Australian Patents Act 1990- Regulation 3.2 ORIGINAL COMPLETE SPECIFICATION STANDARD PATENT Invention Title Multipolar type fuse device The following statement is a full description of this invention, including the best method of performing it known to me/us: P/00/01 1 5102 C:\NRPonbl\DCC\MAS\3712115 .. DOC-/22/201 -la [Technical Field] [0001] 5 This invention relates to a multipolar type fuse device that is fused to cut off a circuit when an excessive current flows in the device and more particularly relates to a multipolar type fuse device that includes a plurality of element portions and output terminal sections. 10 [Background Art] [0002] Heretofore, an electrical equipment system in a motor vehicle has adopted a fuse device that is fused to cut off a circuit when an excessive current flows in the device. 15 Various kinds of electrical equipments connected to the fuse device are protected from smoking and breaking upon the excessive current. In particular, in a motor vehicle on which various kinds of electrical equipments are mounted, a multipolar type fuse device that includes a plurality of 20 element portions and output terminal sections has been utilized in order to connect the various kinds of electrical equipments to an electrical power source. [0003] Such multipolar type fuse device has been disclosed in, 25 for example, JP 2006-313686 A (Patent Document 1) and JP 2004-265766 A (Patent Document 2). The multipolar type fuse device includes a conducting hardware that is formed by punching a metallic sheet and has a bus bar integrally provided with an input terminal section and a plurality of 30 output terminal sections connected through element portions to the bus bar. The conducting hardware is contained in a housing so that the input terminal section and output C:NRPortb\DCCMASU7121I 5_LDOC-622I201 I -2 terminal sections are exposed outward. The housing that covers the element portions is provided with a window so that a continuing condition of each element portion can be viewed from outside. The window is closed by a transparent 5 resin plate. [0004] It is important to stably control a resistance of each element portion within a given range in the multipolar type fuse device in order to secure responsibility of products. 10 Accordingly, in a conventional multipolar type fuse device, resistances between the input and output terminal sections exposed outward from the housing are measured. On the other hand, a circuit width and a plate thickness of each element portion that can be viewed from outside are measured. A 15 predictive resistance of each element portion can be calculated in accordance with the measured resistances and sizes. [0005] However, in the above measuring method, there is a 20 possibility that an accurate resistance of each element portion cannot be calculated. That is, even if the resistances between input and output terminal sections are measured, the measured resistances are nothing but resistances of the whole part including the element portions 25 and the bus bar that is larger than the element portion. Accordingly, even if the measured resistance is out of the rated range, it is difficult to determine whether the measured resistance outside the rated range is exerted on account of the bus bar or the element portion. It will 30 involve a complicated measuring work to measure from outside a dimension of each element portion that is contained in the housing. Furthermore, this will make it difficult to carry H:\mka\1nterwoven\NRPortbl\DCC\MKA\5268208_1.doc-25/07/2013 -3 out an accurate measurement. Consequently, there is a possibility that an error in measurement will occur. Accordingly, there is in the conventional multipolar type fuse device a problem that it is difficult to stably control 5 a resistance of each element portion. [0005A] It is desired, therefore, to provide a multipolar type fuse device that alleviates one or more of the above difficulties, or at least provides a useful alternative. 10 [Prior Technical Document] [Patent Document] [0006] [Patent Document 1] JP 2006-313686 A 15 [Patent Document 2] JP 2004-265766 A [Disclosure of the Invention] [0007] Deleted [0008] 20 In one aspect, the present invention provides a multipolar type fuse device comprising: a conducting hardware, including: (a) a bus bar integrally provided with: (i) an input terminal section; 25 (ii) fusible element portions; and (iii) a plurality of output terminal sections continued through the fusible element portions to said bus bar; and (b) a housing that contains said conducting hardware so 30 that said input and output terminal sections are exposed outward; H:\mka\Interwoven\NRPortbl\DCC\MKA\5268208_1.doc-2 5/07/2013 - 3A said housing being provided with through-holes in positions corresponding to both ends of at least one of said fusible element portions. 5 [0009] In embodiments of the invention, it is possible to contact the probes for measuring a resistance with the both ends of the element portions from outside of the housing by inserting the probes into the through-holes, thereby 10 directly measuring the resistances between the both ends of the element portions. Consequently, it may be possible to more precisely and readily measure the resistances of the C:\NRPonblCC\MASU7121 15_LDOC-6/22/201 I -4 element portions, in comparison with the case where the resistances of the element portions are estimated on the basis of the measured resistances between the input and output terminal sections in the prior art. 5 [00101 In addition, in embodiments, the resistances between the both ends of the element portions may be measured directly, so that it is not necessary to measure dimensions of the both ends of the element portions in order to 10 calculate the resistances of the element portions in the prior art. Consequently, it may be possible to more readily measure the resistances. Since the resistances of the element portions can be measured precisely, it may be possible to positively determine whether or not the 15 resistances of the element portions that are difficult in determination from outside are set to be predetermined values. In the case where the conducting hardware has a plurality of element portions, it is possible to easily determine whether or not the respective element portions are 20 correctly set to be the predetermined resistances. A range of control in resistance of current conducting capacity of each element portion may be able to be set, in which case it may be possible to discriminate between a confirming item and a defective item on the basis of a measured resistance. 25 In the result, it may be possible to simplify a controlling step of the element portions. Furthermore, if increases of the defective items are found in accordance with the measured resistances, it may be possible to estimate that a die for forming the conducting hardware is under an abnormal 30 condition such as abrasion or degradation. [0011] The casing may be provided with through-holes in C:P.ftnblDCC\MASu.7121 15_1.DOC-62fl/21 -5 positions corresponding to both ends of at least one of the element portions in the present invention. However, it will be preferable that the casing may be provided with through holes in positions corresponding to both ends of all of the 5 element portions. Thus, it may be possible to measure the resistances of the all element portions at one time. [0012] The housing may be provided with support projections that support the both ends of the element portions at a 10 surface opposite from a surface faced to the through-holes. The respective ends of the respective element portions that are contacted with the probes inserted into the through holes may be supported by the support projections at an opposite side from the probes. Thus, the element portions 15 may be protected from deformation and damage on account of contact of the probes. [0013] Deleted [0014] 20 The housing may be provided with a through-hole in each of positions corresponding to the bus bar side end portion of each of the element portions and the output terminal side end portion of each of the element portions. The conducting hardware may be formed into a flat plate-like configuration. 25 The housing may include a first casing that covers one surface of the conducting hardware in a plate thickness direction and a second casing that covers the other surface of the conducting hardware. Each of the through-holes in the housing may be provided in either the first casing or 30 the second casing. [0015] The through-holes may be provided in the both ends of C:\NRPonb\DCCMASU712115_1.DOC-6/2/201 I -6 all element portions on the conducting hardware. Since the through-holes are provided in either the first casing or the second casing, the both ends of all element portions may be exposed via the through-holes in the same direction. Thus, 5 it may be possible to measure the resistances of all element portions at one time by inserting the respective probes into all through-holes at the same direction. Thus, it may be possible to enhance efficiency of measuring the resistances. [Effects of the Invention] 10 [0016] In embodiments, the housing that contains the conducting hardware is provided with the through-holes in the positions corresponding to both ends of the element portions and the both ends of the element portions are 15 exposed via the through-holes outside the housing. Thus, it may be possible to bring the probes into contact with the both ends of the element portions outside the housing. Consequently, it may be possible to directly measure the resistances between ends of the element portions, thereby 20 more precisely and readily measuring the resistances of the element portions. Since a precision of measurement of the element portions may be enhanced, a control of the resistances of the element portions may be carried out more stably. 25 [0016A] Embodiments of the present invention may provide a multipolar type fuse device having a new structure that can measure a resistance of each element portion precisely and readily and can control the resistance of each element 30 portion stably. [Brief Explanation of the Drawings] H:\mka\Interwoven\NRPortbl\DCC\MKA\5268208_1.doc-25/07/2013 -7 [0017] Some embodiments of the invention are hereinafter described, by way of example only, with reference to the accompanying drawings in which: 5 [Fig. 1] Figure 1 is a perspective view of an embodiment of a multipolar type fuse device in accordance with an embodiment of the present invention. [Fig. 2] Figure 2 is a plan view of the multipolar type fuse device shown in Figure 1. 10 [Fig. 3] Figure 3 is a plan view of a conducting hardware that constitutes the multipolar type fuse device shown in Figure 1. [Fig. 4] Figure 4 is a cross section view of the conducting hardware taken along lines IV-IV in Figure 2, 15 illustrating a method of measuring a resistance of the conducting hardware by means of a probe. [Detailed Description] [0018] paragraph deleted 20 [0019] Figures 1 and 2 show an embodiment of a multipolar type fuse device 10 in accordance with the present invention. The multipolar type fuse device 10 includes a housing 14 and a conductive hardware 12 contained in the housing 14. The 25 conducting hardware 12 is provided with input terminal sections 16 and 17, and a plurality of output terminal sections 18a to 18f. The sections 16, 17, and 18a to 18f project from the housing 14. [0020] 30 Figure 3 shows the conducting hardware 12. The conducting hardware 12 is formed by pressing, punching, and C:\NRPonb\DCC\%MASU7ili5_,DOC4/22/201 i -8 bending a metallic sheet made of, for example, copper alloy. The conducting hardware 12 includes a bus bar 20 integrally provided with the input terminal sections 16 and 17 and the plural output terminal sections 18a to 18f and is formed 5 into a flat-like shape, as a whole. [0021] The bus bar 20 in the present embodiment includes a battery system bus bar 20a and an alternator system bus bar 20b. The battery system bus bar 20a is integrally provided 10 with the input terminal section 16. The input terminal section 16 stands up vertically from the battery system bus bar 20a to define a tab-like configuration. The input terminal section 16 is provided with a bolt hole 22 into which a bolt is inserted to secure an end of an electrical 15 power source line (not shown) to the input terminal section 16. [0022] Furthermore, the battery system bus bar 20a is provided with a plurality of output terminal sections 18a to 18d that 20 are separated from one another by a given distance in a longitudinal direction (a horizontal direction in Figure 3) of the battery system bus bar 20a to be connected to battery system circuits. The respective output terminal sections 18a to 18d are integrally provided on the battery system bus 25 bar 20a and are formed into tab-like configurations that have the same shapes and smaller cross sections than the input terminal section 16. The output terminal sections 18a to 18d are connected through element portions 24a to 24d to the battery system bus bar 20a. The element portions 24a to 30 24d are formed into substantially narrow crank-like configurations. A bus bar side end portion 26 that is the one end of each of the element portions 24a to 24d is C:\NRPtbrDCCMASU71211 5I.DOC6/22/201I -9 connected to the battery system bus bar 20a, while an output terminal side end portion 28 that is the other end of each of the element portions 24a to 24d is connected to each of the output terminal sections 18a to 18d. 5 [00231 On the other hand, the alternator system bus bar 20b is integrally provided with the input terminal section 17. The input terminal section 17 has the same configuration as that of the input terminal section 16 on the battery system bus 10 bar 20a. An end of an electrical cable (not shown) connected to an alternator is secured to the input terminal section 17 by a bolt. [0024] Furthermore, the alternator system bus bar 20b is 15 integrally provided with the output terminal sections 18e and 18f to be connected to alternator system circuits. The output terminal sections 18e and 18f are separated from each other by a given distance in a longitudinal direction (a horizontal direction in Figure 3) of the alternator system 20 bus bar 20b. The output terminal section 18f has the same configuration as that of each of the output terminal sections 18a to 18d on the battery system bus bar 20a. On the other hand, the output terminal section 18e is formed into a tab-like configuration that has a greater cross 25 section of the output terminal section 18f. The output terminal section 18e is provided with a bolt hole 30. An end of an electrical cable connected to an suitable electrical equipment (not shown) is secured to the output terminal section 18e by a bolt. These output terminal 30 sections 18e and 18f are connected through element portions 24e and 24f to the alternator system bus bar 20b, as is the case with the output terminal sections 18a to 18d on the C:W4Rntb\DCCMAS\3712115 1.DOC-6/22/201 I -10 battery system bus bar 20a. [0025] The battery system bus bar 20a and the alternator system bus bar 20b are interconnected through the element 5 portion 24g to define the conducting hardware 12. Thus, the output terminal sections 18a to 18d provided on the battery system bus bar 20a and the output terminal sections 18e and 18f provided on the alternator system bus bar 20b are interconnected to be separated apart from one another by 10 given distances in the longitudinal direction of the bus bar 20 including the battery system bus bar 20a and alternator bus bar 20b. The element portion 24g is formed into a substantially narrow straight shape. The element portion 24g is connected to the battery system bus bar 20a at a 15 battery side end portion 34 while the element portion 24g is connected to the alternator system bus bar 20b at an alternator side end portion 36. [0026] As publicly known in the prior art, if an excessive 20 current over an predetermined rated current flows in the element portions 24a to 24g, the excessive current is cut off between the both ends 26 and 28 (between the ends 34 and 36 with respect to the element 24g). In the present embodiment, a rated current 5aA ("a" is a positive given 25 value) flows in the elements 24a, 24b, and 24d; a rated current 4aA flows in the elements 24c and 24f; a rated current 6aA flows in the elements 24e; and a rated current 20aA flows in the elements 24g. It should be noted that a specific configuration of each element portion is not 30 limited. Each element may be formed into, for example, an S-shaped configuration.
C:WRPotnblDCC\MAS\37121 IJDOC-6/22O1 I [0027 ] Positioning apertures 38 are provided in the bus bar 20 and the output terminal sections 18a to 18f of the conducting hardware 12 at suitable positions. In 5 particular, the positioning aperture 38 is provided in each of the output terminal sections 18a to 18f in the present embodiment. Each of the output terminal sections 18a to 18d and 18f is provided in an end side of each of the element portions 24a to 24d and 24f with two positioning apertures 10 38 that are juxtaposed in projecting directions (in vertical directions in Figure 3) of the output terminal sections 18a to 18d and 18f. The output terminal section 18e is provided in an end side of the element 24e with three positioning apertures 38 that are arranged on a triangle. 15 [0028] Such conducting hardware 12 is contained in the housing 14. The housing 14 includes a first casing 40 and a second casing 42. The first and second casings 40 and 42 are made of non-conductive synthetic resin and are formed into 20 shallow box-like configurations that are open at the other ends. The second casing 42 is provided on its suitable plural positions with engaging pawls 44. The first casing 40 is provided on its positions corresponding to the engaging pawls 44 with engaging portions 46. When the 25 engaging pawls and portions 44 and 46 are engaged with one another, the first and second casings 40 and 42 are coupled to each other. [0029] As shown in Figures 2 and 4, the first casing 40 is 30 provided with through-holes 48 in positions corresponding to the bus bar side end portion 26 and alternator side end C:\NR nbl\DCC\MAS712 5_i.DOC-6/22/201I -12 portion 28 of the element portions 24a to 24f and in a position corresponding to the battery side end portion 34 and alternator side end portion 36 of the element portion 24g. Each through-hole 48 is formed into a circular cross 5 section suitable for receiving each of probes 60a and 60b (mentioned later) for measuring a resistance. However, it should be noted that a specific shape of the through-hole is not limited to the circular cross section. It may be a rectangle cross section. Preferably, the through-hole 48 is 10 set to be a size in width equal to or slightly smaller than that of each of ends 26 (34) and 28 (36) of the elements 24a to 24g. Thus, since it is possible to expose the ends 26 (34) and 28 (36) of the elements 24a to 24g in the through holes 48, as a whole, it is possible to easily and 15 positively bring the probes 60a and 60b (mentioned later) into contact with the 26 (34) and 28 (36). [0030] On the other hand, as shown in Figure 4, the second casing 42 is provided on its positions corresponding to the 20 through-holes 48 in the first casing 40 with support projections 50 that protrude toward the first casing 40. It will be apparent from this structure that the through-holes 48 are provided in only the first casing 40 and the support projections 50 are provided on only the second casing 42. 25 Each support projection 50 may be formed into a circular or rectangular projecting shape, or a plate-like rib. [0031] The first and second casings 40 and 42 are coupled through the conducting hardware 12 to each other. Thus, the 30 first casing 40 covers a front surface 52a that is one surface of the conducting hardware 12 in its plate thickness direction while the second casing 42 covers a rear surface C:\NRotbF\DCC\MASU7]21 IS..DOC-22/201 I - 13 52b that is the other surface of the conducting hardware 12 in the plate thickness direction. Consequently, the conducting hardware 12 is contained in the housing 14 constructed by the first and second casings 40 and 42. 5 [0032] When the conducting hardware 12 is contained in the housing 14, distal ends of the output terminal sections 18a to 18f of the conducting hardware 12 protrude between opposed surfaces of the first and second casings 40 and 42 10 outward from the housing 14. When positioning projections 54 on the first casing 40 are inserted into the positioning apertures 38 in the bus bar 20, the respective output terminal sections 18a to 18f are positioned on the first casing 40. When the positioning projections 54 are engaged 15 with the positioning apertures 38, it is possible to prevent the respective output terminal sections 18a to 18f from rattling upon connection of electrical circuits. The input terminal sections 16 and 17 of the conducting hardware 12 protrude through tab inserting apertures 56, 56 in the first 20 casing 40 outward from the housing 14 so that the input terminal sections 16 and 17 protrude in perpendicular to the output terminal sections 18a to 18f. [0033] Furthermore, the bus bar side end portion 26 and output 25 terminal side end portion 28 on the element portions 24a to 24f and the battery side end portion 34 and alternator side end portion 36 on the element portion 24g are superimposed on the through-holes 48 in the first casing 40. Thus, the respective ends 26, 28, 34, and 36 are exposed through the 30 through-holes 48 outward from the housing 14. The support projections 50 that protrude from the second casing 42 are superimposed on the rear surface 52b of the respective ends C:\NRnbhOCC\MAS\37121 15_1.DOC-6/2220 II -14 26, 28, 34, and 36. [0034] The multipolar type fuse device 10 is produced preferably by, for example, the following process. Firstly, 5 the conducting hardware is formed by pressing, punching, and bending a metallic sheet made of copper alloy or the like. Secondly, the first and second casings 40 and 42 are formed by a resin-molding method publicly known in the prior art. Thirdly, the formed conducting hardware 12 is disposed 10 between the first and second casings 40 and 42 to assemble the first and second casings 40 and 42 to each other, thereby producing the multipolar type fuse device 10 as a member being measured. These steps are substantially the same as those of a method of producing a conventional 15 multipolar type fuse device. [0035] Then, as shown in Figure 4, the probes 60a and 60b for measuring a resistance are inserted from an outside of the housing into the through-holes 48, 48 that correspond to the 20 bus bar side end portion 26 and output terminal side end portion 28 of the element portions 24a to 24f so that the probes 60a and 60b contact with the bus bar side end portion 26 and output terminal side end portion 28. Thus, resistances of the respective element portions 24a to 24f 25 are measured to determine whether or not the respective element portions 24a to 24f have target resistances. In result of testing, if any fault is not found in the member being measured, the member becomes the multipolar type fuse device 10. As described above, the method of producing the 30 multipolar type fuse device 10 is completed. [0036] According to the multipolar type fuse device 10 of the C:\NRPornbl\DCCMAS712115_t.DOC.W22/21 I - 15 present invention, the bus bar side end portion 26 and output terminal side end portion 28 of the element portions 24a to 24f and the battery side end portion 34 and alternator side end portion 36 of the element portion 24g 5 are exposed through the through-holes 48 in the housing 14 outward from the housing 14. Thus, even if the conducting hardware 12 is contained in the housing 14, the probes 60a and 60b can contact with the both ends 26 (34) and 28 (36) on the element portions 24a to 24g, thereby enabling the 10 resistances of the respective element portions 24a to 24g to be measured. In result, it is possible to more precisely and easily measure the resistances of the element portions 24a to 24g, in comparison with the case where the resistances of the respective element portions 24a to 24g 15 are measured between the input terminal sections 16 and 17 and the output terminal sections 18a to 18f by bringing the probes 60a and 60b into contact with the input terminal sections 16 and 17 and the output terminal sections 18a to 18f. 20 [0037] Since it is possible to measure the resistances of the element portions 24a to 24g by bringing the probes 60a and 60b into contact with the element portions 24a to 24g directly, it is not necessary to measure sizes of the 25 element portions 24a to 24g through windows provided in the housing in order to calculate the resistances of the element portions 24a to 24g in the prior art. In result, since it is possible to more readily and precisely measure the resistances of the element portions 24a to 24g and it is not 30 necessary to provide the housing 14 with windows for viewing the element portions 24a to 24g from outside, it is possible to simplify a structure of the housing14. Furthermore, it C:\NRPoftb\DCC\MASU712IS I DOC-6/22201 I - 16 will be expected that the plural through-holes 48 in the housing 14 can exert a heat radiation effect. The through holes 48 can be utilized to inspect electrical continuity. [0038] 5 Since all through-holes 48 are provided in the first casing 40 in the present embodiment, the ends 26 (34) and 28 (36) on the element portions 24a to 24g are exposed in the same direction. Thus, even if the resistances of the element portions 24a to 24g are measured at the same time, 10 it is possible to insert the plural probes 60a and 60b into the through-holes 48 in the same direction, thereby enhancing a measuring efficiency. The ends 26 (34) and 28 (36) on the element portions 24a to 24g, with which the probes 60a and 60b contact, are supported by the support 15 projections 50, 50 on the second casing 42 from the rear surface 52b opposite from the front surface 52a with which the probes 60a and 60b contact. Thus, it is possible to more stably bring the probes 60a and 60b into contact with the ends 26 (34) and 28 (36), thereby enhancing an accuracy 20 of measuring. It is also possible to reduce possibilities of deformation and damage of the element portions 24a to 24g on account of contact with the probes 60a and 60b. [0039] According to the above producing method, it is possible 25 to precisely and readily measure the resistances of the element portions 24a to 24g, which is one of the important control items for the multipolar type fuse device 10, by inserting the probes 60a and 60b into the through-holes 48 so that the probes 60a and 60b contact with the bus bar side 30 end portion 26 and output terminal side end portion 28 of the element portions 24a to 24f and with the battery side end portion 34 and the alternator side end portion 36 of the C:WRPonbr\DCC\MAS\712115_1 DOC-6/22/2I I - 17 element portion 24g. Further, since the resistances of the element portions 24a to 24g are measured after the first and second casings 40 and 42 are coupled to the conducting hardware 12, there is no possibility that the resistances of 5- the element portions 24a to 24g are changed on account of deformation of the element portions in a step after measuring the resistances and it is possible to obtain the multipolar type fuse device 10 having stable quantity, in comparison with the case where the first and second casings 10 40 and 42 are coupled to the hardware 12 after the resistances are measured at the element portions 24a to 24g of the hardware 12. [00401 Although the embodiment of the present invention is 15 described above in detail, it should be noted that the present invention is not limited to the above embodiment. As mentioned above the through-holes are not always provided in connection with all element portions. In the case where a plurality of element portions are provided on the 20 conducting hardware, the through-holes may be provided in positions corresponding to both ends of at least one of the element portions. [00411 Although the bus bar 20 of the conducting hardware 12 25 in the above embodiment includes the battery system bus bar 20a and the alternator system bus bar 20b that are interconnected through the element portion 24g, the bus bar 20 may include only one of bus bars 20a and 20b. [Explanation of Signs] 30 [00421 10: multipolar type fuse device, 12: conducting hardware, 14: housing, 16, 17: input terminal sections, 18a to 18f: C:NR.Ponbl\DCCVASU7321115_DOC-6/22/201I - 18 output terminal sections, 20: bus bar, 24a to 24g: element portions, 26: bus bar side end portion, 28: output terminal side end portion, 34: battery side end portion, 36: alternator side end portion, 40: first casing, 42: second 5 casing, 48: through-holes, 50: support projection, 52a: front surface (one surface of a conducting hardware in its plate thickness direction), 52b: rear surface (the other surface of a conducting hardware in its plate thickness direction), 60a, 60b: probes. 10 [0043] Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" or "comprising", will be understood to imply the inclusion of a 15 stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps. [044] The reference in this specification to any prior 20 publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in 25 the field of endeavour to which this specification relates.