Electrical connectors – Preformed panel circuit arrangement – e.g. – pcb – icm – dip,... – Within distinct housing spaced from panel circuit arrangement
Reexamination Certificate
2000-01-31
2001-05-01
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
06224397
ABSTRACT:
This application claims the benefit of the priority of Japanese Patent Application No. 11-23785 filed Feb. 1, 1999.
The present invention relates to a branching connector having a circuit unit and a connector for a wire harness and to an electrical connection box which houses the branching connector.
BACKGROUND OF THE INVENTION
Conventionally, automobiles use electrical connection boxes, such as relay boxes and fuse boxes. An electrical connection box houses a branching connector, on which a plurality of relays, fuses, and the like are mounted and to which wire harnesses, coming in from outside, are connected. The branching connector houses a circuit unit from which a plurality of connector terminals project, both above and below the outer surface of the circuit unit. These connector terminals also project through the upper case of the branching connector to connect fuses, relays and the like and into the lower case of the branching connector. The circuit unit is formed by stacking a plurality of circuit boards, one on top of the other. Circuits are formed from a plurality of bus bars, which make up the circuit board, and the connector terminals extend from the bus bars.
Generally, the inner surface of the branching connector abuts the upper surface of the circuit unit and the connector terminals project through the upper case of the branching connector. The individual connector terminals are positioned in and can form, for example, relay cavities, fuse cavities, or connector mounting openings. These fuse cavities, relay cavities and connector mounting openings are generally part of the upper case into which the fuses and connectors are positioned.
When assembling the branching connector, the circuit unit is positioned inside an upper case and a lower case, and the upper and lower cases are connected and fixed to each other by pairs of elastic engagement pieces disposed on each of the cases. If the branching connector is assembled so that the upper surface and the lower surface of the circuit unit do not tightly abut the inner surfaces of the upper case and the lower case, the connector terminals will not project a predetermined length through the case. As a result, the relays, fuses, and the like will not be reliably connected to the connector terminals.
When assembling the branching connector, a tool is used to apply a predetermined load to cause the elastic engagement pieces on the cases to connect. Since it is not possible to confirm whether the upper case, the lower case, and the circuit unit are properly aligned before connecting the two cases, it must be assumed that the circuit unit and the upper and lower cases are aligned when the elastic engagement pieces are aligned and the tool connects the upper and lower cases. Furthermore, since the elastic engagement pieces are disposed on the sides of the cases, it is not possible to confirm whether the central portions of the circuit unit are properly positioned in the casing, even when the elastic engagement pieces are engaged. There is thus a need to provide a branching connector wherein the circuit unit and the upper and lower cases can be properly assembled in a reliable manner.
SUMMARY OF THE INVENTION
The present invention accomplishes this by providing an extension on the circuit unit which extends through the upper case and aligns with a corresponding hole in the upper case. The extension has a top surface that is substantially flat and coplanar with the outer surface of the upper case. With this coplanar arrangement, proper assembly can be visually confirmed, either by the human eye or by a conventional inspection machine. Furthermore, since the extension is preferably positioned in close association with the connector terminals, the extension also allows for confirmation that the central portions of the circuit unit tightly abut the upper case.
As used herein, the term coplanar means that the top surface of the extension is in the same plane as at least a portion of the outer surface of the upper case.
Broadly, the present invention is a branching connector comprising a casing in which a circuit unit is housed, wherein the circuit unit is a plurality of stacked circuit boards on which bus bars form circuits; connecting terminals extend from the circuit boards and project from the surface of the circuit unit in the direction in which the circuit boards are stacked; the connecting terminals project through the outer surface of the casing to form connectors for electronic members; one or more extensions are disposed on the circuit boards, the extensions extending from the surface of the circuit unit in stacking direction; and insertion openings are disposed on the casing to allow for insertion of the extensions therethrough, the relative heights of the extensions and the insertion openings being such that the top of each extension is coplanar with a portion of the outer surface of the casing at the insertion opening to provide for visual inspection from the front of the branching connector and thereby confirm proper assembly.
Preferably, the extensions are terminal supports formed integrally with one or more of the circuit boards through which the connecting terminals are inserted, the terminal supports supporting the connecting terminals so that they are perpendicular to the circuit board.
More preferably, the terminal supports are formed integrally with the uppermost circuit board, i.e. the circuit board that forms the upper surface of the circuit unit.
Still more preferably, the extensions extend through the casing at a point where the inner surface of the casing abuts the upper surface of the circuit unit, and even more preferably, where there is a connector mount opening.
The electrical connection box according to the present invention includes a branching connector as described herein.
According to the preferred embodiment, when a connector mounting opening is integrated with the upper casing of the branching connector, the extension extends from the surface of the circuit unit and into the insertion opening of the connector mounting opening.
The extension can be: (1) a terminal support disposed integrally with a circuit board to provide perpendicular support for a connector terminal; (2) an extension disposed integrally with the circuit board and not associated with the connector terminal; or (3) an extension extending from the bus bar itself. The extension can extend, for example, from a surface on one side of the circuit unit, relative to the direction in which the bodies are stacked.
REFERENCES:
patent: 4781621 (1988-11-01), Sugiyama et al.
patent: 5023752 (1991-06-01), Detter et al.
patent: 5403193 (1995-04-01), Ito et al.
patent: 5618186 (1997-04-01), Saka et al.
patent: 62-177226 (1987-11-01), None
patent: 0160383 (1990-06-01), None
patent: 7-5652 (1995-02-01), None
Bierman, Muserlian and Lucas
Patel Tulsidas
Sumitomo Wiring Systems Ltd.
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