U.S. patent number 3,909,767 [Application Number 05/432,980] was granted by the patent office on 1975-09-30 for miniature plug-in fuse.
This patent grant is currently assigned to Littelfuse, Inc.. Invention is credited to Avinash P. Aryamane, Harold L. Williamson.
United States Patent |
3,909,767 |
Williamson , et al. |
September 30, 1975 |
Miniature plug-in fuse
Abstract
A plug-in fuse assembly is provided comprising a preferably
narrow elongated housing made of insulating material in which is
mounted a plug-in fuse element consisting solely of a stamping from
a strip of fuse metal which preferably forms both a pair of
parallel terminal-forming blades projecting from the inner side of
the housing and a fuse-forming link enveloped by the housing. The
fuse link interconnects current carrying extensions of the parallel
terminal-forming blades and is of much smaller cross-sectional area
than the terminal-forming blades and the current-carrying
extensions thereof. The ends of the housing are adapted to be
grasped by the user's fingers for insertion into or removal from a
mounting panel where a number of assemblies can be placed in
closely laterally spaced relation. The outer wall of the housing is
most advantageously transparent so the fuse link is readily visible
when the fuse assembly is mounted in such closely laterally spaced
relation on a panel with other similar fuse assemblies.
Inventors: |
Williamson; Harold L. (Mount
Prospect, IL), Aryamane; Avinash P. (Mount Prospect,
IL) |
Assignee: |
Littelfuse, Inc. (Des Plaines,
IL)
|
Family
ID: |
23718358 |
Appl.
No.: |
05/432,980 |
Filed: |
January 14, 1974 |
Current U.S.
Class: |
337/264; 337/260;
337/198; 337/295 |
Current CPC
Class: |
H01H
69/02 (20130101); H01H 85/0417 (20130101); H01H
2069/027 (20130101) |
Current International
Class: |
H01H
69/02 (20060101); H01H 85/00 (20060101); H01H
69/00 (20060101); H01H 85/041 (20060101); H01h
085/08 () |
Field of
Search: |
;337/264,255,198,297,201,293,187,206,295,262,263
;339/62,147P,208 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Broome; Harold
Attorney, Agent or Firm: Wallenstein, Spangenberg, Hattis
& Strampel
Claims
We claim:
1. A plug-in fuse element comprising a one-piece coplanar
plate-like body of fuse metal which body comprises a pair of
juxtaposed laterally spaced generally parallel terminal-forming
blade portions to be received by pressure clip terminals in a
mounting panel, the terminal-forming blade portions having
current-carrying extensions at the inner end portions thereof which
are interconnected by a transversely extending fuse-forming link
portion of much smaller cross-sectional area than said
terminal-forming blade portions and the current-carrying extensions
thereof, said terminal-forming blade portions, current-carrying
extensions at the inner end portions thereof and transversely
extending fuse-forming link portion being substantially all in the
same plane parallel to the outer faces of the plate-like body
forming the same.
2. The plug-in fuse element of claim 1 wherein said fuse-forming
link portion of said coplanar plate-like body is both narrower in
width and thinner in thickness than the terminal-forming blade
portions and current-carrying extension thereof.
3. The plug-in fuse element of claim 1 wherein said
current-carrying extensions of said terminal-forming blade portions
have apertures for receiving interlocking projections of a housing
into which the plug-in fuse element can be inserted.
4. The plug-in fuse element of claim 3 combined with a housing into
which the plug-in fuse element is inserted and is immovably held by
portions thereof extending into said aperture of said plug-in fuse
element, said housing forming an insulated gripping body for the
plug-in fuse assembly and a shield for spewing blown fuse metal of
said fuse-forming link portion of the plug-in fuse element when the
current rating thereof is exceeded.
5. The plug-in fuse element of claim 1 wherein said
terminal-forming blade portions have wings projecting transversely
away from the rest of the terminal-forming blade portions to
identify a relatively large current-carrying capacity of the fuse
element.
6. The plug-in fuse assembly of claim 2 wherein said fuse link
portion has a width many times greater than the thickness
thereof.
7. A plug-in fuse assembly consisting solely of a housing made of
insulating material and a plug-in fuse element secured within said
housing, said housing being a synthetic plastic member which is
open at the inwardly facing side thereof for the full width of the
plug-in fuse element so as initially to receive said plug-in fuse
element when it is assembled therewith, said housing and plug-in
fuse element having interlocking means for securing the plug-in
fuse element within the housing, said plug-in fuse element being
made entirely of a fuse metal and comprising a one-piece element
having a pair of terminal-forming blade portions to be received by
pressure clip terminals in a mounting panel, the terminal-forming
blade portions having current-carrying extensions at the inner end
portions thereof which are interconnected by a fuse-forming link
portion of much smaller cross-sectional area than said
terminal-forming blade portions and said current-carrying
extensions, said terminal-forming blade portion of said plug-in
fuse element being exposed on the outside of said housing, and said
housing forming an insulated gripping body for the plug-in fuse
assembly and a shield for spewing blown fuse metal of said
fuse-forming link portion of the plug-in fuse element when the
current rating thereof is exceeded.
8. The plug-in fuse assembly of claim 7 wherein the plug-in fuse
element is a one-piece sheet metal stamping from a sheet of fuse
metal.
9. The plug-in fuse assembly of claim 7 wherein said
terminal-forming blade portions of the plug-in fuse element extend
generally in spaced parallel coplanar relation with one another,
said current-carrying extension there of and said fuse-forming link
portion; and the housing has an outer wall positioned opposite the
fuse-forming link portion of the plug-in fuse element and facing in
the opposite direction from the direction in which said
terminal-forming blade portions of the plug-in fuse element extend,
said outer wall forming at least part of a shield preventing the
outward spewing of fuse metal under fuse blowing current
conditions.
10. The plug-in fuse assembly of claim 9 wherein said outer
shield-forming wall is transparent at least at the portion where it
is contiguous to the portion of the fuse-forming link portion which
will blow under fuse blowing current conditions.
11. A plug-in fuse assembly comprising a housing made of insulating
material forming an insulated gripping body for the plug-in fuse
assembly; a pair of conductive plug-in terminals on the outside of
the housing having extensions thereof in the housing, a fuse link
made of a fuse metal extending between the terminal extensions in
the housing, said housing having terminal access openings which
expose said terminal extensions, and said housing providing shield
wall means for preventing the spewing of blown fuse metal outside
of the housing when fuse blowing current flows through said fuse
link, the defining walls of said access openings having skirt
portions extending inwardly therefrom which, in conjunction with
other wall portions of the housing, act as said shield wall means
to prevent blown fuse material from spewing outside of the
housing.
12. The plug-in fuse assembly of claim 11 wherein said access
openings have inwardly tapering walls to guide resistance measuring
test probes into continuity measuring positions within the
housing.
13. The plug-in assembly of claim 11 wherein said plug-in terminals
of the fuse assembly project in the same direction from one side of
the housing thereof, said housing having an outer wall facing in
the opposite direction from the direction in which said terminals
project, and said terminal access openings are in said outer wall
of the housing.
14. A plug-in fuse assembly consisting solely of a housing made of
insulating material and a plug-in fuse element secured within said
housing, said housing forming an insulated gripping body for the
plug-in fuse assembly and being defined by closely spaced side
walls, end walls bridging the end portions of the side walls and an
outer wall bridging the outer margins of the side walls, at least a
part of said housing being made of substantially transparent
material permitting visibility of a part of the interior of the
housing at this point; and a plug-in fuse unit mounted in said
housing and consisting of a one piece plate-like body made of fuse
metal and including a pair of spaced juxtaposed generally parallel
terminal portions to be received by female pressure clip terminals
or the like in a mounting panel and projecting inwardly from
opposite end portions of the housing and a fuse link extending
transversely between coplanar extensions of said terminal portions
within said housing and visible in said transparent portion of said
housing, said terminal-forming blade portions, current-carrying
extensions at the inner end portions thereof and transversely
extending fuse-forming link portion being substantially all in the
same plane parallel to the outer faces of the plate-like body
forming the same, said outer housing wall terminating at the ends
of the housing in outwardly projecting finger gripping portions
permitting the housing to be gripped between fingers extending over
the opposite longitudinal end portions of the housing.
15. A plug-in fuse assembly comprising a housing made of insulating
material forming an insulated gripping body for the plug-in fuse
assembly and defined by closely spaced side walls, end walls
bridging the end portions of the side walls and an outer wall
bridging the outer margins of the side walls, at least an
intermediate portion of said outer wall being made of substantially
transparent material permitting visibility of the interior of the
housing at this point; and a plug-in fuse unit mounted in said
housing and consisting of a pair of spaced parallel terminal
portions to be received by female pressure clip terminals or the
like in a mounting panel and projecting inwardly from opposite end
portions of the housing, and a fuse link extending transversely
between coplanar extensions of said terminal portions within said
housing and visible in said transparent portion of said outer wall
of the housing, said outer wall of the housing being provided with
terminal access openings opposite the extensions of said terminal
portions of said plug-in fuse unit which extend adjacent to said
outer wall from the inner side of the housing, said terminal access
openings being adapted to receive continuity test probes to make
engagement with the extensions of said terminal portions of the
plug-in fuse unit, and said outer housing wall terminating at the
ends of the housing in outwardly projecting finger gripping
portions permitting the housing to be gripped between fingers
extending over the opposite longitudinal end portions of the
housing, whereby a number of fuse assemblies can be closely spaced
on a support panel with the fuse links therein visible through the
outer wall thereof and be readily inserted into or removed from
sockets despite the very close spacing between the lateral sides of
similar fuse assemblies to be received by female pressure clip
terminals or the like in a mounting panel.
16. The plug-in fuse assembly of claim 15 wherein there is a single
large opening on the bottom side of said housing into which opening
said plug-in fuse unit was initially inserted, and said housing and
plug-in fuse unit having means for interlocking the same for
securely holding the plug-in fuse unit in the housing.
17. The plug-in fuse assembly of claim 14 wherein said terminal and
fuse link-forming portions of said plug-in fuse unit forms a
one-piece stamping from a sheet of fuse metal.
18. A plug-in fuse assembly consisting solely of a housing made of
insulating material and an all metal plug-in fuse element secured
within said housing, said housing being a synthetic plastic member
defined by closely spaced side walls, end walls bridging the end
portions of the side walls and an outer wall bridging the outer
margins of the side walls, said housing and plug-in fuse element
having interlocking means for securing the plug-in fuse element
within the housing, said plug-in fuse element having a pair of
terminal forming blade portions to be received by pressure clip
terminals in a mounting panel and projecting in laterally spaced
parallel relation from said housing on the side thereof opposite to
that containing said outer wall, the terminal-forming blade
portions having current-carrying extensions at the inner end
portions thereof which are interconnected by a fuse-forming link
portion, said terminal-forming blade portions of the plug-in fuse
element being in substantially coplanar relation with one another,
said current-carrying extensions thereof and said fuse-forming link
portion, and said housing providing a narrow space which closely
receives the current carrying extensions of said plug-in fuse
element and a relatively wide space adjacent the fuse-forming link
portion, and said housing forming an insulated gripping body for
the plug-in fuse assembly and a shield for spewing blown fuse metal
of said fuse-forming link portion of the plug-in fuse element when
the current rating thereof is exceeded.
19. The combination of claim 18 wherein said housing is a one-piece
molded synthetic plastic member which is open at the inwardly
facing side thereof for the full width of the plug-in fuse element
so as initially to receive said plug-in fuse element when it is
assembled therewith.
Description
BACKGROUND OF THE INVENTION
The present invention relates to miniature current overload fuses
which, whether they are rated to carry only a few amperes or as
much as 30 amperes, occupy a space which is only a fraction of the
space occupied by the conventional glass envelope cylindrical
fuses.
An overload fuse capable of carrying currents of the above range of
magnitudes commonly comprise a sealed cylindrical glass envelope
with cylindrical terminals projecting from the ends thereof and a
fuse link extending between the fuse terminals within the sealed
cylindrical envelope. Fuses of this type having current ratings of
10-30 amperes commonly have lengths of the order of magnitude of
over one inch and, together with the mounting terminals with which
they are associated, an overall width of approximately one quarter
inch and higher. Some of the disadvantages of this type of fuse are
the large space requirements for mounting the same and difficulty
in removing them from mounting clips.
A marked improvement in overload current fuses of the rating
referred to have been made in that the fuse has a length well under
3/4 inch and a width of under 1/4 inch. Such a fuse is disclosed in
U.S. Pat. No. 3,436,711. Also, the terminals of the improved fuses
plug into socket openings transversely to the length of the fuse
body, so the socket connector can be a much less bulky support
means that than needed for conventional high current rated
fuses.
While the miniature fuses heretofore developed have been a
substantial improvement over the conventional cylindrical glass
envelope fuses, they still left much to be desired from the
standpoint of their cost of manufacture and protection to the user.
For example, in some of the miniature fuses heretofore developed,
the fuse link was exposed so that the insertion thereof into a
shorted circuit would blow the same and spew fuse material onto the
person inserting the fuse. Also, it was possible for a person
inserting or removing such a fuse to make contact with the exposed
fuse link which created a shock hazard if he engaged the fuse
negligently. While in one form of miniature fuse heretofore
developed, the fuse link was enclosed in a transparent housing
having a handle extending from the outer walls thereof, the fuse
was relatively expensive to manufacture, it has less reliability
than the fuse of the present invention, and the fuse link was only
visible on the side of the housing because the handle obstructed a
frontal view thereof, so the fuse link could not be seen when the
fuse was mounted between another pair of similar closely spaced
fuses on a mounting panel. Also, the handle could not be easily
grasped due to the small clearance between adjacent fuses.
It is, accordingly, one of the objects of the invention to provide
a miniature fuse with or without an enclosed fuse link and which is
capable of carrying currents where desired well in excess of 10
amperes, such as up to 30 amperes, and can be manufactured at a
much smaller cost than the miniature fuses heretofore designed.
A related object of the invention is to provide a miniature fuse
having a housing providing an insulated gripping surface and a
shield protecting the user from being contacted by the fuse
material as an inserted fuse is blown, and which further can be
easily inserted into or removed from an appropriate female
connector on a mounting panel where the connectors are very closely
spaced, and also preferably wherein the fuse link thereof is
readily visible when the fuse is mounted on such a mounting
panel.
In the miniature fuses heretofore developed, the design of the
fuses were such that the external configuration and dimensions of
the fuses were identical for widely varying current ratings
thereof. It was, therefore, readily possible for a fuse having a
very high current rating, such as 20-30 amperes, to be
inadvertently placed into a connector associated with a circuit
where the current rating may be from 5-15 amperes, creating a very
hazardous operating condition. While these fuses were generally
marked or color coded to indicate their fuse ratings, the user
could readily make a mistake by misreading the usually small
current rating markings or complicated color codes.
Accordingly, another object of the invention is to provide a fuse
design where, although the different fuse assemblies have
substantially identical configurations and size, the difference
between relatively high and relatively low current rated fuses can
be readily detected.
In most of the miniature fuse designs heretofore proposed, the
terminals have cylindrical pin-like configurations molded into
bases of insulating material, and the fuse links were soldered
between the inner ends of these terminals. The presence of solder
connections sometimes created problems of reliability resulting
from corrosion or hot spots due to poor solder connections or
deterioration with age. Thus, another object of the present
invention is to provide a miniature fuse having features satisfying
one or more of the objectives previously discussed and, in
addition, are devoid of the corrosion or hot spot problems referred
to.
SUMMARY OF THE INVENTION
In accordance with one of the features of the invention, a plug-in
fuse element is provided consisting solely of a single piece
stamping from a sheet or strip of fuse metal which forms a pair of
spaced, generally parallel, substantially coplanar terminal-forming
blade portions to be received in a pair of pressure clip terminals
or the like supported in a mounting panel, the terminal-forming
blade portions having substantially coplanar longitudinal
current-carrying extensions at the inner end portions thereof which
are interconnected by a transversely extending generally coplanar
fuse-forming link portion of much smaller cross sectional area than
the terminal-forming blade portions and the current-carrying
extensions thereof. The smaller cross sectional area of the fuse
link-forming portion of the plug-in fuse element is most
advantageously achieved by reducing both the width and thickness
thereof relative to that of the other current-carrying portions of
the plug-in fuse element. Reduction in thickness of the fuse
link-forming portion can be achieved in a number of ways, such as
by milling and/or compressing the metal, the combination of the two
methods being preferred.
The just described plug-in fuse element can be used as a fuse by
merely plugging it into pressure clip terminals or the like without
any additional elements added thereto, or can be mounted within a
housing in a manner to be described, which is the preferred form of
the invention. The plug-in fuse element just described with or
without a housing can be readily mass produced by simply stamping
the same from the end of a strip of such fuse metal, after selected
areas thereof have been milled and/or compressed to reduce the
cross sectional area of the portions of the strip which are to
constitute the fuse link portion of the plug-in fuse elements to be
severed therefrom. (Such a one piece plug-in fuse element as
described is to be contrasted with a combination fuse and terminal
member attached to an insulating base which has been manufactured
and sold in Europe for many years, which member has an elongated
and compressed C-shaped configuration. The end portions of the
member are on the exterior of the base and are received between a
pair of spaced support clips. Also, U.S. Pat. No. 3,500,463 to
Gregory and U.S. Pat. No. 2,468,351 to Vail show one piece fuse and
terminal elements of a different and more costly construction than
that of the present invention just described. Also, in the fuse of
the Vail patent the one piece fuse and terminal element forms a
subcomponent of a conventional screw socket type fuse and thus is
not a plug-in unit insertable directly into a mounting panel.)
In accordance with the most preferred form of the plug-in fuse
element of the invention, the terminal-forming blade portions of
the plug-in fuse element are provided with transversely projecting
wings when the fuse has a relatively high current rating, giving
the terminals the appearance of a relatively massive and,
therefore, high current-carrying capacity terminals, and preventing
their insertion into low current fuse-receiving sockets.
In accordance with another feature of the invention, the above one
piece plug-in fuse element or one similar to the same, forms an
assembly with a housing made of insulating material which provides
insulated gripping surfaces for the assembly and forms a shield
which prevents the spewing of fuse metal into the surrounding
atmosphere when the fuse is blown. In the most preferred form of
the invention, although the housing can be comprised of two
confronting housing halves snapped around the plug-in fuse element,
the housing is most advantageously a one piece molded element
having an opening in the inwardly facing side thereof into which
the plug-in fuse element is inserted into the housing. Also, the
housing is most advantageously a narrow elongated shape defined by
relatively closely spaced side walls bridged by narrow end walls
and a narrow outer wall. The plug-in fuse element may be anchored
in place in the housing by forming projecting proportions in the
housing which extend into apertures in the plug-in fuse element,
the projections being most advantageously formed by a cold staking
or ultrasonic material softening operation. At least the
aforementioned outer wall of the housing (i.e. the wall which faces
outwardly when the fuse assembly is mounted on a mounting panel),
and preferably the entire housing, is most advantageously made of a
transparent material. The fuse link portion of the plug-in fuse
element is positioned at a point contiguous to this transparent
outer wall where it can be readily seen at all times. At least the
longitudinal end portions of the outer wall preferably overhang the
rest of the housing to provide convenient gripping surfaces at the
ends of the housing, so that the plug-in fuse assembly can be
readily grasped for insertion into and removal from any point in a
mounting panel, despite small clearances between adjacently mounted
plug-in fuse assemblies.
In accordance with still another aspect of the invention, the
housing is preferably provided with a pair of terminal access
openings in the outer wall thereof, which openings preferably taper
inwardly to a point in alignment with the innermost ends of the
terminal extensions, so resistance measuring test probes are guided
into contact with the terminal-forming blade portions of the
plug-in fuse element to test for continuity on the assumption that
the fuse link might have a crack in it which is not readily visible
through the above described transparent housing outer wall. The
defining walls of the access openings preferably have skirt
portions extending therefrom which act as shield walls to prevent
blown fuse material from reaching the terminal access openings.
With a plug-in fuse assembly consisting of a single stamping
forming both the terminal-forming blade portions and the
fuse-forming link portions of a plug-in fuse element, and a housing
into which such single piece stamping may be readily inserted and
locked into place, the design of the fuse assembly lends itself to
a low cost mass production assembly thereof wherein various
stamping and milling operations forming attached blanks for making
many plug-in fuse elements are first performed on longitudinally
spaced areas of a fuse metal strip. Then, a plug-in fuse assembly
is completed by applying a housing over the end of the strip,
securing each housing in place and severing a completed plug-in
fuse assembly from the strip, the housing applying and severance
operations on the strip being repeated in sequence to mass produce
the plug-in fuse assemblies.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a preferred form of the plug-in
fuse assembly of the invention;
FIG. 2 is an exploded view of the housing and plug-in fuse element
making up the plug-in fuse assembly of FIG. 1;
FIG. 3 is a top plan view of the plug-in fuse assembly of FIG.
1;
FIG. 4 is a vertical longitudinal sectional view through the fuse
assembly shown in FIG. 3, taken along section line 4--4
therein;
FIG. 5 is an enlarged bottom view of the plug-in fuse assembly of
FIG. 1;
FIG. 6 is an enlarged transverse vertical sectional view through
the fuse assembly shown in FIG. 4, taken along section line 6--6
thereof;
FIG. 7 is an enlarged vertical transverse sectional view through
the center portion of the fuse assembly shown in FIG. 4, taken
along section line 7--7 thereof;
FIG. 8 is a greatly enlarged framentary sectional view through the
fuse link portion of the plug-in fuse assembly shown in FIG. 2,
taken along section line 8--8 thereof, and showing the manner in
which the fuse-forming link portion thereof is reduced in thickness
by a combination milling and pressing operation;
FIG. 9 illustrates the insertion of the housing of the fuse
assembly of FIGS. 1-8 onto the end of a pre-milled and pre-stamped
strip of fuse metal from which numbers of plug-in fuse elements
like that shown in these figures are formed;
FIG. 10 shows the separation of a completed plug-in fuse assembly
from the strip shown in FIG. 9, after a strip staking and severing
operation has been carried out;
FIG. 11 illustrates a fragmentary longitudinal sectional view
through a portion of a plug-in fuse assembly like that shown in
FIGS. 1-10 but which has been modified by adding a magnifying lens
to the outer wall of the housing thereof; and
FIG. 12 illustrates a fragmentary side elevational view of a
plug-in fuse assembly modified from that shown in FIG. 1-11 in that
the wings on the terminal-forming blade portions of the plug-in
fuse element have been removed to indicate a lower current rated
fuse.
DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE INVENTION
Referring now more particularly to FIGS. 1-4, there is shown a
plug-in fuse assembly 2 made of only two component parts, namely a
plug-in fuse element 4 which most advantageously is a single
stamping from a strip of fuse metal, and a housing 6 which most
advantageously is a single piece synthetic plastic molded part
defining a space therein into which portions of the plug-in fuse
element 4 extend and are secured in any suitable way, but more
preferably by a cold staking operation to be described.
The plug-in fuse element 4 has terminal-forming blade portions 8--8
extending in spaced parallel relationship from the inner or bottom
margin of the housing 6 in what will be referred to as a downward
or inwardly extending direction. The ends of the terminal-forming
blade portions 8--8 of the plug-in fuse element are most
advantageously tapered at 9--9 to form pointed end portions which
readily slip into place between the confronting walls of
conventional spring clip terminals (not shown) supported in
mounting panel apertures. The terminal-forming blade portions 8--8
of the plug-in fuse element 4 have inwardly extending rough current
rating indicating wings or projections 10--10, to provide a more
massive appearnace to the exposed terminal-forming portions 8--8 of
the plug-in fuse element 4, identifying the fact that the fuse
assembly is one having a relatively high current rating, such as in
the range of from 20 to 30 amps. (The exact current rating is
indicated by indicia 13 on the outer walls of the housing as shown
in FIGS. 1-3. Where a plug-in fuse element has a relatively low
current rating such as 5 to 15 amperes, the wings 10--10 are
eliminated so the user knows immediately that the plug-in fuse
element which does not have any wings is for a lower current rated
application. Such a plug-in fuse element is shown in FIG. 12.)
The plug-in fuse element 4 is stamped from a strip 4' of fuse metal
(FIGS. 9 and 10). Prior to the plug-in fuse element being severed
from the strip 4', the wings 10--10 are interconnected to form a
rigidifying web 10' for the strip 4', and so a narrow piece of
material is stamped from the strip to form the terminal-forming
blade portions 8--8 and a gap 12 between the same. The tapered
portions 9--9 of the terminal-forming blade portions 8--8 may be
formed by dies (not shown) during the operation which severs the
plug-in fuse element from the strip.
The terminal-forming blade portions 8--8 have current-carrying
extensions 14--14 projecting into the aforementioned space formed
by the housing 6, which current-carrying extensions project well up
into the upper or outer extremities of the housing 6, to be
contiguous to the front or outer wall of the housing to be
described. The outer end portions of the current-carrying
extensions 14--14 are interconnected by a fuse-forming link portion
20 which is preferably both narrower in width and much smaller in
thickness than the other current-carrying portions of the plug-in
fuse element 4. The current-carrying capacity of the fuse-forming
link portion 20 may be varied by varying the fuse metal composition
or by varying the width and/or the thickness of the fuse-forming
link portion. In the particular configuration of the plug-in fuse
element 4 shown in the drawings, the current-carrying extensions
14--14 join the fuse-forming link portion 20 of the plug-in fuse
element 4 by tapered portions 22--22. All of the various parts of
the plug-in fuse element are substantially in coplanar relation so
no metal beinding operations need be performed in the process of
making the same.
It was found that a reduction of the thickness of the metal of the
fuse-forming link portion 20 is preferably achieved by a milling
operation which mills away the metal on one side thereof to form a
generally curved depression 24 best shown in FIG. 8. The outer
portions of this depression 24 are identified by reference numerals
24a-24a and represent the milled surfaces. The flattened
intermediate portion 24b of the depression 24 is obtained by
squeezing or pressing the metal to further reduce this thickness
thereof. For example, it was found that in one plug-in fuse
element, the thickness of the fuse metal was reduced from an
initial thickness of 0.027 inches to about 0.005 inches by a
milling operation, and a further reduction of 0.002 inches was
achieved by a pressing operation, ending up with a minimum
thickness of the fuse-forming link portion 20 of 0.003 inches. Of
course, the precise thickness of the fuse metal depends upon the
fuse metal composition, the width of the fuse-forming link portion
20 and the desired current rating of the fuse.
While the plug-in fuse element 4 may be used as a fuse element
without its incorporation in the housing 6, for safety reasons it
is preferred to incorporate the plug-in fuse element 4 in the
housing 6. To this end, and for reasons to be explained, the outer
end portions of the terminal extensions 14--14 are provided with
outwardly or upwardly projecting tabs 18--18 adapted to make
contact with test probes to test for the continuity of the
fuse-forming link portion 20 of the plug-in fuse element 4. Also,
to anchor the plug-in fuse element 4 within the housing 6,
anchoring apertures 26--26 and 28--28 are respectively formed in
the terminal extensions 14--14 to receive anchoring projections to
be described formed in the housing walls.
While the housing 6 could be made in two separate parts snappable
together in accordance with the broadest aspects of the invention,
the housing is most advantageously a single piece molded part as
previously indicated. Also, it preferably has a narrow elongated
configuration formed by relatively closely spaced side walls
generally indicated by reference numeral 30-32, the side walls
having end portions 30a-32a and 30a-32a which are spaced together
much more closely than the central or intermediate portions 30b-32b
thereof. The side walls 30-32 are interconnected at their end
margins by narrow end walls 34--34, and at their outer or top
margins by an outer wall 38 which overhangs the rest of the housing
to form downwardly facing shoulder 40--40 at the longitudinal ends
of the outer wall 38 and downwardly facing shoulders 40'--40' along
the longitudinal side margins of the housing 6. The shoulders
40'--40' are coplanar continuations of the shoulders 40--40 at the
ends of the housing 6.
Terminal access openings 42--42 are provided in the outer wall 38
adjacent the opposite end portions thereof in alignment with the
location of the test probe-receiving tabs 18--18 of the plug-in
fuse element 4. The walls of the terminal access openings 42--42
taper down to an inner dimension which approximates the width of
the test probe-receiving tabs 18--18, so that test probes can be
guided into contact with the tabs 18--18. The terminal access
openings 42--42 communicate with the aforementioned plug-in fuse
element receiving space in the housing 4. The portions 44--44 of
this space immediately beneath the access openings 42--42 are
relatively small because of the close spacing of the side wall
portions 30a-32a of the housing at these points, the width of the
space portions 44--44 as viewed in FIG. 6 tapering from the bottom
open end of the housing upwardly toward the terminal access
openings 42--42, reaching a narrow dimension about equal to the
thickness of the plug-in fuse element 4. At the inner margins of
the terminal access openings 42--42 the upper wall 38 is provided
with downwardly extending skirts 46--46 which act as shield walls
preventing spewing fuse metal from gaining entrance to the terminal
access openings 42--42. These shield forming skirts 46--46 also act
as stop or abutment shoulders for the current-carrying extensions
14--14 of the terminal-forming blade portions 8--8 of the plug-in
fuse element.
The fuse-forming link portion 20 of the fuse element 4 is
positioned in a relatively wide portion 44' (FIG. 7) of the housing
interior, to provide for free circulation of air around the center
portion of the fuse-forming link portion, which is the part thereof
which first melts under excessive current flow, so heat does not
accumulate which would adversely affect the current at which the
fuse will blow.
The narrow and wide portions 44--44 and 44' of the space within the
housing 6 open onto the bottom of the housing for the full extent
thereof through an entry opening 48. The opening 48 permits the
housing to be pushed over the end portion of the pre-stamped and
milled strip 4' from which a completed fuse element is punched
immediately following the securing of the housing 6 to the end
portion of the strip as previously indicated.
The housing 6 is preferably a molded part made of a transparent
synthetic plastic material so that the fuse-forming filament
portion 20 of the plug-in fuse element 4 is readily visible through
the intermediate portion of the outer wall 38, to which the
fuse-forming link portion 20 is in space but relatively contiguous
relation. The housing is preferably molded of a high temperature
transparent nylon made by Belding Chemical Industries of New York
City, New York (Product Code No. LX-3330).
While the housing interior 6 could be made with resilient
projections which snap into the anchoring apertures 26--26 and
28--28 in the plug-in fuse element 4, it is preferred to secure the
housing in place by forming projections 52 and 54, by a cold
staking operation, ultrasonic melting or other operation, which
enter the anchoring apertures 26--26 and 28--28 of the plug-in fuse
element 4. The depressions 56 and 58 left by a staking operation
are shown in the side wall 30 in FIGS. 2 and 6.
To improve the visibility of the fuse-forming link portion 20 of
the plug-in fuse element, the outer wall of the housing of the fuse
assembly can be modified as shown in FIG. 11 wherein the housing
outer wall 38' of a modified fuse assembly 2' is thickened and
curved to form a magnifying lens. Also, as shown in FIG. 12, the
fuse assembly 2' is a low current rated fuse assembly as evidenced
by the absence of wings on the terminal-forming blade portion 8'-8'
on the plug-in fuse element 4'.
The exemplary embodiments of the invention just described have thus
provided an exceedingly reliable, compact and inexpensive to
manufacture plug-in fuse assembly which can be readily inserted
into and removed from suitable closely spaced spring clip terminal
connectors in a mounting panel by grasping the shoulders 40--40 at
the longitudinal ends of the housing 6. The transparent material
out of which the housing 6 is made forms a convenient window in the
outer wall through which the fuse-forming link portion of the
plug-in fuse element can be viewed when the plug-in fuse assembly
is mounted on the mounting panel. The terminal access openings
enable test equipment to test the continuity of the fuse if the
user does not desire to rely solely on a visual observation of the
fuse-forming link portion of the fuse. The presence or absence of
wings on the terminal-forming blade forming of the plug-in fuse
element immediately informs the user whether he has selected a
relatively high or low current rated fuse, although the indicia 13
should be examined to determine the actual current rating.
It should be understood that numerous modifications may be made in
the most preferred form of the invention described without
deviating from the broader aspects thereof.
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