U.S. patent application number 09/849206 was filed with the patent office on 2002-03-14 for modular terminal fuse block.
Invention is credited to Davis, Ruel Emmett, Joiner, Matthew Alan.
Application Number | 20020031924 09/849206 |
Document ID | / |
Family ID | 25305308 |
Filed Date | 2002-03-14 |
United States Patent
Application |
20020031924 |
Kind Code |
A1 |
Davis, Ruel Emmett ; et
al. |
March 14, 2002 |
Modular terminal fuse block
Abstract
A power distribution block assembly includes an insulative body
having at least a first modular body section and a second modular
body section, and at least one electrically conductive bus member
having a longitudinally-extending base and a plurality of terminal
blades extending from the base. The base of the bus member has a
site for electrical connection to a power source and a
longitudinally elongated U-shape channel defined by opposite legs.
A plurality of terminal blades extend from the legs of the channel
and include a plurality of sites for electrical connection to a
plurality of removable circuit elements. A plurality of separate
connector elements are contained within the body, and each of the
connector elements are configured to engage a terminal blade of the
bus with a terminal of a respective one of the removable circuit
elements.
Inventors: |
Davis, Ruel Emmett; (St.
Charles, MO) ; Joiner, Matthew Alan; (Fenton,
MO) |
Correspondence
Address: |
John S. Beulick, Esq.
Armstrong Teasdale LLP
Suite 2600
One Metropolitan Sq.
St. Louis
MO
63102
US
|
Family ID: |
25305308 |
Appl. No.: |
09/849206 |
Filed: |
May 4, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
09849206 |
May 4, 2001 |
|
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|
09102100 |
Jun 22, 1998 |
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6227913 |
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Current U.S.
Class: |
439/76.2 |
Current CPC
Class: |
H02B 1/18 20130101; H01H
2085/209 20130101; H01R 31/085 20130101; Y10S 439/949 20130101;
H01H 2085/208 20130101; H01R 9/2491 20130101; H01H 85/0026
20130101; H01H 85/205 20130101; H01H 85/2045 20130101 |
Class at
Publication: |
439/76.2 |
International
Class: |
H01R 012/00; H05K
001/00 |
Claims
What is claimed is:
1. A power distribution block assembly comprising: an insulative
body comprising at least a first modular body section and a second
modular body section; at least one electrically conductive bus
member having a longitudinally-extending base and a plurality of
terminal blades extending from said base, said base having a site
for electrical connection to a power source and comprising a
longitudinally elongated U-shape channel defined by opposite legs,
said plurality of terminal blades extending from said legs, said
terminal blades including a plurality of sites for electrical
connection to a plurality of removable circuit elements; and a
plurality of separate connector elements contained within said
body, each of said connector elements being configured to engage a
terminal blade of said bus with a terminal of a respective one of
said removable circuit elements.
2. A power distribution block assembly in accordance with claim 1,
said insulative body comprising at least a first end section, a
second end section, and a middle section engaged to said first end
section and to said second end section.
3. A power distribution block assembly in accordance with claim 1
wherein said first modular body section and said second modular
body section are configured for snap-fit engagement to one
another.
4. A power distribution block assembly in accordance with claim 1
wherein each of said first and second modular body sections
comprise a plurality of electrical access openings providing access
to said sites of said terminal blades.
5. A power distribution block assembly in accordance with claim 4
wherein said first modular body section comprises a male coupling
and said second modular body section comprises a female coupling,
said male and said female coupling configured for connection to one
another to form said body.
6. A power distribution block assembly in accordance with claim 4
wherein said first modular body and said second modular body are
configured for connection to one another with a tongue and groove
arrangement.
7. A power distribution block assembly comprising: an insulative
body comprised of a plurality of modular sections connected to one
another; a plurality of electrically conductive bus members, each
having a longitudinally extending base and a plurality of terminal
blades extending from said base, said base defining a site for
electrical connection to a power source, said terminal blades
defining a plurality of sites for electrical connection to a
plurality of removable circuit elements; a plurality of separate
connector elements contained within said body, each of said
connector elements being configured to engage a terminal blade of
said bus with a terminal of a respective one of said removable
circuit elements.
8. A power distribution block assembly in accordance with claim 7
wherein said modular sections comprises at least a first end
section, at least one middle section, and at least a second end
section.
9. A power distribution block assembly in accordance with claim 8
wherein said middle section comprises a male end and a female end
for connection to another of said plurality of modular
sections.
10. A power distribution block assembly in accordance with claim 9
wherein said male end of said middle section overlaps a female end
of another of said plurality of modular sections.
11. A power distribution block assembly in accordance with claim 8
further comprising at least two middle sections.
12. A power distribution block assembly in accordance with claim 7
wherein each of said modular sections comprises a plurality of
electrical connector openings, said plurality of openings of each
said section being less in number than said plurality of sites of
said terminal blades.
13. A modular body for a power distribution block assembly
including: at least one electrically conductive bus member having a
longitudinally-extending base and a plurality of terminal blades
extending from said base, the base having a site for electrical
connection to a power source and having a longitudinally elongated
U-shape channel defined by opposite legs, a plurality of terminal
blades extending from the legs, and the terminal blades including a
plurality of sites for electrical connection to a plurality of
removable circuit elements, said body comprising: a first body
section fabricated from an insulative material and comprising a
first number of electrical connection openings therein for
connection to the sites of the terminal blades; a second body
section fabricated from an insulative material and comprising a
second number of said electrical connections opening therein for
connection to the sites of the terminal blades; each of said first
and second body sections configured for snap-fit engagement to one
another to accommodate the plurality of sites of the terminal
blades of the bus member.
14. A modular body in accordance with claim 13 wherein each of said
first and second body sections includes first and second legs for
containing a plurality of separate connector elements, each of said
connector elements being configured to engage a terminal blade of
the bus with a terminal of a respective one of the removable
circuit elements.
15. A modular body in accordance with claim 13 wherein said body
comprises a at least a first end section, at least one middle
section and at least a second end section.
16. A modular body in accordance with claim 15 wherein said first
end section comprises a male end, said second end section comprises
a female end, and said middle section comprises a male end a female
end, said male and female ends of said respective sections
configured for snap-fit engagement to one another.
17. A modular body in accordance with claim 16 wherein said male
ends comprise a tongue and said female ends comprise a groove.
18. A modular body in accordance with claim 17 wherein said male
and female ends overlap one another.
19. A modular body in accordance with claim 13 wherein said number
of openings of said first body section is equal to said number of
openings of said second body section.
20. A modular body in accordance with claim 13 further comprising
an organizing tray disposed about said first and second number of
electrical connection openings.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation in part application of
U.S. application Ser. No. 09/102,100 filed Jun. 22, 1998.
BACKGROUND OF THE INVENTION
[0002] This invention relates to power distribution blocks in
general. In particular, the invention relates to a fuse block
having a common power bus.
[0003] Power distribution blocks are commonly used in the art to
collect a plurality of circuit elements, such as fuses, in one
central location.
[0004] Several fuse blocks are presently available as snap-together
modules that form a multifused panel. These snap-together modules
are excessively large when a large number of fuses are to be held
in the block. The modules also involve costly, labor intensive
assembly.
[0005] Existing fuse block designs also commonly require the user
to individually wire each circuit within the block for power input.
When it is desired to power more than one circuit with the same
power source, a jumper is installed for this purpose. These
multiple wiring procedures, and the installation of a jumper, are
costly, labor intensive, and time consuming to the user. In
addition, added circuits require the use of larger gauge wiring in
order to handle the additional amp load. The use of larger gauge
wire is costly, difficult to handle, and requires more panel space
to mount the fuse block.
[0006] Another problem with existing designs is the inability to
protect the fuse block components from contamination, especially
from liquids. Although "splash covers" are available for some
existing designs, these covers are in the form of additional
components that must be bolted in place. This type of splash cover
poses certain disadvantages in that it requires additional panel
space to be secured, and presents an additional labor cost for
installation.
[0007] U.S. Pat. No. 4,944,691 to Morach discloses a holder for
removable circuit elements. The holder includes a metal bus bar
having a plurality of fuse holders formed integrally therewith.
Output terminals are provided which extend laterally from the bus
bar. A cover member is provided that includes openings in the top
for insertion of fuses.
[0008] U.S. Pat. No. 4,599,679 to Baader discloses a fuse bus bar
assembly that includes a bus bar formed as two separate components
that are stacked on top of each other. The bus bar components
include oppositely bent tangs that cooperate to receive fuse
terminals for electrical connection therewith. A cover member is
provided that includes a plurality of openings for receipt of
fuses. This construction requires rather precise formation and
assembly in order for the tangs to properly receive and mate with
the fuse terminals. If one tang is misformed or damaged, it may be
necessary to replace the entire bus bar component. In addition, the
housing and cover do not serve to effectively isolate the circuit
elements or fuses from contaminants.
[0009] U.S. Pat. No. 5,438,310 to Ikari discloses a fuse box formed
by a plurality of separate components that are mechanically
attached to one another. This construction is overly complex,
costly to manufacture, and less compact when compared to the
present invention.
[0010] U.S. Pat. No. 4,842,534 to Mobley et al. discloses a
fuse/bus bar assembly having a plurality of (female) terminal
members attached thereto. The physical attachment of the terminal
members to the bus bar represents an increase in cost and labor
over the construction of the present invention.
BRIEF SUMMARY OF THE INVENTION
[0011] In an exemplary embodiment of the invention, a power
distribution block assembly includes an insulative body having at
least a first modular body section and a second modular body
section, and at least one electrically conductive bus member having
a longitudinally-extending base and a plurality of terminal blades
extending from the base. The base of the bus member has a site for
electrical connection to a power source and a longitudinally
elongated U-shape channel defined by opposite legs. A plurality of
terminal blades extend from the legs of the channel and include a
plurality of sites for electrical connection to a plurality of
removable circuit elements. A plurality of separate connector
elements are contained within the body, and each of the connector
elements are configured to engage a terminal blade of the bus with
a terminal of a respective one of the removable circuit
elements.
[0012] The modular construction of the insulative body facilitates
use of a wide range of bus bars and different numbers of poles in a
compact, easily assembled, low cost unit. The insulative body
includes at least a first end section, a second end section, and a
middle section engaged to the first end section and to the second
end section. The modular sections are configured for snap-fit
engagement to one another, and each of the sections include a
plurality of electrical access openings providing access to
respective sites of the terminal blades of the conductive bus
member.
[0013] The modular body sections include male and female couplings
configured for connection to one another to form an appropriately
sized body to accommodate a specified bus bar or bus bars for power
input. A tongue and groove arrangement securely connects the
sections to one another, and, by adding or subtracting middle
sections to the modular body, a wide range of power distribution
blocks for accommodating different bus bars and having different
numbers of poles is facilitated in a low cost, versatile, easy to
assemble system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is an exploded perspective view of a power
distribution block constructed according to an embodiment of the
present invention.
[0015] FIG. 2 is a bottom perspective view of power distribution
block of one embodiment of the present invention.
[0016] FIG. 3 is a perspective view of a power bus bar constructed
according to the principles of the present invention.
[0017] FIG. 4 is a bottom perspective view of a power distribution
block body constructed according to the principles of the present
invention.
[0018] FIG. 5 is a top perspective view of the power distribution
block body of FIG. 4;
[0019] FIG. 6 is a partial top view of the power distribution block
of FIG. 5 having a plurality of connector elements housed therein,
and an associated removable circuit element.
[0020] FIG. 6A is a partial perspective view of an alternative
embodiment of a removable circuit element.
[0021] FIG. 7 is a perspective view of the power bus bar of FIG. 3
in combination with an electrical connector element.
[0022] FIG. 8 is a perspective view of a female connector element
utilized in connection with the present invention.
[0023] FIG. 9 is a perspective view of the tray element illustrated
in FIG. 1.
[0024] FIG. 10 is a perspective view of a power distribution block
body as shown in FIG. 1, in combination with a female fuse clip
locking member constructed according to the present invention.
[0025] FIG. 11 is a perspective view of a power distribution block
with an attached tether cover constructed according to the present
invention.
[0026] FIG. 11A is a detailed perspective view of a portion of the
cover member FIG. 11.
[0027] FIG. 12 is a top perspective view of another embodiment of a
power distribution block.
[0028] FIG. 13 is an exploded view of the power distribution block
shown in FIG. 12.
[0029] FIG. 14 is an perspective view of a first end portion of the
power distribution block shown in FIGS. 11 and 12.
[0030] FIG. 15 is an perspective view of a middle portion of the
power distribution block shown in FIGS. 11 and 12.
[0031] FIG. 16 is an perspective view of a second end portion of
the power distribution block shown in FIGS. 11 and 12.
[0032] FIG. 17 is a bottom perspective view of the power
distribution block shown in FIGS. 11 and 12.
DETAILED DESCRIPTION OF THE INVENTION
[0033] Certain components of a power distribution block assembly 1
according to the present invention are illustrated generally in
FIG. 1. An insulative body 5 receives a tray member 15. A
"splash-proof" cover 10 is mounted to the body 5 to enclose the
interior thereof.
[0034] The insulative body 5, in one embodiment, is preferably
constructed as a unitary member. The term "unitary" is intended to
mean a one-piece monolithic member. The body 5 can be constructed
from any suitable material. One preferred material is a strong,
heat-resistant, chemical resistant plastic.
[0035] The body 5 may have one or more mounting flanges 125, each
having an aperture 127, with a threaded insert disposed therein
(FIG. 5) for receiving a suitable fastener (not shown). The body 5
is also provided with an upstanding sidewall 115 and in interior
compartment 120.
[0036] As illustrated in FIG. 2, one or more electrically
conductive bus members 30, 35 are inserted into the bottom of
insulative body 5. The power distribution block assembly 1 may
include a plurality of electrically conductive bus members 30, 35,
each having a means of connecting to a power source. One such means
is a threaded stud 40, although it is possible to use other types
of connectors. If there are more than one conductive bus members
30, 35, they are separated from each other by a gap or an
electrically-insulative spacer element 37. Through the use of
separate conductive bus members 30, 35, it is possible to provide
power to the power distribution block assembly 1 from a plurality
of different sources.
[0037] For example, in vehicular applications it is often
advantageous to provide power to certain circuit elements from a
power source (e.g., a battery) at all times, and to provide power
to other circuit elements only at certain times e.g., when the
ignition system of the vehicle is activated. While the embodiment
illustrated in FIG. 2 shows a 12-pole bus 30 in combination with a
4-pole bus 35, it should be understood that the number of poles
provided on each of the bus members 30, 35, can vary widely
depending upon the requirements of the particular system being
powered. By way of example, 4, 6, 8, 10, 12, 16, 20 and 24-pole
configurations are also possible. Also, more than two bus members
may be utilized. Alternatively, a single bus bar member may be
utilized.
[0038] Details of a representative bus member 45 constructed
according to the present invention are illustrated in FIG. 3. Bus
bar members 30, 35 may be constructed in the manner described below
with respect to representative bus bar 45. The bus member 45 is
made of any suitable electrically conductive material. Preferably,
the material is capable of carrying relatively high currents. One
such suitable material is C1100 alloy, which is 99.9% pure copper
with 1/2 hard temper. The bus member 45 has a longitudinally
extended U-shaped base 55. One or more apertures 50 are provided in
the base 55 to receive a suitable electrical connector, such as
threaded stud 40. An aperture 50 may be located at either end of
base 55. A stud 40 can be located at either end, thereby providing
the most convenient location for connection to a power source and
facilitating connection. The base 55 may optionally include one or
more holes 70 through which a suitable fastener (not shown) may
pass to affix the bus member 45 to the body 5. A plurality of power
output wires 25 are attached to the block assembly 1 in a manner to
be described more fully below.
[0039] As shown in FIG. 3, the conductive bus member 45 also
includes a plurality of terminal blades 60 that extend from the
legs of the U-shaped base 55. A plurality of attachment formations,
preferably in the form of undercuts 65 are provided in the legs of
the U-shaped base 55 at the location of each terminal blade 60. The
construction of the bus member 45 provides several advantages. For
example, the terminal blades 60 permit attachment of a plurality of
circuit elements, as will be described more fully below. These
circuit elements may be powered by a single electrical connection
to the base 55, instead of resorting to jumpers or individual
circuit wiring schemes. The bus member 45 can carry high currents
with a close spacing of circuit elements without overheating,
thereby providing reliability and compactness.
[0040] The manner in which the bus member 45 can be attached to the
insulative body 5 is further explained by reference to FIG. 4.
[0041] Slots 75 are provided in the bottom of body 5 to receive the
terminal blades 60. These slots 75 can be numbered to facilitate
identification of the individual circuit elements attached to each
blade 60.
[0042] An attachment projection 80 is formed integrally with the
body 5 and is located at each slot 75 to provide a snap-fit
engagement with the undercuts 65 of the bus member 45. A bus
attachment beam 90 may also be provided along the bottom of the
body 5. Optionally, holes 85 can be provided in the beam 90. Holes
85 correspond with optional fastener holds 70 in base 55 of the bus
member 45 and accept suitable fasteners (not shown) for providing
added means of securing bus member 45 to the body 5.
[0043] The body 5 further includes a pair of integrally formed
parallel legs 95. Legs 95 define a plurality of open chambers 100
which permit the passage of connector elements, as will be more
fully explained below.
[0044] The other side of body 5 is described by reference to FIG.
5. Located within the interior compartment 120 are a plurality of
passageways 140 for the receipt of a load-side terminal of a
removable circuit element. A plurality of pockets 150 are also
provided within the interior compartment 120. Pockets 150 house a
plurality of connector elements 155 (FIGS. 6 and 7). Terminal blade
slots extend from the bottom of body 5 and are in communication
with the bottom of pockets 150.
[0045] As illustrated in FIGS. 6 and 7, a separate connector
element 155 is located in each pocket 150. Terminal blades 60
extend up into pockets 150 through slot openings 75. Each connector
element 155 fits over a terminal blade 60 in a manner best
illustrated in FIG. 7. Connector elements 155 are formed of any
suitable material, such as stainless steel. An input side terminal
178 of a removable circuit element 177 can then be received between
the spring fingers 160 of the connector element 155 and the
terminal blade 60. In this manner a direct electrical connection is
made between a terminal 178 and terminal blade 60. Connector
element 155 is not intended to be a current-carrying element.
[0046] A load-side female connector 165 is received within each of
the passageways 140. See FIG. 8. A load-side terminal 179 can be
received between two bent over contacts 175 of the female connector
165. A pair of locking members 170 project laterally from the
female connector 175 and rest upon ledges 145 formed within pockets
140. This construction prevents the female connector 16 from
passing through the bottom of open chambers 100. A plurality of
retention tabs 167, 169 are provided at the lower end connector
element 165 which receive and retain the output wires W in a manner
common in the art.
[0047] The female terminal connector 165 illustrated in FIG. 8 is
similar to a "Packard" type connecting terminal. However, the
present invention is not dependent upon the specific type of
load-side connector utilized. Numerous connector designs are
possible for connection to the load-side terminal 179.
[0048] In one embodiment, removable circuit element 177 can
comprise a fuse element. Numerous types of fuse elements can be
utilized. By way of example, an ATC.TM. type fuse (available from
Cooper Industries-Bussmann Division) may be effectively utilized
with the power distribution block of the present invention.
[0049] In an alternative embodiment, the removable circuit
elements(s) may comprise a circuit breaker element 177A which is
schematically illustrated in FIG. 6A.
[0050] As best illustrated in FIGS. 1 and 9, a tray 15 may also be
located within the interior compartment 120 of body 5. Tray 15 is
preferably formed of an insulative material similar to that of body
5. Tray 15 is provided with a plurality of retaining projections
185 that are received with a snap-fit in a plurality of
corresponding retaining apertures 135 in the body 5 (FIG. 5).
Proper insertion of the tray 15 within the internal compartment 120
can be ensured by providing at least one retaining projection 185
which mates with a corresponding retaining aperture 135 only when
tray 15 is properly oriented relative to the body 5.
[0051] The tray 15 is provided with a plurality of openings 190
which receive the removable circuit elements 177. The openings 190
may be numbered so as to correspond with the numbering of terminal
blades slots 75, through facilitating identification of the
circuits and circuit elements 177.
[0052] Openings 190 also include enlarged area 195 which permits
the insertion of a removal tool (not shown) to withdraw load-side
connector 165.
[0053] By this construction, tray 15 guides and organizes the
removable circuit elements 177. Tray 15 also serves to enclose and
retain box connectors 155 and female connectors 165.
[0054] In an alternative embodiment, the power distribution block
assembly 1 may include an additional means for securing the female
connector elements 165. One possible supplemental locking member
200 is illustrated in FIG. 10. Locking member 200 can be formed of
any suitable material, such as insulative material similar to that
of body 5. Locking member 200 includes a plurality of bosses 205
that are adapted to fit within corresponding slot head recessed
openings 105 formed in side surfaces 110 of legs 95. Locking
projections 207 include snap-fit tongues 210 that retain the
locking member 200 once it is inserted into the openings 105.
Locking projections 207 are configured to engage an engagement
portion or shelf 180 formed on the female connector 165 (FIG. 8).
Therefore, locking member 200 acts to further retain female
connectors 165 within the open chambers 100.
[0055] Another aspect of the present invention involves providing a
cover member 10 which effectively seals off the interior
compartment 120 of the body 5, thereby preventing contamination of
the circuit elements 177 and electrical connections housed therein.
Cover member 10 can be formed of any suitable material, such as an
insulative material similar to that of body 5.
[0056] As best illustrated in FIGS. 1 and 11, cover 10 may include
a plurality of retaining projections 13 that are received with a
snap-fit engagement in corresponding apertures 16 provided within
body 5. Cover 10 may also have an integral tether 11. Tether 11 has
a aperture 12 located at an end thereof for receiving a suitable
fastener F. By this construction, the cover is prevented from being
lost or dropped when removed. Cover member 10 may further be
provided with side walls in the form of a U-shaped channel 14. The
U-shaped channel 14 is constructed to receive the upstanding
sidewall 115 of the body 5 therein. The arrangement forms an
effective seal between the cover 10 and sidewall 115 that
effectively excludes contaminants from the interior compartment
120, especially splashed liquids. Although not specifically
illustrated, cover 10 may also include means to further facilitate
grasping and removal, such as tabs, projections, recesses, etc.
[0057] FIG. 12 is a top perspective view of another embodiment of a
power distribution block 300 including an insulative body 302 and
an organizing tray 304 including indicia (not shown) such as
numbers for making desired electrical connections with power
distribution block 300. More specifically tray 304 at least
partially defines a plurality of openings 306 which receive
removable circuit elements, such as elements 177 shown and
described above. Tray openings 306, in one embodiment, are numbered
so as to correspond with the numbering of terminal blade slots (not
shown in FIG. 12 but similar to slots 75 shown in FIG. 4) through
facilitating identification of the circuits and circuit elements
177.
[0058] As desired, power distribution block 300 further includes a
protective cover (not shown in FIG. 12), such as splash proof cover
10 illustrated and described above. An upstanding sidewall 308
extends around an upper perimeter of insulative body 302 for
sealing engagement with the protective cover, and further to define
an interior compartment 310 for making electrical connections.
[0059] Unlike the unitary one-piece monolithic insulative body 5 of
power distribution block 1 (shown and described above), insulative
body 302 of power distribution block 300 is modular and includes a
first end section 312, three middle sections 314, and a second end
section 316 engaged to one another to aggregately form internal
compartment 310 that receives tray 304. As is evident from FIG. 12,
power distribution block contains twenty openings 306 for
electrical connections, or in other words a 20-pole distribution
block is provided to accommodate a power input bus (not shown in
FIG. 12) or combination of power input buses (not shown in FIG. 12)
having twenty terminal blades, such as terminal blades 60 of bus
bar 45 (shown and described above in relation to FIG. 3). Modular
body sections 312, 314, 316 allow snap-together assembly of housing
302 to accommodate different bus bar members or additional bus bar
members and therefore to provide a practically unlimited number of
pole variations for a specific application. As will become evident
below, each body section 312, 314, 316 includes two pairs of
connection openings, or four openings apiece, and the total number
of poles in power distribution block 300 may be varied by adding or
subtracting middle sections 314 from the assembly.
[0060] FIG. 13 is an exploded view of modular power distribution
block body 302 illustrating assembly of end section 312, middle
sections 314 and end section 316. As depicted in FIG. 13, end
section 316 is coupled to a middle section 314 to form a first
subassembly 320, and two middle sections 314 are coupled to one
another to form a second subassembly 322. As used herein, the term
subassembly simply refers to a joining of two modular body
sections. It is understood that body sections 312, 314, 316 could
be assembled in any order to form a number of different
combinations or subassemblies of modular body sections. The
assemblies illustrated in FIG. 13 are therefore set forth for
illustrative purposes only and are in no way intended to limit the
invention to any particular combination of subassemblies in forming
power distribution block body 302.
[0061] Referring again to FIG. 13, first subassembly 320 and second
subassembly 322 are positioned for engagement to one another, and
second subassembly 322 is positioned for engagement to end section
312. An overlapping tongue and groove arrangement 324 is employed
to secure body sections 314 to end sections 312, 316, and
subassemblies 322 and 324 to one another. A male tongue member 326
is provided on leading edges of respective body sections for
engagement with a female groove or slot 328 of adjacent sections.
Tongues 326 extend beneath leading edges of adjacent sections are
received in complementary slots (not shown In FIG. 13) inside
grooves 328 of mating sections so that the mating ends of adjacent
sections slightly overlap one another and form a secure,
structurally stable fit with one another. In one embodiment,
sections 312, 314, 316 snugly fit together with a resistance fit
that facilitates assembly and disassembly by hand and without
employing tools.
[0062] FIGS. 14-16 illustrate individual modular body sections 312,
314, 316, respectively. Referring to FIG. 14, end section 312
includes four electrical connection openings 306, a wrap-around
upstanding wall portion 340 forming an end portion of compartment
320 (shown in FIG. 12), and tongues 326 extending from leg
extensions 342 for coupling to a modular body middle section 314.
Parallel legs 344 depend below wall portion 340 to define a
plurality of open chambers (not shown in FIG. 14 but similar to
chambers 100 shown and described above in relation to FIG. 4) which
permit the passage of electrical connector elements, such as those
described above.
[0063] While end section 312 is illustrated with four electrical
connection openings 306, it is contemplated that end sections 312
having greater or fewer than four electrical connection openings
may be employed without departing from the scope of the present
invention.
[0064] Referring to FIG. 15, middle section 314 includes four
electrical connection openings 306, parallel upstanding wall
portions 346 further defining compartment 320 (shown in FIG. 12)
when middle section 314 is coupled to an end section 312 or 316. A
first engagement side 347 of middle section 314 includes a pair of
coupling tongues 348 extending from leg extensions 350 for coupling
to another modular body middle section 314, or to an end section
316, further described below. A second engagement side 352 includes
grooves or slots 328 (shown in FIG. 13) extending opposite tongues
348 for connection to another middle section 314 or to an end
section 312 (shown in FIG. 14). Parallel legs 354 depend below wall
portions 346 to define a plurality of open chambers (not shown in
FIG. 15 but similar to chambers 100 shown and described above in
relation to FIG. 4) which permit the passage of electrical
connector elements, such as those described above.
[0065] While middle section 314 is illustrated with four electrical
connection openings 306, it is contemplated that middle sections
314 having greater or fewer than four electrical connection
openings may be employed without departing from the scope of the
present invention. In addition, when more than one middle section
is employed for a given application, such as body 302 illustrated
in FIGS. 12 and 13, middle sections 314 need not have the same
number of openings. Thus, for example, a middle section having four
electrical connection openings 306 may be employed with a middle
section having six electrical connection openings 406. Thus, larger
and smaller middle sections relative to one another may be
separately employed or utilized in combination with one another to
effectively meet the needs of specified applications.
[0066] Referring to FIG. 16, end section 316 includes four
electrical connection openings 306, a wrap-around upstanding wall
portion 360 forming an end portion of compartment 320 (shown in
FIG. 12), and groove 362 for accepting tongues 354 of middle
section 314 (shown in FIG. 15) or for accepting tongues 326 of
another end section 312. Parallel legs 364 depend below wall
portion 360 to define a plurality of open chambers (not shown in
FIG. 14 but similar to chambers 100 shown and described above in
relation to FIG. 4) which permit the passage of electrical
connector elements, such as those described above.
[0067] While end section 316 is illustrated with four electrical
connection openings 306, it is contemplated that end sections 316
having greater or fewer than four electrical connection openings
may be employed without departing from the scope of the present
invention.
[0068] It should now be evident that modular body sections 312,
314, 316 may be connected to one another by coupling respective
male and female ends of the sections 312, 314, 316. Assembling
sections 312, 314, 316 to one another, as shown in FIG. 13
therefore results in a rigid body 302 (shown in FIG. 12) having a
selected number of electrical connections openings 306 and an
associated number of open chambers depending from an opposite side
of body 302 for passage of connector elements. Once modular body
302 is assembled in this fashion, power distribution block assembly
300 (shown in FIG. 12) is operable substantially as described above
in relation to power distribution block 1 set forth above.
[0069] FIG. 17 is a bottom perspective view of power distribution
block 300 including an assembled modular body 302 and first and
second input bus bars 380, 382 coupled to an underside of modular
housing 302 with threaded fasteners 384, and further including
respective stud terminals 386, 388 for power input connections via
nuts 390, 392. It is appreciated that other connection schemes and
fasteners could be employed in lieu of terminal studs 386, 388 in
alternative embodiments without departing from the scope of the
present invention.
[0070] As noted above, first and second bus bars 380, 382
facilitate providing power to certain circuit elements from a power
source (e.g., a battery) at all times, and to provide power to
other circuit elements only at certain times, such as for vehicle
ignition systems.
[0071] In the illustrated embodiment, bus member 380 is similar to
bus bar member 45 (shown and described above in relation to FIG. 3)
but includes six terminal blades 60, while bus member 382 is
similar to bus bar member 45 (shown and described above in relation
to FIG. 3) but includes fourteen terminal blades 60. Thus a total
of twenty terminal blades are provided to 20-pole operation of
power distribution block 300 through twenty access openings 306
(shown in FIG. 12) in an opposite side of modular body 302. It is
recognized, however, that the modular nature of body 302
facilitates a wide range of bus member options to accommodate a
particular application.
[0072] For example, an additional middle section 314 could be
employed to accommodate for instance, a first bus bar having
sixteen terminal blades and a second bus bar having eight terminal
blades for 24-pole operation of the power distribution block. As
another example, one of middle sections 314 could be subtracted
from power distribution block 300 to form a 16-pole distribution
block having, for instance, two input bus bars having eight
terminal blades apiece. In yet another example, two additional
middle sections 314 could be added to power distribution block 300
to accommodate a third power input bus bar having eight terminal
blades, in addition to bus bars 380, 382. Finally, the modular
construction of body 102 could be equally employed with a variety
of single power bus input bars. While only a few examples are set
forth, it should now be realized that modular body 302 permits a
practically unlimited number of pole combinations for different
applications in a simple, compact, easily assembled, and low cost
package.
[0073] While the invention has been described in terms of various
specific embodiments, those skilled in the art will recognize that
the invention can be practiced with modification within the spirit
and scope of the claims.
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