives the terminal of the separately mounted replacement fuse includes a second groove or slot defined by the middle projection and a second outer projection. The second portion, which receives the terminal of a separately mounted replacement fuse, extends further from the fuse block than does the first portion. This enables the fuse element, which contacts the first portion, to remain closer to the fuse block than the replacement fuse. In this manner, a protective member can be placed over the fuse elements but beneath the second portion, which needs to be accessible by an operator to place a replacement fuse therein. 
   In another embodiment, the terminal includes a male projection. The male projection receives a female type fuse, such as the JCASE® fuse. Here, when the fuse element is a separate type, for example, a spiral wound fuse element, the first portion that contacts the fuse element again includes the first groove defined by the male projection and an outer projection. When the fuse element is of a surface mount variety, no outer projection is required. The second portion of the male projection terminal, which receives the female terminal of the separately mounted female replacement fuse does not define a separate groove via an outer projection but simply includes the male projection. 
   Besides the first and second portions of the terminal, the above described terminals also include another area or portion that contacts an electrical lead. The electrical lead can be a buss wire or a wire to a load device. For the bussing, the additional area or portion in one embodiment, as described above, is the connecting area along the strip of fuses. For the load wires, the additional portion of the terminal in an embodiment includes a projection extending from the opposing side of the fuse block than the side from which the first and second portions extend. Here, the additional portion or projection electrically communicates with a wire or electrical lead that terminates inside a plug-in module. The module snap-fits or bolts to the opposing side of the fuse block. 
   In a further aspect of the present invention, a method of providing fuse protection is provided. The method includes providing a body and fixing a plurality of terminals to the body, so that the terminals are exposed on at least one side of the body. The method also includes contacting at least two of the plurality of terminals with a fuse element. Further, a location on the plurality of terminals is provided for receiving a terminal of a replacement fuse when the fuse element opens. The terminal of the replacement fuse can be a male or female terminal. 
   The terminals are placed in sets or rows, so that the fuse element contacts one of the terminals from one of the sets or rows and another of the terminals from an adjoining set or row. The first and second rows are spaced apart and arranged so that the terminals of the rows can receive the male or female replacement fuse. 
   The method includes contacting a plurality of adjacent terminals from the rows with a plurality of unique fuse elements, so as to create a plurality of electrical connections. The method includes positioning and arranging the sets or rows of terminals so that a plurality of replacement fuses can be received by a unique terminal from each set or row. 
   The method includes electrically connecting at least two and possibly all the terminals of a particular set or row of terminals to a power supply line and in particular a common line. In an alternative embodiment, the method includes arranging three rows or sets of fuses, wherein one or more fuse elements contacts three terminals from each row. The three terminals produce two separate electrical connections, whereas the earlier embodiment needed four terminals to make two electrical connections. The terminals of the middle set or row in an embodiment electrically connect to a common power line. 
   In still another aspect of the present invention, a method for providing fuse connections in an automobile is provided. The method includes locating a plurality of junction boxes having fuse-linked terminals proximate to localized loads within the automobile. The method includes electrically connecting one of the terminals from the fuse-linked terminals to the localized loads. Further, the method includes bringing power to another one of the terminals from the fuse-linked terminals. 
   It should be appreciated that while the multi-element array of the present invention is particularly suited for automobiles, the present invention is expressly not limited to such use. For example, the multi-element array of the present invention is suitable for any type of two, three, four or multi-wheeled vehicle employing a multitude of fuses. Moreover, the multi-element array of the present invention can be used in any device employing a multitude of fuses. 
   It is therefore an advantage of the present invention to provide an automobile fuse array of a size and arrangement such that a plurality of same may be located at strategic points within an automobile, so as to reduce the amount and weight of wire needed to harness the automobile. 
   Another advantage of the present invention is to provide a simplified fuse block. 
   A further advantage of the present invention is to provide a simplified junction box. 
   Yet another advantage of the present invention is to provide a fuse block and junction box therefore, which is readily assembled. 
   Yet a further advantage of the present invention is to provide a fuse block, which reduces the number of components needed. 
   Additional features and advantages of the present invention are described in, and will be apparent from, the following Detailed Description of the Invention and the figures. 

   
     BRIEF DESCRIPTION OF THE FIGURES 
       FIG. 1  is an exploded perspective view illustrating a prior art fuse block and junction box employing same. 
       FIGS. 2  to  5  are elevation views of a prior art terminal superimposed with a multitude of embodiments of the terminal of the present invention. 
       FIG. 6  is a perspective view of one embodiment of a terminal arrangement for the fuse block of the present invention. 
       FIG. 7  is a sectioned elevation view from one of the sides of the terminal arrangement embodiment illustrated in FIG.  6 . 
       FIG. 8  is a sectioned elevation view from another of the sides of the terminal arrangement embodiment illustrated in FIG.  6 . 
       FIG. 9  is a perspective view of the terminal arrangement of  FIG. 6 , which illustrates one embodiment for providing a surface mount or thin film fuse element. 
       FIG. 10  is the same sectioned view as illustrated in  FIG. 7 , which illustrates one embodiment for providing the wire bussing of the present invention. 
       FIG. 11  is a perspective view of another embodiment of a terminal arrangement for the fuse block of the present invention. 
       FIG. 12  is an exploded perspective view of one embodiment of a junction box employing the fuse block of the present invention. 
       FIG. 13  is an assembled perspective view of the junction box of FIG.  12 . 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Referring now to the drawings and in particular to  FIGS. 2  to  5 , various terminals of the present invention are illustrated.  FIG. 2  illustrates the terminal  50   a  superimposed in solid onto the prior art terminal  30 , which is illustrated in phantom. With respect to the prior art terminal  30 , the terminal  50   a  of the present invention includes forked projections  52  and  54  that extend upwardly as opposed a single upwardly extending projection  38  of the prior art terminal  30 . As will be illustrated below, the forked projections  52  and  54  are positioned and arranged to receive a terminal of an externally mounted replacement fuse. The forked projections  52  and  54  are extended further upwardly with respect to the projection  38  of the prior art terminal  30 . 
   The prior art terminal  30  also includes the upwardly extending projection  36 , which is used for wiring. As may be seen from  FIG. 2 , the projection  36  has been lowered to produce the upwardly extending projection  56  of the terminal  50   a  of the present invention. As will be illustrated below, the projection  56  cooperates with the forked projections  52  and  54  to hold a fixedly attached, e.g., soldered, fuse element. 
   A middle portion  58  of the terminal  50   a  defines a hole or aperture  60 , which aids the terminal  50   a  in being mounted to the fuse block body as illustrated more fully below. The aperture  60  in an embodiment enables liquidous plastic in a plastic molding operation to penetrate through the terminal  50   a  to more securely attach same. With respect to the prior art terminal  30 , the downwardly extending projection  34  has been eliminated. Also, the projection  62  that extends downwardly from the middle portion  58  has been narrowed in certain places. 
   The terminal  50   a  of  FIG. 2  is used with a male type replacement fuse, such as a blade fuse, for example, a MINI® fuse. The terminal  50   a  of  FIG. 2  is also used when a separate fuse element, such as a spiral wound fuse element is employed. Referring now to  FIG. 3 , the terminal  50   b  is also used with a male type replacement fuse and therefore includes the forked projections  52  and  54 . The terminal  50   b , however, is used with a surface mount fuse element, which removes the need for a separate groove or notch. Accordingly, terminal  50   b  does not provide or include the projection  56 . 
   One embodiment of the present invention includes using the bussing arrangements currently employed in automobile fuse blocks with the other features and advantages described herein. In such as case, any of the embodiments for the terminals  50   a  to  50   d  discussed herein may alternatively include the projection  34 , which is currently used for bussing. 
   Referring now to  FIG. 4 , the terminal  50   c  is used with a female type replacement fuse, such as a JCASE® fuse. Accordingly, the terminal  50   c  includes only a single projection  53 , which receives the female terminal of the female fuse. The terminal  50   c  of  FIG. 2  is also used when a separate fuse element, such as a spiral wound fuse element is employed. Accordingly, the terminal  50   c  includes the extra projection  56 , to which the separate fuse element electrically connects. 
   Referring now to  FIG. 5 , the terminal  50   d  is used with the female type replacement fuse and therefore includes the single projection  53 , which receives the female terminal of the female fuse. The terminal  50   d , however, is used with a surface mount fuse element, which removes the need for a separate groove or notch. Accordingly, terminal  50   d  does not provide or include the projection  56 . 
   Referring now to  FIG. 6 , an arrangement  70  of terminals includes a plurality of terminals of the present invention arranged in sets or rows. The arrangement  70  is illustrated with the terminals  50   a  and a male type blade fuse  26 , however, any of the other terminals  50   b  to  50   d  and/or a female type blade fuse  26  could alternatively be used and illustrated. The arrangement  70  is illustrated as having two sets or rows  72  and  74 . Each set or row  72  and  74  includes two terminals  50   a . The present invention is adaptable to have any number of sets or rows of terminals  50   a , wherein each set or row can have any number of the terminals  50   a . The terminals  40   a  of the sets  72  and  74  are permanently fixed to a fuse block body  76 , which is illustrated in  FIG. 6  in a cutaway manner for convenience. 
   The fuse block body in one embodiment is any type of plastic suitable for an electrical and an automotive application. Plastics suitable for the fuse block body  76  include, but are not limited to, polyamide, polyethylene-terephthalate and polyphthalamide. The fuse block body  76  may have any suitable configuration and thickness and in an embodiment includes a relatively flat surface  78  from which the forked projections  52  and  54  and the third projection  56  project. The terminals  50   a  are conductive. The terminals  50   a  may be made of any metal suitable for automotive fuse terminals, such as C151, C425 and C7025 alloys. 
   In the arrangement  70 , one of the terminals  50   a  from the row  72  makes an electrical connection with one of the terminals  50   a  from the row  74  via a fuse element  80 . The fuse element  80  may be made of any material known to those of skill in the art. The fuse element  80  may be made of any shape known to those of skill in the art. In an embodiment, the fuse element  80  includes a resistance wire. In an embodiment, the fuse element  80  includes a punched element. 
   In one embodiment, the fuse element  80  is spiral wound. For example, the fuse element  80  can use tin plated copper wire wound about a substrate. The spiral wound fuse element  80  creates a time delay fuse element. U.S. Pat. Nos. 4,409,729, 4,560,971 and 4,736,180 involve spiral wound fuse elements, the teachings of which are incorporated herein by reference. 
   In the arrangement  70 , each of the terminals  50   a  of the row  72  makes an electrical connection with an adjacent terminal  50   a  of the row  74 , via a fuse element  80 . In this manner, the terminals  50   a  of the sets  72  and  74  in combination with the fuse elements  80  embedded into the fuse block body  76 , form a multi-element fuse array. Indeed, the terminal pairs  50   a  from the respective rows  72  and  74  in electrical communication with the fuse element  80  form fuses or fuse connections. Although each of the rows  72  and  74  in the arrangement  70  includes the same number of terminals, it is possible that the rows do not have the same number of terminals  50   a.    
   In an embodiment, the fuse element  80  solders to, mechanically links to or otherwise maintains a fixed electrical connection with the terminals  50   a . In the illustrated embodiment for the arrangement  70 , the fuse elements  80  solder to the terminals  50   a  via a solder joint  82 . Thus, it should be appreciated that the terminals  50   a  have a first portion that contacts or electrically connects to the fuse element  80 . The first portion in the illustrated embodiment includes the projection  56 , the projection  54  and a groove or notch defined therebetween. 
   Each of the terminals  50   a  also includes a second portion that a receives a terminal of a replacement fuse  26 . The replacement fuse  26  in an embodiment is a standard automotive blade fuse. For example, in one embodiment, the replacement fuse  26  is a MINI® fuse manufactured by the assignee of the present invention. As is well known, automotive replacement fuses, such as the fuse  26  include a pair of terminals  92  and a plastic housing  94  enclosing a portion of same. 
   The second portion of the terminal  50   a  that electrically engages the terminals  92  of the replacement fuse  26  includes the forked projections  52  and  54  and a groove or notch defined therebetween. The forked projections  52  and  54  are spaced apart so as to frictionally engage the terminals  92  and thereby hold the replacement fuse  26  firmly in place. To aid such frictional, press-fit, engagement, the terminals  50   a  in an embodiment include projections  84  that extend inwardly and laterally from the forked projections  52  and  54  towards the groove defined by same. The forked terminals  52  and  54  can include one or more of these inwardly extending projections  84 . 
   In operation, the fuse block of the arrangement  70  initially does not require any separate or replacement fuses  26 . Herein lies one advantage of the present invention over the prior art fuse blocks as illustrated in FIG.  1 . When one of the fuse elements  80  opens due to an overcurrent condition, only then does an operator insert a replacement fuse  26  between the forked projections  52  and  54  of the terminals  50   a  having the open fuse condition. 
   It should be appreciated that the present invention is facilitated by the fact that the terminals  92  of the replacement fuse  26  have been generally standardized in terms of their spacing by the different manufacturers making such replacement fuses. The terminals  50   a  therefore can be spaced apart a predetermined distance so that the projections  52  and  54  of terminals  50   a  in adjacent rows  72  and  74  will engage both terminals  92  of any manufactured replacement fuse  26  for a given amperage rating or range of amperage ratings. 
   If the replacement fuse  26  opens, the replacement fuse  26  is replaced by another replacement fuse  26  as is well known in the art. However, not only does the present invention eliminate the need to initially supply separate fuses because of the fuse elements  80 , the fuse block of the arrangement  70  also does not require the female inserts  28  illustrated in FIG.  1 . That is, because the terminals  50   a  include the female groove or notch defined by the projections  52  and  54 , there is no need to convert a male terminal into a female terminal as is done in prior art fuse blocks. 
   Referring now to  FIG. 7 , a sectioned view of a fuse block  100  having the arrangement  70  of  FIG. 6  is illustrated. More particularly,  FIG. 7  illustrates a sectioned view from the direction X illustrated in FIG.  6 . The illustrated fuse block  100  includes a multitude of terminals  50   a , wherein  FIG. 6  only illustrates two of these. As described above, in an embodiment each of the terminals  50   a  solders to a fuse element  80  at a portion of the terminal  50   a  defined between the projections  54  and  56 . As illustrated, the fuse elements  80  are contacted or held by the terminals  50   a  at a relatively low point above the surface  78  of the fuse block body  76 . Indeed, the fuse elements  80  are soldered or electrically connected to the terminals  50   a  below a protective member  102 . 
   The protective member  102  in an embodiment is a thin plastic piece of material. The protective member  102  may be made of any suitable material, however, in a preferred embodiment the protective member  102  is clear, translucent or transparent. The protective member  102  enables an operator to view the fuse element  80  from above or outside the fuse block  100 . The protective member  102  also precludes the operator from contacting or damaging the fuse elements when inserting a replacement fuse  26  into two of the terminals  50   a.    
   The forked projections  52  and  54  extend past the protective member  102 , so that the operator can insert the replacement fuse  26  into the terminals  50   a  without having to remove the protective member  102 . The protective member  102  therefore defines a number of apertures that fit over and around the forked projections  52  and  54 . As illustrated in  FIG. 7 , the first, third and fourth fuse elements  80  from the left have at some previous point in time opened due to some type of overcurrent event, wherein an operator has removed a cover  104  from the fuse block  100  and has inserted a replacement fuse  26  into terminals  50   a  of adjacent rows of terminals. 
   A number of standoffs or mounts  106  extend from the surface  78  of the fuse block  100 . The protective member  102  defines apertures that fit over a portion of the mounts  106 . In one embodiment, the protective member  102  is held permanently in place through a staking process. That is, the protective member  102  sits on a portion of the mounts  106 , wherein another portion of the mounts  106  extends through the apertures defined by the protective member  102 . The mounts  106  in an embodiment are plastic or otherwise deform due to heat. When the protective member  102  is put in place, an assembler applies heat to the portion of the mounts  106  extending through the member  102 , so that the portion deforms and moves outward over the top surface of the protective member  102 . When the staked portion cools and hardens, the mounts  106  hold the member  102  firmly in place. This process is commonly referred to as a “hot rivet”. Obviously, in other embodiments, the protective member  102  can be bolted to, adhered to or otherwise permanently affixed to the mounts  106  through any process known to those of skill in the art. 
   The section of  FIG. 7  cuts through the middle of the terminals  50   a  so that the apertures  60  defined by the middle portion  58  of the terminal  50   a  are illustrated. In an embodiment, the fuse block  100  is made by a plastic molding process. In the molding process, the terminals  50   a  are placed into a dye, whereupon the liquid plastic or other material making up the fuse block  100  is poured in around the terminals  50   a . The molten plastic is also able to flow through the aperture  60 . In this manner, the fuse block  100  mechanically couples through the terminals  50   a  as opposed to simply forming around and frictionally engaging the terminals  50   a.    
   Referring now to  FIG. 8 , a sectioned view of the arrangement  70  of the fuse block  100  is illustrated from the direction Y shown in FIG.  6 . The section is taken through the middle of the elements  80  so that the apertures  60 , which are generally located in the center of the middle portions  58 , reside behind the sectioned portion illustrated in FIG.  8  and are not seen. The section taken along the terminal  50   a  in  FIG. 8  also cuts through the downwardly extending projection  62  that extends beneath a lower surface  86  of the fuse block body  76  of the fuse block  100 . 
     FIG. 8  illustrates the clear or transparent protective member  102  mounted above the fuse elements  80  via the staked surfaces of the mounts  106 .  FIG. 8  illustrates the Y direction spacing of the mounts  106 .  FIGS. 7 and 8  illustrate an arrangement having eight sets or rows such as the sets or rows  74  and  72  of terminals  50   a . The rows in the arrangement  70  create four electrical connections. Each of the rows as indicated by  FIG. 7  includes seven terminals  50   a . Thus, the fuse body  100  of  FIGS. 7 and 8  having the arrangement  70  of  FIG. 6  can hold up to twenty-eight replacement fuses  26 . 
     FIG. 8  illustrates that the second fuse element  80  from the left has opened, wherein an operator has inserted a replacement fuse  26  into the terminals  50   a  that are soldered to or electrically connected to the opened fuse element  80 . The terminals  92  of the replacement fuse  26  insert behind the projection  54 , which is seen in the section of FIG.  8 . 
   As illustrated in  FIG. 8 , the cover  104  is sized so that the cover fits over the fuse block  100  in a manner such that the cover does not contact or obstruct the housing  94  of the replacement fuse  26  when same has been inserted to remedy an open fuse condition. 
   Referring now to  FIG. 9 , an embodiment of a surface mount fuse element  88  of the present invention is illustrated. The fuse block includes the same terminal arrangement  70  of as illustrated in  FIGS. 6 ,  7  and  8 . Here, a plurality of sets or rows of terminals  50   b , such as rows  72  and  74 , are provided. The projection  56  of the terminals  50   a  or  50   c  is not needed because the fuse element  88  is surface mounted. The illustrated embodiment shows the blade type replacement fuse  26 . In an alternative embodiment, a female replacement fuse is used, wherein the terminals would then be the terminals  50   d.    
   The surface mount fuse element  88  in an embodiment includes one or more copper traces as is well known to those of skill in the art. It should be appreciated however that the fuse element  88  can include any type of conductive material or combination thereof. The fuse element  88  includes a portion  90  that extends between two adjacent terminals  50   b  of different rows and a portion  96  that extends around the terminals  50   b.    
   In an embodiment, a separate member or substrate  110  is provided for the fuse element  88 . The terminals  50   b  are still molded into the fuse block body  76  as discussed above. The substrate  110 , which defines apertures that fit around the arrayed terminals  50   b , is placed over the terminals  50   b  and butted against the surface  78  of the body  76 . In an embodiment, the terminals  50   b  are soldered to the portions  96  of the fuse elements  88  via solder joints  98 . 
   The substrate  110  in an embodiment is made of an FR-4 epoxy sheet. FR-4 epoxy sheets are manufactured by Allied Signal Laminate Systems, Hoosick Falls, N.Y. with a copper plating on both sides thereof. The substrate  110  attaches to the surface  78  of the fuse block body  76  via any suitable method known to those of skill in the art. For example, the substrate  110  in an embodiment adheres to the surface  78 . In another embodiment, the substrate  110  bolts to or otherwise mechanically fastens to the body  76 . In another embodiment, the substrate  110  solders to the surface  78 . Further alternatively, any combination of these embodiments may be employed. 
   In an alternative embodiment, the surface mount fuse traces can be placed directly onto the surface  78  of the body  76 . However, it is likely easier to put the substrate  110  through a surface mount process, such as a photoresist process, than the generally three-dimensional and plastic fuse block body  76 . Also, using the substrate  110  avoids the problem of deciding whether or not to plate the terminals  50   b . The fuse elements  88  can be applied to the substrate  110  via any suitable method for placing copper traces onto substrates. In an embodiment, the fuse element  88  is applied to the substrate  110  via a known photoresist process. 
   In one embodiment of the photoresist process, the substrate  110  is initially stripped of copper and replated with a copper layer. The reapplication of copper occurs through the immersion of the substrate  110  into an electroless copper plating bath. This method of copper plating is well known in the art. The copper plating step results in the placement of a copper layer having a uniform thickness on all exposed surfaces of substrate  110 . In an embodiment, the apertures that slide over the terminals  50   b  are made before the plating step so that the aperture walls are plated. The plated walls may or may not be stripped of the copper. In a further embodiment, the apertures are made at the end of the process so that the aperture walls are not plated. 
   After the copper application, the substrate  110  is covered with a so-called photoresist polymer. After the substrate  110  is covered with the photoresist, a clear mask is placed over portions of the substrate  110  and photoresist. The masked portions include all regions on the substrate  110  which are not to have a conductive metal layer or trace. The clear mask is made of an UV light-opaque substance. Placing the mask onto portions of the copper plated substrate  110  and photoresist effectively shields these portions from the effects of UV light. Again, these portions or regions include all areas of the substrate  110  not covered by either a fuse element  88 . 
   The masked regions therefore define the shapes and sizes of the fuse elements  88 . The width, length, shape, configuration and number of fuse elements  88  may be altered by changing the size and shape of the UV light-opaque regions. For example the illustrated fuse element  88  includes a plurality of copper strands  95 , which act in parallel to connect the portion  90  to the portion  96 . The strands  95  provide a time delay characteristic to the fuse element  88  much the same as does spiral winding the fuse element  80 . 
   The plated, photoresist-covered, and partially masked substrate  110  is then subjected to UV light for a time sufficient to ensure curing of all of the photoresist that is not covered by the masked regions. Thereafter, the masks are removed from the substrate  110 . The photoresist that has been below the masks remains uncured and is washed from portions of the substrate  110 . 
   The cured photoresist on the remainder of the plated substrate  110  sheet provides protection against the next step in the process. Particularly, the cured photoresist on the plated substrate  110  prevents the removal of copper beneath those areas of cured photoresist. The regions formerly below the masks have no cured photoresist and no such protection. An etching process is then used to remove the copper from portions of the substrate  110 . Etching includes a ferric chloride solution applied through well known etching concepts. 
   After the copper has been removed from the areas formerly below the masked regions, all that remains in these areas is the FR-4 or other material of the substrate  110 . The substrate  110  is finally placed in a chemical bath to remove the cured photoresist to reveal the copper tracings of the fuse element  88  of the present invention. 
   The completed substrate is then placed over the terminals  50   b , wherein the portions  96  are soldered to same via solder joints  98 . U.S. Pat. Nos. 5,552,757, 5,790,008 and 5,884,477 involve surface mount or thin film fuse elements, the teachings of which are incorporated herein by reference. 
   Referring now to  FIG. 10  one embodiment for electrically connecting a multitude of terminals of the same row is illustrated.  FIG. 10  is illustrated using the terminals  50   a  for a male type blade fuse  26 , however, any of the other terminals  50   b  to  50   d  and/or a female type replacement fuse could alternatively be used and illustrated. 
     FIG. 10  includes the same components illustrated in FIG.  7 . The fuse block  100  includes a body  76 . A cover  104  sits atop the fuse block  100 . A number of standoffs or mounts  106  extend from the fuse block  100  and attach the protective member  102 . The fuse block  100  mechanically couples the terminals  50   a  via the apertures  60  defined by the middle portions  58  of the terminals  50   a.    
   The terminals  50   a  are provided in a single strip  120  of terminals, wherein bridging portions  108  couple the middle portions  58  of adjacent terminals  50   a . It is common to provide a strip of terminals and separate or break off individual terminals. Here, the terminals  50   a  are left in the form of a strip  120 , where the entire strip  120  is molded into the body  76  of the fuse block  100 . In an embodiment, the bridging portions  108  include one or more apertures  112  to enable liquid plastic to flow through same, which helps to secure the strip  120  of terminals  50   a  in the body  76  of the fuse block  100 . 
   The strip  120  enables the terminals  50   a  to electrically communicate, which is commonly termed “bussing”. In the prior art  FIG. 1 , the bussing is provided on one or both surfaces of the upper press-fit layer  18  and the lower press-fit layer  20 . The bussing typically includes a complicated series of channels, wherein copper wire runs throughout the channels and connects to certain terminals at certain points.  FIG. 10  illustrates that the bussing can more easily take place by being provided within the fuse block body  76 . 
   The terminals are typically bussed to provide power to one side of the fuse connections. Typically, the bussing provides a common power line that runs to one side of the electrical connection, wherein the terminal on the other side of the fuse elements electrically connects to a wire that runs to a load device. The strip  120  of terminals  50   a  therefore in an embodiment electrically connects to a common power line, wherein the strip  120  brings power to each of the terminals that have a fuse connection to the strip  120 . 
   The bridging portions  108  of the strip  120  are sized so that the terminals  50   a  are spaced apart in the set or row a desired distance. The strip  120  can be broken in one or more places so that the only selected terminals  50   a  or selected groups of terminals  50   a  in a set or row are electrically connected. 
   In an embodiment, a plurality of pairs of rows of fuse-linked terminals each include one row that has strip  120  of terminals electrically connected to a common power supply line. For instance, in  FIGS. 6 and 9 , one of the illustrated rows  72  or  74  includes the strip  120  of terminals.  FIG. 8  illustrates another example. In each of the pairs of terminals  50   a  linked by a fuse element  80 , one of the terminals  50   a  belongs to a strip  120  of terminals. In each of these examples, power conducts along the strip  120  to the fuse elements (separate fuse element  80  or surface mount fuse element  88 ) and to the terminals of the fuse-linked row, wherein these terminals electrically connect with wires that run to various load devices, for example, within an automobile. Once one of the fuse elements  80  or  88  opens, a replacement fuse  26  (or a female replacement fuse) remakes a fuse-linked power connection. 
   In alternative embodiments, the bussing could be provided by separate wires or through surface mount traces. If by separate wires, the wires in an embodiment could solder to the terminals. If by surface mount traces, the bussing could be added to the substrate having the surface mount fuse elements. 
   Referring now to  FIG. 11 , an alternative arrangement  140  for the terminals of the present invention is illustrated. The alternative arrangement  140  differs from the arrangement  70  in that three rows  142 ,  144  and  146  of terminals work in cooperation with one another as opposed to the dual row of the arrangement  70 . Three adjacent terminals of the rows  142 ,  144  and  146  work together to form two electrical connections, wherein the arrangement  70  requires four adjacent rows to form two electrical connections. Thus, the arrangement  140  decreases the amount of space needed for the same number of fuse connections by about twenty-five percent. 
   The arrangement  140  provides two different types of terminals, namely the terminals  50   a , which are placed in the outer rows. It should be appreciated that the arrangement  140  can alternatively operate with a substrate, similar to the substrate  110  having the surface mounted fuse elements  88 , wherein terminals  50   b  are placed in the outer rows. Further, the arrangement  140  can alternatively operate with a female replacement fuse, wherein terminals  50   c  or  50   d  are placed in the outer rows. 
   The arrangement  140  also includes double terminals  150 , which are placed in the middle row  144 . The double terminals  150  include mirrored projections  154  and  156  that provide first and second portions for holding two separate elements  80 , for example, via solder joints  82 . The double terminals  150  include a single center projection  152  that cooperates with the mirrored projections  154  to provide two slots for two replacement fuses  26 . Therefore, the alternative arrangement  140  allows for adjacent terminals of adjacent rows of open fuse elements to be replaced with a replacement fuse  26 . 
   In an alternative embodiment, the arrangement  140  provides two male projections, such as two male projections  53  illustrated in  FIGS. 4 and 5 , wherein the arrangement  140  would allow for adjacent terminals of adjacent rows of open fuse elements to be replaced with a female replacement fuse, such as a JCASE® fuse. 
   In the alternative arrangement  140 , the outer rows  142  and  146  of the threesome of rows are staggered to receive the fuse elements  80  from the mirrored grooves defined by the projections  154  and  156 . Also, the terminals  50   a  of the rows  142  and  146  are oriented in opposite directions so as to align the notch or groove defined by the projections  52  and  54  with the notch or groove defined by the projections  152  and  154  of the double terminal  150 . 
   The arrangement  140  includes each of the advantages and embodiments described above in connection with the arrangement  70 . For example, the middle row  144  of terminals  150  can be electrically linked or bussed, for example, by being made and installed in a strip. The strip of terminals  150  enables a common line to bring power to two different rows of electrically connected terminals, which lead to various loads, for example, within an automobile. 
   In an alternative embodiment (not illustrated) a single longer separately mounted fuse element could be woven through and soldered at multiple points to the double terminal  150  and then electrically connected to the two outer adjacent terminals  50   a  via a solder joint  82  as described above. The longer fuse element in an embodiment has the same diameter as the fuse element  80  and is made from any of the materials discussed above for the fuse element  80 . The longer fuse element can also be spiral wound to exhibit time delay characteristics. 
   Referring now to  FIGS. 12 and 13 , a junction box  160  employing the terminal arrangements of the present invention is illustrated. The junction box  160  includes a cover  104 , the protective member  102 , the fuse block  100  and a plug-in wire module  164 . The plug-in wire module  164  connects to a plurality of wires  166 , which are connected to various loads, for example, loads within automobile. The wires  166  also include one or more power wires. 
   Each of the components of the junction box  160  may be made of various desired materials, such as plastic. The fuse block  100  may be cast as a single piece or be assembled from multiple pieces. In a preferred embodiment, the terminals are molded into one of the pieces as described above. The fuse block  100  is illustrated employing the arrangement  70 , which includes two rows of terminals cooperating to produce one fuse connection for each pair of terminals. It should be appreciated however that the fuse block  100  could alternatively employ any of the terminal arrangements disclosed above. 
   The plug-in module  164  enables the wires  166  to make quick electrical connections with the downwardly extending projections  62  of the terminals  50  ( FIGS. 2  to  5 ). The module  164  in an embodiment snap-fits or bolts to the fuse block  152 . The module  164  in one preferred embodiment is removable so that an operator may easily connect and disconnect the wires  166  from the module  164 . 
     FIG. 13  illustrates the assembled junction box  160 , wherein the module is hidden behind the fuse block  100  and the cover  104  is removable.  FIG. 13  also illustrates that the rows  168 ,  170 ,  172 ,  174 ,  176  and  178  of terminals include fuse elements having different ratings. These ratings, as illustrated, are clearly marked on the protective member  102 . In an alternative embodiment, pairs of rows could alternatively have different fuse ratings. For example, each of the fuse elements between the rows  168  and  170  could be rated for thirty amps, while the fuse elements between the rows  172  and  174  are rated for twenty amps, and while the fuse elements between the rows  176  and  178  are rated for ten amps. 
   The terminals electrically connect to the separate fuse elements  80  having varying diameters or to the traces of the surface mount fuse elements  88  having varying width or height. Obviously, the fuse ratings of the junction box  160  can be arranged in any order and be provided in any quantity to suit an automobile manufacturer or other user of the fuse block  100  of the junction box  160  of the present invention. It is also possible to mix and match the various embodiments for the terminals  50   a  to  50   d , and use both male and female replacement fuses. 
   The junction box  160  is simple and lightweight enough to be simultaneously placed in a multitude of different positions within an automobile. Multiple junction boxes  160  having the same or different combinations of fuse ratings could therefore be placed near the loads to which they supply power. A single common power supply line feeds each module  164 . The multitude of wires that run to the loads are shorter because they do not have to run from one master junction box as is now the case in the majority of automobiles. The present invention therefore cuts down on the length and weight of wire that is needed inside of a vehicle. This reduces cost and potential for shorts while increasing dependability and fuel efficiency. 
   It should be understood that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications can be made without departing from the spirit and scope of the present invention and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims.