Patent Publication Number: US-8976000-B2

Title: Blade fuse

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This is a continuation of U.S. Non-Provisional patent application Ser. No. 12/013,997, filed Jan. 14, 2008 entitled “Blade Fuse,” the entirety of which application is incorporated herein by reference. 
    
    
     BACKGROUND 
     The present disclosure relates to fuses and more particularly to blade fuses. 
     Blade fuses, such as automotive blade type fuses are known in the art. Blade fuses protect electrical automotive circuits from short circuits and current overloads. The protection results from a melting of an element of the fuse and therefore an opening of the circuit protected by the fuse. Upon a short circuit or current overload of a certain magnitude and over a predetermined length of time, the fuse element or link breaks or opens. 
     Blade fuses are used extensively in automobiles. Automobile manufacturers are constantly looking for ways to reduce cost, weight and space as much as possible. Blade fuse manufacturers also strive to reduce costs, such as material and manufacturing costs, as much as possible. 
     Automobile manufacturers on the other hand are increasing the amount of electronic control and electrical devices and accessories used in automobiles. The increasing amount of electrical content is forcing increased electrical function within the same space. 
     A need therefore exists for a robust blade type fuse that saves space. 
     SUMMARY 
     The present disclosure relates to blade fuses and in particular blade fuses for use in automobile applications. Automobile manufacturers seek fuses having higher and higher ratings in smaller and smaller packages. The fuses discussed herein attempt to address those needs. 
     In one embodiment, a blade fuse includes a pair terminals and a fuse element. The terminals at their inner edges are narrowed at certain portions to allow a particular fuse element to maintain its desired width, while allowing the overall width of the combined terminals and element to be narrower than they would otherwise would be. This allows an overall narrower fuse to be provided, which saves space. In one embodiment, a gap is provided between the inner edges of the terminals that is at least fifty percent of the overall width of the terminals at the lower edge of fuse mounting portions of the terminals. The gap can be achieved for example by notching out at least thirty-five percent of the inner edges of the terminals. The remaining portions of the terminals at the notches are wide enough to accept or define stake holes that allow the housing to be staked to the terminal portion of the fuse. 
     The notched portions of the terminals can extend through the top edges of the terminals or can be notched only at the portions needed to attach to the fuse element. The notched portions can be aligned with one another or be offset as required by the terminal. The notched edges can alternatively be symmetrical or not symmetrical about a centerline through the fuse. Further, the outer edges of the terminals can be straight or have one or more jog as desired. 
     The elements as discussed herein can have various shapes that fit within the widened gap created by the notches. The shapes can be U-shaped, S-shaped, V-shaped, serpentine or otherwise be curved. The elements can also be straight, e.g., diagonally disposed relative to the terminals. 
     The mounting portions or lower portions of the terminals can be straight. The widths of the lower terminal portions with respect to a gap between the lower portions in one embodiment are structured such that the widths are larger than the gap. This is achieved or aided by the addition of protrusions that extend inwardly from the inside edge of the terminals. Such structure prevents the terminals from extending upwardly into a housing of a second fuse, e.g., during shipping, which could damage the second fuse protected by the housing. Such configuration enables the fuse housing to not have a bottom tab that folds up between the terminals, protecting the inside of the housing. 
     In another primary embodiment, the fuse includes three terminals, wherein the center terminal is a common or buss terminal. The outer terminals are each connected to the inner buss terminal via a separate fuse element. Thus the overall fuse provides two fuses. The inner edges of the three terminals are again notched to allow the element to be as wide sized as desired, while providing an overall narrower fuse than would otherwise be provided if such notches are not provided. The lower or mounting portions of the terminals of the three terminal fuse also have a width that is greater than gaps formed between the terminals, such that again the terminals of one fuse cannot extend between the terminals of another fuse and into the housing of the other fuse covering the two fuse elements. Such structure again allows the housing to not have in this case two lower tabs that would bend up between the three terminals to protect the underside or the housing. 
     The fuse elements of the three terminal fuse can have like or different shapes and ratings. The elements can have any of the shapes discussed herein for the two terminal fuse. Further, the elements can be structured such that the notches defined at the upper portions of the inner edges of the terminals can be aligned, misaligned, continuous, discontinuous, extended through an upper edge or surface of the terminal or not. 
     It is accordingly an advantage of the present disclosure to provide an improved blade fuse. 
     It is another advantage of the present disclosure to provide a narrowed blade fuse. 
     It is a further advantage of the present disclosure to provide a multi-element, triple terminal fuse, which provides an overall narrower profile than two like separate fuses. 
     Moreover, it is an advantage of the present disclosure to structure the lower portions of the fuse terminals such that the lower portions cannot be inserted between like lower portions of another fuse during shipping, in which case the fuses can become wedged together undesirably. 
     Still further, it is an advantage of the present disclosure to provide a blade fuse having a housing, which does not require a lower flap bent up between the terminals of the fuse. 
     Additional features and advantages are described herein, and will be apparent from, the following Detailed Description and the figures. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIGS. 1 to 3  are front, side and top views, respectively, of one embodiment of an assembled blade fuse of the present disclosure. 
         FIGS. 4 to 6  are front, side and top views, respectively, of one embodiment of a metal portion of the fuse of  FIG. 1 . 
         FIGS. 7 to 11  illustrate alternative embodiments for a fuse element of the metal portion the fuse of  FIG. 1 . 
         FIG. 12  is a perspective view of one embodiment of an assembled three-legged, dual fuse element fuse of the present disclosure. 
         FIGS. 13 to 15  are front, side and top views, respectively, of an alternative embodiment of an assembled three-legged, dual fuse element fuse of the present disclosure. 
         FIGS. 16 and 17  are front and top views, respectively, of one embodiment of a metal portion of the fuse of  FIGS. 13 to 15 . 
         FIG. 18  is an exploded front view of the fuse element of section of the metal portion of  FIGS. 16 and 17 . 
     
    
    
     DETAILED DESCRIPTION 
     Referring now to the drawings and in particular to  FIGS. 1 to 11 , one embodiment of a fuse  10  of the present disclosure is illustrated. Fuse  10  includes a conductive or metal portion  20  and an insulating housing  50 . Conductive or metal portion  20  can be made of any suitable conductive material, such as metal. In various embodiments, conductive portion  20  is made of copper, aluminum, zinc, nickel, tin, gold, silver and any alloys or combinations thereof. In alternative embodiments, the conductive portion  20  or sections thereof can be plated with one or more metal or conductive plating. In various embodiments, conductive portion  20  is stamped (cut and trimmed) and coined (made thinner), wire electrical discharge machining (“EDM”) cut and milled, laser cut and milled or electro-etched. 
     Insulating housing  50  is made of any suitable plastic or non-conductive material. For example, housing  50  can be made of any of the following materials: polycarbonate, polyester, polyethylene, polypropylene, polystyrene, polyvinylchloride, polyvinylidene chloride, acrylic, nylon, phenolic, polysulfone and any combination or derivative thereof. Housing  50  in one embodiment is injection molded or extrusion molded. 
     As seen in  FIGS. 1 and 4 , metal portion  20  includes a pair of terminals  22  and  24 . Terminals  22  and  24  are sized and shaped appropriately to be mated to a pair of female terminals (not illustrated) that extend from a fuse block, for example, a fuse block of an automobile. Terminal  22  includes an inner edge  26   a , an outer edge  28   a , an upper edge  30   a  and a lower edge  32   a . Likewise, terminal  24  includes an inner edge  26   b , an outer edge  28   b , an upper edge  30   b  and a lower edge  32   b . Upper edges  30   a  and  30   b  serve as probe points for a user to detect the integrity of a fuse element  40  linking terminals  22  and  24  electrically. 
     As mentioned above, conductive portion  20  includes a fuse element or fuse link  40  that connects terminals  22  and  24  electrically. Fuse element or link  40  is illustrated in  FIGS. 4 ,  7  and  8  as having an inverted “U” or “V” shaped portion  42 , in which the ends of the “U” are connected respectively to terminals  22  and  24  via conductive interfaces  44   a  and  44   b .  FIGS. 9  to  11  illustrate that portion  42  of fuse link  40  can have alternative shapes as desired, such as a serpentine shape, “S” shape, “N” shape, straight shape, etc. 
     As seen best in  FIG. 6 , element  40  can be thinned and/or contoured as needed to produce a fuse  10  having desired electrical opening characteristics. Element  40  is coined, milled or otherwise machined on one surface or side, so that element  40  resides closer to one surface of terminals  22  and  24  as seen best in  FIG. 6 . Element or link  40  and terminals  22  and  24  in an alternative embodiment share a common mid-plane. 
     Fuse element  40  can be made of the same type or different type of material as terminals  22  and  24 . Fuse element  40  and thus fuse  10  are accordingly rated for a desirable amperage. For automotive uses, for example, element  40  and fuse  10  can be rated for from one amp to about eighty amps for short circuits and low-overload events (e.g., events at 135% of fuse rating). For uses other than automotive uses, fuse  10  and element  40  can have different amperage ratings as desired. 
     Terminal  22  defines an upper aperture  34   a  and a lower aperture  36   a . Terminal  24  defines an upper aperture  34   b  and a lower aperture  36   b . Apertures  34   a ,  34   b ,  36   a  and  36   b  are stake holes, which allow housing  50  to be staked to conductive portion  20  as discussed herein. 
     As seen in  FIGS. 1 to 3 , insulating housing  50  includes a top  52  and a body  54 . Top  52  defines probe apertures  56 . Body  54  of housing  50  covers element  40  and at least a portion of the front and back surfaces of terminals  22  and  24 . As seen in  FIG. 2 , housing  50  in the illustrated embodiment covers the outer edges  28   a  and  28   b  of terminals  22  and  24 . Alternatively, because the faces of fuse housing  50  are securely attached to conductive portion  20  via cold or hot staking, housing  50  does not have to cover outer edges  28   a  and  28   b  of terminals  22  and  24 . 
     Body  54  (on both sides) includes or defines outwardly extending projections  60 . Each projection  60  extends outwardly on its side of housing  50  from insulating flange sections  62   a  and  62   b . Flange section  62   a  covers outer parts of the front and rear faces of terminal  22 . Likewise, flange section  62   b  covers outer parts of the front and rear faces of terminal  24 . Flange sections  62   a  and  62   b  include staking areas  64   a ,  66   a ,  64   b  and  66   b , respectively. Those staking areas are provided on both sides of housing  50  in one embodiment. Areas  64   a ,  66   a ,  64   b  and  66   b  are cold staked. The areas are alternatively heated to a temperature sufficient to melt or deform the insulation or plastic material of housing  50  for hot staking. Insulating material (cold staked or heated) extends into apertures  34   a ,  36   a ,  34   b  and  36   b  of terminals  22  and  24 , respectively. The cold or hot staked material provides mechanical attachment between terminal portion  20  and housing  50 . 
     Staking holds housing  50  and conductive portion  20  together and tends to prevent outward pivoting of the surfaces of body  54  relative to top  52  of housing  50 . Staking as shown is performed in multiple places for each terminal  22  and  24 . Staking also tends to prevent element  40 , which is thinner and weaker than the terminals, from bending inadvertently. Staking further tends to prevent terminals  22  and  24  from translating with respect to each other and from pivoting inwardly or outwardly about multiple axes extending perpendicularly from the broad face ( FIG. 4 ) and narrow face ( FIG. 6 ) of terminal portion  20 . 
     As illustrated, housing  50  in one embodiment does not include a flap at its bottom that extends across an opening at the bottom of body  54 , between the faces of body  54 . One important purpose of such tab found on other blade fuses is to prevent a terminal of one fuse from lodging within the housing of another fuse during shipping or otherwise when the fuses are placed together loosely. As seen in  FIG. 4 , the width w 1  and w 2  of terminals  22  and  24 , respectively (which can be the same for both terminals), is wider than a gap distance “g” between terminals  22  and  24 . This prevents terminals  22  and  24  of one fuse  10  from being forced between the terminals of another fuse at any angle. That is, the equivalent width of the other fuse at any angle relative to fuse  10  is wider than the gap distances “g”. 
       FIGS. 2 ,  4 ,  7  and  8  also illustrate that terminal portion  20  of fuse  10  includes projections  72   a  and  72   b , which project inwardly from inner edges  26   a  and  26   b  of terminals  22  and  24 , respectively. Projections  72   a  and  72   b  prevent terminals  22  and  24  of one fuse  10  from being forced into housing  50  of another fuse  10  without having to provide housing  50  with the above-described flap that bends upwardly to close off the bottom of the housing. 
       FIG. 4  shows metal portion  20  of fuse  10  in an intermediate state of manufacturing. Here, a tab  74  connects terminal  22  to terminal  24  to hold terminals  22  and  24  together while various parts of metal portion  20  are stamped and coined (or otherwise formed). Tab  74  protects terminals  22  and  24  from becoming bent or deformed during such process steps. Tab  74  is eventually stamped away (or otherwise removed) to separate terminals  22  and  24  as seen in  FIG. 1 . Outer edges  28   a  and  28   b  of terminals  22  and  24  as seen in  FIGS. 1 and 4  each include a jog  76   a  and  76   b , respectively, which helps to position housing  50  onto metal portion  20 . 
     Fuse  10  of  FIGS. 1 to 11  is advantageous in one respect because it has a terminal portion  20  having a nominal overall width W as seen in  FIG. 4 , which is thinner than that of previously used fuses. In one embodiment, the nominal overall width W as seen in  FIG. 2  is 7.8 mm: the widths w 1  and w 2  of terminals  22  and  24  respectively are the same and are about 2.8 mm. A small gap width g between terminals  22  and  24  is accordingly 2.2 mm. Applicants note that other dimensions can be used, however, the above dimensions yield a center to center distance between terminals  22  and  24  of approximately 5 mm, which Applicants feel will be desirable in the automotive market especially. 
     One constraint in attempting to provide a narrower fuse  10  is that the width of element  40 , shown in  FIG. 4  as larger gap width G, needs to leave enough space for the curved portion  42  of element  40  to have a necessary length and make its necessary bend(s) given the width of the curved portion  42  and the constraints of the forming technique. The bend(s) of curved portion  42  is made so that the overall length of element  40  is sufficient for whatever rating the element is supposed to have. Accordingly, fuse  10  includes notches  46   a  and  46   b  in terminals  22  and  24 , respectively, which narrow the upper portions of the terminals. 
     As illustrated, in one example the terminals are narrowed from 2.8 mm at the bottom to about 1.8 mm at the top. It is expected that the terminals can be narrowed about 35 percent or greater to provide the desired gap width G for terminal  40 , while holding the overall width to a desired narrowed width. Narrowing the terminals  22  and  24  in the illustrated case to about 35.7 percent from 2.8 mm to 1.8 mm and holding the overall nominal width to 7.8 mm yields a big gap width G of about 4.2 mm, which is sufficient to provide the different elements  40  shown in  FIGS. 4 ,  7  and  8 . Thus the gap width G for element  40  can be at least 50 percent of the overall (nominal) width W of fuse  10 . In the illustrated example, terminal gap width G is about 54 percent of the overall nominal width W. Gap width G could be a larger percentage of overall width W if desired. 
     One constraint limiting how big gap width G can be is that the upper widths t 1  and t 2  of terminals  22  and  24  respectively need to be large enough to support staking apertures  34   a ,  34   b ,  36   a  and  36   b , respectively. Those apertures are laser cut, wire EDM&#39;d, punched, stamped, or otherwise formed mechanically and require a sufficient amount of material around the outer diameter of the holes, so that the upper portions of elements  22  and  24  do not bend, rip or become otherwise deformed in forming staking apertures  34   a ,  34   b ,  36   a  and  36   b  and in the staking process itself. 
       FIGS. 7 and 8  show different examples of elements  40  that can be provided within gap width G shown in connection with  FIG. 4 . Each of elements  40  in  FIGS. 7 and 8  includes attachment portions  44   a  and  44   b , which are in at least approximate alignment with one another. Accordingly, notches  46   a  and  46   b  are also in approximate alignment with another. In the embodiment illustrated in  FIGS. 1 to 8 , notches  46   a  and  46   b  are straight from the bottom of the notches through the tops  30   a  and  30   b , respectively, of terminals  22  and  24 . It should be appreciated however that the notches do not have to be straight as shown in more detail below. 
     In  FIG. 7 , element  40  includes a tightly bent U-shaped section  42 , in which the legs of the U are substantially vertical, substantially parallel, although the bend at the top of U-shaped section  42  may actually be slightly greater than 100 degrees. The connection sections  44   a  and  44   b  are rounded and made more robust than the thin bent portion  42 . The width of element  40  can be about 0.5 mm. Element  40  in  FIG. 7  has a rating of about five amps. 
       FIG. 8  illustrates a more V-shaped element  40 , which is wider than the element of  FIG. 7 . For example, the element can be 1 mm wide. Element  40  of  FIG. 8  has a rating of about thirty amps. The gap width G of about 4.2 mm accordingly provides enough room for a full line of fuse element ratings. 
       FIG. 10  illustrates alternative notches  46   a  and  46   b , which can include slanted rather than right-angle notching. Further, connection section  44   a  of terminal  22  is located above connection section  44   b  of terminal  24 , illustrating that the connection sections and associated notches do not have to be aligned or symmetrical to each other. Terminal  24  of  FIG. 10  illustrates that notch  46   b  does not extend all the way through the top  30   b  of the terminal. 
       FIG. 11  illustrates that terminal  40  in one embodiment is straight. Here to achieve the needed length, element  40  is disposed diagonally from an upper connection section  44   a  to a lower connection section  44   b . Notch  46  does not extend all the way through the top  30   b  of terminal  24 . In both  FIGS. 10 and 11 , notch  46   a  begins at a higher elevation point than notch  46   b.    
       FIG. 9  illustrates an inverted U terminal  40 , similar to that of  FIGS. 4 ,  7  and  8 . Here however, as with  FIGS. 10 and 11 , notch  46   a  is located elevationally above notch  46   b . Connection section  44   a  is located above and is not aligned with connection section  44   b . Further, notch  46   b  does not extend through the top of  30   b  of terminal  24 . 
     Referring now to  FIGS. 12 to 18 , fuse  110  illustrates another embodiment of a narrowed fuse of the present disclosure. Fuse  110  includes many of the same components as fuse  10  discussed above. Fuse  110  includes a metal portion  120  and a housing  150 . Any of the materials discussed above for metal portion  20  and housing  50  are equally applicable to metal portion  120  and housing  150  of fuse  110 , including any of the materials for dual elements  140   a  and  140   b.    
     As seen, fuse  110  includes two outer terminals  122  and  124  and a middle terminal  148 . Outer terminal  122  includes an outer edge  128   a , an inner edge  126   a , an upper edge  130   a  and a bottom edge  132   a . Outer terminal  124  likewise includes an inner edge  126   b , an outer edge  128   b , an upper edge  130   b  and a bottom edge  132   b . Middle terminal  148  includes two inner edges  126   c  and  126   d , a top edge  130   c  and a bottom edge  132   c.    
     First outer terminal  122  and middle terminal  148  are connected electrically via a first fuse element  140   a . Middle terminal  148  and second outer terminal  124  are connected electrically via a second fuse element  140   b . In  FIG. 12 , terminals  122 ,  124  and  148  include or define stake holes  134   a ,  134   b ,  136   a ,  136   b ,  138   a  and  138   b , respectively. The stake holes receive staked portions  164   a ,  164   b ,  166   a ,  166   b ,  168   a ,  168   b  of housing  150 , respectively, as discussed above for the staking operation of fuse  10 . 
       FIGS. 13 to 15  show a slightly alternative embodiment of housing  150 . Here, a single staking portion  164 ,  166  and  168  of housing  150  is provided for each terminal. Each terminal as seen in  FIGS. 16 and 18  includes a single stake hole  134 ,  136  and  138 . The metal portions around the stake holes are beefed-up to allow for the stake holes. Elements  140   a  and  140   b  are located above the stake holes  134 ,  136  and  138 . 
     In each embodiment, housing  150  includes a top  152  and body  154 . In the illustrated embodiments, body  154  completely closes conductive portion  120  at the top of portion  120  and does not expose the outer edges  128   a  and  128   b  of terminals  122  and  124  at the top of conductive portion  120 . It should be appreciated that fuse  110  alternatively does expose outer edges  128   a  and  128   b  of terminals  122  and  124 . Body  154 , like body  54  is open at the bottom. This is enabled because gaps g 1  and g 2  between terminals  122 ,  148  and  124 , respectively, are smaller than the widths w 1 , w 2  and w 3  of each of terminals  122 ,  124  and  148 , respectively. Thus, terminals  122 ,  124  and  148  cannot wedge themselves within gaps g 1  and g 2  during shipping. 
     Also, middle terminal  148  includes projections  172   a  and  172   b , which further prevent terminals of other fuses from becoming jammed up inside body  154  of housing  150  without the need for the housing to have dual tabs that bend upward between the terminals to prevent such jamming.  FIG. 16  also shows metal portion  120  in an intermediate stage of manufacture, which has tabs  174   a  and  174   b  between terminals  122 ,  148  and  124 , respectively. Tabs  174   a  and  174   b  are provided for machining stability and are eventually removed to expose separate terminals  122 ,  148  and  124  as seen in  FIG. 13 . 
     As seen in the embodiment of  FIGS. 13 ,  16  and  18 , the staking of housing  150  to conductive portion  120  is done beneath elements  140   a  and  140   b . Here, middle portions of terminals  122 ,  124  and  148  are provided with the staking holes. This configuration allows upper portions of the terminals having widths t 1 , t 2  and t 3  as seen in  FIG. 15  to be narrower if necessary because those portions do not have to support a stake hole. Alternatively or additionally, one or more stake hole is provided near the top of terminals  122 ,  124  and/or  148 . Staking of housing  150  to conductive portion  120  provides each of the benefits discussed above for fuse  10 . 
     Also, the width t 2  is thickened (relative to t 1  and t 3 , such that the upper portion of center terminal  148  can serve as a common buss for the fuse. In one embodiment the centers of curved portions  142   a  and  142   b  of terminals  140  and  140   b  are not aligned with the centers between centerlines of the bottom of terminals  122 ,  148  and  124 . That is, if each of the centers of terminals  122  and  148  and  148  and  124  are spaced apart 5 mm, the centers of curved portions  142   a  and  142   b  are not spaced apart 2.5 mm between the centers of terminals  122  and  148  and  148  and  124 . Instead the centers of curved portions  142   a  and  142   b  are moved, e.g., outwardly to account for the thickening of center thickness t 2 . 
       FIGS. 12 and 15  show that housing  150  provides three probe openings  156 ,  158  and  160 , such that each of top edges  130   a ,  130   b  and  130   c  of terminals, respectively, can be accessed to determine the integrity of, in this case, two separate fuses. In the illustrated embodiment, middle terminal  148  is a common buss for both outer terminals  122  and  124 . Thus to test integrity of element  140   a  the operator tests edges  130   a  and  130   c . Likewise to test the integrity of element  140   b  the operator tests probes points  130   b  and  130   c . Making middle terminal  148  the common terminal or buss terminal between the two fuses allows elements  140   a  and  140   b  to be placed between terminals  122  and  148  and terminals  148  and  124 , respectively, such that overall space consumed by conductive portion  120  is minimized. 
     Fuse  10  indeed provides two independently operating fuses. The collective width of the overall fuse is narrowed via the same apparatus discussed above for fuse  10 . In particular, the upper portions of terminals  122 ,  124  and  148  provided along the inner edges  126  (referring collective to edges  126   a  to  126   d ) are notched at notches  146   a ,  146   b ,  146   c  and  146   d , respectively. Such notches allow elements  140   a  and  140   b  to be sized as needed, while allowing the overall (nominal) width W to be narrowed with respect to how wide it would have to be if such notches were not provided. Elements  140   a  and  140   b  can be rated the same or differently. Further, elements  140   a  and  140   b  can have any of the configurations shown in connection with fuse  10 . Any of the alternative embodiments for attachment sections  144  (referring collectively to attachment sections  144   a  to  144   d ) and notches  146  (referring collectively to notches  146   a  to  146   d ) discussed above for corresponding connection points and notches for fuse  10  are also applicable for fuse  110 . 
     Fuse  110  in an embodiment also provides terminals  122 ,  124  and  148  that have a center to center distance of 5 mm. That is, in one implementation the center to center distance between terminals  122  and terminal  148  is 5 mm, while the center to center distance of terminal  148  to terminal  124  is also 5 mm. In one embodiment, the nominal overall width W is 12.8 mm. Each terminal with w 1 , w 2  and w 3  is the same and is 2.8 mm. Terminal gaps g 1  and g 2  are the same and are each 2.2 mm in one implementation. Outer surfaces  128   a  and  128   b  of outer terminals  122  and  124  as seen in  FIGS. 12 and 16  each show a jog  176   a  and  176   b , respectively, which helps to position housing  150  onto metal portion  120 . 
     In an embodiment, widths t 1  and t 2  are the same. Width t 3  is thickened as discussed above and sized to allow element gaps G to each be about 4.2 mm for both fuses of the pair included in overall fuse  110 . Alternatively, gap G for element  140   a  is different than gap G for element  140   b.    
     In any of the embodiments described herein, the metal portion  20  or  120  begins with a stock metal, such as zinc. The stock is then plated, e.g., with copper or nickel and then silver or tin. The element area ( 40 ,  140 ) of the metal portion  20  or  120  is then skived to remove any unwanted plating, e.g., to remove a copper/silver plating, a copper/tin plating, a nickel/silver plating or a nickel/tin plating, leaving the bare base metal, e.g., zinc at element area ( 40 ,  140 ) and the terminals plated. Metal portion  20  or  120  is then formed as discussed herein, e.g., via repeated coining (thinning) and stamping (metal removing) steps. 
     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 subject matter and without diminishing its intended advantages. It is therefore intended that such changes and modifications be covered by the appended claims.