Description:FUSE FOR FLAT RIBBON CABLE IN ELECTRIC VEHICLE
FIELD OF INVENTION
[0001] The present disclosure relates to electrical circuit protection devices, and more particularly to a fuse assembly specifically designed for integration with flat ribbon cables to provide overcurrent protection in electrical and electronic systems.
BACKGROUND
[0002] Electrical and electronic systems in various applications, including automotive, industrial, and consumer electronics, rely on circuit protection devices to prevent damage from overcurrent conditions such as short circuits and overloads. Fuses serve as protective elements that interrupt electrical circuits when current exceeds predetermined levels, thereby safeguarding downstream components and preventing potential hazards.
[0003] Traditional fuses are typically designed for use with round cables and are housed in dedicated fuse holders or fuse boxes. These conventional protection systems work well in many applications where space constraints are minimal and accessibility for maintenance is straightforward. Round cable systems allow for relatively simple integration of standard fuse configurations, as the circular cross-section of such cables readily accommodates conventional fuse holder designs.
[0004] However, modern electronic systems increasingly utilize flat ribbon cables, particularly in applications where space efficiency and organized routing of multiple conductors are desired. Flat ribbon cables, which typically employ conductors of smaller gauge such as 28 AWG, offer advantages in terms of space utilization and cable management. These cables are commonly found in automotive applications connecting vehicle control units to various electrical loads, as well as in other electronic systems where multiple parallel connections are required in a compact form factor.
[0005] The integration of circuit protection in flat ribbon cable systems presents challenges that are not encountered with round cable configurations. Existing fuse technologies are generally incompatible with the flat profile and specific dimensional constraints of ribbon cable assemblies. When circuit protection is required in systems employing flat ribbon cables, designers often resort to PCB-mounted fuses positioned at various points in the circuit. While functional, this approach can present accessibility challenges, particularly when PCB enclosures are sealed for environmental protection, making fuse replacement or resetting a complex procedure that may require disassembly of the entire system.
[0006] The limitations of current protection methods in flat ribbon cable applications highlight the need for protection solutions that can be directly integrated with the cable assembly itself, providing both effective circuit protection and practical accessibility for maintenance operations.
SUMMARY
[0007] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
[0008] According to an aspect of the present disclosure, a fuse compatible with flat ribbon cable is provided for protection of electrical and electronic systems from short circuits. The fuse is specifically designed to work with flat ribbon cables having 28 AWG conductors, addressing the current lack of available fuses for such cable configurations.
[0009] The fuse enables cable-mounted protection rather than requiring PCB-mounted fuses, thereby facilitating easier replacement and maintenance since PCB enclosures are typically completely sealed. The fuse can be incorporated into multicore flat ribbon cable harnesses connecting vehicle control units to multiple electrical loads including headlamps, tail lamps, electronic steering column locks, seat locks, motor control units, and instrument clusters.
[0010] Unlike existing fuses which are designed only for use with round cables, this fuse provides protection capability specifically for flat ribbon cable applications where conventional fuse solutions are not compatible.
[0011] The foregoing general description of the illustrative embodiments and the following detailed description thereof are merely exemplary aspects of the teachings of this disclosure and are not restrictive.
BRIEF DESCRIPTION OF FIGURES
[0012] FIG. 1 shows a perspective view of the flat ribbon cable fuse assembly, according to aspects of the present disclosure.
[0013] Fig. 2 shows an exploded view of a flat ribbon cable fuse assembly, according to aspects of the present disclosure.
[0014] Fig. 3A illustrates an isometric view of the flat ribbon cable fuse assembly.
[0015] Fig. 3B depicts a top view of the flat ribbon cable fuse assembly.
[0016] Fig. 4A shows a sectional view of the flat ribbon cable fuse assembly with an intact fuse link, according to aspects of the present disclosure.
[0017] Fig. 4B depicts a sectional view of the flat ribbon cable fuse assembly with a blown fuse link, according to aspects of the present disclosure.
[0018] Fig. 5 illustrates the flat ribbon cable fuse assembly integrated into a flat ribbon cable, according to an embodiment.
DETAILED DESCRIPTION
[0019] The following description sets forth exemplary aspects of the present disclosure. It should be recognized, however, that such description is not intended as a limitation on the scope of the present disclosure. Rather, the description also encompasses combinations and modifications to those exemplary aspects described herein.
[0020] Referring to FIG. 1, the flat ribbon cable fuse assembly may be presented in a perspective view that demonstrates the overall construction and spatial arrangement of the housing structure and internal components. The perspective view illustrates how the assembly consists of a housing structure with a top100 is shown in a perspective view. The assembly includes a top housing 1 and bottom housing 5 that enclose the internal components. In one embodiment, the housing structure accommodates flat ribbon wire with 28 AWG conductors. The top housing 1 and bottom housing 5 are assembled together using crimping tool, to create a stable mechanical structure that withstands operational stresses while maintaining electrical integrity.
[0021] The perspective view shows wire crimping areas 7 and contact terminals 3 that facilitate secure electrical and mechanical connections with flat ribbon cable conductors. These features are positioned to allow proper termination of individual conductors while maintaining the spatial organization of ribbon cable systems. The contact terminals 3 provide reliable electrical contact points that accommodate the conductor spacing of flat ribbon cables.
[0022] The internal arrangement includes contact terminals 3 positioned within the housing and separated by separation wall 2, which includes first portion of separation wall 2a and second portion of separation wall 2b. These walls provide structural support and electrical isolation between different circuit paths. The separation wall 2 cuts the ribbon wire which are placed on wire crimping area, into two piece using the second portion of separation wall 2b.
[0023] A fuse link 4 is incorporated between the contact terminals 3 to provide circuit protection. The fuse link 4 is positioned within the housing structure to create a controlled failure point that allows normal current flow under standard operating conditions while providing overcurrent protection when electrical faults occur. The positioning of the fuse link 4 facilitates replacement operations when the protective element has operated due to an overcurrent condition.
[0024] The housing structure includes lock in bottom housing 6 that secures the assembly together and provides mechanical stability during installation and operation. The lock in bottom housing 6 engages between the top housing 1 and bottom housing 5 to create a secure connection that prevents separation under normal handling and operational conditions. The locking features are integrated into the housing design without adding excessive bulk or complexity to the overall assembly.

[0025] The complete flat ribbon cable fuse 100 is designed for easy integration with flat ribbon cable 8, maintaining electrical continuity through ribbon wire 9 while providing overcurrent protection. The assembly facilitates cable-mounted protection that can be positioned at strategic locations along ribbon cable runs rather than requiring integration into sealed electronic enclosures. Multiple units can be integrated into a single ribbon cable 8 system to provide individual circuit protection for different conductors or circuit groups.
[0026] Referring to FIG. 2, a flat ribbon cable fuse 100 may be provided in an exploded view configuration showing the individual components arranged for assembly. The flat ribbon cable fuse 100 comprises a top housing 1 and a bottom housing 5 that together form a housing structure configured to accommodate a flat ribbon cable having 28 AWG conductors. The top housing 1 and bottom housing 5 may be designed to accommodate the flat configuration of ribbon cables, providing a form factor that matches the planar geometry of such cable assemblies. A separation wall 2 may be positioned within the housing structure to provide internal compartmentalization and structural support for the electrical components.
[0027] The separation wall 2 includes a first portion of separation wall 2a and a second portion of separation wall 2b that may work together to create distinct regions within the housing assembly. Contact terminals 3 may be disposed within the housing structure and positioned to establish electrical connections with conductors of the flat ribbon cable. The contact terminals 3 may be arranged to facilitate electrical continuity through the fuse assembly while providing connection points for the protective circuitry. A fuse link 4 may be provided as a fuse element disposed within the housing and electrically connected to at least one conductor of the flat ribbon cable through the contact terminals 3. The fuse link 4 may be configured to interrupt electrical current when current exceeds a predetermined level to provide overcurrent protection for the connected circuits.
[0028] The bottom housing 5 incorporates a lock in bottom housing 6 that may serve as a securing mechanism to maintain the assembled configuration of the flat ribbon cable fuse 100. The lock in bottom housing 6 may engage with corresponding features on the top housing 1 to create a stable mechanical connection between the housing components. Wire crimping areas 7 may be provided within the housing structure to facilitate secure electrical and mechanical connections with the individual conductors of the flat ribbon cable. The wire crimping areas 7 may be positioned to allow for proper termination of the 28 AWG conductors while maintaining the integrity of the electrical connections under operational conditions.
[0029] The flat ribbon cable fuse 100 may be configured for use in multicore flat ribbon cable applications on specific circuits, allowing individual conductors within a multi-conductor ribbon cable to be protected independently. The arrangement of components shown in FIG. 2 demonstrates how the top housing 1, bottom housing 5, separation wall 2 with the first portion of separation wall 2a and second portion of separation wall 2b, contact terminals 3, fuse link 4, lock in bottom housing 6, and wire crimping areas 7 may be assembled to create a functional protection device. The exploded view illustrates the spatial relationships between these components and how the assembly process may proceed to integrate the fuse assembly with 28 AWG flat ribbon cable conductors.
[0030] Referring to FIG. 3A and FIG. 3B, the flat ribbon cable fuse 100 may be shown in assembled views that demonstrate the integration of components in a functional configuration. FIG. 3A presents an isometric view from the left side that illustrates the spatial arrangement of the top housing 1 and bottom housing 5 in the assembled state. The top housing 1 and bottom housing 5 may be joined together to form a housing that accommodates the flat configuration of the ribbon cable, creating a unified structure that maintains the planar geometry characteristic of flat ribbon cable systems. A ribbon wire 9 may extend through the fuse assembly, demonstrating how individual conductors from a flat ribbon cable having multiple 28 AWG conductors may be integrated with the protection device. The ribbon wire 9 may represent one or more conductors that pass through the housing structure while maintaining electrical continuity through the fuse assembly.
[0031] FIG. 3B provides a top view of the same assembly, showing the arrangement of the top housing 1 and the ribbon wire 9 between points B-B in a linear configuration.
[0032] Referring to FIG. 4A and FIG. 4B, sectional views of the flat ribbon cable fuse 100 may illustrate the operational states of the fuse assembly during normal and fault conditions. FIG. 4A shows a section view with an intact fuse link 4 positioned between the top housing 1 and the bottom housing 5, demonstrating the normal operational configuration where electrical continuity may be maintained through the fuse assembly. The fuse link 4 may be disposed within the housing structure formed by the top housing 1 and bottom housing 5, providing a controlled failure point that allows current to flow under normal operating conditions. A ribbon wire 9 extends through both sides of the housing assembly, showing how the fuse assembly may be integrated into a flat ribbon cable to provide inline protection capabilities.
[0033] The positioning of the fuse link 4 within the housing assembly may provide a strategic location for current interruption when electrical faults occur. In some cases, the fuse link 4 may be configured to interrupt electrical current when current exceeds a predetermined level, providing overcurrent protection for connected circuits and electrical components. The sectional view shown in FIG. 4A demonstrates how the fuse link 4 may be mechanically and electrically positioned between the contact terminals to create a current path that passes through the fusible element. The ribbon wire 9 may maintain electrical continuity from one side of the housing assembly to the other through the intact fuse link 4, allowing normal current flow while providing protection against overcurrent conditions.
[0034] FIG. 4B depicts the same sectional view but shows the condition where the fuse link 4 has blown, illustrating the protective operation of the fuse assembly during an overcurrent event. The blown fuse link 4 may create an open circuit condition that interrupts electrical current flow through the ribbon wire 9, preventing damage to downstream electrical components and motors. The sectional view demonstrates how the fuse link 4 may physically separate or melt when subjected to overcurrent conditions, creating a gap that prevents further current flow while maintaining the mechanical integrity of the housing assembly formed by the top housing 1 and bottom housing 5.
[0035] The operational states shown in FIG. 4A and FIG. 4B may demonstrate how the fuse assembly may be positioned inline with the flat ribbon cable to provide cable-mounted protection for various electrical systems wherever the flat ribbon cable 8 is used in the electrical vehicle. The ribbon wire 9 may represent individual conductors within a multicore flat ribbon cable system, where each conductor may be protected by a separate fuse assembly or where selected conductors may be protected based on the specific circuit protection requirements. The blown state illustrated in FIG. 4B shows how the fuse assembly may respond to fault conditions by creating an open circuit that isolates the protected circuit from the power source.
[0036] Referring to FIG. 5, the flat ribbon cable fuse 100 may be shown integrated into a flat ribbon cable 8, demonstrating how the fuse assembly may be incorporated within a complete cable system while maintaining the planar configuration characteristic of ribbon cable assemblies. The flat ribbon cable 8 comprises multiple parallel conductors arranged in a planar configuration, providing a multi-conductor cable system that may accommodate various electrical connections within a compact form factor. The flat ribbon cable fuse 100 may be mounted along the length of the flat ribbon cable 8, providing circuit protection capabilities while preserving the flat profile of the cable assembly. The integration shown in FIG. 5 illustrates how the fuse assembly may be positioned to provide inline protection without disrupting the overall geometry or flexibility of the flat ribbon cable 8. In some cases, the flat ribbon cable fuse 100 may be configured for use in automotive applications connecting vehicle control units to electrical loads, where the flat profile of the cable assembly may provide advantages in routing through confined spaces within vehicle structures.
[0037] The integrated configuration demonstrated in FIG. 5 may show how the flat ribbon cable fuse 100 maintains electrical continuity through selected conductors within the flat ribbon cable 8 while providing overcurrent protection for connected circuits. The flat ribbon cable 8 may contain multiple 28 AWG conductors that extend through the fuse assembly, allowing individual conductors or groups of conductors to be protected based on the specific circuit protection requirements. The fuse assembly may be positioned at strategic locations along the flat ribbon cable 8 to provide protection for power lines connecting to various electrical loads such as headlamps, tail lamps, electronic steering column locks, seat locks, motor control units, and instrument clusters. In some cases, the flat ribbon cable 8 with integrated flat ribbon cable fuse 100 may be used to establish connections between vehicle control units and multiple electrical components, providing both signal transmission and power distribution capabilities within a single cable assembly.
[0038] A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. Accordingly, other implementations are within the scope of the following claims.

CLAIMS
I/we Claim
1. A fuse assembly for flat ribbon cable, comprising:
a top housing (1) and a bottom housing (5) configured to form an enclosure;
a separation wall (2) disposed within the enclosure, the separation wall (2) including a first portion (2a) and a second portion (2b);
contact terminals (3) positioned within the enclosure;
a fuse link (4) electrically connected between the contact terminals (3) and configured to interrupt electrical current when current exceeds a predetermined level; and
wire crimping areas (7) configured to secure electrical connections with conductors of a flat ribbon cable (8);
2. The fuse assembly of claim 1, further comprising a locking mechanism (6) configured to secure the top housing (1) and bottom housing (5) together.

3. The fuse assembly of claim 1, wherein the separation wall (2) is configured to physically separate individual conductors of the flat ribbon cable (8) within the enclosure.

4. The fuse assembly of claim 3, wherein the second portion (2b) of the separation wall (2) is configured to cut ribbon wire (9) placed in the wire crimping areas (7).

5. The fuse assembly of claim 1, wherein the flat ribbon cable (8) comprises conductors having 28 AWG wire gauge.

6. The fuse assembly of claim 5, wherein the locking mechanism (6) comprises a lock integrated into the bottom housing (5) and configured to engage with the top housing (1) to secure the enclosure.

7. The fuse assembly of claim 1, wherein the fuse assembly is configured to protect electrical circuits connected to at least one of headlamps, tail lamps, electronic steering column locks, seat locks, motor control units, and instrument clusters in a vehicle.

7. A method of providing circuit protection in a flat ribbon cable system, comprising:
positioning a fuse assembly (100) along a flat ribbon cable (8), the fuse assembly (100) including a housing with contact terminals (3) and a fuse link (4) disposed therein;
connecting conductors of the flat ribbon cable (8) to the contact terminals (3) through wire crimping areas (7); and
interrupting electrical current flow through the fuse link (4) when current exceeds a predetermined level to protect electrical components connected to the flat ribbon cable (8).

8. The method of claim 7, wherein the flat ribbon cable (8) comprises conductors having 28 AWG wire gauge.

9. The method of claim 7, wherein the fuse assembly (100) comprises a top housing (1) and a bottom housing (5) secured together by a locking mechanism (6).

10. The method of claim 9, wherein connecting the conductors comprises crimping the conductors in wire crimping areas (7) positioned within the housing.

11. The method of claim 7, wherein the electrical components comprise at least one of headlamps, tail lamps, electronic steering column locks, seat locks, motor control units, and instrument clusters in a vehicle. , Claims:CLAIMS
I/we Claim
1. A fuse assembly for flat ribbon cable, comprising:
a top housing (1) and a bottom housing (5) configured to form an enclosure;
a separation wall (2) disposed within the enclosure, the separation wall (2) including a first portion (2a) and a second portion (2b);
contact terminals (3) positioned within the enclosure;
a fuse link (4) electrically connected between the contact terminals (3) and configured to interrupt electrical current when current exceeds a predetermined level; and
wire crimping areas (7) configured to secure electrical connections with conductors of a flat ribbon cable (8);
2. The fuse assembly of claim 1, further comprising a locking mechanism (6) configured to secure the top housing (1) and bottom housing (5) together.

3. The fuse assembly of claim 1, wherein the separation wall (2) is configured to physically separate individual conductors of the flat ribbon cable (8) within the enclosure.

4. The fuse assembly of claim 3, wherein the second portion (2b) of the separation wall (2) is configured to cut ribbon wire (9) placed in the wire crimping areas (7).

5. The fuse assembly of claim 1, wherein the flat ribbon cable (8) comprises conductors having 28 AWG wire gauge.

6. The fuse assembly of claim 5, wherein the locking mechanism (6) comprises a lock integrated into the bottom housing (5) and configured to engage with the top housing (1) to secure the enclosure.

7. The fuse assembly of claim 1, wherein the fuse assembly is configured to protect electrical circuits connected to at least one of headlamps, tail lamps, electronic steering column locks, seat locks, motor control units, and instrument clusters in a vehicle.

7. A method of providing circuit protection in a flat ribbon cable system, comprising:
positioning a fuse assembly (100) along a flat ribbon cable (8), the fuse assembly (100) including a housing with contact terminals (3) and a fuse link (4) disposed therein;
connecting conductors of the flat ribbon cable (8) to the contact terminals (3) through wire crimping areas (7); and
interrupting electrical current flow through the fuse link (4) when current exceeds a predetermined level to protect electrical components connected to the flat ribbon cable (8).

8. The method of claim 7, wherein the flat ribbon cable (8) comprises conductors having 28 AWG wire gauge.

9. The method of claim 7, wherein the fuse assembly (100) comprises a top housing (1) and a bottom housing (5) secured together by a locking mechanism (6).

10. The method of claim 9, wherein connecting the conductors comprises crimping the conductors in wire crimping areas (7) positioned within the housing.

11. The method of claim 7, wherein the electrical components comprise at least one of headlamps, tail lamps, electronic steering column locks, seat locks, motor control units, and instrument clusters in a vehicle.