Information
-
Patent Grant
-
6359227
-
Patent Number
6,359,227
-
Date Filed
Tuesday, March 7, 200024 years ago
-
Date Issued
Tuesday, March 19, 200222 years ago
-
Inventors
-
Original Assignees
-
Examiners
- Reichard; Dean A.
- Mayo, III; William H.
Agents
-
CPC
-
US Classifications
Field of Search
US
- 174 84 R
- 174 84 C
- 174 74 R
- 174 79
- 174 35 C
- 439 893
- 439 621
-
International Classifications
-
Abstract
A fusible link for a cable assembly is provided. The fusible link has a link segment having a first member extending transversely from the link segment, and a second member extending transversely from the link segment. A first end of the link segment engaging a first cable of the cable assembly, and a second end of the link segment engaging a second cable of the cable assembly. A method of manufacturing the fusible link is also provided.
Description
TECHNICAL FIELD
The invention relates to the field of electrical protection, and is particularly directed to a fusible link for protecting electrical devices.
BACKGROUND OF THE INVENTION
Automobiles are increasingly reliant on electronic controls and engine management systems. As a result of these controls and systems, modern automobiles are much more dependable than prior autos, which instead used more vulnerable mechanical systems. Although the hardware embodying the electronic controls and systems is rather dependable, the failure of the means for directly or indirectly bringing electrical current to such hardware continues to be a rare but, nevertheless, significant source of automotive breakdowns. An automotive breakdown, especially in a deserted area or on a very busy high-speed road, is obviously a safety hazard to the automobile and its passengers.
One specific type of failure in prior art means can lead to an even more hazardous condition than automotive breakdown. The failure results when the junctions between the fusible link and the cables loosen, causing a high resistance between the fusible link and cable. The increased resistance leads to high temperatures in these regions. One cause of the failure at the connection of the fusible link and the cable is due to the flexibility of the fusible link. If the fusible link is not sufficiently rigid it may twist and bend during use of the cable assembly, thereby causing the connection between the fusible link and the cable to fail. Under certain conditions the increased temperatures can reach sufficiently high levels to split the insulation on the conventional copper-wire fusible links, initiating an engine compartment fire that can quickly destroy the automobile and endanger its occupants.
U.S. Pat. No. 5,591,366 issued to Schmidt et al. discloses a series of protective coverings over a heating wire connected to a power wire. The heating wire is connected in series to an electrical pin which directly joined to a fuse wire. The fuse wire is then joined to the power wire. Two opposing metal caps are bonded on their inner surfaces to a ceramic tube to form a hermetically sealed shell surrounding the junctions between the fuse wire and pin, and between the fuse wire and power wire. Then, a heat shrinkable tubing is used to grip the caps and ceramic tubing, encasing the fuse area.
Like other prior art devices, the disclosure of U.S. Pat. No. 5,591,366 does not solve the problem of protecting failure at the junctions of the fusible link.
Accordingly, a fusible link for a cable assembly in accordance with the present invention eliminates the drawbacks of the prior art devices described above.
SUMMARY OF THE INVENTION
According to one aspect of the present invention, a fusible link is provided for a cable assembly. The fusible link has a link segment having a first member extending transversely from the link segment, and a second member extending transversely from the link segment. The link segment is adapted to be electrically connected to first and second cables of the cable assembly.
According to another aspect of the present invention, the link segment has a first end and a second end, a first surface and a second surface, and a first side and a second side. The first end of the link segment is adapted to engage the first cable of the cable assembly and the second end of the link segment is adapted to engage the second cable of the cable assembly to electrically connect the fusible link with the first and second cables. The first member extends from the first side of the link segment and the second member extends from the second side of the link segment. The first and second members are transverse to the link segment.
According to another aspect of the present invention, the first member extends in a first direction transverse from the link segment, and the second member extends in a second direction from the link segment. In one embodiment, the second direction is substantially the same direction as the first direction. In another embodiment the second direction is substantially the opposite as the first direction.
According to another aspect of the present invention, the link segment is substantially planar and a plurality of apertures extend through the link segment. The fusible link may be made of a first conductive material that is the same as the conductive material as the first and second cables, and a second conductive material having a lower melting temperature than the first conductive material may be deposited on the link segment.
According to another aspect of the present invention, a method of manufacturing the fusible link is provided. The method includes providing a strip of conductive material having a first surface and a second surface. An aperture is created in the conductive material. The aperture extends from the first surface of the conductive material to the second surface of the conductive material. Additionally, transverse members are created on the fusible link.
According to another aspect of the present invention, the step of creating the transverse members comprises bending a first side of the strip of conductive material at an angle to the first surface to create a first transverse member, and bending the second side of the conductive material at an angle to the first surface to create a second transverse member.
According to another aspect of the present invention, a method of manufacturing a plurality of fusible links is provided. The method includes dicing the strip of conductive material into individual fusible links prior to creating the transverse members.
According to yet another aspect of the present invention, an additional step is provided including adding a second conductive material having a lower melting temperature than the first conductive material on one of the first and second surfaces of the fusible link. The second conductive material is added adjacent the aperture in the conductive material.
Other features and advantages of the invention will be apparent from the following specification taken in conjunction with the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
To understand the present invention, it will now be described by way of example, with reference the accompanying drawings in which:
FIG. 1
is an exploded perspective view of the cable assembly, including a protective housing andthe fusible link of the present invention;
FIG. 2
is a top plan view of a strip of conductive material utilized to create a plurality of fusible links of the present invention;
FIG. 3
is a top plan view of one fusible link of the present invention;
FIG. 4
is a top plan view of the fusible link of
FIG. 1
;
FIG. 5
is a side elevation view of the fusible link of
FIG. 4
;
FIG. 6
is a top plan view of another embodiment of the fusible link; and,
FIG. 7
is a side elevation view of the fusible link of FIG.
6
.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated.
Referring now in detail to the Figures, and initially to
FIG. 1
, there is shown a preferred embodiment of the fusible link
16
of the present invention. The fusible link
16
is generally utilized with a cable assembly
10
, including a first cable
12
and a second cable
14
connected to ends of the fusible link
16
, and a protective housing
18
encasing the fusible link
16
. The present fusible link
16
is an improvement over prior art fusible links in that it provides a rigid member to electrically connect the first and second cables
12
,
14
. Thus, the present invention offers stability and safety features previously not available with prior fusible links.
As shown in
FIG. 1
, the first and second cables
12
,
14
are conventional insulated electrical cables and are generally comprised of a core of a plurality of elongated strands of wires
20
surrounded by a protective insulation layer
22
, such as polyethylene. Nonetheless, a solid wire or cable could be employed as the core for the present invention in lieu of a stranded cable. The cable core
20
is made of a first material, preferably a conductive metal, and more preferably copper. Each of the cables
12
,
14
generally have a first or proximal end
24
, and a second or distal end
26
. A portion of the protective covering
22
or insulation adjacent the first or proximal end
24
of each cable is removed or stripped away from the cable. Preferably, approximately a ½″ portion of insulating covering
22
is removed from the first end
24
of the cable. Thus, the end portion of the cables or wires extends past their respective protective coverings
22
.
In the preferred embodiment of the present invention the first cable
12
is made of 6 gauge wire. The first cable
12
may have a terminal
28
at the second or distal end
26
of the cable for connecting the cable to a power source (not shown). The second cable
14
is similarly made of a 6 gauge wire. The second cable
14
may have a terminal
28
at the second or distal end
26
of the cable for connecting to a desired electrical device (not shown) such as the starter of an automobile. Even though a 6 gauge wire is utilized in the preferred embodiment, much larger and much smaller gauge wires, for example, from 10 gauge up to at least 2 gauge or larger, may be used as either the first cable, the second cable, or both the first and second cables. Furthermore, it is understood that the gauge thickness of the first cable could be different from the gauge thickness of the second cable.
The fusible link of the preferred embodiment is illustrated in
FIGS. 1
, and
4
-
7
. The fusible link
16
is adapted to be electrically connected to the first and second cables
12
,
14
of the cable assembly. The fusible link
16
comprises a link segment
17
having a first end
30
and a second end
32
, a first surface
36
and a second surface
38
, and a first side
39
and a second side
41
. Generally, the link segment
17
is substantially planar. The first end
30
of the link segment
17
is adapted to engage the first cable
12
, and the second end
32
of the link segment
17
is adapted to engage the second cable
14
. Further, first and second members
40
,
42
extend from the link segment. In the preferred embodiments of the present invention, the first member
40
extends from the first side
39
of the link segment
17
, and the second member
42
extends from the second side
41
of the link segment
17
. The first and second members
40
,
42
are transverse to the link segment
17
. The transverse members
40
,
42
of the fusible link
16
provide superior bending strength and rigidity for the fusible link
16
.
One preferred embodiment of the fusible link of the present invention is illustrated in
FIGS. 4 and 5
. In this embodiment the first transverse member
40
extends in a first direction transverse from the link segment
17
, and the second transverse member
42
extends in a second direction which is substantially the same direction as the first member
40
. The first member
40
and the second member
42
extend from or are adjacent one of the surfaces
36
,
38
of the link segment. As shown in
FIG. 4
, the first member
40
extends from the first surface
36
adjacent the first side
39
thereof, and the second member
42
extends from the first surface
36
adjacent the second side
41
thereof. Thus, both the first and second members
40
,
42
extend away from the link segment
17
in the same direction (away from and adjacent to the first surface), and the fusible link
16
of this embodiment is approximately U-shaped. As shown in
FIG. 5
, the first and second members
40
,
42
are substantially perpendicular to the link segment
17
. The transverse members
40
,
42
, however, need not be at exact right angles (i.e., at 90°) to the link segment
17
, and are generally within ±30° of 90°.
The improved rigidity in the fusible link
16
is provided from the transverse portion of a member adjacent the link segment
17
of the fusible link
16
. Accordingly, any angle that the first and second members
40
,
42
depend from the link segment
17
provides improved rigidity. Preferably, the first and second members
40
,
42
extend at least at a 30° angle to the link segment
17
. More preferably, the first and second members
40
,
42
extend at least at a 45° angle to the link segment
17
. Most preferably, the first and second members
40
,
42
extend at an angle between 45° and 90° to the link segment
17
.
Another preferred embodiment of the fusible link of the present invention is illustrated in
FIGS. 6 and 7
. In this embodiment the first transverse member
40
extends in a first direction transverse from the link segment
17
, and the second transverse member
42
extends in a second direction which is substantially the opposite direction as the first member
40
. Thus, the first member
40
, the link segment
17
, and the second member
42
form the shape of an “S” or “Z.” As shown in
FIG. 7
, the first member
40
extends from or adjacent the first surface
36
of the link segment
17
adjacent the first side
39
thereof, and the second member
42
extends from or adjacent the second surface
38
of the link segment
17
adjacent the second side
41
thereof. Like the embodiment illustrated in
FIGS. 4 and 5
, the first and second members
40
,
42
are substantially perpendicular to the link segment
17
. Also like the above embodiment, the transverse members
40
,
42
need not be at exact right angles (i.e., at 90°) to the link segment
17
, but are generally within ±30° of 90°.
The fusible link
16
is generally a 0.032 inch thick piece of conductive material, preferably copper or a copper alloy. In the preferred embodiment, the fusible link
16
is made of the same conductive metal, i.e. copper, as the first and second cables
12
,
14
. Notwithstanding the above, the fusible link
16
can be made of any suitable conductive metal which can form a fuse element that, when properly configured, melts to open the circuit under both short circuit conditions and under prolonged modest overload conditions.
Further, in both of the above-described preferred embodiments, a plurality of apertures or cutouts
44
extend through the link segment
17
of the fusible link
16
. The apertures
44
create regions of high electrical resistance. Additionally, a second conductive material
48
having a lower melting temperature than the material of the fusible link
16
may be distributed on the fusible link
16
adjacent the apertures
44
to lower the melting temperature of the fusible link. Preferably a tin or tin/lead spot
48
is distributed on the upper or first surface
36
of the fusible link
16
for such purposes.
The fusible link
16
is manufactured by conventional stamping and bending techniques. The method of manufacturing the fusible links
16
described above generally begins with providing a substantially planar strip of conductive material
19
having a first surface
36
and a second surface
38
. Next, the apertures
44
are created in the strip of conductive material as shown in FIG.
3
. The apertures
44
extend through the strip from the first surface
36
thereof, to the second surface
38
thereof. The apertures
44
may be created by any method, including stamping, punching, and with the use of lasers and chemicals.
The next step includes creating members
40
,
42
transverse to the first and second surface
36
,
38
of the link segment
17
. Generally, this is accomplished by bending a portion of the conductive material adjacent the first and second sides
39
,
41
of the link segment
17
. In the preferred embodiments, a portion of the material at the first side
39
of the strip of conductive material is bent at an angle to the first surface
36
to create the first transverse member
40
, and a portion of the material at the second side
41
of the strip of conductive material is bent at an angle to the first surface
36
to create the second transverse member
42
. The angle may be positive or negative, as shown in FIG.
7
. In the embodiment of
FIG. 7
, the first transverse member
40
extends roughly 90° from the first surface
39
, while the second transverse member
42
extends roughly −90° from the first surface
39
.
Additionally, as shown in both
FIGS. 4 and 6
, the first and second transverse members
40
,
42
extend in a direction from the first end
39
of the fusible link to the second end
41
of the fusible link. Notwithstanding the preferred embodiment which includes bent sides, the transverse members
40
,
42
may be additional material connected to the link segment
17
of the fusible link
16
. Further, the transverse members
40
,
42
may extend the entire length from the first end
30
of the fusible link
16
to the second end
32
of the fusible link
16
as shown in
FIG. 4
, or the transverse members
40
,
42
may extend along a portion of the sides
39
,
41
of the fusible link
16
as illustrated in FIG.
6
. As shown in
FIG. 1
, if the transverse members
40
,
42
extend the entire length from the first end
30
to the second end
32
of the fusible link
16
, they provide additional retaining means for the cables
12
,
14
.
As shown in
FIG. 2
, the method of manufacturing the fusible links
16
allows for manufacturing a plurality of links simultaneously. As such, a strip of conductive material is provided
19
. The strip is much longer than a single fusible link
16
. The process commences as if a single fusible link
16
were being manufactured. As such, a plurality of apertures
44
are created in the strip of material
19
. The apertures
44
are located in appropriate clusters for each resulting fusible link. After the strip
19
has the appropriate apertures therein, the strip is diced into individual link segments
17
. The strip may be diced lengthwise or widthwise, depending on the configuration of the fusible link. Each diced link segment
17
from the long strip
19
shown in
FIG. 2
becomes an individual link segment
17
as shown in FIG.
3
. Once the link segments
17
are diced, the transverse members
40
,
42
are created as described above.
Additionally, a second conductive material
48
may be placed on one of the first and second surfaces
36
,
38
of the fusible link. As shown in
FIG. 1
, the second conductive material
48
is preferably located adjacent one of the apertures
44
.
The first end portion
24
of each of the first and second cables
12
,
14
is electrically connected to the fusible link
16
adjacent the opposing first and second ends
30
,
32
of the fusible link, respectively. The first end portion
24
of the first cable
12
is electrically connected to the fusible link
16
adjacent the first end
30
of the fusible link, thereby creating a first connection point. Similarly, the first end portion
24
of the second cable
14
is electrically connected to the fusible link
16
adjacent the second end
32
of the fusible link, thereby creating a second connection point. As such, the fusible link
16
is located between and electrically connects the first and second cables
12
,
14
. The means for electrically connecting the cables
12
,
14
to the fusible link
16
is preferably accomplished by brazing the cable to the fusible link. Other means, including compressing, welding, soldering and sonic welding, can be employed as well. As shown in
FIG. 1
, the first cable
12
and the second cable
14
are preferably connected to the top surface of the fusible link
16
, and between the transverse sides
40
,
42
thereof.
As shown in
FIG. 1
, the protective housing
18
comprises a pair of housing members. Preferably, the pair includes a first housing member
60
and a second housing member
62
. Each housing member
60
,
62
is generally made of a heat resistant plastic material. The protective housing
18
itself, as well as the first and second housing members
60
,
62
of the protective housing, each have a first end portion
72
, a second end portion
74
, and an intermediate section
76
therebetween. The first end portion
72
of each housing member has a first cavity
78
, the second end portion
74
of each housing member has a second cavity
80
, and the intermediate section
76
of each housing member has an intermediate cavity
82
. The intermediate cavity
82
of the first and second housing members has a greater volume than that of the first and second cavities
78
,
80
of the first and second housing members. The protective housing
18
securably engages the first and second cables
12
,
14
, to prevent both axial and rotational movement of the cables
12
,
14
. As such, a much more rigid assembly is provided to prevent loosening or breaking of the connection between the first and second cables
12
,
14
or wires and the fusible link
16
. Additionally, features of the housing
18
provide for increased protection for the components within the housing
18
from outside elements.
The first and second housing members
60
,
62
each have a shoulder
68
and groove
70
therein. One shoulder
68
is adjacent a side of each of the first and second housing members
60
,
62
. Similarly, one groove
70
is adjacent the opposing side of each of the first and second housing members
60
,
62
. The shoulder
68
that extends from the first housing member
60
mates with the groove
70
in the second housing member
62
when the first and second housing members
60
,
62
are coupled, and the shoulder
68
that extends from the second housing member
62
mates with the groove
70
in the first housing member
60
when the first and second housing members
60
,
62
are coupled. The grooves
70
and shoulders
68
not only operate as a locating means for the first and second housing members during coupling thereof, but the mated shoulders
68
and grooves
70
also provide a seal area about the sides of the protective housing
18
.
The first and second housing members
60
,
62
also have interconnecting members
64
,
66
which mate to assist in locating the first and second housing members
60
,
62
together for coupling thereof The interconnecting members comprise a post
64
and a mating aperture
66
. Each housing member
60
,
62
has a post
64
at the first and second end portions
72
,
74
of each respective housing member
60
,
62
. The posts are adjacent one of the sides of the respective housing member
60
,
62
. Additionally, each housing member
60
,
62
has an aperture
66
at the first and second end portions
72
,
74
of each respective housing member
60
,
62
. The apertures
66
are adjacent the opposing side of the respective housing member
60
,
62
as that of the posts
64
. Accordingly, the post
64
at the first end portion
72
of the first housing member
60
mates with the aperture
66
at the first end portion
72
of the second housing member
62
, the post
64
at the second end portion
74
of the first housing member
60
mates with the aperture
66
at the second end portion
74
of the second housing member
62
, the post
64
at the first end portion
72
of the second housing member
62
mates with the aperture
66
at the first end portion
72
of the first housing member
60
, and the post
64
at the second end portion
74
of the second housing member
62
mates with the aperture
66
at the second end portion
74
of the first housing member
60
. When coupled, the protective housing
18
covers the fusible link
16
and portions of the first and second cables
12
,
14
.
As shown in
FIG. 1
, when the first and second housing members
60
,
62
are coupled together to form the overall protective housing
18
, the protective housing
18
can be said to have a first channel portion
84
at a first end
72
thereof which houses a portion of the first cable
12
; a second channel portion
86
at the second end
74
thereof which houses a portion of the second cable
14
; and, an intermediate channel portion
88
between and connecting the first channel
84
and the second channel
86
which houses the fusible link
16
. The first channel portion
84
is comprised of the first cavity
78
of the first and second housing members
60
,
62
, the second channel portion
86
is comprised of the second cavity
80
of the first and second housing members
60
,
62
, and the intermediate channel portion
88
of the protective housing
18
is comprised of the intermediate cavities
82
of the first and second housing members
60
,
62
. The individual channel portion
84
,
86
,
88
cooperate to form a continuous channel extending from the first end
72
of the protective housing
18
to the second end
74
of the protective housing
18
. The intermediate channel
88
houses the fusible link
16
. A portion of the intermediate channel
88
is spaced a distance away from the fusible link
16
to create a gap between the fusible link
16
and an interior wall of the intermediate channel
88
.
The protective housing
18
further has a plurality of ribs
90
,
91
extending into the channel. As shown in
FIG. 1
, in the preferred embodiment, two first ribs
90
and two second ribs
91
extend from the protective housing
18
and into the channel at the first end portion
72
of the protective housing
18
, and two first ribs
90
and two second ribs
91
extend from the protective housing
18
and into the channel at the second end portion
74
of the protective housing. More specifically, in the preferred embodiment a first rib
90
extends from the first housing member
60
, at both the first and second end portions
72
,
74
thereof, and into the channel; and, a second rib
91
extends from the first housing member
60
, at both the first and second end portions
72
,
74
thereof, and into the channel. Similarly, a first rib
90
extends from the second housing member
62
, at both the first and second end portions
72
,
74
thereof, and into the channel; and, a second rib
91
extends from the second housing member
60
, at both the first and second end portions
72
,
74
thereof, and into the channel.
The first and second housing members
60
,
62
have a longitudinal axis (L) which generally extends from the first end
72
of the respective housing member to the second end
74
of the respective housing member. The first ribs
90
of the first and second housing members
60
,
62
generally extend about a portion of the longitudinal axis (L) of the respective housing member
60
,
62
. Accordingly, when the first and second housing members
60
,
62
are coupled to form the protective housing
18
, the first ribs
90
extend axially from the protective housing
18
. The second ribs
91
are transverse to the first ribs
90
, and conversely, the first ribs
90
are transverse to the second ribs
91
. In the preferred embodiment, the second ribs
91
extend substantially perpendicular to the first ribs
90
. As such, in the preferred embodiment the second ribs
91
do not have to be at exact right angles to the first ribs
90
.
Moreover, in the preferred embodiment the first housing member
60
and the second housing member
62
are identical components. Even though the protective housing
18
has been described as having a first housing member
60
and a second housing member
62
, the protective housing
18
can be comprised of either two first housing members
60
, or two second housing members
62
, that is a pair of housing members. To mate the housing members, one housing member is rotated
180
degrees to allow the mating grooves/shoulders and posts/apertures to correspond.
The first and second ribs
90
,
91
at the first end portion
72
of the first and second housing members
60
,
62
contacts the protective covering
22
of the first cable
12
to grip and contain the first cable
12
at the first end portion
72
, and the first and second ribs
90
,
91
at the second end portion
74
of the first and second housing members
60
,
62
contacts the protective covering
22
of the second cable
14
to grip and contain the second cable. Generally, the ribs
90
,
91
comprise a protrusion extending from the housing member. In the preferred embodiment, the ribs
90
,
91
have an apex for securely engaging the cable. Further, in the preferred embodiment the ribs
90
,
91
at the first end portion
72
extend from an interior wall of the first channel and the ribs
90
,
91
at the second end portion
74
extend from an interior wall of the second channel. When the two housing members
60
,
62
of the protective housing
18
are mated and firmly connected together, portions of the ribs
90
,
91
are indented into the insulative layer
22
of the cable. This allows the engaging ribs
90
,
91
to securely grip and contain the cable
12
,
14
such that the cable is not capable of movement with respect to the protective housing
18
. Specifically, the first ribs
90
which extend about a portion of the longitudinal axis (L) of the protective housing
18
prevent rotational movement of the cables
12
,
14
with respect to the protective housing
18
. And, the second ribs
91
which extend transversely to the first ribs
90
prevent axial movement of the cables (i.e., movement of the cables into and out of the protective housing). By having ribs that are transverse to other ribs, whether the transverse ribs are perpendicular to the axial ribs or not, any type of movement of the cable with respect to the protective housing is substantially eliminated. Preventing movement of the cable with respect to the protective housing assists in ensuring that the cable assembly will not fail at the connection points of the cables and the fusible links. Additionally, having transverse members
40
,
42
depending from the fusible link
16
further assists in prevent failure of the connection points. As such, the first cable
12
, the protective housing
18
, the fusible link
16
, and the second cable
14
form a unitary element when the protective housing
18
is secured around the cable assembly.
The inside diameter of the first and second cavities
78
,
80
, and thus of the formed channels
84
,
86
can be varied to accommodate different size cables. Additionally, the height of the ribs
90
,
91
may vary accordingly with the variation in the cavity diameter. For a 6 gauge cable the cavity diameter is approximately 0.266″ and the height of the ribs are 0.032″. For an 8 gauge cable the cavity diameter is approximately 0.182″ and the height of the ribs are 0.032″. For a 4 gauge cable the cavity diameter is approximately 0.310″ and the height of the ribs are 0.032″. Even though the cavity diameter and rib height can be varied, a small change in the size of the cable does not necessarily require a change in the cavity diameter of the housing. The parameters of the cavity
84
,
86
and ribs
90
,
91
are such that a certain size cavity can accommodate small increases and decreases in the diameter of the cable
12
,
14
.
Once the first and second housing members
60
,
62
are mated around and over the fusible link
16
and portions of the first and second cables
12
,
14
, the first and second housing members
60
,
62
are fixedly connected with rivets
93
which extend through apertures
94
in the housing members
60
,
62
. In the preferred embodiment apertures
94
for rivet
93
are located adjacent each of the four corners of the protective housing
18
. It should be known however, that the first and second housing members
60
,
62
could be fixedly connected by any other means, including adhesives, welding, or any other connecting means. By fixedly connecting the first and second housing members
60
,
62
together, the ribs
90
,
91
are maintained securely in the protective covering
22
of the cables
12
,
14
to maintain the cables in place. As such, the cable
12
,
14
and fusible link
16
are securely connected to the housing
18
.
While the specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention, and the scope of protection is only limited by the scope of the accompanying Claims.
Claims
- 1. A fusible link for a cable assembly comprising:a link segment having a first end and a second end, a first surface and a second surface, and a first side and a second side, wherein a first member extends from the first side of the link segment and a second member extends from the second side of the link segment, the first and second members being substantially planar and further being transverse to the link segment, and wherein the first end of the link segment is adapted to engage a first cable of the cable assembly and the second end of the link segment is adapted to engage a second cable of the cable assembly.
- 2. The fusible link of claim 1, wherein the first member extends in a first direction transverse from the link segment, and wherein the second member extends in substantially the same direction as the first member.
- 3. The fusible link of claim 1, wherein the first member extends in a first direction transverse from the link segment, and wherein the second member extends in substantially an opposite direction as the first member.
- 4. The fusible link of claim 1, wherein the first member and the second member extend adjacent the first surface of the link segment.
- 5. The fusible link of claim 1, wherein the first member extends adjacent the first surface of the link segment, and wherein the second member extends adjacent the second surface of the link segment.
- 6. The fusible link of claim 1, wherein the first and second members extend substantially perpendicular to the first surface of the link segment.
- 7. The fusible link of claim 1, wherein the link segment is substantially planar.
- 8. The fusible link of claim 7, wherein a plurality of apertures extend through the link segment.
- 9. The fusible link of claim 7, wherein the fusible link is made of a first conductive material, and wherein a second conductive material is deposited on the link segment, the second conductive material having a lower melting temperature than the first conductive material.
- 10. The fusible link of claim 1, wherein the fusible link is made of a conductive material that is the same conductive material as the first and second cables.
- 11. The fusible link of claim 1, wherein the fusible link is made of a conductive material that is an alloy of the conductive material of the first and second cables.
- 12. A fusible link for a cable assembly, comprising:a link segment having a first member extending transversely from the link segment, and a second member extending transversely from the link segment, the link segment adapted to be electrically connected to first and second cables of the cable assembly, wherein the link segment has a first end and a second end, and wherein the first and second members extend adjacent the first end to adjacent the second end.
- 13. The fusible link of claim 12, wherein the link segment has a first surface and a second surface, and a first side and a second side, wherein the first member extends from the first surface of the link segment, and wherein the second member extends from the second surface of the link segment.
- 14. The fusible link of claim 13, wherein the first member extends from the first surface adjacent the first side thereof, and wherein the second member extends from the second surface adjacent the second side thereof.
- 15. The fusible link of claim 12, wherein the link segment a first surface and a second surface, and a first side and a second side, and wherein the first member and the second member extend from the first surface of the link segment.
- 16. The fusible link of claim 15, wherein the first member extends from the first surface adjacent the first side thereof, and wherein the second member extends from the first surface adjacent the second side thereof.
- 17. The fusible link of claim 12, wherein the first member extends in a first direction from the link segment, and wherein the second member extends in a second direction from the link segment.
- 18. The fusible link of claim 17, wherein the second direction is substantially the same direction as the first direction.
- 19. The fusible link of claim 17, wherein the second direction is substantially the opposite direction as the first direction.
- 20. The fusible link of claim 12, wherein a plurality of apertures extend through the link segment.
- 21. A method of manufacturing a fusible link for a cable assembly comprising the steps of:providing a substantially planar strip of conductive material having a first surface and a second surface, and a first end and a second end; creating an aperture in the conductive material, the aperture extending from the first surface to the second surface; creating members transverse to the first and second surface of the conductive material, the transverse members extending from substantially the first end to the second end.
- 22. The method of claim 21, further comprising the step of dicing the strip into individual fusible links prior to creating the transverse members.
- 23. The method of claim 21, further comprising the step of adding a second conductive material on one of the first and second surfaces, the second conductive material having a lower melting temperature than the first conductive material, the second conductive material being added adjacent the aperture in the conductive material.
- 24. The method of claim 21, wherein the strip of conductive material has a first side and a second side, wherein the first side of the strip of conductive material is bent at an angle to the first surface to create a first transverse member, the first transverse member extending in a direction from the first end to the second end, and wherein the second side of the strip of conductive material is bent at an angle to the first surface to create a second transverse member, the second transverse member extending in a direction from the first end to the second end.
- 25. The method of claim 21, further comprising the step of connecting the first end of the fusible link to a first cable and connecting the second end of the fusible link to a second cable.
- 26. The method of claim 21, further comprising the step of creating a plurality of apertures in the conductive material, the apertures extending from the first surface to the second surface of the conductive material.
- 27. A fusible link for a cable assembly, comprising:a link segment having a first surface and a second surface, and a first side and a second side, the link segment further having a first member extending transversely from the link segment and a second member extending transversely from the link segment, wherein the first member extends adjacent the first surface of the link segment, and wherein the second member extends adjacent the second surface of the link segment, the link segment adapted to be electrically connected to first and second cables of the cable assembly.
- 28. The fusible link of claim 27, wherein the first member extends from the first side of the link segment and wherein the second member extends from the second side of the link segment.
- 29. The fusible link of claim 27, wherein the first member extends in a first direction from the link segment, and wherein the second member extends in a second direction from the link segment.
- 30. The fusible link of claim 29, wherein the second direction is substantially the opposite direction as the first direction.
US Referenced Citations (31)