Patent Description:
Components such as fuses, relays, diodes, and the like, are used in automobiles to provide a connection between a power source and various components, such as the starter, generator, and so forth. Fuses are used as circuit protection devices to protect against damage caused by an overcurrent condition. A fuse is constructed to physically open or interrupt a circuit path and isolate electrical components from damage upon the occurrence of specified overvoltage and/or overcurrent conditions in the circuit.

Electrical systems in vehicles typically include a number of fuses to protect electrical circuitry, equipment, and components from damage caused by these conditions. For example, power sources (e.g. batteries) in vehicles utilize a fuse fitted over a terminal bolt to which a ring terminal of an electrical cable is connected. A nut is usually threaded onto the bolt to keep the ring terminal and fuse in position. When an excess current condition exists, the fuse on the terminal bolt protects the components connected to the power source from this excess current. Unintended shorting may occur when the ring terminal comes into direct electrical contact with the bolt rather than through the fuse. To overcome this problem, an insulating nut fitted over the bolt has been used to isolate the fuse and the ring terminal to prevent current from bypassing the fuse and damaging the protected circuit.

Fuses may be provided in a fuse assembly within a housing. Document <CIT> discloses an exemplary fuse assembly. An upper or lower housing of the housing assembly may defines apertures, wherein projections extend into the apertures so that an operator may place a fuse into the pair of projections. However, power distribution assemblies including multiple components and multi-part housings are expensive to manufacture and assemble, and lack scalable customization to meet the needs of a various applications.

In view of the foregoing, embodiments herein provide an improved modular fuse holder for single bolt fuses. In one exemplary approach of the present disclosure, a fuse holder according to claim <NUM> is provided.

Another exemplary approach of the present disclosure includes a circuit protection assembly according to claim <NUM>.

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.

A fuse holder, a circuit protection assembly, and a modular fuse holder assembly 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 holder, a circuit protection assembly, and modular fuse holder assembly, 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.

For the sake of convenience and clarity, terms such as "top," "bottom," "upper," "lower," "vertical," "horizontal," "lateral," and "longitudinal" will be used herein to describe the relative placement and orientation of these components and their constituent parts, each with respect to the geometry and orientation of a modular fuse holder as they appear in the figures. Said terminology will include the words specifically mentioned, derivatives thereof, and words of similar import.

As used herein, an element or operation recited in the singular and proceeded with the word "a" or "an" should be understood as not excluding plural elements or operations, unless such exclusion is explicitly recited.

Approaches herein provide for customized power distribution using a fuse holder for single bolt fuses. According to the present invention, fuse holder includes a base having a lower wall and a set of sidewalls, the lower wall including a plurality of bolt openings provided therethrough. The fuse holder further includes a cover securable with the base, the cover including an upper wall and a set of outer walls, the outer walls including a plurality of cable openings, wherein the base and the cover define an interior cavity for housing a bolt assembly. In some approaches, the fuse holder may include a busbar atop the lower wall of the base, the busbar including a set of openings aligned with one or more of the bolt openings of the lower wall. In some embodiments, a side cover may extend over some of the plurality of cable openings in the outer wall of the cover.

One of ordinary skill in the art will appreciate that embodiments herein provide at least the following technical improvements and advantages over the existing art. Firstly, the modular fuse holder assembly allows multiple configurations to be easily attainable at the time of assembly. Even in the case of different overall capacity (e.g., number of fuses) holders, a common flexible architecture is shared. Secondly, press fit isolated bolt assemblies allow multiple configurations, including multiple bolt sizes and locations. Thirdly, using two rows of bolt assembly locations within the housing allows for entry of wires from either side of the housing, while still permitting sufficient strain relief and minimizing overall foot print. Fourthly, a combination side cover (i.e., dust cover) and fuse retainer keeps Z-case fuses in place for transportation without having to add a nut and lock washer. This saves labor on the installation side as the wires can be placed on the fuses and nuts tightened without having to remove all of the nuts first. Fifthly, flexible busing allows multiple configurations with common components. Sixthly, a dovetail feature along an exterior of the housing allows multiple fuse holders to be coupled together and bussed together.

Referring to <FIG>, an exemplary embodiment of a modular fuse holder assembly (hereinafter, assembly <NUM>) in accordance with the present disclosure is shown. The assembly <NUM> includes a housing assembly <NUM> having a base <NUM> coupled to a cover <NUM>, the cover <NUM> removably connected to the base <NUM> and covering the components therein. The cover <NUM> can be removed, for example, to replace one or more fuse components. As shown, the base <NUM> includes a lower wall <NUM> and a set of sidewalls <NUM> extending from the lower wall <NUM>. In some embodiments, the set of sidewalls <NUM> extend perpendicularly from an upper surface of the lower wall <NUM>. The lower wall <NUM> may include a plurality of bolt openings <NUM> provided therethrough. As will be described in greater detail below, the plurality of bolt openings <NUM> permit one or more bolt assemblies to extend into a cavity <NUM> defined by an open area within the base <NUM> and the cover <NUM>.

The assembly <NUM> may further include one or more lower capping strips <NUM> coupled to a bottom side of the base <NUM>. As shown, the lower capping strips <NUM> may having alternating circular opening plugs <NUM> and linking members <NUM>, wherein the circular opening plugs <NUM> are configured to cover the plurality of bolt openings <NUM> in the lower wall <NUM>. In some embodiments, the lower capping strips <NUM> may be snap-fit into position by one or more undercut features <NUM> securable to corresponding mating lips (not shown) within each bolt opening <NUM>.

As further shown, the cover <NUM> includes an upper wall <NUM> and set of outer walls <NUM>, the set of outer walls <NUM> including a plurality of cable openings <NUM> to permit one or more cables (i.e., wires) to enter the housing assembly <NUM> for connection with the bolt assemblies. In some embodiments, the cable openings <NUM> may have an arched or semicircular shape. Other shapes and dimensions for the cable openings <NUM> are possible within the scope of the present disclosure.

In some embodiments, the cover <NUM> may be snap-fit to the base <NUM> and/or include one or more brackets or latches <NUM> to releasably secure the cover <NUM> to the base <NUM>. In an alternative embodiment, the cover <NUM> is threaded onto the base <NUM> and can include a spring seal that provides a tensile force against the cover <NUM>, which tends to hold the cover <NUM> in a tight, threaded relationship with the base <NUM> even when the vehicle is moving and creating vibrations that could otherwise loosen the cover <NUM>. The spring mechanism can also provide a seal between the cover <NUM> and the base <NUM>. Although not specifically illustrated, the cover <NUM> may also include means to further facilitate grasping and removal, such as tabs, projections, recesses, etc..

The base <NUM> may include a sidewall interlocking feature <NUM> for mounting multiple housing assemblies together. In some embodiments, the sidewall interlocking feature <NUM> may include one or more dovetail-type members. Although not limited to any particular material, the housing assembly <NUM> may be made of an insulating material, such as plastic, which is molded to form a demonstrated shape. In some embodiments, the base <NUM> and the cover <NUM> can be made of the same or different materials, such as an insulating plastic, e.g., nylon, glass-filled nylon, polyester and polycarbonate.

In some embodiments, the latches <NUM> may be coupled to a pin <NUM> (<FIG>) of the base <NUM>, to permit the latches <NUM> to pivot about an axis defined by the pin <NUM>. When the cover <NUM> is not in use, the latches <NUM> may rotate and extend away from the cover <NUM>. Then, as the cover <NUM> is positioned onto the base <NUM>, the latches <NUM> may be rotated towards the cover <NUM>, and clamped about a securement ridge <NUM> of the cover <NUM>.

As best shown in <FIG>, the housing assembly <NUM> may include a set of interlocking features for coupling the cover <NUM> to the base <NUM>. For example, the base <NUM> may include a plurality of pillar supports <NUM> extending upwardly from a lower portion <NUM> of the set of sidewalls <NUM>. Each of the pillar supports <NUM> may include a pair of outer flanges <NUM> defining a middle slot <NUM> therebetween. The middle slot <NUM> is configured to receive one or more opening walls <NUM> of the cover <NUM>. During securement of the housing assembly <NUM>, the opening walls <NUM> may be inserted into the middle slot <NUM> until an interior surface of an upper wall <NUM> engages the pair of outer flanges <NUM>.

Referring now to <FIG>, an exemplary embodiment of another modular fuse holder assembly (hereinafter, assembly <NUM>) in accordance with the present disclosure is shown. As shown, the assembly <NUM> includes many of the features previously described in relation to the assembly <NUM> of <FIG> and, as such, may not be described in full detail for the sake of brevity. The assembly <NUM> includes a housing assembly <NUM> having a base <NUM> coupled to a cover <NUM>, the cover <NUM> removably connected to the base <NUM> and covering the components therein. As shown, the base <NUM> includes a lower wall <NUM> and a set of sidewalls <NUM> extending from the lower wall <NUM>. In some embodiments, the set of sidewalls <NUM> extend perpendicularly from an upper surface of the lower wall <NUM>. The lower wall <NUM> includes a plurality of bolt openings <NUM> (<FIG>) provided therethrough. The plurality of bolt openings <NUM> permit one or more studs or bolt assemblies <NUM> to extend into a cavity <NUM> defined by an open area within the base <NUM> and the cover <NUM>. In some embodiments, the cover <NUM> may be attached to the base <NUM> by a tether <NUM>, which may be a looped silicon rubber connector coupled to each of the base <NUM> and the cover <NUM>.

As shown, the assembly <NUM> includes one or more bolt assemblies <NUM> (e.g., Ni/Sn plated steel) extending through the plurality of bolt openings <NUM>, as well as through a plurality of bus openings <NUM> of a busbar <NUM>. For example, the bottom side of the base <NUM> may include recesses sized slightly larger than the heads of each bolt assembly <NUM> within which these heads are disposed such that the respective bolts are secured in position through the lower wall <NUM>. The bolt assemblies <NUM> may be force fit into respective recesses of the bolt openings <NUM>, wherein the bolt openings <NUM> have the same shape as respective heads of each bolt assembly <NUM> with body portions of each of the bolt assemblies <NUM> extending through lower wall <NUM>. In this manner, the bolt assemblies do not need to be integrally molded with the base <NUM>, thereby reducing manufacturing and labor costs.

The busbar <NUM> may be disposed atop the lower wall <NUM> of the base <NUM>, wherein the plurality of bus openings <NUM> are aligned with one or more of the plurality of bolt openings <NUM> of the lower wall <NUM>. In some embodiments, the bolt assemblies <NUM> may be secured to the busbar <NUM> by corresponding nuts <NUM>. Furthermore, the busbar <NUM> may be secured to the top surface of the lower wall <NUM> of the base by one or more fasteners <NUM> (e.g., press-fit tabs) extending from the lower wall <NUM> of the base. During use, the bolt assemblies <NUM> supply power to the busbar <NUM>, the bolt assemblies <NUM> being configured to receive fuses (not shown). Once the bolt assemblies <NUM> are inserted into the housing assembly <NUM>, one or more capping strips <NUM> may be inserted into the plurality of bolt openings <NUM> in the lower wall <NUM>. It will be appreciated that bolts of various size and position may be employed.

The assembly <NUM> further includes a side cover <NUM> coupleable with the base <NUM>, the side cover <NUM> configured to extend between at least one of the plurality of cable openings <NUM> in the outer wall <NUM> of the cover <NUM>, as well as over at least one of a plurality of openings <NUM> defined by each of a plurality of pillar supports <NUM> of the base <NUM>. As shown, the side cover <NUM> may include a plurality of channels <NUM> configured to receive and surround corresponding pillar supports <NUM>. More specifically, each of the side covers <NUM> may include one or more slotted side walls <NUM> slidably engaged with corresponding outer flanges <NUM> of the pillar supports <NUM>. In some embodiments, extending between each of the plurality of channels <NUM> is a central block <NUM> arranged within openings <NUM> between each of the plurality of pillar supports <NUM>. The side cover <NUM> may include a set of tabs <NUM> for engaging a channel <NUM> of one or more of the plurality of pillar supports <NUM> to secure the side cover <NUM> to the base <NUM>.

As will be appreciated, the side cover <NUM> may act as a debris cover for minimizing intrusion of dust or other contaminants into the cavity <NUM>. In some embodiments, the side cover <NUM> may be a series of unconnected components arranged side by side, enabling flexible, interchangeable placement over the openings <NUM> between each of the pillar supports <NUM>. In other embodiments, the side cover <NUM> may be a continuous piece of material (e.g., silicon rubber) covering all of the plurality openings <NUM>.

After the side cover <NUM> is coupled to the base <NUM>, the cover <NUM> may be placed atop the base <NUM>. That is, the middle slot <NUM> of each pillar support <NUM> is configured to receive one or more opening walls <NUM> of the cover <NUM>. The opening walls <NUM> may be inserted into the middle slot <NUM> until an interior surface of an upper wall <NUM> engages the pair of outer flanges <NUM>.

As better shown in <FIG>, the side cover <NUM> may include a plurality of fuse supports <NUM> extending between the central block <NUM> and a fuse alignment wall <NUM>. In some embodiments, each of the plurality of fuse supports <NUM> is a corner shelf or stop configured to engage a fuse (not shown) to keep the fuse in place without a nut. The plurality of fuse supports <NUM> of the side cover <NUM> may advantageously save assembly time because there's no need to unscrew the nut before attaching the wire. Furthermore, in some embodiments, with the fuses and the side cover <NUM> assembled, the busbar <NUM> may also be kept in place without any screw, snap-in locking or similar.

Turning now to <FIG>, a circuit protection assembly (hereinafter "assembly") <NUM> according to embodiments of the present disclosure will be described in greater detail. As shown, the assembly <NUM> includes many the features previously described in relation to the assembly <NUM> and the assembly <NUM> and, as such, will not be described in full detail for the sake of brevity. The assembly <NUM> includes a housing assembly <NUM> having a base <NUM> coupled to a cover <NUM> (<FIG>), the cover <NUM> removably connected to the base <NUM> and covering the components therein. As shown, the base <NUM> includes a set of sidewalls <NUM> extending from the lower wall <NUM>. The lower wall <NUM> includes a plurality of bolt openings <NUM> (<FIG>) provided therethrough. The plurality of bolt openings <NUM> permit one or more bolt assemblies <NUM> to extend into a cavity <NUM> defined by an open area within the base <NUM> and the cover <NUM>.

As shown, the assembly <NUM> includes one or more bolt assemblies <NUM> extending through the plurality of bolt openings <NUM>, as well as through a plurality of busbar openings <NUM> of a busbar <NUM>. The busbar <NUM> may be disposed atop an upper/inner surface of the lower wall <NUM> of the base <NUM>, wherein the plurality of busbar openings <NUM> may be aligned with one or more of the plurality of bolt openings <NUM> of the lower wall <NUM>. In some embodiments, the bolt assemblies <NUM> may be secured in place by corresponding nuts <NUM>.

The assembly <NUM> may include one or more side covers <NUM> coupleable with the base <NUM>, the side cover <NUM> is configured to extend across one or more openings <NUM> between each of the plurality of pillar supports <NUM>. As shown, the assembly <NUM> may further include one or more cable covers <NUM> extending over at least one of a plurality of openings between each of the plurality of pillar supports <NUM>. The cable covers <NUM> include an opening for receiving a wire or cable <NUM>. The cable covers <NUM> may further include a pair of slotted end walls <NUM> slidably engaged with the outer flanges <NUM> of the pillar supports <NUM>. As will be appreciated, the cable covers <NUM> may act as debris covers for minimizing intrusion of dust or other contaminants into the base <NUM>.

The side cover <NUM> may include a plurality of fuse supports <NUM>, such as a corner shelf, tab, or stop configured to engage the fuse <NUM> to keep the fuse in place without a nut. The plurality of fuse supports <NUM> of the side cover <NUM> may advantageously save assembly time because there's no need to unscrew the bolt assembly <NUM> before attaching the wire or cable <NUM>.

In some embodiments, the cable <NUM> and the bolt assembly <NUM> are coupled to a fuse <NUM>, wherein the bolt assembly <NUM> is disposed through a receiving bore in the fuse <NUM>. The fuse <NUM> may be a ceramic "block" fuse having a generally central aperture that receives the bolt assembly <NUM>. In some embodiments, an insulator isolates the bolt assembly <NUM> from the fuse <NUM>. A ring terminal <NUM>, connected to the cable <NUM>, is mounted over the bolt assembly <NUM>, while the nut <NUM> threadedly engages the bolt assembly <NUM> to retain both the fuse <NUM> and the ring terminal <NUM> in position. As shown, the cables <NUM> may extend outside of the base <NUM> on either side, through the cable covers <NUM>, thus providing increased design flexibility. In some cases, depending on the size of the ring terminal <NUM> and cable <NUM>, no cable cover <NUM> is present between a pair of pillar supports <NUM>. This is demonstrated with cable <NUM>-<NUM>, which may be a relatively larger wire coupled to, e.g., an M10 bolt.

Claim 1:
A fuse holder (<NUM>), comprising:
a base (<NUM>) including a lower wall (<NUM>) and a set of sidewalls (<NUM>), the lower wall (<NUM>) including a plurality of bolt openings (<NUM>) provided therethrough wherein the set of sidewalls (<NUM>) of the base (<NUM>) comprises a plurality of pillar supports (<NUM>) defining a plurality of openings (<NUM>) into an interior cavity (<NUM>),
a cover (<NUM>) securable with the base (<NUM>), the cover (<NUM>) including an upper wall (<NUM>) and a set of outer walls (<NUM>), the set of outer walls (<NUM>) including a plurality of cable openings (<NUM>) and wherein the base (<NUM>) and the cover define the interior cavity (<NUM>) for housing a bolt assembly,
characterized in that
each of the plurality of pillar supports (<NUM>) comprises:
a pair of outer flanges (<NUM>); and
a middle slot (<NUM>) between the pair of outer flanges (<NUM>); and
the set of outer walls (<NUM>) includes a plurality of opening walls (<NUM>),
wherein the middle slot (<NUM>) of each pillar support of the plurality of pillar supports (<NUM>) receives a corresponding opening wall of the plurality of opening walls (<NUM>).