Patent Grant
7292130
The invention claims priority to Japanese Patent Application No. JP 2003-403456 filed on Dec. 2, 2003. The disclosure of the prior application is incorporated herein by reference in its entirety.
1. Field of Invention
This invention relates to a fusible link and a battery fuse unit containing the fusible link and more particularly relates to a fusible link adapted to be connected to a battery terminal to be engaged with a battery post and relates to a battery fuse unit that contains the fusible link and the battery terminal in a casing and is adapted to be mounted on a top part of a battery box.
2. Description of Related Art
Heretofore, an output side electrical cable is connected through a battery fuse to a battery terminal to be connected to a battery post. The battery fuse utilizes a fusible link in which a U-shaped terminal member includes an input terminal section, an output terminal section, a fusible section having a narrow width and provided between the input and output terminal sections, and a resin casing embedding a narrow portion of the fusible section. The fusible link permits upsizing due to the resin casing. When the fusible section is blown out, the fusible section cannot be viewed from outside and may generate smoke due to heat generation, because the fusible section is embedded in the resin casing.
In the case where a battery fuse unit that contains the battery terminal and battery fuse is disposed on a top part of a battery box and the battery terminal is joined to a battery post by bolt and nut means, because the battery fuse to be contained in a casing is upsized, the whole of the unit is upsized. An intermediate terminal is disposed between the battery fuse and the battery terminal in many cases. This increases the number of parts to be contained in the unit.
The applicant has previously disclosed a fuse with an electrical cable, which is not a battery fuse to be connected to the battery terminal, in Japanese Patent Public Disclosure 2001-52591. As shown in
In the case of using the fuse 1 with an electrical cable, there is an advantage that an electrical cable is directly connected to the fuse. However, because the protection member 2 contains the fusible sections 1c, heat generation due to overcurrent is consumed to melt the molded resin and the fusible section is hardly blown out even by overcurrent greater than a setting value. This will lower reliability in fuse blowing. The blowing in the fusible section cannot be viewed from outside.
Because the above fuse cannot be directly connected to the battery terminal and an input terminal section and an output terminal section are disposed on the opposite ends of the fusible section, when the input terminal section is connected through an intermediate terminal and the output terminal section is connected to an electrical cable, the fuse cannot be efficiently arranged in a casing. This may upsize the battery fuse unit.
In view of the above problems, an object of various exemplary embodiments of the invention is to provide a fusible link that has a compact and thin configuration, is positively blown out when overcurrent greater than a setting value flows in the fusible link, and a blown portion can be viewed from outside. Particularly, the fusible link connected to a battery terminal is adapted to be contained in a battery fuse unit.
In order to achieve the above object, a fusible link of the present invention formed by punching out an electrically conductive metallic plate includes an input side connecting-section, an output side connecting-section, a fusible section having a narrow width and provided between the input and output side connecting-sections, and a resin section enclosing the fusible section. The input and output side connecting-sections are arranged on the angled positions with respect to the fusible section. Coupling portions between the fusible section and the input and output side connecting-sections are molded in the resin section.
According to the above construction, the resin section encloses the fusible section so that a cavity is defined around the fusible section and the coupling portions between the fusible section and the input and output side connecting-sections are molded in the resin section. Consequently, it is possible to reinforce the fusible section, to protect it from being interfered with external components, and to blow out the fusible section when overcurrent greater than a setting value flows in the fusible section.
The input and output side connecting-sections are arranged in the angled position with respect to the fusible section. In more detail, the fusible link is formed into an L-shape in plan view (or T-shape having one input side connecting section and two output side connecting sections). In comparison with the conventional fusible link in which the input and output side connecting-sections are aligned longitudinally, the fusible link of various exemplary embodiments of the invention can take an efficient arrangement in accordance with the arranged position of the input and output side connecting-sections. For example, the L-shaped fusible link can dispose terminals coupled to the input and output side connecting-sections in parallel to each other. On the other hand, the T-shaped fusible link can couple the respective output members to the rectangular output side connecting-sections.
The input side connecting-section is provided on an end with an inclined projection. The inclined projection is provided with a first bolt hole for joining a mating member. A battery terminal is provided on an end with a pair of fastening pieces for fastening a battery post. Each of the fastening pieces is provided with a second bolt hole. The first and second bolt holes are aligned axially and fastened to each other by bolt and nut means.
According to the above structure, the fastening pieces of the battery terminal and the input side connecting-section of the fusible link can be interconnected by the bolt and nut means directly without using any intermediate terminal. At this time, the inclined projection of the input side connecting-section can be disposed along the fastening pieces of the battery terminal, thereby facilitating a fastening work using bolt and nut means.
The battery terminal can be secured to the battery post by engaging the arc portions of the fastening pieces with the battery post, inserting a bolt into the second bolt holes in a pair of fastening pieces and into the first bolt hole in the input side connecting-section of the fusible link, and fastening the bolt holes by the bolt and nut means. This fastening work using only one bolt can perform a work of securing the battery terminal to the battery post and a work of joining the battery terminal to the input side connecting-section of the fusible link simultaneously.
A third bolt hole is provided in the output side connecting-section. A fourth bolt hole is provided in a male terminal connected to an end of an output side electrical cable. The third and fourth bolt holes are aligned axially and fastened to each other by bolt and nut means.
According to the above structure, the output side connecting-section of the fusible link can be connected to the cable-connecting male terminal directly without using any intermediate terminal. When the fusible section is blown out, the output side connecting-section is disconnected from the male terminal and only the blown fusible link is changed to a new fusible link. This can facilitate a work of changing the fusible link.
An electrical cable crimping barrel portion may be provided on the output side connecting-section.
According to the above structure, because the output side can be connected connecting-section of the fusible link to the electrical cable directly, the number of the parts can be reduced and a bolt-fastening work can be omitted.
A battery fuse unit of various exemplary embodiments of the invention includes the fusible link described above and a battery terminal connected to the input side connecting-section of the fusible link. The battery fuse unit contains the fusible link and battery terminal in a casing so that arc portions of the battery terminal enclose a battery post and are exposed from the casing. The arc portions are adapted to engage the battery post.
The fusible link is formed into a thin configuration and contained in the battery fuse unit. The input side connecting-section of the fusible link is directly connected to the battery terminal. This can reduce the number of parts and make a thin and compact battery fuse unit.
To be more specific, the fusible link is formed into an L-shape in plan view and disposed on an end of the casing having a quadrangular shape in a front and rear direction. The battery terminal is disposed on a side of the casing in a right and left direction. The battery terminal is connected to the input side connecting-section of the fusible link. The output side connecting-section of the fusible link is disposed on the other side of the casing in the right and left direction and connected to an electrical cable connecting terminal or crimped on an electrical cable. According to the above structure, the battery terminal, fusible link, and output side electrical cable can be efficiently contained in the quadrangular casing and to make a compact battery fuse unit, and to reduce an installing space that has been required in the prior art by mounting the battery fuse unit on the top surface of the battery box.
It will be apparent from the foregoing that because the fusible link in the first aspect of various exemplary embodiments of the invention is formed by punching out an electrically conductive metallic plate and includes the fusible section having a narrow width and the input and output side connecting-sections provided angularly on the opposite sides of the fusible section, the input and output side connecting-sections can be arranged in parallel with each other and to make a compact and thin casing that contains the fusible link. Because the fusible section is not molded in the resin section but is enclosed by the resin section, the fusible section can be blown out positively when overcurrent greater than the setting value flows in the fusible section and the blown fusible section can be viewed from outside.
Since the battery fuse unit in the second aspect of various exemplary embodiments of the invention contains the input side connecting-section of the fusible link directly connected to the battery terminal in the casing, it is possible to make a compact and thin battery fuse unit and furthermore to reduce the number of parts. Because the unit is mounted on the battery box directly, it is not necessary to dispose another fuse box and to effectively utilize a restricted space of a vehicle.
The accompanying drawings, which are incorporated into and constitute a part of the specification, illustrate one or more embodiments of the invention and, taken with the detailed description, serve to explain the principles and implementations of the invention.
In the drawings:
By referring now to the drawings, embodiments of a battery fuse unit in accordance with various exemplary embodiments of the invention will be described below.
Punching out an electrically conductive metallic plate forms the fusible link 20 to be contained in the battery fuse unit 10. As shown in
The input side connecting-section 22 is provided on an end with an inclined projection 22a having a first bolt hole 22b. The first bolt hole 22b is aligned axially with second bolt holes 32a and 33a in fastening pieces 32 and 33 of the battery terminal 30 so that the inclined projection 22a and fastening pieces 32, 33 are fastened to one another by bolt and nut means. The output side connecting-section 23 includes a first barrel portion 25a for crimping an insulation sheath of the output side electrical cable w1 and a second barrel portion 25b for crimping a core wire of the cable w1. A protection cover 28 is disposed above the fusing section 24 coupling the input and output side connecting-sections 22 and 23 to each other.
Coupling portions between the fusing section 24 and the input and output side connecting-sections 22 and 23 are molded in a resin section 27 so that the resin section 27 encloses the fusible section 24. The protection cover 28 is formed into a transparent resin cover that has a U-shape in cross section and encloses the opposite sides of the fusing section 24.
As shown in
As shown in
Under the above condition, the fusible link 20 and battery terminal 30 are contained in the lower casing member 12 of the battery fuse unit 10.
As shown in
The upper casing member 11 is joined to the lower casing member 12 to cover a part except the barrel portion 34 of the battery terminal 30. The barrel portion 34 of the battery terminal 30 is covered by the lid 12g pivotally connected to the lower casing member 12.
According to the above structure, because the fusing section 24 of the fusible link 20 is not molded with resin but enclosed by a molded resin section 27, a melting action caused in the molded resin section will not absorb heat generated in the fusing section 24 when overcurrent flows in the fusing section 24. Consequently, the fusing section 24 will be blown out when overcurrent greater than a setting value flows in the section 24. This can enhance reliability in fuse blowing. In addition, a blown condition can be visibly confirmed through the transparent cover 28 when the upper casing member 11 is removed.
Upon securing the battery terminal 30 to the battery post 51, the battery terminal 30 can be joined to the input side connecting-section 22 of the fusible link 20 at the same time. This can reduce the number of man-hours and eliminate an intermediate terminal that is disposed between the battery terminal and the fuse and has been essential to the conventional battery fuse unit. This will also reduce the number of parts. Because the fusible link 20 is formed into an L-shape in plan view and connected between the battery terminal and the output side electrical cable, the fusible link 20 can be efficiently contained in a compact and quadrangular casing. Consequently, it is possible to make the battery unit compact. Furthermore, because the fusible link is formed into a conventional fusible link integrated together with a substrate, it can be formed into a thin configuration and thus the battery fuse unit can be also formed into a thin configuration.
A fusible link 20′ in the second embodiment is formed by punching out an electrically conductive metallic plate. As shown in
A first bolt hole 22b′ is formed in the inclined projection 22a′ so that the first bolt hole 22a′ is joined to the fastening pieces 32 and 33 of the battery terminal 30 by the bolt and nut means. On the other hand, as shown in
A quadrangular frame shape resin section 27′ encloses the fusible section 24′ with a certain cavity. Coupling portions 29 between the fusible section 24′ and the input and output side connecting-sections 22′ and 23′ are molded in the resin section 27′.
A bolt hole is provided in an end of the male terminal 41 to be connected to the output side connecting-section 23′ of the fusible link 20′. The male terminal 41 is provided on the other end with an insulation sheath crimping barrel portion 41a and a core wire crimping barrel portion 41b. The crimping barrel portions 41a and 41b are crimped on the output side electrical cable w1.
As described above, the input side connecting-section 22′ of the fusible link 20′ is joined to the fastening pieces 32 and 33 of the battery terminal 30 by the bolt and nut means in conjunction with the output side connecting-section of the fusible link 20′ is joined to the male terminal 41 connected to the end of the output side electrical cable w1. The fusible link 20′ constructed above is contained in the lower casing member 12 of the battery fuse unit 10 and the upper casing member 11 is mounted on the lower casing member 12 by the same manner as the first embodiment. The battery fuse unit 10 constructed above is mounted on the upper surface of the battery box 50 and the battery terminal 30 is secured to the battery post 51.
According to the above construction, it is possible to obtain the same effects as those in the first embodiment. It is also possible to utilize the male terminal connected to the electrical cable again so that the male terminal is joined to a new fusible link by disconnecting the output side connecting-section 23′ from the male terminal 41 when the fusible section 24′ of the fusible link 20′ is blown out, because the male terminal 41 connected to the electrical cable is joined to the output side connecting-section 23′ by the bolt and nut means.
Since the other constructions and operational effects in the second embodiment are the same as those in the first embodiment, the explanation of them are omitted here merely by giving the same signs to the elements in the second embodiment.
The input connecting section 22″ may be provided on the distal end with an inclined projection in the same manner as the above embodiments.
Because the other constructions and operational effects in the third embodiment are the same as those in the above embodiments, the explanation of them are omitted here merely by giving the same signs to the elements in the third embodiment.
While the invention has been particularly described, in conjunction with specific preferred embodiments, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art of the foregoing description. It is therefore contemplated that the appended claims will embrace any such alternatives, modifications, and variations as falling within the true scope and spirit of the invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2003-403456 | Dec 2003 | JP | national |
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| 20040070485 | Andoh et al. | Apr 2004 | A1 |
| Number | Date | Country |
|---|---|---|
| 2001-052591 | Feb 2001 | JP |
| 2001-256878 | Sep 2001 | JP |
| Number | Date | Country | |
|---|---|---|---|
| 20050116805 A1 | Jun 2005 | US |
