U.S. patent application number 10/616791 was filed with the patent office on 2004-04-08 for electrical fuse relay box, apparatus, method and articles of manufacture.
This patent application is currently assigned to Tyco Eletro-Eletronica Ltda.. Invention is credited to De Faria, Pedro La Martine, Roosdorp, Joannes Willen Maria, Vicenza, Aguinaldo.
Application Number | 20040067691 10/616791 |
Document ID | / |
Family ID | 31188606 |
Filed Date | 2004-04-08 |
United States Patent
Application |
20040067691 |
Kind Code |
A1 |
Vicenza, Aguinaldo ; et
al. |
April 8, 2004 |
Electrical fuse relay box, apparatus, method and articles of
manufacture
Abstract
A pre-assembled electrical fuse relay box comprising an upper
frame having an upper compartment and a first locking receiver, a
plurality of electrical components pre-assembled within the upper
compartment, a lower frame having a lower compartment and a second
locking receiver, wherein the lower frame is dimensioned and
configured to engage the upper frame, a plurality of connector
modules pre-assembled within the lower compartment, wherein the
connector modules are dimensioned and configured to electrically
engage electrical wires, spacers positioned within the lower
compartment for locking the electrical wires, an upper cover
pivotally mounted on the upper compartment, and a lower cover
pivotally mounted on the lower compartment, wherein the upper cover
comprises a first locking member dimensioned and configured to
engage the first locking receiver, and wherein the lower cover
comprises a second locking member dimensioned and configured to
engage the second locking receive.
Inventors: |
Vicenza, Aguinaldo;
(Braganca Paulista, BR) ; De Faria, Pedro La Martine;
(Braganca Paulista, BR) ; Roosdorp, Joannes Willen
Maria; (Braganca Paulista, NL) |
Correspondence
Address: |
TYCO ELECTRONICS CORPORATION
4550 NEW LINDEN HILL ROAD, SUITE 450
WILMINGTON
DE
19808
US
|
Assignee: |
Tyco Eletro-Eletronica
Ltda.
Braganca Paulista
BR
|
Family ID: |
31188606 |
Appl. No.: |
10/616791 |
Filed: |
July 10, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60399649 |
Jul 30, 2002 |
|
|
|
Current U.S.
Class: |
439/620.27 |
Current CPC
Class: |
H01H 85/2045 20130101;
B60R 16/0238 20130101; H01H 2085/208 20130101; H01R 2201/26
20130101 |
Class at
Publication: |
439/621 |
International
Class: |
H01R 013/68 |
Claims
What is claimed is:
1. An electrical fuse box comprising: an upper frame; a plurality
of electrical components pre-assembled within said upper frame; a
lower frame, wherein said lower frame is dimensioned and configured
to engage said upper frame; a plurality of connector modules
pre-assembled within said lower frame, wherein said connector
modules are dimensioned and configured to electrically engage
electrical wires; an upper cover mounted on said upper frame; and a
lower cover mounted on said lower frame.
2. The electrical fuse box of claim 1, wherein said electrical
components comprise relays, circuit breakers, J-case fuses, and
blade fuses.
3. The electrical fuse box of claim 1, further comprising spacers
positioned within said lower frame for locking said electrical
wires.
4. The electrical fuse box of claim 1, wherein said connector
modules make an electrical connection with said electrical
components.
5. The electrical fuse box of claim 1, wherein each of said upper
frame and lower frame comprises at least one locking receiver.
6. The electrical fuse box of claim 5, wherein each of said upper
cover and said lower cover comprise a locking member dimensioned
and configured to engage said locking receiver of said upper frame
and said lower frame, respectively.
7. The electrical fuse box of claim 1, wherein each of said upper
cover and said lower cover are pivotally mounted on said upper
frame and said lower frame, respectively.
8. An electrical fuse relay box comprising: an upper frame having
an upper compartment; a plurality of electrical components
pre-assembled within said upper compartment; a lower frame having a
lower compartment, wherein said lower frame is dimensioned and
configured to engage said upper frame; a plurality of connector
modules pre-assembled within said lower compartment, wherein said
connector modules are dimensioned and configured to electrically
engage electrical wires; an upper cover mounted on said upper
compartment; and a lower cover mounted on said lower
compartment.
9. The electrical fuse relay box of claim 8, wherein said
electrical components comprise relays, circuit breakers, J-case
fuses, and blade fuses.
10. The electrical fuse relay box of claim 8, further comprising
spacers positioned within said lower compartment for locking said
electrical wires.
11. The electrical fuse relay box of claim 8, wherein said
connector modules make an electrical connection with said
electrical components.
12. The electrical fuse relay box of claim 8, wherein each of said
upper frame and said lower frame comprises at least one locking
receiver.
13. The electrical fuse relay box of claim 12, wherein each of said
upper cover and said lower cover comprise a locking member
dimensioned and configured to engage said locking receiver of said
upper frame and said lower frame, respectively.
14. The electrical fuse relay box of claim 8, wherein each of said
upper cover and said lower cover are pivotally mounted on said
upper frame and said lower frame, respectively.
15. An electrical fuse relay box comprising: an upper frame having
an upper compartment and a first locking receiver; a plurality of
electrical components pre-assembled within said upper compartment;
a lower frame having a lower compartment and a second locking
receiver, wherein said lower frame is dimensioned and configured to
engage said upper frame; a plurality of connector modules
pre-assembled within said lower compartment, wherein said connector
modules are dimensioned and configured to electrically engage
electrical wires; spacers positioned within the lower compartment
for locking said electrical wires; an upper cover pivotally mounted
on said upper compartment; and a lower cover pivotally mounted on
said lower compartment, wherein said upper cover comprises a first
locking member dimensioned and configured to engage said first
locking receiver, and wherein said lower cover comprises a second
locking member dimensioned and configured to engage said second
locking receiver.
16. The electrical fuse relay box of claim 15, wherein said
electrical components comprise relays, circuit breakers, J-case
fuses, and blade fuses.
17. The electrical fuse relay box of claim 15, wherein said
connector modules make an electrical connection with said
electrical components.
18. A method of pre-assembling an electrical fuse relay box, said
electrical fuse relay box comprising an upper frame attached to a
lower frame, said upper frame having an upper compartment and said
lower frame having a lower compartment, said method comprising:
mounting a plurality of electrical components within said upper
compartment in a pre-locked position; mounting a plurality of
connector modules and spacers within said lower compartment,
wherein said connector modules being configured for electrically
engaging electrical wires; positioning an upper cover on said upper
compartment; positioning a lower cover on said lower compartment;
locking said electrical wires into position with said spacers;
pushing said electrical components into a set position; and
attaching said upper frame to said lower frame.
19. The method of claim 18, wherein said electrical components
comprise relays, circuit breakers, J-case fuses, and blade
fuses.
20. The method of claim 18, wherein said connector modules make an
electrical connection with said electrical components.
21. The method of claim 18, wherein each of said upper frame and
said lower frame comprises at least one locking receiver.
22. The method of claim 21, wherein each of said upper cover and
said lower cover comprise a locking member dimensioned and
configured to engage said locking receiver of said upper frame and
said lower frame, respectively.
23. The method of claim 18, further comprising locking said
electrical fuse box by pivotally mounting said upper cover and said
lower cover on said upper frame and said lower frame, respectively.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Patent Application No. 60/399,649 filed Jul. 30, 2002, the complete
disclosure of which is hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention generally relates to electrical fuse
relay boxes, apparatus, methods, and articles of manufacture, and
more particularly to pre-assembled electrical fuse relay boxes for
mounting in the engine or passenger compartment of a motor
vehicle.
BACKGROUND OF THE INVENTION
[0003] Fuse boxes are utilized in many applications, one example of
which being motor vehicles. Typically, fuse boxes are placed in
within a designated area on a motor vehicle, such as, for example,
under the hood within the engine compartment or under the dashboard
and near the foot area of the interior of the motor vehicle.
Generally, fuse boxes accept house electrical fuses for individual
electrical load components consumers within the motor vehicle, such
as individual lights or small electrical equipment items, and also
accept house electrical fuses for large cables strands carrying
larger amounts of current splitting off from the fuse box for
servicing entire load sections within the motor vehicle. Moreover,
fuses are also used in automotive electrical systems to protect
circuits against potential damage caused by overload conditions,
such as a result of multiple electrical load requirements and
surges occurring simultaneously. Usually, fuses for various
circuits are collected together at a confluence point, known as a
fuse box, a fuse relay box, a power distribution block, or a
junction block.
[0004] Conventionally and as practiced in the art, a fuse box is a
molded plastic structure containing electrical terminals, one or
more bus bars, and various other electrical components, such as
circuit breakers and diodes integrated together. The fuses are
maintained in terminal sockets integrally molded on the outer
surface of the fuse box. Typical automotive fuses have a generally
rectangular plastic body with a pair of contacts extending from one
end, and when the fuse is fully inserted into its respective
terminal socket, the contacts engage electrical terminals inside of
the fuse box to complete a circuit.
[0005] However, each electrical subcomponent that is incorporated
into a conventional electrical fuse relay box, such as a plastic
box, relays, fuses (e.g., mini, maxi, J-Case), circuit breakers,
and diodes, etc. (collectively referred to as "electrical
components"), are often ordinarily manufactured separately and
purchased individually from different suppliers, and must be
assembled collectively to be integrated within a finished fuse
relay box. This process of assembly is often time consuming,
expensive, and susceptible to errors in connections, and overall
deficient quality. Moreover, conventional fuse boxes are generally
manufactured without covers, and therefore are susceptible to
damage.
[0006] Therefore, there is a need for a novel pre-assembled fuse
box system having all electrical components preset to their correct
position, and which may be readily mounted within motor vehicle
compartments quickly, easily, and without error. Moreover, there is
a need for a system that enables customers to receive all of the
electrical components already incorporated in the fuse box without
requiring further assembly of the electrical components to form a
unified device.
SUMMARY OF THE INVENTION
[0007] In view of the foregoing and other problems, disadvantages,
and drawbacks of the conventional fuse boxes the present invention
has been devised, various embodiments and it is an object of the
present invention to provide a structure for aof a pre-assembled
electrical fuse relay box are disclosed herein.
[0008] In accordance with one exemplary embodiment, a pre-assembled
electrical fuse relay box, and a method of manufacturing the same
is disclosed, comprising an upper frame having an upper compartment
and a first locking receiver, a plurality of electrical components
pre-assembled within the upper compartment, a lower frame having a
lower compartment and a second locking receiver, wherein the lower
frame is dimensioned and configured to engage the upper frame, a
plurality of connector modules pre-assembled within the lower
compartment, wherein the connector modules are dimensioned and
configured to electrically engage electrical wires, spacers
positioned within the lower compartment for locking the electrical
wires, an upper cover pivotally mounted on the upper compartment,
and a lower cover pivotally mounted on the lower compartment,
wherein the upper cover comprises a first locking member
dimensioned and configured to engage the first locking receiver,
and wherein the lower cover comprises a second locking member
dimensioned and configured to engage the second locking receiver.
Moreover, the electrical components comprise relays, circuit
breakers, J-case fuses, and blade fuses. Additionally, the
connector modules make an electrical connection with the electrical
components.
[0009] One advantage of embodiments disclosed herein is that
electrical components such as relays, fuses, diodes, and circuit
breakers are already pre-assembled and are mounted in such a manner
that they can easily be fixed into their final position. Therefore,
the customer is not required to use special diagnostic equipment to
assure that the components and connector modules are properly
mounted and in the correct position.
[0010] Another advantage of embodiments disclosed herein is that an
electrical fuse relay box is provided that includes both an upper
cover and a lower cover, which allows mounting in the engine
compartment of a car or other motor vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The foregoing will be better understood from the following
detailed description with reference to the drawings, in which:
[0012] FIG. 1 is a perspective view of an electrical fuse relay box
according to one embodiment of the present invention;
[0013] FIG. 2 is a schematic diagram of the electrical fuse relay
box of FIG. 1;
[0014] FIG. 3 is a schematic diagram of the electrical fuse relay
box of FIG. 1 shown in the closed position; and
[0015] FIG. 4 is a flow diagram illustrating an exemplary method in
accordance with the present invention.
DETAILED DESCRIPTION
[0016] An embodiment of the present invention provides a fuse box
having the capability to have electrical components pre-assembled
and preset in such a manner that they can be easily fixed into
their correct position, and which may also be readily mounted
within a compartment quickly, easily, and without error.
[0017] Referring now to the drawings in detail, and more
particularly to FIGS. 1 through 4, there are shown exeplary
embodiments of the structures and methods according to the present
invention. FIGS. 1 through 3 illustrate an electrical fuse relay
box 100 comprising a plurality of electrical components 20
including relays 1, a circuit breaker 2, J-case fuses 3, and blade
fuses 4 collectively pre-assembled, preset, and mounted in a
pre-locked position within an upper frame 5, wherein the upper
frame 5 is pivotally attached to an upper cover 7. Moreover,
connector modules 6 are mounted in a final position within a lower
frame 9, wherein the lower frame 9 is pivotally attached to a lower
cover 8.
[0018] Preferably, the electrical fuse box 100 comprises an upper
frame 5 and lower frame 9, a plurality of electrical components 20
pre-assembled within the upper frame 5, a plurality of connector
modules 6 pre-assembled within the lower frame 9, an upper cover 7
mounted on the upper frame 5, and a lower cover 8 mounted on the
lower frame 9, wherein the connector modules 6 are dimensioned and
configured for electrically engaging electrical wires.
[0019] The upper frame 5 and lower frame 9 each comprise a locking
receiver 32, 33, respectively, and each of the upper cover 7 and
lower cover 8 comprise a locking member 34, 35, respectively,
dimensioned and configured to engage the locking receiver 32, 33,
respectively. Moreover, the upper cover 7 is pivotally mounted on
the upper frame 5, and likewise, the lower cover 8 is pivotally
mounted on the lower frame 9.
[0020] Preferably, the upper frame 5 includes an upper compartment
75 and the lower frame 9 includes a lower compartment 76, wherein
the upper compartment 75 houses the electrical components 20, and
the lower compartment 76 houses a plurality of connector modules 6.
Moreover, the upper frame 5 comprises a pair of generally elongated
sidewalls 51, 52, which are positioned opposite one another, and
are separated by a pair of end walls 30, 31. Similarly, the lower
frame 9 comprises a pair of generally elongated sidewalls 61, 62,
which are positioned opposite one another, and are separated by a
pair of end walls 70, 71.
[0021] As illustrated in FIGS. 2 and 3, end wall 30 comprises a
lock catch (locking receiver) 32, which is angled to provide a
stable locking unit mechanism for the fuse box 100 upon closure.
Moreover, end wall 30 on the upper frame 5 includes a generally
U-shaped locking bracket 80, which engages a corresponding bracket
guide 81 located on end wall 70 of the lower frame 5. Upon uniting
the upper frame 5 with the lower frame 8, the locking bracket 80
slides within the bracket guide 81, and engages the lock catch 33
to provide stable closure of the fuse box 100.
[0022] As further illustrated in FIGS. 2 and 3, end walls 31, 71
each comprise at least one pivot hinge 38, 68, respectively,
dimensioned and configured to receive a corresponding pivot member
36, 66, respectively. At least one pivot member 36 is positioned on
the upper cover 7 and pivotally mounts to pivot hinge 38, thereby
allowing the upper cover 7 to articulate from an open to closed
position. Likewise, at least one pivot member 66 is positioned on
the lower cover 8 and pivotally mounts to pivot hinge 68, thereby
allowing the lower cover 8 to articulate from an open to closed
position.
[0023] The lower cover 8 further includes at least one locking clip
35, fixably attached to the free end 55 of the lower cover 8 in
this embodiment, wherein the locking clip 35 protrudes outwardly
from the lower cover 8. Furthermore, an opening 40 is provided in
the lower cover 8 to allow for wires (not shown) to be guided into
the fuse box 100. The locking clip 35 is dimensioned and configured
to provide stable union with end wall 70 upon closure of the lower
cover 8 upon the lower frame 9.
[0024] The upper cover 7 further includes a locking member 34,
fixably attached to the free end 65 of the upper cover 7 in this
embodiment, wherein the locking member 34 comprises a protruding
lip 42 for engaging the lock catch 32 of the end wall 30 of upper
frame 9. Upon closure of the upper cover 7, the lip 42 engages lock
catch 32, and the upper cover 7 becomes locked. Unlocking the upper
cover 7 is accomplished by engaging a bias member 43, which is
positioned opposite the lip 42 on the locking member 34.
[0025] Connector modules 6 are included in a pre-assembled, and
preferably unlocked position, as best shown in FIG. 2. The
connector modules 6 are used for connecting the fuse box 100 with
electrical power and are capable of receiving wire terminals (not
shown) for wire connections.
[0026] According to the present embodiment, upper cover 7 is
preferably supplied in a closed position and will be opened in
order to push electrical components 20 into their final position,
after terminals with wires (not shown) have been inserted. In this
embodiment, the connector modules 6 in the lower frame 9 are
preferably in their final position, and separate spacers 10 are
provided to lock the terminals with wires, after their insertion.
The lower cover 8 is preferably supplied coupled and closed and
will be opened to insert terminals with wires. Lower cover 8 is
also known as a wire dress to those of ordinary skill in the art,
because it protects and guides the wires after harness assembly.
Again, lower cover 8 need only be opened to insert the electrical
wires into the terminals.
[0027] The electrical components 20 in upper frame 5 are located in
their final position but only in a pre-locked position, and are
retained in place by upper frame 5 and by upper cover 7. The
connector modules 6, which will receive the terminals with wires
(not shown), are already in their final and locked position in the
lower frame 9. Preferably, the lower cover 8 is pre-assembled
coupled to the lower frame 9. Thereafter, the upper frame 5 and
lower frame 9 are engaged using the locking clips 35 and locking
bracket 80 as seen in FIG. 3, thereby locking electrical components
20 into their final position to achieve an electrical
connection.
[0028] A method of pre-assembling an electrical fuse relay box 100
is illustrated in the flow diagram shown in FIG. 4. The method
comprises mounting a plurality of electrical components in a
pre-locked position within the upper compartment 75 of the upper
frame 5 of the fuse box 100 at step 200. Second, a plurality of
connector modules 6 and spacers 10 are mounted within the lower
compartment 76 of the lower frame 9 of the fuse box 100 at step
210, wherein the connector modules 6 are configured for
electrically engaging electrical wires, and wherein the connector
modules 6 make an electrical connection with the electrical
components 20. Next, an upper cover 7 is positioned on the upper
compartment 75 of the upper frame 5 at step 220. Then, a lower
cover is positioned on the lower compartment 76 of the lower frame
9 at step 230. Thereafter, the spacers 10 lock the electrical wires
into position at step 240. Next, the electrical components 20 are
pushed into a set position at step 250. Finally, the electrical
fuse relay box 100 is locked by attaching the upper frame to the
lower frame at step 260.
[0029] The present embodiment has an advantage over conventional
fuse frames whereby electrical components such as relays, fuses,
diodes, and circuit breakers are already mounted in their final
position. Therefore, the customer is not required to use special
diagnostic equipment to assure that the components and connector
modules are properly mounted and in the correct position.
[0030] Also, unlike the conventional systems, the electrical fuse
relay box 100 of the present embodiment includes both an upper
cover 7 and a lower cover 8, that enable mounting in the engine
compartment of a car or other vehicles.
[0031] Although this invention has been described with reference to
particular embodiments, it will be appreciated that many variations
may be resorted to without departing from the spirit and scope of
this invention as set forth in the appended claims.
* * * * *