Patent Description:
An electrical relay is a device that enables a connection to be made between two electrodes in order to transmit a current. Some relays include a coil and a magnetic switch. When current flows through the coil, a magnetic field is created proportional to the current flow. At a predetermined point, the magnetic field is sufficiently strong to pull the switch's movable contact from its rest, or de-energized position, to its actuated, or energized position pressed against the switch's stationary contact. When the electrical power applied to the coil drops, the strength of the magnetic field drops, releasing the movable contact and allowing it to return to its original de-energized position. As the contacts of a relay are opened or closed, there is an electrical discharge called arcing, which may cause heating and burning of the contacts and typically results in degradation and eventual destruction of the contacts over time.

A solenoid is a specific type of high-current electromagnetic relay. Solenoid operated switches are widely used to supply power to a load device in response to a relatively low level control current supplied to the solenoid. Solenoids may be used in a variety of applications. For example, solenoids may be used in electric starters for ease and convenience of starting various vehicles, including conventional automobiles, trucks, lawn tractors, larger lawn mowers, and the like.

Current solenoids and fuses are typically separated into separate systems, thus requiring different modules and associated wiring. Additionally, internal fuses and solenoids are not sufficiently protected from harsh operating environments, leading to damage of the solenoids and/or fuses.

The abstract of <CIT> that discloses an apparatus according to the preamble of claim <NUM> states: An electrical junction box has a fuse module with a plurality of fuse attachment portions open into a first side face and arranged side by side in a plurality of tiers that are placed one above another. A plurality of connector attachment portions and in which respective input terminals and of the fuse module are disposed are provided so as to open into a second side face that is perpendicular to the first side face and are disposed in mutually shifted positions in a direction in which the tiers of the fuse attachment portions are placed one above another.

The abstract of <CIT> states: The electric vehicle electrical component assembly provided by the invention includes a housing, a cover, electrical components, a fuse and a laminated busbar assembly. The housing and the cover form an inner cavity; the electrical components and the fuse are located in the inner cavity. The laminated busbar assembly includes a metal busbar group and an insulating substrate, and the electrical components include a motor control module, a charging module and a battery connection module; the metal busbar group is detachably connected between the charging module and the battery connection module; the metal busbar group is detachably connected to the Connected between the motor control module and the battery connection module. System integration design of key electrical components of electric vehicles. Some important electrical components share some electronic components. The product is easy to install, simplifies circuit design, reduces the difficulty of vehicle electrical layout, reduces the vehicle space occupied by the electrical system, and improves the electromagnetic compatibility of the system. ,reliability. The integrated heat dissipation efficiency can be higher than that of the original discrete components, thereby increasing the power density of the entire integration and reducing costs.

In view of the foregoing, it would be advantageous to provide an apparatus according to the features of independent claim <NUM>.

The addition to the state of the art is defined in the appended claims.

The drawings are merely representations, not intended to portray specific parameters of the disclosure. The drawings are intended to depict typical embodiments of the disclosure, and therefore should not be considered as limiting in scope. In the drawings, like numbering represents like elements.

Furthermore, certain elements in some of the figures may be omitted, or illustrated not-to-scale, for illustrative clarity. Cross-sectional views may be in the form of "slices", or "near-sighted" cross-sectional views, omitting certain background lines otherwise visible in a "true" cross-sectional view, for illustrative clarity. Furthermore, for clarity, some reference numbers may be omitted in certain drawings.

Fuse apparatuses and assemblies in accordance with the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which embodiments of the system and method are shown. The fuse apparatuses and assemblies, however, may be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the system and method to those skilled in the art.

Approaches herein provide a solution to combine solenoids and fuses into an integrated, compact housing assembly. In some embodiments, a printed circuit board assembly (PCBA) may be provided within the housing to allow sharing of power and multiple outputs, which may be controlled by a PCBA controller. A sealed cover of the housing protects the internally positioned fuses and solenoids from harsh environmental conditions.

As will be further evident by the discussion that follows, at least the following advantages are achieved by the embodiments of the present disclosure. Firstly, the present disclosure integrates multiple solenoids and fuses into one smart structure, thus eliminating the need for different modules and associated wirings. Instead, the wiring layout is simplified, and thus the assembly time reduced. Secondly, the fuses and solenoids are housed in a sealed box that protects the components from dust, water, and other contaminants. Thirdly, protection is also ensured by a vent that is waterproof yet air permeable, thus permitting circulation within the housing. Fourthly, when bi-stable solenoids are employed, pulse control to drive coils in a short time may eliminate thermal issues.

Referring to <FIG>, an exemplary embodiment of a fuse apparatus/assembly (hereinafter, "assembly") <NUM> in accordance with the present disclosure is shown. The exemplary assembly <NUM> includes a housing <NUM> including a main body <NUM>, a cover <NUM> coupled to a first side <NUM> of the main body <NUM>, and a base <NUM> coupled to a second side <NUM> of the main body <NUM>. Although non-limiting, the various components of the housing <NUM> may be made of an insulating material, such as an insulating plastic, e.g., nylon, glass-filled nylon, polyester and polycarbonate. In various embodiments, the main body <NUM>, the cover <NUM>, and the base <NUM> can be made of the same or different materials.

As will be described in greater detail below, the cover <NUM> and the main body <NUM> defines a fuse cavity <NUM>. The fuse cavity <NUM> includes a plurality of circuit protection devices, e.g., fuses <NUM>, disposed therein. Furthermore, the base <NUM> and the main body <NUM> define a main cavity <NUM> housing a plurality of solenoids <NUM> and a printed circuit board (PCB) <NUM> therein. More specifically, the main cavity <NUM> may be surrounded by a first wall <NUM>, a pair of side walls <NUM> and <NUM>, a pair of end walls <NUM> and <NUM>, and the base <NUM>. In some embodiments, the solenoids <NUM> may be electrically connected to the PCB <NUM>.

The cover <NUM> can be removed, for example, to replace an opened fuse <NUM> within the fuse cavity <NUM>. In some embodiments, the cover <NUM> can snap-fit to the main body <NUM> and/or include one or more latching fasteners <NUM> to releasably secure the cover <NUM> to the main body <NUM>. Although not specifically illustrated, the cover <NUM> may also include means to further facilitate grasping and removal, such as tabs, projections, recesses, etc. In some embodiments, the cover <NUM> may be tethered to the main body <NUM> by a flexible connector <NUM>. As further shown, the cover <NUM> may include a sealing member <NUM> that prevents dust, moisture, and other contaminants from entering the fuse cavity <NUM> and the main cavity <NUM>.

Turning now to <FIG>, the main body <NUM> of the housing <NUM> according to embodiments of the present disclosure will be described in greater detail. As shown, the main body <NUM> may include the first wall <NUM> connected to the pair of side walls <NUM>, <NUM> and to the pair of end walls <NUM>, <NUM>. In some embodiments, the main body <NUM> may include a fuse perimeter wall <NUM> extending from the first wall <NUM>, wherein the fuse perimeter wall <NUM> is configured to extend around and above the fuses <NUM> (<FIG>). As shown, the fuse perimeter wall <NUM> may define at least an upper portion of the fuse cavity <NUM>. A lower wall <NUM> of the fuse cavity <NUM> may include one or more recesses <NUM> configured to receive one or more fuses <NUM> therein.

Although non-limiting, the fuse perimeter wall <NUM> may generally extend normal to a plane defined by an outer surface of the first wall <NUM>. As shown, the fuse perimeter wall <NUM> may include an outer ledge <NUM> and one or more support walls <NUM> operable to engage and support the cover <NUM> (<FIG>) when the main body <NUM> and the cover <NUM> are joined together. As further shown, a pin <NUM> may extend between the support walls <NUM>, wherein the pin <NUM> permits rotation of the latching fasteners <NUM> (<FIG>) thereabout.

Turning now to <FIG>, a close-up view of a physical connection between the cover <NUM> and the main body <NUM> according to embodiments of the present disclosure will be described in greater detail. As shown, the cover <NUM> may be directly coupled to the fuse perimeter wall <NUM> along the first side <NUM> of the main body <NUM>. In some embodiments, the cover <NUM> may include an attachment component <NUM> engaged with the fuse perimeter wall <NUM> and with the fastener <NUM>. Specifically, the attachment component <NUM> may include a head <NUM> extending from a neck <NUM>, wherein the neck <NUM> extends from an outer surface <NUM> of the cover <NUM>. As further shown, an inner surface <NUM> of the head <NUM> may engage an outer surface <NUM> of the fuse perimeter wall <NUM>. In some embodiments, a bottom corner of the head <NUM> may engage with the outer ledge <NUM> along the outer surface <NUM> of the fuse perimeter wall <NUM>. At an opposite end of the inner surface <NUM>, an upper corner <NUM> and/or engagement surface of the head <NUM> may engage with a corresponding latching surface <NUM> of the fastener <NUM> to maintain a secure connection between the fastener <NUM> and the cover <NUM> when the fastener <NUM> is in a closed position.

As further shown, the sealing member <NUM> may extend around the outer surface <NUM> of the cover <NUM>, and along/adjacent an inner surface <NUM> of the fuse perimeter wall <NUM>. More specifically, the sealing member <NUM> may be disposed within a slot <NUM> of the cover <NUM>. As shown, a portion of the fuse perimeter wall <NUM> may also extend into the slot <NUM>. In some embodiments, the slot <NUM> may extend around an entire perimeter of the cover <NUM> to provide protection to the components enclosed by the cover <NUM> and the main body <NUM>. The sealing member <NUM> may include a cap <NUM> configured to extend over, and engage with, an upper surface <NUM> of the fuse perimeter wall <NUM>. Connected with the cap <NUM> may be a series of ridges <NUM> engaged with the inner surface <NUM> of the fuse perimeter wall <NUM>. During use, the sealing member <NUM> acts as a mechanical gasket seated in the slot <NUM>, wherein compression resulting from engagement between the cover <NUM> and the main body <NUM> creates a seal at the interface thereof. Specifically, the cap <NUM> may be pressed against the upper surface <NUM> by the head <NUM> and the neck <NUM> of the attachment component <NUM>, while the ridges <NUM> may be sandwiched between the inner surface <NUM> of the fuse perimeter wall <NUM> and the outer surface <NUM> of the cover <NUM>. Although non-limiting, the sealing member <NUM> may be an elastomer or a polymer, such as polyethylene, PVC, nylon, etc..

As further shown in <FIG>, the plurality of fuses <NUM> is be disposed within the fuse cavity <NUM>. In some embodiments, one or more fuses <NUM> are retained within respective recesses <NUM> in the lower wall <NUM>, while fuse 124A may be directly coupled to an inner side <NUM> of the cover <NUM>. The fuse 124A is be secured to the cover <NUM> by a pair of bolts or screws <NUM>. In some embodiments, the PCB <NUM> may be coupled to the lower wall <NUM> by a plurality of fasteners <NUM> (e.g., screws) secured within corresponding openings, wherein the PCB <NUM> is retained within the main cavity <NUM>. Although non-limiting, the lower wall <NUM> may generally separate the fuse cavity <NUM> from the main cavity <NUM> of the housing <NUM>.

Turning now to <FIG>, a cross-sectional view of the assembly <NUM> taken along cutline <NUM>-<NUM> of <FIG> will be described in greater detail. As shown, the assembly <NUM> may include a solenoid housing <NUM> disposed within the main cavity <NUM>, wherein the solenoid housing <NUM> includes a plurality of cavities <NUM> each containing a respective solenoid <NUM> therein. In some embodiments, the solenoid housing <NUM> may be disposed directly atop and/or adjacent an inner surface <NUM> of the base <NUM>.

During use, each solenoid <NUM> may be operable to electrically engage and disengage one or more conductive plates <NUM> coupled to respective fuses <NUM> (not shown) upon respective application of power to the solenoid <NUM>. As shown, the conductive plate(s) <NUM> may have one or more contacts <NUM> operable to engage a corresponding contact <NUM> of the solenoid <NUM>.

Although non-limiting, one or more of the solenoids <NUM> may be a bi-stable electrical solenoid switch having a plunger responsive to a magnetic field. Although not shown, the solenoids <NUM> may be connected to a circuit. For example, a controller, such as printed circuit board assembly (PCBA) controller, may operate with the solenoids <NUM> to provide electrical connection between the solenoids <NUM>, one or more power sources, and other circuitry. In exemplary embodiments, the PCB <NUM> may the electromechanical connection between these various components.

Turning now to <FIG>, the base <NUM> of the housing <NUM> according to embodiments of the present disclosure will be described in greater detail. As shown, the base <NUM> may include a main wall <NUM> joined together with a pair of sidewalls <NUM>, <NUM> and a pair of end walls <NUM>, <NUM>. When joined together, the base <NUM> and the main body <NUM> are generally planar or flush with one another along the second side <NUM>, as demonstrated in <FIG>. The base <NUM> and the main body <NUM> may be joined together using virtually any means, such as a plurality of fasteners <NUM>. Embodiments herein are not limited in this context, however.

As shown in <FIG>, the base <NUM> may include a plurality of support pillars <NUM> extending into the main cavity <NUM>. The support pillars <NUM> may be operable to support one or more components of the assembly <NUM>, e.g., the PCB <NUM> (not shown). In exemplary embodiments, the support pillars <NUM> may be integrally formed with the main wall <NUM> Embodiments herein are not limited to any number or configuration of support pillars <NUM> however.

As further shown in <FIG>, a vent <NUM> may be formed through the main wall <NUM> of the base <NUM>. In other embodiments, the vent <NUM> may be formed through any of the sidewalls <NUM>, <NUM> or the end walls <NUM>, <NUM>. Advantageously, the vent <NUM>, which may be provided directly adjacent a mounting surface (not shown), allows a fluid such as air to flow in and out of the housing <NUM>, thus ensuring that a large pressure differential does not occur, e.g., due to self-heating of components (e.g., the fuses <NUM>) within the housing <NUM>. Minimizing the pressure differential between the interior of the housing <NUM> and the exterior of the housing <NUM> also decreases stress on the seals (e.g., sealing member <NUM>) and fasteners (e.g., latch). In some embodiments, the vent <NUM> may include multiple channels (not shown) extending along main wall <NUM> of the base <NUM> to increase air flow and decrease potential for obstruction from contaminants. Furthermore, providing the vent <NUM> through main wall <NUM> of the base <NUM> may enable the housing <NUM> to be mounted in a variety of diverse locations, thus increasing versatility and value.

In some embodiments, the vent <NUM> may include a cover <NUM> including a membrane, such as an expanded polytetrafluoroethylene membrane. The cover <NUM> may be both waterproof and air permeable/breathable to allow air to pass therethrough. Although not shown, the vent <NUM> may include one or more support components extending across a vent opening for supporting the cover <NUM>. Furthermore, although the vent <NUM> and cover <NUM> are depicted as cylindrically shaped, other shapes and configurations for both the vent <NUM> and the cover <NUM> are possible in various alterantive embodiments.

As described above, the PCB <NUM> may provide the circuit routing between the fuses and terminal connections. In some embodiments, the PCB <NUM> includes traces that run from the fuse mounting terminals to the connector terminals, stud connectors, etc. The PCB <NUM> may be made of FR-<NUM> material but can alternatively be ceramic if a more rigid material is needed. The PCB <NUM> can be single or multilayered and is customized as desired by the customer. The PCB <NUM> can provide a wider trace that serves as a buss bar or common connection for the fuse mounting terminals and connector terminals.

The PCB <NUM> can also hold other types of circuit protection, such as overvoltage protection in the form of medal oxide varistors ("MOV's"), diodes, and thyristors. The overvoltage protection devices can be used for example to protect low operating voltage or signal level devices placed in the automobile. The overvoltage protection devices can be mounted on a same side of the PCB <NUM> as the fuses or be located on the opposite or bottom side of the PCB <NUM>.

The foregoing discussion has been presented for purposes of illustration and description and is not intended to limit the disclosure to the form or forms disclosed herein. For example, various features of the disclosure may be grouped together in one or more aspects, embodiments, or configurations for the purpose of streamlining the disclosure. However, it should be understood that various features of the certain aspects, embodiments, or configurations of the disclosure may be combined in alternate aspects, embodiments, or configurations. Moreover, the following claims are hereby incorporated into this Detailed Description by this reference, with each claim standing on its own as a separate embodiment of the present disclosure.

Accordingly, the terms "including," "comprising," or "having" and variations thereof are open-ended expressions and can be used interchangeably herein.

The phrases "at least one", "one or more", and "and/or", as used herein, are open-ended expressions that are both conjunctive and disjunctive in operation.

All directional references (e.g., proximal, distal, upper, lower, upward, downward, left, right, lateral, longitudinal, front, back, top, bottom, above, below, vertical, horizontal, radial, axial, clockwise, and counterclockwise) are only used for identification purposes to aid the reader's understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of this disclosure. Connection references (e.g., attached, coupled, connected, and joined) are to be construed broadly and may include intermediate members between a collection of elements and relative movement between elements unless otherwise indicated. As such, connection references do not necessarily infer that two elements are directly connected and in fixed relation to each other.

Furthermore, identification references (e.g., primary, secondary, first, second, third, fourth, etc.) are not intended to connote importance or priority, but are used to distinguish one feature from another. The drawings are for purposes of illustration only and the dimensions, positions, order and relative sizes reflected in the drawings attached hereto may vary.

Claim 1:
An apparatus (<NUM>), comprising:
a housing (<NUM>) including a main body (<NUM>), a cover (<NUM>) coupled to a first side (<NUM>) of the main body, and a base (<NUM>) coupled to a second side (<NUM>) of the main body, wherein the cover and the main body define a fuse cavity (<NUM>), and wherein the base and the main body define a main cavity (<NUM>);
a plurality of circuit protection devices (<NUM>) disposed within the fuse cavity (<NUM>); and
a plurality of solenoids (<NUM>) electrically connected to a printed circuit board (PCB) (<NUM>), wherein the plurality of circuit protection devices is disposed above the PCB, and wherein the PCB is positioned within the main cavity, characterized in that at least one (124A) of the plurality of circuit protection devices (<NUM>) is directly coupled to an inner side (<NUM>) of the cover (<NUM>).