Electrical connectors – Contact comprising cutter – Insulation cutter
Reexamination Certificate
1999-12-21
2001-03-20
Sircus, Brian (Department: 2839)
Electrical connectors
Contact comprising cutter
Insulation cutter
C439S947000
Reexamination Certificate
active
06203358
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an electrical connection box and a method for manufacturing such an electrical connection box. The invention particularly is designed to enhance a range of application and to deal flexibly with a circuit change in an electrical connection box, such as a junction box, that is to be incorporated into an automotive harness.
2. Description of the Related Art
A prior art electrical connection box, such as a junction box, has branch circuits accommodated at high density. Internal circuits are formed by a combination of wires and push-in terminals or by wires, push-in terminals and a busbar. These internal circuits may be arranged in different layers with insulating plates or the like provided between the layers of internal circuits. Internal circuits in the prior art electrical connection box are connected with external circuits by special connectors provided in the upper casing and the lower casing.
A prior art electrical connection box, as described above, is shown in FIG.
8
. This prior art electrical connection box has a layered array comprising a strand of wire (single core wire) as a bottommost layer, a first insulating plate
6
, a busbar
7
, and a second insulating plate
8
and another strand of wire as an uppermost layer. The wire in the bottommost layer of the lower casing
1
is connected to the wire in the uppermost layer of the upper casing
2
by placing the lower casing
1
and the upper casing
2
side by side on the same plane and then laying a strand of wire w on and between the casings
1
and
2
as shown in FIG.
9
. The upper casing
2
then is turned onto the lower casing
1
and fitted thereto.
The lower and upper casings
1
and
2
are formed integrally with connectors
3
, relay sockets
4
and fuse sockets
5
for connection with external circuits. Push-in terminals
5
are inserted into the connectors
3
. The push-in terminals
5
each have a connection portion
5
a
formed at one end for the connection with the wires w and for the connection with the external circuit. Push-in terminals also are inserted into the relay sockets
4
and fuse sockets
5
which are to be connected with the wire w.
The connectors
3
are formed integrally with the lower casing
1
and the upper casing
2
as described above. Thus coupling positions of wiring harnesses to be connected with the external circuits are restricted. This is a hindrance to a change in circuit design. Further, due to the restrictions, one kind of prior art electrical connection box can be used for limited types of vehicles and specifications, and may be not used for another type of vehicles and specifications.
The insertion positions of the push-in terminals
5
are restricted by the positions of the connectors
3
. Hence even if the prior art electrical connection boxes are for the same type of vehicles, the wires w and the push-in terminals
5
may not be connected if the layout pattern of the wires w is changed due to a change in the internal circuits resulting from an improvement in function, because this makes it difficult to change and add circuits. To avoid these problems, the lower and upper casings need to be newly designed every time the type of vehicle is changed and/or the circuits are changed. However, this disadvantageously leads to huge production costs for the fabrication of molds.
As noted above the wire is laid in the lower and upper casings
1
and
2
that have been placed on the same plane, as shown in
FIG. 9
in the manufacturing process of the electrical connection box. Consequently wire portions w-a that connect the wires in the upper and the lower layers may bulge out from the casing when the lower and upper casings
1
and
2
are assembled.
The present invention was developed in view of the above problems, and an object thereof is to prevent wires constructing internal circuits from bulging out during a manufacturing process of an electrical connection box.
SUMMARY OF THE INVENTION
According to the invention, there is provided an electrical connection box, comprising internal circuits formed by wires and push-in terminals. The internal circuits are provided on the inner sides of a first or lower casing and a second or upper casing. A plurality of through holes are formed in the first or lower casing and/or the second or upper casing for receiving connectors. The connectors may have push-in terminals mounted thereon and may be mounted fixedly in the through holes in accordance with a circuit construction. Thus the push-in terminals are connected with the wires and preferably are connected with an external circuit. Accordingly, the present invention can accommodate different types and specifications of vehicles or easily can accommodate a design change by employing a first or lower casing and a second or upper casing of one type.
If the through holes into which the connectors are detachably mountable are formed in the first or lower casing and second or upper casing, the connectors can be mounted in necessary positions in accordance with the circuit construction. Thus the electrical connection box can be used for a wider range of vehicles without being limited to one type of vehicle. Further, since the layout patterns of the wires to be connected with the push-in terminals mounted in the connectors can be changed easily, circuits also can be changed easily and/or added. Therefore, a circuit change can be realized very easily in accordance with a change in the mount positions of the connectors, with the result that the electrical connection box can be used for many types of vehicles.
Preferably, at least one busbar is arranged between the upper and lower wires while substantially providing insulating plates between the busbar and the upper and lower wires. Tabs project from the busbar and are connectable with the connectors and relays and fuses to be mounted in the second or upper casing and/or the first or lower casing.
If the circuit formed by the busbar is used in addition to the circuits formed by the wires and the push-in terminals, a circuit corresponding to a current amount can be constructed.
Preferably, the second or upper casing and/or the first or lower casing are formed with through holes into which the relays and fuses are detachably mountable. Push-in terminals are mounted for connection with the wires and/or the tabs of the busbar and for connection with the relays and/or fuses to be mounted into these through holes. If the mount positions of the relays and/or fuses can be changed easily as well as those of the connectors, the same electrical connection box can be used for different circuit constructions, thereby enhancing a flexibility.
Preferably, the wires laid in the upper or second layer and the lower or first layer are or can be connected by at least one connection busbar to be mounted along one side surface of the casing. If the wires laid in the first or lower casing and the second or upper casing are connected by the connection busbar mounted on the side surface of the casing, the corresponding wires in the first or lower casing and second or upper casing need not be continuous. This solves the problem of the prior art that the folded portions of the strand of wire bulge out of the casing. Alternatively, the wires can be separately laid in the first or lower and second or upper casings, thereby making it easier to lay the wires.
According to the invention, there is further provided a method for manufacturing an electrical connection box, comprising laying a plurality of wires on inner surfaces of first and second casings. The method continues by mounting at least one connection busbar on at least one side surface of the first and second casings such that second and first wires are connected to the respective second and first ends of the connection busbar.
According to a preferred embodiment, the method comprises a step of cutting a strand of wire that has laid between the first and second casings that have been placed substantially side by side. Alternatively the
Casella Anthony J.
Hespos Gerald E.
Nguyen Son V.
Porco Michael J.
Sircus Brian
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