Electrical connectors – Preformed panel circuit arrangement – e.g. – pcb – icm – dip,... – Within distinct housing spaced from panel circuit arrangement
Reexamination Certificate
1999-08-08
2001-04-24
Patel, Tulsidas (Department: 2839)
Electrical connectors
Preformed panel circuit arrangement, e.g., pcb, icm, dip,...
Within distinct housing spaced from panel circuit arrangement
C439S949000
Reexamination Certificate
active
06220875
ABSTRACT:
This Application claims the priority of Japanese Application 10-255,721, filed Sep. 9, 1998.
The present Invention is directed to an electrical connection box, particularly designed for use in automobiles. More specifically, it provides a high-density branching circuit wherein the wire connection section is on a busbar stacked on an insulative plate and the wire serves as an intermediate connection, thereby increasing the wire efficiency of the busbar. Preferably, the elements are within the electrical connection box. The Invention will be described with relation to an automobile, but its use is not limited thereto.
BACKGROUND OF THE INVENTION
In recent years, the number and diversity of electronic parts to be installed in automobiles has increased rapidly. As a result, the circuits contained in automotive electrical connection boxes have also been increased. In an attempt to form high density branch circuits, busbars and pressure-connections between the wire and the terminal have been used. As shown particularly in
FIG. 3
, busbars
7
and
8
are to be connected to each other. However, busbar
9
is located between them. In order to avoid electrical contact between busbars
7
and
8
and busbar
9
, wire
6
is pressed between blades
11
, thereby avoiding busbar
9
and securing the electrical connection between busbars
7
and
8
.
As shown in
FIG. 4
, insulative plate
4
D carries busbars
7
and
8
. Connection sections
10
pass through openings
17
in insulative plate
4
E and blades
11
cut through the insulation on wires
6
to make electrical contact with the cores thereof. A further modification is shown in
FIG. 5
, wherein insulative plate
4
C carries busbar
9
and insulative plate
4
D carries busbars
7
and
8
. Connection section
10
of busbar
9
passes through opening
17
in insulative plate
4
D and through opening
17
in insulative plate
4
E. Since busbars
7
and
8
are resting on insulative plate
4
D, connection sections
10
thereof only have to pass through openings
17
in insulation plate
4
E. However, since busbar
9
rests on insulative plate
4
C, section
10
passes through openings
17
in plates
4
D and
4
E.
However, the busbar method is such that an increased number of circuits in the connection box is accompanied by a decrease in the number of circuits which can be placed on a single layer. Thus, a greater number of layers must be provided, thereby making the connection box larger and more complex.
On the other hand, if pressure-connection methods are used, the circuit density is increased and design changes can be readily implemented; however, greater equipment costs result. In some cases, the two methods are combined. In such structures, busbar layers are stacked with layers formed from wires and pressure-connection terminals. These layers are connected to external circuits. However, this combined method results in higher production costs, creating problems in manufacture of low cost automobiles.
SUMMARY OF THE INVENTION
It is an object of the present Invention to provide a simple structure for the internal circuits in an electrical connection box, while permitting these circuits to be arranged in a highly dense configuration. It is also an object of the present Invention to provide such circuitry wherein the wires can be pressure-connected to the busbars at one time, the circuits can easily be changed and which results in a low-cost connection box suitable for mass production of inexpensive automobiles.
In practicing the present Invention, there is provided an electrical connection box containing at least one generally planar base insulative plate. There is at least one busbar on or adjacent the first surface of the insulative plate which can electrically contact a first plurality of insulated wires. For this purpose, the busbar has one or more pressure connection sections, each of which includes a pair of blades which cut through the insulation on the wires to make electrical contact with the core thereof. There is a plurality of openings extending through the base insulative plates in line with the points on the wires at which electrical contacts are desired.
The busbars are bent so that they are in alignment with the predetermined points and the plurality of openings giving access thereto. The bent portions of the busbars form connection sections which, when the box is assembled, extend through the openings and terminate in contact blades. The blades are adapted to receive the insulated wires; when the wires are pressed therein, the blades cut through the insulation and make electrical contact with the wire core.
The insulated wires are straight, parallel to each other, and located in a wire concentration section on or adjacent the second surface of the base insulative plates. The wire concentration section is in register with the pressure connection section. Thus, since the wires are suitably aligned and closely adjacent each other, the various blades can engage the wires and make electrical contact therewith by means of a single application of pressure. Thus, all of the wires are connected at one time and it is not necessary to insert each wire individually. Preferably, all of the wires should be of the same length so that they can be easily placed in the wire concentration section. After the circuits have been formed by making the desired electrical contacts, unneeded portions of the wires are cut away and removed, thereby simplifying the final product.
In order to retain the wires on the insulative plates, pairs of wire guides are provided. These constitute protuberances extending from the second surface of the insulative plates and are spaced apart transversely to the axes of the wires by a distance which does not exceed the diameter of an individual wire. Preferably, the distance should be slightly less than the wire diameter. Some of the connection sections may extend, not only through an opening in the base insulative plate, but also through further opening(s) in one or more additional insulative plates, thereby making contact with the plurality of wires on one of the additional insulative plates.
It is also within the scope of the present Invention to provide a second plurality of insulated wires which are also straight and located within the wire concentration section. They are parallel for most of their length but cross over each other at a particular point. At least one pair of blades contacts this point under pressure to form the electrical contact with the wires. Here, too, it is advantageous if the wires are all of the same length.
In view of the complexity of the electrical systems of automobiles, a preferred form of the Invention consists of a plurality of interleaved insulative plates. These stacked plates carry either the busbar(s), the wires, or both.
In a modification of the Invention, the busbars may be spaced from the wires to which they are to be connected by one or more insulative plates. In such cases, the openings are aligned with one another and with the point at which the connections between the wires and the busbars are desired.
REFERENCES:
patent: 4950168 (1990-08-01), Watanabe et al.
patent: 5057026 (1991-10-01), Sawai et al.
patent: 5295842 (1994-03-01), Ozaki et al.
patent: 5327643 (1994-07-01), Sakamoto et al.
patent: 5782651 (1998-07-01), Konoya
patent: 0720256 (1996-03-01), None
patent: 0824282 (1998-02-01), None
patent: 2293052 (1996-03-01), None
patent: 2318226 (1998-04-01), None
European Search Report EP 99 11 7811 (No Date).
JP Patent Unexamined Publication No. 5-344632 (No Date).
JP Utility Model Unexamined Publication No. 5-78130 (No Date).
JP Utility Model Examined Publication No. 7-47935 (No Date).
Bierman, Muserlian and Lucas
Patel Tulsidas
Sumitomo Wiring Systems Ltd.
Webb Brian S.
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