Patent Description:
In the global automotive market there has been a trend toward implementing so-called "pre-fuse boxes" that are disposed within automobile engine compartments and connected to automobile battery terminals. The primary purpose of a pre-fuse box in an automobile is to prevent electrical damage that may result from short-circuiting in high-current-conducting wires, such as may occur in the event of an accident.

Existing pre-fuse boxes are typically quite large and are mounted adjacent automobile batteries with flexible, conductive leads providing electrical connections therebetween. This type of arrangement requires a great deal of space within an automobile engine compartment where space is already very limited. In some implementations, a pre-fuse box may be connected directly to a terminal of an automobile battery, with a substantial portion of the pre-fuse box hanging off of the side of the battery so that the pre-fuse box does not extend into a required, empty "pedestrian protection zone" above the battery and below the hood of an automobile. However, such "hanging" configurations necessitate strain relief features in the pre-fuse box that increase design complexity and cost. Fuse modules are for instance disclosed in <CIT>.

A fuse module in accordance with the present invention includes a mounting block formed of an electrically insulating material, the mounting block having a rear wall extending from a base, a fuse plate including a planar, electrically conductive bus bar disposed immediately adjacent and in a parallel relationship with a rear surface of the rear wall, a fusible element electrically connected to the bus bar and disposed adjacent a front surface of the rear wall, and a fuse terminal electrically connected to the fusible element and extending onto a top of the base. The fuse module includes an electrically conductive terminal post extending from the top of the base through the fuse terminal for facilitating connection to an electrical component.

A low profile integrated fuse module in accordance with the present disclosure will now be described more fully with reference to the accompanying drawings, in which preferred embodiments of the fuse module are presented. It will be understood, however, that the fuse module 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 convey certain exemplary aspects of the fuse module to those skilled in the art.

Referring to <FIG>, a perspective view illustrating a low profile integrated fuse module <NUM> (hereinafter "the fuse module <NUM>") in accordance with an example not part of the present invention is shown. As will be described in greater detail below, the fuse module <NUM> may be coupled directly to a positive terminal of an automobile battery with no flexible electrical conductors extending therebetween, and may provide overcurrent protection for a plurality of electrical loads that are powered by the battery. Advantageously, the fuse module <NUM> has a low profile and includes an integrated mounting structure that allows the fuse module <NUM> to be implemented in a compact, space-saving form factor relative to pre-fuse boxes that are currently available on the market.

For the sake of convenience and clarity, terms such as "front," "rear," "top," "bottom," "up," "down," "vertical," and "horizontal" may be used herein to describe the relative placement and orientation of various components of the fuse module <NUM>, each with respect to the geometry and orientation of the fuse module <NUM> as it appears in <FIG>. Said terminology will include the words specifically mentioned, derivatives thereof, and words of similar import.

The fuse module <NUM> may generally include a mounting block <NUM>, a plurality of terminal posts 14a-d, a fuse plate <NUM>, and a cover <NUM>. Referring to <FIG>, a perspective view illustrating the mounting block <NUM> and the terminal posts 14a-d is shown with the fuse plate <NUM> and the cover <NUM> omitted for clarity. The mounting block <NUM> may be an elongate body formed of an electrically insulting material (e.g., plastic, polymer, etc.), and may generally include a base <NUM> and a rear wall <NUM> that adjoin one another at a right angle to define a substantially L-shaped cross section as best shown in <FIG>. A plurality of base ridges 24a-e and rear wall ridges 26a-e may extend from the top surface of the base <NUM> and the rear surface of the rear wall <NUM>, respectively, horizontally intermediate and/or adjacent the terminal posts 14a-d. The mounting block <NUM> may further include substantially planar crimping flanges 25a, b extending from longitudinal ends thereof.

The terminal posts 14a-d may be disposed intermediate the base ridges 24a-e and may extend vertically from the top surface of the base <NUM> to a height substantially equal to that of the rear wall <NUM>. The terminal posts 14a-d may include respective threaded shafts 27a-d with respective mounting flanges 28a-d extending from lower ends thereof. The mounting flanges 28a-d may be disposed within respective cavities 30a-d in the base <NUM> as best shown in <FIG>. The top surfaces of the flanges 28a-d may be exposed and may be substantially coplanar with, or disposed slightly above, the top surface of the base <NUM>. In one example, the base <NUM> of the mounting block <NUM> may be over molded onto the flanges 28a-d. The flanges 28a-d may include radial protrusions <NUM> (see <FIG>), similar to the teeth of a gear, which may prevent rotation of the flanges 28a-d within the cavities 30a-d.

Referring to <FIG>, a plan view illustrating the fuse plate <NUM> in isolation and in an unassembled state is shown. The fuse plate <NUM> may be formed from a single piece of conductive material (e.g., stamped from a sheet of copper) and may include a plurality of fuse terminals 32a-d connected to a bus bar <NUM> by respective fusible elements 36a-d. The fuse plate <NUM> is depicted as including four fuse terminals 32a-d and four fusible elements 36a-d, but this is not intended to be limiting, and it is contemplated that the fuse plate <NUM> may include a fewer number (as few as one) or a greater number of fuse terminals and fusible elements without departing from the present disclosure. In a non-limiting example, fuse plate <NUM> may be formed of <NUM>-millimeter-thick copper sheet, and each of the fusible elements 36a-d may have a rating of <NUM> amps. It will be appreciated that the fuse plate <NUM> is not limited in this regard, and that the fuse plate <NUM> may be formed of various other conductive materials and/or with different thicknesses to achieve different current ratings in the fusible elements 36a-d.

The fuse plate <NUM> may further include first and second crimping tabs 38a, b extending from a rear and a longitudinal end of the bus bar <NUM>, respectively. The bus bar <NUM> may further include a mounting aperture <NUM> formed therethrough adjacent a longitudinal end thereof, and the fuse terminals 32a-d may include respective mounting apertures 42a-d formed therethrough.

During assembly of the fuse module <NUM>, the fuse plate <NUM> may be bent or folded such that the fuse plate <NUM> may be wrapped about, and secured to, the mounting block <NUM> in a substantially conformal relationship with various surfaces thereof. For example, referring to <FIG>, a series of views are presented that illustrate one manner in which the fuse plate <NUM> may be bent or folded during assembly of the fuse module <NUM>. Specifically, in a first assembly step shown in <FIG>, the fuse terminals 32a-d may be bent or folded <NUM> degrees in a first direction about a first fold line L1 that is parallel to the bus bar <NUM> and that is proximate the fusible elements 36a-d, and may be bent or folder <NUM> degrees in a second direction opposite the first direction about a second fold line L2 that is parallel to the bus bar <NUM> and that is intermediate the first fold line L1 and the mounting apertures 42a-d.

In a second assembly step shown in <FIG>, the fuse plate <NUM> may be placed on the mounting block <NUM> with the bent fuse terminals 32a-d disposed in engagement with the top surface of the base <NUM> and the front surface of the rear wall <NUM>, and with the terminal posts 14a-d extending through the mounting apertures 42a-d (not within view), respectively. With the fuse plate <NUM> positioned thusly, the fuse terminals 32a-d may be bent or folded <NUM> degrees about a third fold line L3 that is parallel to the bus bar <NUM> and that is intermediate the first fold line L1 (see <FIG>) and the fusible elements 36a-d. The fusible elements 36a-d may extend over respective recesses 46a-d defined by, and located intermediate, respective pairs of the rear wall ridges 26a-e, with the fusible elements 36a-d spaced apart from the rear surface of the rear wall <NUM> by respective pairs of shoulders 48a-d that extend from the rear surface of the rear wall <NUM> inward of the rear wall ridges 26a-e. While the fusible elements 36a-d are shown and described herein as being disposed behind and adjacent the rear surface of the rear wall, various alternative examples of the present disclosure are contemplated in which one or more of the fusible elements 36a-d may be disposed in front of and adjacent the front surface of the rear wall <NUM>.

In a third assembly step shown in <FIG>, the fuse plate <NUM> may be bent or folded <NUM> degrees about a fourth fold line L4 that is parallel to the bus bar <NUM> and intermediate the first fold line L1 and the bus bar <NUM>. The bus bar <NUM> may thus be disposed in flat abutment with the bottom surface of the base <NUM> with the mounting aperture <NUM> of the bus bar <NUM> located beyond a longitudinal end of the base <NUM>.

In a fourth assembly step shown in <FIG>, the first and second crimping tabs 38a, b may be bent about the crimping flanges 25a, b of the mounting block <NUM>, respectively. The fuse plate <NUM> may thus be securely held to the mounting block <NUM>. It will be appreciated that the depicted arrangement and configuration of the crimping tabs 38a, b and crimping flanges 25a, b is merely exemplary, and that the arrangement, configuration, location, size, and/or shape of one or more of the crimping tabs 38a, b and crimping flanges 25a, b may be varied without departing from the present disclosure. It will also be appreciated that, in various alternative examples of the fuse module <NUM>, it is contemplated that one or more of the crimping tabs 38a, b and crimping flanges 25a, b may be omitted, and/or that the fuse plate <NUM> may be secured to the mounting block <NUM> using any of a variety of mechanical fasteners, adhesives, etc..

Referring now to <FIG>, the cover <NUM> of the fuse module <NUM>, which may be formed of an electrically insulating material similar to that from which the mounting block <NUM> is formed, may be an elongated member having a generally L-shaped cross sectional shape defined by a rear wall <NUM> and a top wall <NUM>. The rear wall <NUM> may be disposed in flat abutment with the rear wall <NUM> of the mounting block <NUM> and may be securely fastened thereto, such as by ultrasonically welding the rear wall <NUM> to the rear wall ridges 26a-e (not within view), for example. The top wall <NUM> may extend over a top edge of the rear wall <NUM> of the mounting block <NUM>. The cover <NUM> may be disposed over the fusible elements 36a-d (not within view) for protecting the fusible elements 36a-d from ambient particulate as well as for containing electrical arcing in the fusible elements 36a-d that may occur during overcurrent conditions.

Referring to <FIG>, a front view illustrating the fuse module <NUM> installed on an automobile battery <NUM> is shown. The fuse module <NUM> may be entirely disposed on a top surface of the automobile battery <NUM> with a positive terminal <NUM> of the automobile battery <NUM> extending through the mounting aperture <NUM> of the bus bar <NUM>. A nut or other fastener (not shown) may be tightened onto the positive terminal <NUM> and may secure the bus bar <NUM> to the positive terminal <NUM> in electrical communication therewith. The terminal posts 14a-d may receive ring terminals of conductors (not shown) which may be secured the against the fuse terminals 32a-d in electrical communication therewith with nuts (not shown) that may be tightened onto the threaded shafts 27a-d. Thus, various electrical systems or components of an automobile may be electrically coupled to the positive terminal <NUM> of the automobile battery <NUM> via the fuse terminals 32a-d, the fusible elements 36a-d, and the bus bar <NUM>, with the fusible elements 36a-d providing over-current protection between the automobile battery <NUM> and such electrical systems or components.

It will be appreciated by those of ordinary skill in the art that the fuse module <NUM> of the present disclosure provides numerous advantages relative to pre-fuse boxes that are currently available on the market. For example, the entire fuse module <NUM> can be mounted directly to a positive terminal of an automobile battery in close proximity thereto without any flexible conductors extending therebetween. This provides a significant space and material savings relative to conventional pre-fuse boxes. Additionally, owing to the low profile (i.e., short) form factor of the fuse module <NUM>, the fuse module <NUM> may be entirely disposed on top of an automobile battery (as shown in <FIG>) and may extend to a vertical height that is shorter than that of other components within an automobile engine compartment. The fuse module <NUM> therefore does not extend into the required pedestrian protection zone below a hood of an automobile. For example, as shown in <FIG>, the fuse module <NUM> extends to a vertical height that is shorter than that of the positive terminal <NUM> of the automobile battery <NUM>. Additionally, since the fuse module <NUM> can be entirely disposed on top of an automobile battery, the fuse module <NUM> does not require any strain relief features or structures that are typically necessary for the implementation of conventional pre-fuse boxes that hang off of the side of an automobile battery.

Referring to <FIG> a fuse module <NUM> in accordance with another example not part of the present invention is shown. The fuse module <NUM> may be substantially similar to the fuse module <NUM> described above, with a fuse plate <NUM> wrapped about a mounting block <NUM> and with terminal posts 114a-d extending through respective mounting apertures 142a-d in fuse terminals 132a-d of the fuse plate <NUM>. The fuse module <NUM> differs from the above described fuse module <NUM> in that the mounting block <NUM> does not have a rear wall (e.g., the rear wall <NUM> shown in <FIG>), and that the fusible elements 136a-d extend over a trough or recess <NUM> in the top surface of the mounting block <NUM>.

Additionally, the mounting block <NUM> does not have crimping tabs, and the fuse plate <NUM> does not have crimping flanges (e.g., like the first and second crimping tabs 38a, b and first and second crimping flanges 25a, b shown in <FIG>) for securing the fuse plate <NUM> to the mounting block <NUM>. Instead, as shown in <FIG>, the fuse plate <NUM> is secured to the mounting block <NUM> by a cover <NUM> that extends over the fusible elements 136a-d and the recess <NUM> (not within view) and that is coupled to the mounting block <NUM> (e.g., via ultrasonic welding, heat staking, adhesives, etc.).

Referring to <FIG>, a fuse module <NUM> in accordance with another example not part of the present invention is shown. The fuse module <NUM> may be substantially similar to the fuse module <NUM> described above, with a fuse plate <NUM> wrapped about a mounting block <NUM> and with terminal posts 214a-c extending through respective mounting apertures 242a-c in fuse terminals 232a-c of the fuse plate <NUM>. The fuse module <NUM> differs from the above described fuse module <NUM> in that the fuse plate <NUM> does not have a mounting aperture in a longitudinal end of a bus bar thereof (e.g., like mounting aperture <NUM> of the bus bar <NUM> shown in <FIG>). Rather, the fuse plate <NUM> may include an input terminal 232d that is substantially similar to the fuse terminals 232a-c except that the input terminal 232d has, instead of a terminal post extending therefrom, a mounting aperture <NUM> formed therethrough, the mounting aperture <NUM> being aligned with a mounting aperture <NUM> formed in the bus bar <NUM> of the fuse plate <NUM> (see <FIG>). Referring to the cross-sectional view of the input terminal 232d and surrounding components of the fuse module <NUM> shown <FIG>, an electrically conductive, tubular sleeve <NUM> may be disposed within a pass-through aperture <NUM> in the base <NUM> of the mounting block <NUM> and may be sandwiched between the input terminal 232d and the bus bar <NUM>. The tubular sleeve <NUM> may thus provide an electrically conductive pathway between the input terminal 232d and the bus bar <NUM>. In an alternative example of the fuse module <NUM>, the tubular sleeve <NUM> may be formed of an electrically insulating material (e.g., plastic, thermoset, etc.), and may thus force electrical current to flow through corresponding fusible element 236d and prevent electrical current from circumventing the fusible element 236d and flowing directly between the bus bar <NUM> and the input terminal 232d.

Referring to the exemplary implementation of the fuse module <NUM> illustrated in <FIG>, the fuse module <NUM> may be disposed within an electrically insulating cradle <NUM> having a pass-through bolt <NUM> rigidly affixed to, and extending vertically from, a floor <NUM> thereof. The pass-through bolt <NUM> may extend through the mounting aperture <NUM> in the bus bar <NUM> (see <FIG>), the pass-through aperture <NUM> in the base <NUM> (see <FIG>), and the mounting aperture <NUM> in the input terminal 232d. The pass-through bolt <NUM> may receive a ring terminal of conductor extending from a source of electrical power (not shown), and the ring terminal may be secured the against the input terminal 232d in electrical communication therewith with a nut (not shown) that may be tightened onto the pass-through bolt <NUM>. Additionally, the terminal posts 214a-c may receive ring terminals of conductors extending from electrical components that are to be protected (not shown), and the ring terminals may be secured the against the fuse terminals 232a-c in electrical communication therewith with nuts (not shown) that may be tightened onto the threaded shafts 227a-c. Electrical current may flow from the input terminal 232d, through the tubular sleeve <NUM>, to the bus bar <NUM>, and may thus be distributed to the fuse terminals 232a-c via respective fusible elements (not within view, but substantially identical to the fusible elements 36a-d described above and shown in <FIG>, for example). Thus, various electrical systems or components may be electrically coupled to a source of electrical power via the fuse terminals 232a-c, respective fusible elements (not within view), the bus bar <NUM>, and the input terminal 232d, with the fusible elements providing over-current protection between the source of electrical power and such electrical systems or components.

Referring to <FIG>, an alternative example not part of the present invention of the fuse module <NUM> is shown. This alternative example, referred to hereinafter as "fuse module <NUM>-<NUM>," may be similar to the fuse module <NUM> described above but may include only a single fuse terminal <NUM>-<NUM>. The fuse terminal <NUM>-<NUM> may be substantially similar to the input terminal 232d described above, having a mounting aperture <NUM>-<NUM> formed therethrough, the mounting aperture <NUM>-<NUM> being aligned with a mounting aperture <NUM>-<NUM> formed in the bus bar <NUM> of the fuse plate <NUM>-<NUM> (see <FIG>). Referring to the cross-sectional view of the fuse module <NUM>-<NUM> shown <FIG>, an electrically insulating tubular sleeve <NUM>-<NUM> may be disposed within a pass-through aperture <NUM>-<NUM> in the base <NUM>-<NUM> of the mounting block <NUM>-<NUM> and may be sandwiched between the fuse terminal <NUM>-<NUM> and the bus bar <NUM>-<NUM>. The tubular sleeve <NUM>-<NUM> may force electrical current to flow through the fusible element <NUM>-<NUM> and prevent electrical current from circumventing the fusible element <NUM>-<NUM> and flowing directly between the bus bar <NUM>-<NUM> and the fuse terminal <NUM>-<NUM>. Thus, an electrical system or component may be electrically coupled to a source of electrical power via the fuse terminal <NUM>-<NUM>, the respective fusible element <NUM>-<NUM>, the bus bar <NUM>, and the fuse terminal <NUM>-<NUM>, with the fusible element <NUM>-lproviding over-current protection between the source of electrical power and such electrical system or component.

Referring to <FIG>, a fuse module <NUM> in accordance with another example not part of the present invention is shown. The fuse module <NUM> may be substantially similar to the fuse module <NUM> described above, and may include a mounting block <NUM>, a plurality of terminal posts 314a-d, a fuse plate <NUM> having a mounting aperture <NUM> in a longitudinal end thereof, and a cover <NUM>. However, instead of the fuse plate <NUM> being wrapped or folded about the mounting block <NUM> as in the fuse module <NUM>, the mounting block <NUM> may be molded onto the pre-folded fuse plate <NUM> (e.g., via insert molding), such that portions of the fuse plate <NUM> are embedded within the mounting block <NUM>. The fuse terminals 332a-d and the fusible elements 336a-d of the fuse plate <NUM>, which may be substantially similar to the fuse terminals 32a-d and fusible elements 36a-d of the fuse plate <NUM> described above, may be left exposed. The cover <NUM> (omitted in <FIG>) may be fastened to the mounting block <NUM> over the fusible elements 336a-d for protecting the fusible elements 336a-d from ambient particulate as well as for containing electrical arcing in the fusible elements 336a-d that may occur during overcurrent conditions.

Referring to <FIG>, a fuse module <NUM> in accordance with another example not part of the present invention is shown. The fuse module <NUM> may be substantially similar to the fuse module <NUM> described above, and may include a mounting block <NUM>, a plurality of terminal posts 414a, 414b, a fuse plate <NUM>, and a cover <NUM>, wherein the mounting block <NUM> may be molded onto the fuse plate <NUM> (e.g., via insert molding), such that portions of the fuse plate <NUM> are embedded within the mounting block <NUM>. The fuse module <NUM> differs from the above described fuse module <NUM> in that the fuse plate <NUM> does not have a mounting aperture in a longitudinal end of a bus bar thereof (e.g., like mounting aperture <NUM> of the bus bar <NUM> shown in <FIG>). Rather, the fuse plate <NUM> may include a fuse terminal 432b that is substantially similar to the fuse terminals 432a, 432c, except that the fuse terminal 432b has, instead of a terminal post extending therefrom, a mounting aperture <NUM> formed therethrough, the mounting aperture <NUM> being aligned with a mounting aperture <NUM> formed in the bus bar <NUM> of the fuse plate <NUM> (see <FIG>). Additionally, a portion <NUM> of the underside of the bus bar <NUM> surrounding the mounting aperture <NUM> may be exposed (i.e., not covered by the mounting block <NUM>).

Referring to the cross sectional view of the of the fuse terminal 432b and surrounding components of the fuse module <NUM> shown in <FIG>, an electrically insulating, tubular sleeve <NUM> may be disposed within (e.g., may be molded within) the base <NUM> of the mounting block <NUM> and may be sandwiched between the fuse terminal 432b and the bus bar <NUM>. The tubular sleeve <NUM> may thus force electrical current to flow through the fusible element 436b and prevent electrical current from circumventing the fusible element 436b and flowing directly between the bus bar <NUM> and the fuse terminal 432b. The tubular sleeve <NUM> may be formed of any suitable, electrically insulating material, including, but not limited to, plastic, ceramic, thermoset, etc. In an alternative example of the fuse module <NUM>, the tubular sleeve <NUM> may be formed of an electrically conductive material, thus providing a shunt between the fuse terminal 432b and the bus bar <NUM> for allowing electrical current to flow directly therebetween to circumvent the fusible element 436b.

Referring to the exemplary implementation of the fuse module <NUM> illustrated in <FIG>, an electrically conductive battery clamp <NUM> may be coupled to the exposed portion <NUM> of the bus bar <NUM>, with a pass-through bolt <NUM> extending from the battery clamp <NUM> through the mounting aperture <NUM> in the bus bar <NUM>, the tubular sleeve <NUM> (see <FIG>), and the mounting aperture <NUM> in the fuse terminal 432b. The pass-through bolt <NUM> may receive a ring terminal of a conductor extending from an electrical component to be protected (not shown), and the ring terminal may be secured the against the fuse terminal 432b in electrical communication therewith with a nut (not shown) that may be tightened onto the pass-through bolt <NUM>. The pass-through bolt <NUM> may be formed on an electrically insulating material and/or may otherwise be electrically isolated from the battery clamp <NUM> to ensure that current flows through the fusible element 436b instead of shunting directly from the bus bar <NUM>, through the pass-through bolt <NUM>, to the fuse terminal 432b. Additionally, the terminal posts 414a, 414b may receive ring terminals of conductors extending from electrical components that are to be protected (not shown), and the ring terminals may be secured the against the fuse terminals 432a, 432c in electrical communication therewith with nuts (not shown) that may be tightened onto the terminal posts 414a, 414b. Thus, the battery clamp <NUM> may be coupled to a positive terminal of a battery <NUM> as shown in <FIG>, and electrical current may flow from the battery <NUM>, through the battery clamp <NUM> to the bus bar <NUM>, and may thus be distributed to the fuse terminals 432a-c via respective fusible elements (now within view, but substantially identical to the fusible elements 36a-d described above and shown in <FIG>, for example). Thus, various electrical systems or components may be electrically coupled to the battery <NUM> via the fuse terminals 432a-c, respective fusible elements (not within view), the bus bar <NUM>, and the battery clamp <NUM>, with the fusible elements providing over-current protection between the battery <NUM> and such electrical systems or components.

Referring to <FIG>, a fuse module <NUM> in accordance with another example not part of the present invention is shown. The fuse module <NUM> may be substantially similar to the fuse module <NUM> described above, and may include a mounting block <NUM>, a plurality of terminal posts 514a, 514b, a fuse plate <NUM>, and a cover <NUM>, wherein the mounting block <NUM> may be molded onto the fuse plate <NUM> (e.g., via insert molding), such that portions of the fuse plate <NUM> are embedded within the mounting block <NUM>. The fuse module <NUM> differs from the above described fuse module <NUM> in that the fuse plate <NUM>, which is shown in isolation in <FIG>, may additionally include a bus extension <NUM> that is contiguous with the bus bar <NUM>. The bus extension <NUM> may be formed of a substantially planar sheet of material (e.g., a contiguous extension of the fuse plate <NUM>), and may be bent or folded to define a substantially right angle with respect to the bus bar <NUM> (this is not critical).

The bus extension <NUM> may facilitate the connection of fuses having low-medium amperage ratings (e.g., <NUM>-<NUM> amps) to the fuse module <NUM>. For example, the top edge of the bus extension <NUM> may facilitate connection to slotted cartridge fuses <NUM>, <NUM> (see <FIG>) that may be seated within respective recesses <NUM>, <NUM> (see <FIG>) formed in the top of the mounting block <NUM> and connected to respective electrical conductors (not shown) that extend through apertures <NUM>, <NUM> in bottom of the mounting block <NUM>.

Referring to <FIG>, a fuse module <NUM> in accordance with another example not part of the present invention is shown. The fuse module <NUM> may be similar to the fuse module <NUM> described above (shown in <FIG>-c), and may include a mounting block <NUM>, a plurality of terminal posts 614a, 614b, 614c, 614d, a fuse plate <NUM>, and a cover <NUM>, wherein the mounting block <NUM> may be molded onto the fuse plate <NUM> (e.g., via insert molding), such that portions of the fuse plate <NUM> are embedded within the mounting block <NUM>. The fuse module <NUM> differs from the above described fuse module <NUM> in that the bus bar <NUM> of the fuse plate <NUM>, which is shown in isolation in <FIG>, may include a first portion <NUM> and a second portion <NUM> that are connected to one another by a fusible element <NUM> that provides overcurrent protection between the first portion and the second portion. The fuse plate <NUM> may include fuse terminals 632a, 632b, 632c, 632d, 632e, wherein the fuse terminals 632a, 632b are connected to the first portion <NUM> of the bus bar <NUM> and the fuse terminals 632c-e are connected to the second portion <NUM> of the bus bar <NUM>.

During normal operation of the fuse module <NUM>, electrical current may be supplied to the bus bar <NUM> (e.g., by a battery terminal coupled to the fuse terminal 632d), and may be distributed to the fuse terminals 632a-c and 632e. If the fusible element <NUM> is fused, such as may occur if there is an overcurrent condition in an electrical component that is connected to one of the fuse terminals 632a, 632b, current flowing to both of the fuse terminals 632a, 632b connected to the first portion <NUM> of the bus bar <NUM> may be arrested, while current is still allowed to flow to the fuse terminals 632c, 632e connected to the second portion <NUM> of the bus bar <NUM>.

Referring to <FIG>, a fuse module <NUM> in accordance with another example not part of the present invention is shown. The fuse module <NUM> may be substantially similar to the fuse module <NUM> described above (shown in <FIG>), and may include a mounting block <NUM>, a plurality of terminal posts 714a, 714b, 714c, a fuse plate <NUM>, and a cover <NUM>, wherein the fuse plate <NUM> is wrapped or folded about the mounting block <NUM> in a conformal relationship with exterior surfaces thereof. Referring to <FIG>, the fuse module <NUM> differs from the above described fuse module <NUM> in that the mounting block <NUM> may be a modular structure that includes a plurality of separate components that are disposed adjacent, and in abutment with, one another (and optionally joined/bonded together). For example, the mounting block <NUM> may include a base portion <NUM> disposed between the bus bar <NUM> and the fuse terminals 732a, 732b, 732c and input terminal 732d, and a separate rear wall portion <NUM> oriented perpendicular to the base portion <NUM> and disposed adjacent the fusible elements 736a, 736b, 736c. The base portion <NUM> may include keying features <NUM> for facilitating routing of cables/wires to the fuse terminals 732a, 732b, 732c and input terminal 732d in a desired manner. The modular configuration of the mounting block <NUM> may simplify the manufacture of the mounting block <NUM> and/or the assembly of the fuse module <NUM> relative to equivalent mono-structure mounting blocks.

Referring to <FIG>, a fuse module <NUM> in accordance with an exemplary embodiment of the present disclosure is shown. The fuse module <NUM> may be substantially similar to the fuse module <NUM> described above (shown in FIGS. 1a-<FIG>), and includes a fuse plate <NUM> wrapped about a mounting block <NUM>, terminal posts 814a-d extending through respective mounting apertures 842a-d in fuse terminals 832a-d of the fuse plate <NUM>, and a cover <NUM> disposed over fusible elements 836a-d of the fuse plate <NUM> (the cover <NUM> is omitted in <FIG> for clarity). The fuse module <NUM> differs from the above-described fuse module <NUM> in that a substantially planar bus bar <NUM> of the fuse plate <NUM> is disposed immediately adjacent to, and in a parallel relationship with, a rear surface of a rear wall <NUM> of the mounting block <NUM>, rather than being located below a base <NUM> of the mounting block <NUM> as in the case of the bus bar <NUM> of the fuse module <NUM>.

Additionally, the fusible elements 836a-d of the fuse plate <NUM> may be disposed immediately adjacent to, and in a parallel relationship with, a front surface of the rear wall <NUM> of the mounting block <NUM>, rather than being located immediately adjacent the rear surface of the rear wall <NUM> as in the case of the fusible elements 36a-d of the fuse module <NUM>. Additionally, the fuse plate <NUM> may include a generally planar mounting tab <NUM> extending rearwardly (i.e., away from the terminal posts 814a-d) from a lower edge of the bus bar <NUM> and having a mounting aperture <NUM> formed therein, the mounting tab <NUM> being disposed in a generally perpendicular relationship with the bus bar <NUM> and in a generally parallel relationship with the fuse terminals 832a-d.

While the mounting block <NUM> and the fuse plate <NUM> of the fuse module <NUM> do not have crimping tabs and crimping flanges such as the crimping tabs 38a, 38b and crimping flanges 25a, 25b of the fuse module <NUM>, various alternative embodiments of the fuse module <NUM> are contemplated in which such crimping tabs and crimping flanges may be provided. Moreover, in various embodiments, one or more portions of the fuse plate <NUM> may be embedded within the mounting block <NUM> (e.g., over molded) in a manner similar to the fuse plate <NUM> and mounting block <NUM> of the above described fuse module <NUM> (see <FIG>).

In various alternative embodiments of the fuse module <NUM>, the location and orientation of the mounting tab <NUM> may be varied. For example, referring to <FIG>, a non-limiting, alternative embodiment of the fuse module <NUM> is depicted wherein the bus bar <NUM> has an extended portion <NUM> that extends longitudinally beyond a longitudinal end of the mounting block <NUM>, and wherein the mounting tab <NUM> extends perpendicularly forward (i.e., toward the terminal posts 814a-d) from a top edge of the extended portion <NUM> of the bus bar <NUM>. In various embodiments, the extended portion <NUM> may be an integral, contiguous extension of the bus bar <NUM> as shown in <FIG>. Alternatively, the extended portion <NUM> may be a separate piece of metal that is clinched or otherwise mechanically coupled to the bus bar <NUM> as shown in <FIG>. In various embodiments, the bus bar <NUM> may be generally exposed (e.g., as shown in <FIG>). Alternatively, the bus bar <NUM> may be partially or entirely encapsulated in plastic or another electrically insulating material (e.g., via insert molding).

Claim 1:
A fuse module (<NUM>) comprising:
a mounting block (<NUM>) formed of an electrically insulating material, the mounting block (<NUM>) including a rear wall (<NUM>) extending from a base (<NUM>);
a fuse plate (<NUM>) comprising:
a planar, electrically conductive bus bar (<NUM>)
a fusible element (836a-d) electrically connected to the bus bar and disposed adjacent a front surface of the rear wall; and
a fuse terminal (832a-d) electrically connected to the fusible element and extending onto a top of the base; and
an electrically conductive terminal post extending from the top of the base through the fuse terminal for facilitating connection to an electrical component,
characterized in that the conductive bus bar (<NUM>) is disposed immediately adjacent and in a parallel relationship with a rear surface of the rear wall (<NUM>).