Information
-
Patent Grant
-
6558198
-
Patent Number
6,558,198
-
Date Filed
Monday, November 26, 200122 years ago
-
Date Issued
Tuesday, May 6, 200321 years ago
-
Inventors
-
Original Assignees
-
Examiners
- Bradley; P. Austin
- Hammond; Briggitte R.
Agents
-
CPC
-
US Classifications
Field of Search
US
- 439 622
- 439 830
- 439 249
- 439 250
- 439 251
- 439 787
- 439 723
- 337 295
- 337 290
- 337 256
-
International Classifications
-
Abstract
A fuse device is provided with a plurality of separate fuse main bodies in which fuse terminals and fuse terminals are formed at the opposite ends of fusing elements, and a plurality of connection terminals which are members separate from the fuse main bodies. A fuse circuit in which the fusing elements are provided between the connection terminals is formed by directly connecting the fuse terminals of the respective fuse main bodies with the connection terminals. The fusing characteristics of the fusing elements and the strength of the connection terminals can be adjusted without influencing each other.
Description
BACKGROUND OF THE INVENTION
This invention relates to a fuse device mounted in an electrical connection box used, for example, in a vehicle to prevent an overcurrent from flowing into electrical circuits built in the electrical connection box.
Known conventional fuse devices of the aforementioned type are shown in
FIGS. 13 and 14
. The fuse device of
FIG. 13
is constructed such that a fusing element
300
has connection terminals
301
thicker than the fusing element
300
connected at the opposite ends thereof and the fusing element
300
and the connection terminals
301
are covered by an insulating resin member
302
except leading end portions of the connection terminals
301
. The fusing element
300
and the connection terminals
301
are formed by stamping out a single metallic plate having a portion corresponding to the fusing element
300
adjusted to a smaller thickness. This fuse device is mounted in an electrical connection box by connecting the connection terminals
301
thereof with unillustrated busbars provided in the electrical connection box.
On the other hand, a fuse device of
FIG. 14
is constructed such that each of two fusing elements
310
has a common connection terminal (input terminal)
311
thicker than the fusing element
310
connected at one end thereof and has two separate connection terminals (output terminals)
312
having the same thickness as the connection terminal
311
connected at the other end thereof, and the respective fusing elements
310
and connection terminals
311
,
312
are covered by an insulating resin member
313
except leading end portions of the connection terminals
311
,
312
. The fuse device includes a pair of pieces each including two fusing elements
310
, one connection terminal
311
and two connection terminals
312
. The fusing element
310
and the connection terminals
311
,
312
are formed by stamping out a single metallic plate having portions corresponding to the fusing elements
310
adjusted to a smaller thickness. Similar to the above fuse device of
FIG. 13
, this fuse device is mounted in an electrical connection box by connecting the connection terminals
311
,
312
thereof with unillustrated busbars provided in the electrical connection box.
Since the unitary piece of the fusing element(s) and the connection terminals forming the conventional fuse devices is formed by stamping out the single metallic plate as described above, there is a limit in adjusting the fusing characteristic of the fusing element and the strength of the connection terminals without influencing each other.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a fuse device and fuse connecting structure which are free from the problems residing in the prior art.
According to an aspect of the invention, a fuse device is provided with connection terminals; and a fuse main body including fuse terminals and a fusing element whose opposite ends are connected with the fuse terminals. The fuse terminals are directly connected with the respective connection terminals to form a fuse circuit in which the fusing element is between the connection terminals.
The device makes it possible to adjust the fusing characteristic of the fusing element and the strength of connection terminals without influencing each other.
These and other objects, features and advantages of the present invention will become more apparent upon a reading of the following detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1
is a perspective view showing an external configuration of a fuse device according to a first embodiment of the invention;
FIG. 2
is a perspective view showing an interior of the fuse device;
FIG. 3
is an exploded perspective view of the fuse device;
FIG. 4
is a perspective view showing how the fuse device is connected with tab terminals;
FIG. 5
is a plan view in section showing a state where connection terminals of the fuse device are connected with the tab terminals of an electrical connection box;
FIGS. 6A
to
6
E are diagrams showing modes of a plurality of fuse main bodies forming the fuse device;
FIG. 7
is a perspective view showing an external configuration of a fuse device according to a second embodiment of the present invention;
FIG. 8
is an exploded perspective view of the fuse device of
FIG. 7
immediately before assembling;
FIG. 9
is a perspective view showing an interior of a fuse casing forming the fuse device of
FIG. 7
;
FIG. 10
is a perspective view showing an interior of a connection terminal casing forming the fuse device of
FIG. 7
;
FIG. 11
is a perspective view showing how the fuse device of
FIG. 7
is connected with tab terminals;
FIG. 12
is a plan view in section showing a state where connection terminals of the fuse device of
FIG. 7
are connected with the tab terminals of an electrical connection box;
FIG. 13
is a perspective view showing an external configuration of an exemplary conventional fuse device;
FIG. 14
is a perspective view showing an external configuration of another exemplary conventional fuse device;
FIG. 15
is an equivalent circuit diagram of a fuse circuit in which a plurality of fuses are connected with one battery output terminal; and
FIG. 16
is an exploded perspective view showing the construction of an electrical connection box in which the conventional fuses are mounted.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION
A preferred embodiment of the invention is specifically described. As shown in
FIG. 1
, a fuse device includes a fuse casing
10
which is comprised of a fuse casing main body
10
a
and a cover
10
b.
As shown in
FIG. 2
(the cover
10
b
is not shown), a plurality of (six in the shown example) fuse main bodies
1
,
2
,
3
,
4
,
5
,
6
, the same number of input connection terminals
12
,
13
,
14
,
15
,
16
,
17
as the fuse main bodies, and two output connection terminals
11
,
18
are accommodated in the fuse casing
10
except portions thereof.
Each fuse main body
1
to
6
is a plate member made of a low-melting metal such as Zn in which a fuse terminal
1
b
to
6
b
is provided at one end of a fusing element
1
a
to
6
a
and a fuse terminal
1
c
to
6
c
is provided at the other end thereof. These fuse main bodies
1
to
6
can be mass-produced by stamping out a metallic plate having portions corresponding to the fusing elements
1
a
to
6
a
thinned by, for example, carving in advance. In the fuse main bodies
1
to
6
thus formed, the fuse terminals
1
b
to
6
b
and the fuse terminals
1
c
to
6
c
have the same thickness and are thicker than the fusing elements
1
a
to
6
a
. Specific examples of dimensions of the fuse main bodies
1
to
6
are described later.
The input connection terminals
12
to
17
are shorter than the output connection terminals
11
,
18
. Connecting portions
12
a
to
17
a
are provided at the ends of the input connection terminals
12
to
17
located at the inner side of the fuse casing main body
10
a
by, for example, being bent at right angles, whereas forked inserting portions
12
b
to
17
b
each having a specified slit are formed at the ends of the input connection terminals
12
to
17
at the outer side of the fuse casing main body
10
a
. The connecting portions
12
a
to
14
a
and the connecting portions
15
a
to
17
a
are bent in opposite directions as clearly shown in FIG.
3
.
Further, connecting portions
11
a
,
18
a
are provided at the ends of the longer output connection terminals
11
,
18
located at the inner side of the fuse casing main body
10
a
by, for example, being bent at right angles, whereas forked inserting portions
11
b
,
18
b
each having a specified slit are formed at the ends of the output connection terminals
1
,
18
at the outer side of the fuse casing main body
10
a
. The connecting portions
11
a
,
18
a
are bent in opposite directions as clearly shown in FIG.
3
and have such a length that their projecting ends reach a substantially middle position of the fuse casing main body
10
a
with respect to longitudinal direction.
These connection terminals
11
to
18
are set at specified positions inside the fuse casing main body
10
a
, and the fuse terminals
1
b
to
6
b
,
1
c
to
6
c
of the fuse main bodies
1
to
6
are placed on the connecting portions
11
a
to
18
a
of the set connection terminals
11
to
18
and electrically connected therewith, for example, by welding.
More specifically, the fuse terminals
1
c
,
1
b
of the fuse main body
1
are respectively placed on the connecting portion
12
a
and the connecting portion
11
a
; the fuse terminals
2
c
,
2
b
of the fuse main body
2
are respectively placed on the connecting portion
13
a
and the connecting portion
11
a
; and the fuse terminals
3
c
,
3
b
of the fuse main body
3
are respectively placed on the connecting portion
13
a
and the connecting portion
11
a
. The respective fuse terminals and the respective connecting portions are connected, for example, by welding. In other words, the connecting portion
11
a
is commonly used by three fuse main bodies
1
to
3
.
Further, the fuse terminals
4
c
,
4
b
of the fuse main body
4
are respectively placed on the connecting portion
15
a
and the connecting portion
18
a
; the fuse terminals
5
c
,
5
b
of the fuse main body
5
are respectively placed on the connecting portion
16
a
and the connecting portion
18
a
; and the fuse terminals
6
c
,
6
b
of the fuse main body
6
are respectively placed on the connecting portion
17
a
and the connecting portion
18
a
. The respective fuse terminals and the respective connecting portions are connected, for example, by welding. In other words, the connecting portion
18
a
is commonly used by three fuse main bodies
4
to
6
.
The fuse device of this embodiment is completed by putting the cover
10
b
on the fuse casing main body
10
a
in which the fuse main bodies
1
to
6
and the connection terminals
11
to
18
are mounted in this manner. It should be noted that the ends of the connection terminals
11
to
18
where the forked inserting portions
11
b
to
18
b
are formed project out through a plurality of slits
10
c
formed in the fuse casing
10
and are arrayed while being opposed to each other.
FIG. 4
is a perspective view in section showing the construction of a mating electrical connection box
40
with which this fuse device is to be connected. In
FIG. 4
, a casing portion
40
a
of the electrical connection box
40
is shown in section along the line
5
—
5
.
A busbar board (not shown) including busbars
41
A to
48
A having tab terminals
41
to
48
at their ends is accommodated in this electrical connection box
40
, and the upper ends of the tab terminals
41
to
48
reach up to the vicinity of the inner surface of the outermost casing portion
40
A of the electrical connection box
40
. The thickness of the tab terminals
41
to
48
is substantially equal to the width of the slits of the forked inserting portions
11
b
to
18
b.
The outermost casing portion
40
A is made of, e.g., an insulating resin, and slit-shaped insertion holes
51
to
58
into which the connection terminals
11
to
18
of the fuse device are insertable are so formed in a portion of the casing portion
40
A covering the tab terminals
41
to
48
as to extend in a direction normal to widthwise directions B of the tab terminals
41
to
48
. At the longitudinal center positions of the respective insertion holes
51
to
58
, the centers of the respective tab terminals
41
to
48
with respect to widthwise directions B are exposed.
The length of the insertion holes
51
to
58
are substantially equal to the width of the connection terminals
11
to
18
, whereas the width thereof is substantially equal to the thickness of the connection terminals
11
to
18
. Suspended pieces
61
to
63
which are integral parts of the outermost casing portion
40
A are provided between four adjacent tab terminals
41
to
44
, whereas suspended pieces
64
to
66
which are integral parts of the outermost casing portion
40
A are provided between four adjacent tab terminals
45
to
48
. Further, bent portions
67
,
68
,
69
of the outermost casing portion
40
A are provided between the tab terminals
44
and
45
and at the outer sides of the tab terminals
41
and
48
, respectively.
The fuse device is connected with the electrical connection box
40
thus constructed as follows. By inserting the connection terminals
11
to
18
of the fuse device into the insertion holes
51
to
58
, the connection terminals
11
to
18
are guided by the insertion holes
51
to
58
so that the tab terminals
41
to
48
are inserted into the forked inserting portions
11
b
to
18
b
of the connection terminals
11
to
18
as shown in
FIG. 5
, thereby electrically connecting the connection terminals
11
to
18
and the tab terminals
41
to
48
.
FIGS. 6A
to
6
E are diagrams showing examples of the aforementioned fuse main bodies
1
to
6
, wherein
FIG. 6A
shows a fuse main body having a fuse capacity of 30A,
FIG. 6B
shows a fuse main body having a fuse capacity of 20A,
FIG. 6C
shows a fuse main body having a fuse capacity of 15A,
FIG. 6D
shows a fuse main body having a fuse capacity of 1A and
FIG. 6E
shows a fuse main body having a fuse capacity of 7.5 A.
These five kinds of fuse main bodies are fabricated by stamping a metallic plate out, respectively. Upon this fabrication, thickness (t), height (H) and width (W) (i.e., shape) of a portion of the metallic plate before stamping corresponding to the fusing element
1
a
to
6
a
are adjusted to adjust the fuse capacity of the fusing element. The shape of the fusing element
1
a
to
6
a
is pointed at one side in
FIGS. 6A
to
6
D while being sinuous in FIG.
6
E. Further, spacing L between the fuse terminals
1
b
to
6
b
and
1
c
to
6
c
at the opposite sides is constantly set at 5.4 mm and the shape and size of the fuse terminals
1
b
and
1
c
are same in order to enable each fuse main body to be used as a substitute for another.
Specifically, the thickness t of the fusing element
1
a
to
6
a
of the fuse main body having a fuse capacity of 30A shown in
FIG. 6A
is 0.3 mm; the thickness t of the fusing element
1
a
to
6
a
of the fuse main body having a fuse capacity of 20A shown in
FIG. 6B
is 0.2 mm, which is thinner than the thickness t of the fusing element shown in
FIG. 6A
; the thickness t of the fusing element
1
a
to
6
a
of the fuse main body having a fuse capacity of
15
A shown in
FIG. 6C
is 0.2 mm which is same as the thickness t of the fusing element shown in
FIG. 6B
; the thickness t of the fusing element
1
a
to
6
a
of the fuse main body having a fuse capacity of
10
A shown in
FIG. 6D
is 0.15 mm, which is thinner than the thickness t of the fusing elements shown in
FIG. 6B and 10C
; and the thickness t of the fusing element
1
a
to
6
a
of the fuse main body having a fuse capacity of 7.5 A shown in
FIG. 6E
is 0.15 mm. The shape, height H, and width W of the fusing element
1
a
to
6
a
are suitably set according to the fuse capacity. The shape and the dimensions of the fusing elements
1
a
to
6
a
of these five kinds of fuse main bodies are merely examples, and fuse main bodies having fuse capacities different from those of the above five kinds of fuse main bodies may be fabricated.
In this embodiment, for example, the fuse main bodies having a fuse capacity of 30 A are arranged like mirror images as the fuse main bodies
1
,
6
; the fuse main bodies having a fuse capacity of 20 A are arranged like mirror images as the fuse main bodies
2
,
5
, and the fuse main bodies having a fuse capacity of 10 A are arranged like mirror images as the fuse main bodies
3
,
4
. Since the respective fuse main bodies of this embodiment have a constant spacing L between the fuse terminals
1
b
to
6
b
and
1
c
to
6
c
, desired ones of the fuse main bodies shown in
FIGS. 6A
to
6
E can be used.
As described above, the respective fuse main bodies
1
to
6
to be directly connected with the connection terminals
11
to
18
are members separate from the connection terminals
11
to
18
in the first embodiment. Thus, the fusing characteristics of the fusing elements
1
a
to
6
a
and the strength of the connection terminals
11
to
18
can be adjusted without influencing each other. Further, the respective fuse main bodies
1
to
6
are separate members having the fuse terminals
1
b
to
6
b
,
1
c
to
6
c
at the opposite ends of the fusing elements
1
a
to
6
a
. Thus, a fuse circuit including a plurality of kinds of fusing elements
1
a
to
6
a
having different fusing characteristics can be constructed as a single unit by preparing a plurality of kinds of fuse main bodies
1
to
6
having the fusing elements
1
a
to
6
a
of different thicknesses in large quantities using different metallic plates for the respective thicknesses and using a single metallic plate for the same thickness, and selecting the fusing elements
1
a
to
6
a
from a plurality of kinds of fuse main bodies thus prepared and connecting them with the connection terminals
11
to
18
. Further, since the fuse main bodies
1
to
6
having the fusing elements
1
a
to
6
a
of the same thickness can be mass-produced by, for example, stamping out a single metallic plate as described above and suitable ones may be selected from the mass-produced fuse main bodies and combined, productivity will not be degraded. Furthermore, since the single unit includes a plurality of fuse main bodies
1
to
6
, the number of the fuse devices to be mounted on the busbar board can be reduced without complicating the construction of the busbar board.
In the first embodiment, the thicknesses of the fusing elements
1
a
to
3
a
of the three fuse main bodies
1
to
3
differ from each other, and the thicknesses of the fusing elements
4
a
to
6
a
of the three fuse main bodies
4
to
6
differ from each other. Thus, a fuse circuit including six fusing elements having different fusing characteristics can be realized as a single unit. Further, since the spacing L between the fuse terminals
1
b
to
6
b
and
1
c
to
6
c
at the opposite sides of a plurality of fuse main bodies, for example, shown as examples in
FIGS. 6A
to
6
E is the same, the fuse main bodies having different fusing characteristics can be replaced by each other and the connection terminals
11
to
18
can be used common to these fuse main bodies.
Further, since the connection terminals
11
to
18
and the fuse main bodies
1
to
6
are separate members, materials suited to the purposes can be used for the fusing elements
1
a
to
6
a
aimed to be fused and the connection terminals
11
to
18
aimed to be connected with the tab terminals
41
to
48
. Specifically, the connection terminals
11
to
18
and the tab terminals
41
to
48
can be held satisfactorily connected over a long time by using a material such as Zn having a desired fusing characteristic for the fuse main bodies
1
to
6
while using a material such as Cu having a high strength for the connection terminals
11
to
18
. Further, in the case that the connection terminals
11
to
18
and the fuse main bodies
1
to
6
are separate members, they can be connected, for example, by welding. This makes the connection terminals
11
to
18
and the fuse main bodies
1
to
6
firmly integral to each other, thereby making the fuse device easier to handle and bettering a connectability with the tab terminals
41
to
48
.
Further, in the first embodiment, the connection terminals
11
to
18
of the fuse device are electrically connected with the tab terminals
41
to
48
by inserting the tab terminals
41
to
48
into the forked inserting portions
11
b
to
18
b
formed at the connection terminals
11
to
18
. Thus, the fuse device can be directly connected with the tab terminals
41
to
48
without using the intermediate terminals
321
as described above. Furthermore, since the width of the slits of the forked inserting portions
11
b
to
18
b
is substantially equal to the thickness of the tab terminals
41
to
48
to be inserted into these slits of the forked inserting portions
11
b
to
18
b
, the connection terminals
11
to
18
and the tab terminals
41
to
48
can be securely connected with each other. Further, if the connection terminals
11
to
18
of the fuse device are inserted into the insertion holes
51
to
58
, the tab terminals
41
to
48
are automatically guided to and inserted into the forked inserting portions
11
b
to
18
b
of the connection terminals
11
to
18
, thereby easily establishing an electrical connection between the connection terminals
11
to
18
and the tab terminals
41
to
48
. Further, the insertion holes
51
to
58
make it possible for the tab terminals
41
to
48
not to project out from the outermost casing portion
40
A. Furthermore, since the suspended pieces
61
to
66
which are integral parts of the outermost casing portion
40
A generally made of an insulating material are present between adjacent tab terminals
41
to
48
to thereby insulate the adjacent tab terminals
41
to
48
from each other, a short circuit between the adjacent tab terminals
41
to
48
can be prevented.
Further, in the first embodiment, even though the fuse main bodies
1
to
6
and the connection terminals
11
to
18
are separate members and intersect with each other, the connecting portions
11
a
to
18
a
with which the fuse terminals
1
b
to
6
b
,
1
c
to
6
c
are to be connected are parallel with the fuse terminals
1
b
to
6
b
,
1
c
to
6
c
. Thus, connection by welding is easier. Furthermore, since the fuse terminals
1
b
to
3
b
connected with the three fusing elements
1
a
to
3
a
are connected with the common connecting portion
11
a
and the fuse terminals
4
b
to
6
b
connected with the three fusing elements
4
a
to
6
a
are connected with the common connecting portion
18
a
in the first embodiment, the number of the connection terminals can be reduced as compared to a case where the respective fuse terminals
1
b
to
3
b
,
4
b
to
6
b
are connected with separate connecting portions, which brings about an advantage of low production costs.
Although the three fuse main bodies
1
to
3
,
4
to
6
are connected with the common connection portion
11
a
,
18
a
in the first embodiment, the present invention is not limited thereto. The present invention is also applicable to cases where two, four or more fuse main bodies are connected with the common connecting portion
11
a
,
18
a
. Further, the present invention is applicable not only to the construction provided with two common connecting portions
11
a
,
18
a
, but also to constructions provided with one, three or more common connecting portions.
In the case of changing the fusing characteristics, i.e., the fuse capacities of the respective fusing elements in the first embodiment, the fuse casing
10
and the connection terminals
11
to
18
can be commonly used, thereby advantageously improving mass productivity.
Although the connection terminals of the fuse device are connected with the tab terminals of the electrical connection box in the first embodiment, the present invention is not limited thereto. The present invention is also applicable to general connection casings for accommodating busbars having tab terminals at their ends similar to the electrical connection box.
FIG. 7
is a perspective view showing an external configuration of a fuse device according to a second embodiment,
FIG. 8
is an exploded perspective view of the fuse device of
FIG. 7
immediately before assembling,
FIG. 9
is a perspective view showing an interior of a fuse casing, and
FIG. 10
is a perspective view showing an interior of a connection terminal casing.
This fuse device includes a fuse casing
110
and a connection terminal casing
130
as shown in FIG.
8
.
The fuse casing
110
is comprised of a fuse casing main body
110
a
and a cover
110
b
. As shown in
FIG. 9
(cover
110
b
is not shown), two plate-shaped fuse main bodies
101
,
111
are accommodated in the fuse casing
110
except portions thereof. The fuse main body
101
is made of a low-melting material such as Zn and is an integral piece comprised of a plurality of (three in the shown example) fusing elements
102
, fuse terminals (output terminals)
103
,
104
,
105
separately connected with ends of the three fusing elements
102
and a fuse terminal (input terminal)
106
connected with the other ends of the three fusing elements
102
. The fuse main body
111
is also made of the same material and has the same construction as the fuse main body
101
. Specifically, the fuse main body
111
is an integral piece comprised of a plurality of (three in the shown example) fusing elements
112
, fuse terminals (output terminals)
113
,
114
,
115
separately connected with ends of the three fusing elements
112
and a fuse terminal (input terminal)
116
connected with the other ends of the three fusing elements
112
.
The fuse main bodies
101
,
111
are formed by, after being stamped out from a plate material, thinning the fusing elements
102
,
112
by carving. It should be noted that the fuse main bodies
101
,
111
are identical members mounted like mirror images.
The fuse main bodies
101
,
111
are mounted in the fuse casing
110
such that the respective fuse terminals
103
to
106
,
113
to
116
of the fuse main bodies
101
,
111
project out from the fuse casing
110
while being located on the same plane, i.e., while being arranged along an opening edge
110
c
of the fuse casing
110
a.
On the other hand, the connection terminal casing
130
is U-shaped so as to have a hollow portion
131
into which the fuse casing
110
is fitted, and is comprised of lower and upper half pieces
130
a
,
130
b
placed one over the other in FIG.
8
.
As shown in
FIG. 10
, eight connection terminals
121
,
122
,
123
,
124
,
125
,
126
,
127
,
128
are accommodated in the connection terminal casing
130
except portions thereof. These connection terminals
121
to
128
are made of Cu or like electrically conductive metal having a larger strength than the fuse main bodies
101
,
111
.
The connection terminals
121
,
122
,
123
have the same construction, and connecting portions
121
a
,
122
a
,
123
a
to be connected with the fuse terminals
103
,
104
,
105
are formed at the base ends by bending portions of the respective connection terminals
121
,
122
,
123
in such a manner as to be parallel with the fuse terminals
103
,
104
,
105
, whereas forked inserting portions
121
b
,
122
b
,
123
b
each having a specified slit are formed at the leading ends of the connection terminals
121
to
123
.
The connection terminal
124
is longer than the connection terminals
121
to
123
, and a connecting portion
124
a
to be connected with the fuse terminal
106
is formed at the base end by bending a portion of the connection terminal
124
in such a manner as to be parallel with the fuse terminal
106
, whereas a forked inserting portion
124
b
having a specified slit is formed at the leading end.
The connection terminals
125
,
126
,
127
have the same construction, and connecting portions
125
a
,
126
a
,
127
a
to be connected with the fuse terminals
113
,
114
,
115
are formed at the base ends by bending portions of the respective connection terminals
125
,
126
,
127
in a direction opposite from the connecting portions
121
a
to
123
a
in such a manner as to be parallel with the fuse terminals
113
,
114
,
115
, whereas forked inserting portions
125
b
,
126
b
,
127
b
each having a specified slit are formed at the leading ends of the connection terminals
125
to
127
.
The connection terminal
128
is longer than the connection terminals
125
to
127
, and a connecting portion
128
a
to be connected with the fuse terminal
116
is formed at the base end by bending a portion of the connection terminal
128
in a direction opposite from the connecting portion
124
a
in such a manner as to be parallel with the fuse terminal
116
, whereas a forked inserting portion
128
b
having a specified slit is formed at the leading end. It should be noted that the connection terminals
121
to
128
intersect with, e.g., are normal to the fuse terminals
103
to
106
,
113
to
116
except the connecting portions
121
a
to
128
a.
These eight connection terminals
121
to
128
are, as shown in
FIG. 8
, accommodated in the connection terminal casing
130
such that the respective connecting portions
121
a
to
128
a
are exposed through openings
130
c
formed at the periphery of the hollow portion
131
of the upper half piece
130
b
and the forked inserting portions
121
b
to
128
b
project out from a side opposite from the hollow portion
131
.
When the fuse casing
110
is fitted into the hollow portion
131
of such a connection terminal casing
130
from the exposed sides of the connecting portions
121
a
to
128
a
, i.e., from the state of
FIG. 8
to the state of
FIG. 7
, the respective fuse terminals
103
to
106
,
113
to
116
are brought into contact with the corresponding connecting portions
121
a
to
128
a
. The casings
110
,
130
are made integral to each other by coupling these contact portions by, e.g., welding, thereby completing the fuse device.
FIG. 11
is a perspective view showing the construction of a mating electrical connection box
140
with which the fuse device is to be connected. In
FIG. 11
, a casing portion
140
A of the electrical connection box
140
is shown in section along
12
—
12
.
Busbars
141
A to
148
A having tab terminals
141
to
148
at their ends are accommodated in this electrical connection box
140
, and the upper ends of the tab terminals
141
to
148
reach up to the vicinity of the inner surface of the outermost casing portion
140
A of the electrical connection box
140
. The thickness of the tab terminals
141
to
148
is substantially equal to the width of the slits of the forked inserting portions
121
b
to
128
b.
The outermost casing portion
140
A is made of, e.g., an insulating resin, and slit-shaped insertion holes
151
to
158
into which the connection terminals
121
to
128
of the fuse device are insertable are so formed in a portion of the casing portion
140
A covering the tab terminals
141
to
148
as to extend in a direction normal to widthwise directions D of the tab terminals
141
to
148
. At the longitudinal center positions of the respective insertion holes
151
to
158
, the centers of the respective tab terminals
141
to
148
with respect to widthwise directions D are exposed.
The length of the insertion holes
151
to
158
are substantially equal to the width of the connection terminals
121
to
128
, whereas the width thereof is substantially equal to the thickness of the connection terminals
121
to
128
. Suspended pieces
161
to
163
which are integral parts of the outermost casing portion
140
A are provided between four adjacent tab terminals
141
to
144
, whereas suspended pieces
164
to
166
which are integral parts of the outermost casing portion
140
A are provided between four adjacent tab terminals
145
to
148
. Further, bent portions
167
,
168
,
169
of the outermost casing portion
140
A are provided between the tab terminals
144
and
145
and at the outer sides of the tab terminals
141
and
148
, respectively.
The fuse device is connected with the electrical connection box
140
thus constructed as follows. By inserting the connection terminals
121
to
128
of the fuse device into the insertion holes
151
to
158
, the connection terminals
121
to
128
are guided by the insertion holes
151
to
58
so that the tab terminals
141
to
148
are inserted into the forked inserting portions
121
b
to
128
b
of the connection terminals
121
to
128
as shown in
FIG. 12
, thereby electrically connecting the connection terminals
121
to
128
and the tab terminals
141
to
148
.
As described above, since the connection terminals
121
to
128
include the forked inserting portions
121
b
to
128
b
into which the tab terminals
141
to
148
are inserted for connection in the second embodiment, the connection terminals
121
to
128
and the tab terminals
141
to
148
can be directly connected, thereby improving a connection operability. At this time, since the connection terminals
121
to
128
are connected with the corresponding tab terminals
141
to
148
such that the widthwise direction thereof intersects with (is normal to) that of the tab terminals
141
to
148
, the tab terminals
141
to
148
can be easily inserted into the forked inserting portions
121
to
128
. Further, since the connection terminals
121
to
128
and the fuse main bodies
101
,
111
having the fusing elements
102
,
112
are separate members, materials suited to the purposes can be used for the fusing elements
102
,
112
aimed to be fused and the connection terminals
121
to
128
aimed to be connected with the tab terminals
141
to
148
. Specifically, the connection terminals
121
to
128
and the tab terminals
141
to
148
can be held satisfactorily connected over a long time by using a material such as Zn having a desired fusing characteristic for the fusing elements
102
,
112
while using a material such as Cu having a high strength for the connection terminals
121
to
128
. Further, since the connection terminals
121
to
128
and the fuse main bodies
101
,
111
having the fusing elements
102
,
112
are made firmly integral to each other by welding, the fuse device can be easily handled and can have a better connectability with the tab terminals
141
to
148
.
Further, according to the fuse device connecting structure of the second embodiment, when the connection terminals
121
to
128
of the fuse device are inserted into the insertion holes
151
to
158
, the tab terminals
141
to
148
are automatically inserted into the forked inserting portions
121
b
to
128
b
of the connection terminals
121
to
128
, thereby easily establishing an electrical connection between the connection terminals
121
to
128
and the tab terminals
141
to
148
. Further, since the width of the slits of the forked inserting devices
121
b
to
128
b
is substantially equal to the thickness of the tab terminals
141
to
148
, the connection terminals
121
to
128
and the tab terminals
141
to
148
can be securely connected. Furthermore, since the tab terminals
141
to
148
are accommodated inside the outermost casing portion
140
A, it can prevent the tab terminals
141
to
148
from projecting out of the outermost casing portion
140
A. Further, since the suspended pieces
161
to
166
which are integral parts of the outermost casing portion
140
A made of the insulating material are present between adjacent tab terminals
141
to
148
to thereby insulate the adjacent tab terminals
141
to
148
from each other, a short circuit between adjacent tab terminals
141
to
148
can be prevented.
Further, in the second embodiment, even though the fuse main bodies
101
,
111
and the connection terminals
121
to
128
are separate members and the fuse terminals
103
to
106
,
113
to
116
of the fuse main bodies
101
,
111
and the connection terminals
121
to
128
intersect with each other, the connecting portions
121
a
to
128
a
with which the fuse terminals
103
to
106
,
113
to
116
are to be connected are parallel with the fuse terminals
103
to
106
,
113
to
116
. Thus, connection by welding is easier. Furthermore, since three fusing elements
102
,
112
are connected with the common fuse terminal
106
,
116
in the second embodiment, the number of the fuse terminals can be reduced as compared to a case where the respective fusing elements are connected with separate fuse terminals, which brings about an advantage of low production costs. Further, in the second embodiment, the respective fuse terminals
103
to
106
,
113
to
116
are brought into contact with the respective connecting portions
121
a
to
128
a
when the fuse casing
110
is fitted into the hollow portion
131
of the connection terminal casing
130
from the exposed side of the connecting portions
121
a
to
128
a
. This brings about an advantage of fairly easy assembling.
Although each fuse main body is provided with three fusing elements in the second embodiment, the present invention is not limited thereto. The present invention is similarly applicable even if each fuse main body is provided with one, two, four or more fusing elements.
In the case of changing the fusing characteristics, i.e., the fuse capacities of the respective fusing elements in the second embodiment, the connection terminal casing
130
can be commonly used only by changing the fuse casing
110
, thereby advantageously improving mass productivity.
Although the connection terminals of the fuse device are connected with the tab terminals of the electrical connection box in the second embodiment, the present invention is not limited thereto. The present invention is similarly applicable to general connection casings for accommodating busbars having tab terminals at their ends like the electrical connection box.
As described in detail above, an inventive fuse device, comprising a fuse main body in which the opposite ends of a fusing element are connected with fuse terminals, a plurality of connection terminals which are members separate from the fuse main body. A fuse circuit in which the fusing element is provided between the connection terminals is formed by directly connecting the fuse terminals of the fuse main body with the connection terminals.
Since the fuse main body to be directly connected with the connection terminals are formed separately from the connection terminals, the fusing characteristic of the fusing element and the strength of the connection terminals can be adjusted without influencing each other. In the inventive fuse device, the fuse main body may be such that the fuse terminals are formed at the opposite ends of the fusing element and a plurality of such fuse main bodies may be provided.
With this construction, a plurality of kinds of fuse main bodies having the fusing elements of different thicknesses can be prepared beforehand in large quantities, and a desired one whose fusing element has a thickness in conformity with a specified fusing characteristic can be selected from the plurality of kinds of fuse main bodies thus prepared and connected with the connection terminal.
In constructing a fuse circuit in which a plurality of fuses are connected with one battery output terminal (E), for example, as shown in
FIG. 15
, if the fuse device of
FIG. 13
is used, the same number of fuse devices as the fuses are necessary and a busbar board becomes complicated in construction since this fuse device has only one fusing element. On the other hand, since the fuse device of
FIG. 14
has two fusing elements, the number of the fuse devices can be reduced and a busbar board which is a mount object of the fuse devices can be advantageously simpler in construction.
In the case that the fusing characteristics (fuse capacities) of the respective fuse portions (fusing elements) are desired to be changed, for example, when the fuse circuit shown in
FIG. 15
is constructed by the fuse devices of
FIG. 14
, technique of changing the lengths and widths of the respective fusing elements is adopted. However, such a technique has a limit in differing the fuse capacities. A most effective technique in differing the fuse capacities may be to change the thicknesses of the respective fusing elements. However, since the metal pieces of the fuse device of
FIG. 14
are stamped out from the single metallic plate, it is necessary to apply processing, e.g., carving to the outer surfaces of the individual fusing elements
310
after stamping in order to change the thicknesses of the fusing elements
310
. This results in a poor productivity. Thus, in the case of constructing the fuse circuit including a plurality of fuses having different capacities, it is an only way in view of mass productivity to use a plurality of kinds of fuse devices of the type having only a single fusing element as shown in
FIG. 13
in combination, obliging the busbar board to become complicated in construction.
Contrary to this, according to the present invention, the fuse main bodies whose fusing elements have thicknesses in conformity with desired fusing characteristics can be selected and connected with the connection terminals. Therefore, a fuse circuit including a plurality of fusing elements having different fusing characteristics can be constructed as a single unit. Further, the respective kinds of fuse main bodies can be mass-produced by stamping out, for example, a metallic plate having a thickness substantially equal to that of the fusing elements of the fuse main bodies. Productivity can be remarkably improved as compared to, for example, a case where the respective fusing elements of the conductors made of a single metallic plate as shown in
FIG. 14
are individually carved to adjust their thicknesses. Further, since the single unit includes a plurality of fuse main bodies, the number of the fuse devices to be mounted on a mount object such as a busbar board can be reduced without complicating the construction of the mount object.
Preferably, the fusing elements of at least two fuse main bodies have different thicknesses. With this construction, it can be realized to construct the fuse circuit including a plurality of fusing elements having different fusing characteristics as a single unit.
Preferably, the fuse terminals of each of the plurality of fuse main bodies are spaced apart by the same distance. With this construction, the fuse main bodies having different fusing characteristics can be replaced by each other, and the connection terminals can be commonly used.
Preferably, the connection terminals are provided with forked inserting portions, and tab terminals of a busbar board are inserted into the forked inserting portions, thereby electrically connecting the tab terminals with the connection terminals.
With this construction, the fuse device can be directly connected with the tab terminals without using intermediate terminals. More specifically, the connection terminals
301
shown in FIG.
13
and the connection terminals
311
,
312
shown in
FIG. 14
are male terminals in the conventional fuse devices. If the tab terminals to be connected with these connection terminals
301
,
311
,
312
are also male terminals, intermediate terminals
321
having female terminals at their opposite ends as shown in
FIG. 16
need to be used (identified by
320
in
FIG. 16
is an electrical connection box). However, in the case of this connecting structure, it is not necessary to use intermediate terminals even if the tab terminals are male terminals since the connection terminals of the fuse device have the forked inserting portions.
Preferably, the connection terminals and the fuse terminals of the fuse main body which are separate members are connected by welding. Then, the connection terminals and the fuse main body can be made firmly integral to each other, thereby making it easier to handle the fuse device and bettering a connectability with the tab terminals.
Preferably, the connection terminals are made of a material having a higher strength than the fuse main body. Then, the connection terminals and the tab terminals can be held satisfactorily connected over a long time by using a material having a desired fusing characteristic for the fuse main body while using a material having a high strength for the connection terminals.
Preferably, the connection terminals are arranged such that the widthwise direction thereof intersects with that of the tab terminals. Then, the tab terminals can be easily inserted into the forked inserting portions of the connection terminals.
An inventive fuse device connecting structure, comprises a fuse device according to the first aspect of the present invention, and tab terminals formed at ends of a busbar. The width of a slit of a forked inserting portion provided at each connection terminal of the fuse device is substantially equal to the thickness of the tab terminals.
With this connecting structure, since the connection terminals and the tab terminals can be connected with each other by directly inserting the tab terminals into the forked inserting portions of the respective connection terminals, it is not necessary to use intermediate terminals and a connecting operability can be improved. In addition, since the width of the slits of the forked inserting portions is substantially equal to the thickness of the tab terminals to be inserted into the slits of the forked inserting portions, the connection terminals and the tab terminals can be securely connected.
Preferably, the fuse device connecting structure further comprises a connection casing for accommodating the tab terminals, and insertion holes into which the connection terminals of the fuse device are insertable are so formed in a portion of the connection casing covering the tab terminals as to extend in a direction normal to the widthwise direction of the tab terminals.
With this construction, the tab terminals are automatically inserted into the forked inserting portions of the connection terminals when the connection terminals of the fuse device are inserted into the insertion holes, thereby easily establishing an electrical connection between the tab terminals and the connection terminals. Further, the tab terminals can be prevented from projecting out of the casing.
Preferably, part of the connection casing is present between adjacent tab terminals to insulate the adjacent tab terminals from each other. With this construction, since the part of the connection casing generally made of an insulating material is present between adjacent tab terminals to insulate them from each other, a short circuit between the adjacent tab terminals can be prevented.
This application is based on patent application Nos. 2000-364604 and 2000-371771 filed in Japan, the contents of which are hereby incorporated by references.
As this invention may be embodied in several forms without departing from the spirit of essential characteristics thereof, the present embodiment is therefore illustrative and not restrictive, since the scope of the invention is defined by the appended claims rather than by the description preceding them, and all changes that fall within metes and bounds of the claims, or equivalence of such metes and bounds are therefore intended to embraced by the claims.
Claims
- 1. A fuse device comprising:a plurality of connection terminals that each lead outside the fuse device; a plurality of fuse elements which are to melt in response to over-current passing therethrough; and a plurality of pairs of fuse terminals, each pair of fuse terminals being provided on opposite sides of a respective one of the fuse elements, each fuse terminal being fixedly and directly connected with one of the connection terminals, wherein the connection terminals include at least one output connection terminal, one of each pair of the fuse terminals being fixedly connected with one of the at least one output connection terminal, and a plurality of input connection terminals respectively connected with the other of each pair of the fuse terminals.
- 2. The fuse device according to claim 1, wherein the fuse elements and fuse terminals are integrally made of a same material.
- 3. The fuse device according to claim 2, wherein a plurality of groups of the fuse elements and the fuse terminals are provided, and the at least one output connection terminal comprises a plurality of output connection terminals, with one of each pair of the fuse terminals of a same group being connected with one of the output connection terminals and the other of each pair of fuse terminals being connected with a respective one of the input connection terminals.
- 4. The fuse device according to claim 2, wherein at least two of the fuse elements have different melting characteristics from each other.
- 5. A fuse device comprising:a plurality of connection terminals; a plurality of fuse elements which are to melt in response to over-current passing therethrough; a plurality of fuse terminals respectively provided at first ends of the fuse elements, the fuse terminals being fixedly connected with the connection terminals, and a common fuse terminal connected with second ends of the fuse elements, the common fuse terminal being connected with a connection terminal which is different from the connection terminals connected with the fuse terminals provided on the first ends of the fuse elements.
- 6. A fuse device comprising:a plurality of connection terminals; a plurality of fuse elements which are to melt in response to over-current passing therethrough; and fuse terminals provided on opposite sides of each fuse element, the fuse terminals being fixedly connected with the connection terminals, and at least two of the fuse elements having different melting characteristics from each other, wherein each of the connection terminals respectively connected with the fuse terminals on one side of the fuse elements has a bifurcated inserting portion with a plate shape including bifurcated branches separated by a slit, the slit being adapted to receive a plate-shaped tab terminal of a busbar for electric connection of the connection terminal with the tab terminal.
- 7. A fuse device according to claim 6, wherein the fuse terminals and fuse elements are integrally made of material having a desired fusing characteristic and the connection terminals are made of material different from and having higher strength than that of the fuse terminals and fuse elements.
- 8. A fuse device according to claim 6, wherein the bifurcated inserting portions are arranged to be coupled with corresponding ones of the tab terminals in a manner that each plate-shaped inserting portion and tab terminal intersect with each other with planes of their plate shapes being normal to each other.
- 9. A fuse device connecting structure comprising:a fuse device including a plurality of connection terminals and a plurality of fuse bodies, each fuse body having a fuse clement which is to melt in response to over-current, and fuse terminals provided on opposite sides of the fuse element, the fuse terminals being fixedly connected with the connection terminals, each of the connection terminals connected with the fuse terminals on one side of the fuse elements, respectively has a bifurcated inserting portion including bifurcated branches separated by a slit; and a plurality of busbars each of which has a tab terminal formed at one end of the busbar, the tab terminal being coupled with a corresponding one of the bifurcated inserting portions of the connection terminals.
- 10. A fuse device connecting structure according to claim 9, wherein the inserting portions and tab terminals each have a plate shape and are coupled with each other in a manner that planes of the inserting portions and tab terminals are normal to each other and the tab terminals fit into the slits of the inserting portions.
- 11. A fuse device connecting structure according to claim 10, wherein the slit of each of bifurcated inserting portions has a width substantially equal to a thickness of the tab terminal to accept the tab terminal.
- 12. A fuse device connecting structure, comprising:a fuse device comprising connection terminals, and a fuse main body including fuse terminals and a fusing element whose opposite ends are connected with the fuse terminals, wherein the fuse terminals are directly connected with the respective connection terminals to form a fuse circuit in which the fusing element is between the connection terminals; tab terminals formed at ends of a busbar; and a connection casing for accommodating the tab terminals; wherein the connection terminals are provided with forked inserting portions, and the tab terminals of the busbar are inserted into the forked inserting portions, thereby electrically connecting the tab terminals with the connection terminals; wherein a width of a slit of a forked inserting portions is substantially equal to the thickness of the tab terminals; and wherein insertion holes into which the connection terminals of the fuse device are insertable are so formed in a portion of the connection casing covering the tab terminals as to extend in a direction normal to the widthwise direction of the tab terminals.
- 13. The fuse device connecting structure according to claim 12, wherein part of the connection casing is present between adjacent tab terminals to insulate the adjacent tab terminals from each other.
Priority Claims (2)
| Number |
Date |
Country |
Kind |
| 2000-364604 |
Nov 2000 |
JP |
|
| 2000-371771 |
Dec 2000 |
JP |
|
US Referenced Citations (10)
Foreign Referenced Citations (4)
| Number |
Date |
Country |
| A 59-23430 |
Feb 1984 |
JP |
| A 61-142623 |
Jun 1986 |
JP |
| A 1-241729 |
Sep 1989 |
JP |
| A 2000-182506 |
Jun 2000 |
JP |
