The present invention provides a fuse unit which facilitates a work such as inspection and a method of manufacturing the fuse unit. Disclosed is a method of manufacturing a fuse unit, which has a metal part including an input terminal and an external connection terminal and a connector part for attaching an external terminal C3 to the external connection terminal and is manufactured by integrating the metal part and a resin covering body by insert molding. In this manufacturing method, the metal part and the resin covering body are integrated by insert molding such that a distal end of the external connection terminal of the metal part protrudes from the resin covering body, and then, the connector part separate from the resin covering body is attached to the resin covering body so that the external connection terminal protruding from the resin covering body can be connected to the external terminal C3.

A power distribution box assembly can include a power distribution box housing, a fuse block, and a plurality of eyelet terminals. The fuse block can include a stamped busbar assembly, a plurality of studs, and a housing. The stamped busbar assembly can include a main power supply portion, a plurality of fuse elements, and a plurality of terminal connecting portions coupled to the plurality of fuse elements. Each of the plurality of terminal connecting portions can: (i) extend from its respective fuse element in a terminal direction that is orthogonal to both directions that the main power supply portion and the fuse elements extend.

A method of making printed circuit board vias using a double drilling and plating method is disclosed. A first hole is drilled in a core, the first hole having a first diameter. The first hole is filled and/or plated with an electrically conductive material. A circuit pattern may be formed on one or two conductive layers of the core. A multilayer structure may then be formed including a plurality of cores that also include pre-drilled and plated via holes, wherein at least some of the pre-drilled and plated via holes are aligned with the first hole. A second hole is then drilled within the first hole and the aligned pre-drilled and plated holes, the second hole having a second diameter where the second diameter is smaller than the first diameter. A conductive material is then plated to an inner surface of the second hole.

A straight bus bar includes an axial direction and having a rigid first portion with a first contact surface connectable to a first fuse, an axially spaced rigid second portion with a second contact surface connectable to a second fuse, and a connecting portion electrically connecting the first portion and the second portion. The connecting portion is a resilient compensation portion having at least two lateral recesses extending from opposite sides into the bus bar making the connecting portion elastically bendable to allow a relative axial movement of the first and second portions when an axial force is applied to the bus bar.

A circuit protection assembly includes a mounting block, a unitary fuse assembly, a post assembly and a plug connector. The unitary fuse assembly is disposed the mounting block and includes a plurality of fuses each of which is defined by a portion of a bus plate disposed on the lower surface of the mounting block to form a first terminal of the fuse, a second terminal disposed at least partially on the upper surface of the mounting block and a fuse element connecting the first terminal and the second terminal. The post assembly is disposed at least partially within the mounting block and a post extending from the block. The plug connector extends from a portion of the first terminal of at least one of the plurality of fuses.

A fuse module including an battery clamp, a fuse assembly including a mounting block, a bus bar on a first side of the mounting block in contact with the battery clamp, fuse terminals on a second side of the mounting block connected to the bus bar by fusible elements, and a terminal post extending through one of the fuse terminals for facilitating electrical connection to a first electrical component, the fuse module further including a mounting cradle holding the fuse assembly and the battery clamp, the mounting cradle including a mounting post extending through the battery clamp, the bus bar, the mounting block, and one of the fuse terminals for facilitating connection to a second electrical component and for securing the fuse module components together, wherein the mounting post is surrounded by a tubular sleeve extending between the bus bar and the fuse terminal through which the mounting post extends.

A method of making printed circuit board vias using a double drilling and plating method is disclosed. A first hole is drilled in a core, the first hole having a first diameter. The first hole is filled and/or plated with an electrically conductive material. A circuit pattern may be formed on one or two conductive layers of the core. A multilayer structure may then be formed including a plurality of cores that also include pre-drilled and plated via holes, wherein at least some of the pre-drilled and plated via holes are aligned with the first hole. A second hole is then drilled within the first hole and the aligned pre-drilled and plated holes, the second hole having a second diameter where the second diameter is smaller than the first diameter. A conductive material is then plated to an inner surface of the second hole.

A breaker device for connecting in an electrical circuit, the device includes a pyrotechnic initiator and a body having present therein: a pressurizing chamber in communication with an outlet from the pyrotechnic initiator; at least one electrically conductive portion for connection to the electrical circuit; at least one fusible element connected in series with the conductive portion, the initiator being connected to the terminals of the fusible element and the fusible element being configured to trip when the current passing through it exceeds a predetermined value, thereby actuating the initiator; and a movable breaker element; the pyrotechnic initiator being configured to cause the breaker device to pass from a current-passing first configuration to a circuit-breaking second configuration, the movable breaker element being moved on passing from the first configuration to the second in order to disconnect the conductive portion.

A fuse assembly includes an insulating block having an upper surface, a lower surface, and a side surface therebetween. The insulating block defines cavities extending therethrough. Each cavity defines a resilient lock arm. A fuse assembly also includes a first terminal stud secured within a first cavity by a first lock arm, a second terminal stud secured within a second cavity by a second lock arm, and a bus bar disposed parallel to the bottom surface of the insulating block. The bus bar is interconnected to the first terminal stud by a lower terminal connected to the bus bar and an upper terminal disposed parallel to the upper surface. The bus bar is interconnected to the second terminal stud by a fusible link having a lower fuse terminal connected to the bus bar and an upper fuse terminal disposed generally parallel to the upper surface.

A circuit protection assembly includes a mounting block, a unitary fuse assembly, a post assembly and a plug connector. The unitary fuse assembly is disposed the mounting block and includes a plurality of fuses each of which is defined by a portion of a bus plate disposed on the lower surface of the mounting block to form a first terminal of the fuse, a second terminal disposed at least partially on the upper surface of the mounting block and a fuse element connecting the first terminal and the second terminal. The post assembly is disposed at least partially within the mounting block and a post extending from the block. The plug connector extends from a portion of the first terminal of at least one of the plurality of fuses.