An electrical unit includes a first housing member, a second housing member, and a fuse assembly. The fuse assembly may include a pre-fuse bus bar disposed at least partially in the first housing member. The first housing member may be configured to receive a first electrical connector. A plane may extend through the pre-fuse bus bar and the first electrical connector. The fuse assembly may include a fuse, and the plane may extend through the pre-fuse bus bar, the first electrical connector, and/or the fuse. The first housing member may be configured to receive a second electrical connector.

A harness holder for holding a harness therein, includes: a holder main body whose upper portion is open; a holder cover which covers the upper portion of the holder main body. The holder main body has a reinforced part which extends from a bottom of the holder main body toward the upper portion thereof and which is integrally provided on the holder main body, and the holder cover has an opening through which the reinforced part passes.

The present invention provides a fuse unit, which reduces the number of components of a bus bar and eliminates alignment of tuning fork terminals, and a method of manufacturing the fuse unit. Disclosed is a method of manufacturing a fuse unit, which includes a bus bar including a battery terminal, a fuse connection terminal, and an external connection terminal and is manufactured by integrating the bus bar and a resin covering body by insert molding. In this manufacturing method, the fuse connection terminal is constituted of an input side tuning fork terminal connected to the battery terminal and an output side tuning fork terminal connected to the external connection terminal, the input side tuning fork terminal and the output side tuning fork terminal are connected by a joining portion so as to face each other, the bus bar including the fuse connection terminal is integrated with the resin covering body by insert molding. After the insert molding, the joining portion is cut and removed through a cutting window of the resin covering body, which exposes the joining portion to the outside, and the input side tuning fork terminal and the output side tuning fork terminal are separated.

A fuse holder provides a safe device for connecting fuses to a three-phase busbar device. Each phase includes a corresponding load conductor and line conductor mounted within a housing. A mechanical lock is provided for each phase that locks a knife of the fuse to one of the conductors for the phase. In a further aspect, the fuse knives are frictionally locked within the housing. In both the mechanical lock and frictional lock, a release mechanism is provided that can be activated by a screwdriver to release the fuse knives from the fuse holder. In another aspect, certain conductors are provided with heat dissipation wings that contact the housing to dissipate heat generated by current flowing through the conductor.

A fuse block assembly includes a nonconductive base formed with pedestal surfaces attachable to terminals from a location above the base, while providing a clearance between the body of a fuse and the middle portion of the base when a fuse is installed.

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 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 harness holder for holding a harness therein, includes: a holder main body whose upper portion is open; a holder cover which covers the upper portion of the holder main body. The holder main body has a reinforced part which extends from a bottom of the holder main body toward the upper portion thereof and which is integrally provided on the holder main body, and the holder cover has an opening through which the reinforced part passes.

A fuse holder including a main body portion formed of an electrically insulating material, the main body portion defining a hollow interior and having first and second through holes formed in opposing rear and front walls thereof, respectively, the first and second through holes being aligned with one another, an integrated first electrical cable having a first ring terminal extending into the hollow interior of the main body portion, the first ring terminal disposed on the rear wall and aligned with the first through hole in the rear wall, and an integrated second electrical cable having a second ring terminal extending into the hollow interior of the main body portion, the second ring terminal disposed on the front wall and aligned with the second through hole in the front wall.

A reduced height relay block for use within a power distribution device for a vehicle electrical system. In one embodiment, there is provided a power distribution device that routes or distributes power throughout a vehicle electrical system and includes a lower housing, a relay block assembly, a module with a printed circuit board (PCB), an array of serviceable electrical components, and an upper cover. The relay block assembly includes a relay block with an upper side that is generally planar and includes a number of cavities for receiving the serviceable electrical components. An underside of the upper cover includes clearance ribs specifically designed to oppose certain serviceable electrical components and prevent them from backing out of their respective cavities.