In one embodiment, a method of manufacturing a high voltage power fuse includes inserting a housing over a first assembly leg of an assembly frame, assembling a first terminal fabrication to the first assembly leg of the assembly frame, assembling a second terminal fabrication to a second assembly leg of the assembly frame, connecting a full-range fuse element assembly in a gap between the first terminal fabrication and the second terminal fabrication, sliding the housing over the connected full-range fuse element assembly, securing the housing in position to enclose the full-range fuse element assembly, and applying a silicated filler material to the assembled housing, full-range fuse element, and first and second terminals to establish a mechanical bond between the silicated filler material and the assembled housing, full-range fuse element, and first and second terminals.

A distribution block element having opposed input and output couplings and integral complimentary mechanical connectors to additional adjacent distribution block elements, allowing expansion by addition of distribution block elements. Fuse couplings are spaced apart for a mini2 blade fuse and have a length that is are spaced apart for a maxi APX heavy duty fuse and for direct conductors. When two elements are connected adjacently, the spacing between the adjacent crossbar couplings is the same as the spacing between the opposed input and output fuse couplings in each element. Thus, identical crossbar conductors can be used both for electrically connecting opposed input and output couplings and for electrically connecting input couplings of adjacent elements.

A device is provided for use with an electrical apparatus. The device comprises a wiring lug having a side and a base configured to receive a mounting screw. The wiring lug is configured to connect with a wire. The device further comprises a shaped spring configured to apply a force to a fuse for maintaining an electrical connection between the fuse and the wiring lug thus eliminating a separate electrical bus part that in a typical installation would pass a current from a conductive fuse clip to the wiring lug. The shaped spring provides a fuse clip with one side defined by the shaped spring and other side defined by the side of the wiring lug to contact a ferrule on the fuse or contact a blade extending from the ferrule on the fuse.

A power distribution assembly which may be a fuse clip or a switch includes a lug mounted to a block in association with a spring clip which confronts one side of the lug. A portion of the spring clip is mounted to the block and an upper spring arm of the clip is positioned on one side of the lug. The lug is mounted to the block and includes a downwardly projecting tang which is inserted through a slot in the bottom portion of the assembly to thereby couple the spring arm to the lug and block and to receive the end of the fuse or a blade between the spring arm and the lug.

Power connectors with integrated fuse support, and associated systems and methods are disclosed. A representative power connector can include a power port and a mating plug. The power port can include a fuse support having first and second fuse receptacles, wherein the first fuse receptacle is connectable to a first supply cable. The power port can include first and second port terminals, wherein the first port terminal is connectable to a second supply cable. A jumper cable can be connected between the second port terminal and the second fuse receptacle. The plug can include a housing configured to enclose the fuse support between the plug and the power port when the plug is mated to the power port. The plug can include first and second plug terminals mateable with the first and second port terminals.

A distribution block element having dual-level opposed input and output couplings and integral mechanical connectors to additional adjacent distribution block elements, allowing expansion by addition of distribution block elements. First levels of the couplings are spaced apart for a fuse of a first size and the second, lower levels of the couplings are spaced apart for a fuse of a second size, and for direct flat plate conductors. When two elements are connected adjacently, the spacing between the second level of adjacent couplings is the same as the spacing between the second level of opposed couplings in each element. Thus, the flat plate conductors can be used both for electrically connecting opposed input and output couplings and for electrically connecting input couplings of adjacent elements. Notches in the flat plate connectors receive fasteners and two flat plate connectors can be juxtaposed to receive the same fastener without stacking.

A fusible disconnect switch devices includes dual sets of switch contacts to connect or disconnect a current path through an overcurrent protection fuse with reduced arcing severity. Faster acting and longer contact path switch mechanisms are described providing satisfactory switching of DC circuits without excessive electrical arcing in a reduced physical package size.

Approaches herein provided surface mounted devices each configured as a stand-alone component suitable for attachment to a substrate such as a printed circuit board (PCB). In some embodiments, a method includes forming a base housing, coupling an electronic component to the base housing, and forming a cover over the electronic component, wherein the cover is coupled to the base housing. The electronic component may include a fusible link/element extending between terminals, the terminals wrapped around an exterior of base housing. The device may then be coupled to the PCB, for example, by attaching the terminals to an upper surface of the PCB.

An embodiment of a power distribution system has been disclosed. The power distribution system includes a fuse holder having a plurality of line-side terminals. The power distribution system also includes a bus module having an enclosure and a conductor disposed within the enclosure. The conductor includes a comb-type bus bar having a base member and a plurality of branch members extending from the base member and each embodying a terminal connectable to one of the line-side terminals of the fuse holder.

A fuse assembly according to an exemplary aspect of the present disclosure includes, among other things, a housing, a fuse received within a receptacle of the housing and a retention device configured to retain the fuse within the receptacle and cover a conductive surface of the fuse.