U.S. patent application number 11/853146 was filed with the patent office on 2009-03-12 for power distribution bus bar.
Invention is credited to Christopher J. Darr.
Application Number | 20090067122 11/853146 |
Document ID | / |
Family ID | 40365525 |
Filed Date | 2009-03-12 |
United States Patent
Application |
20090067122 |
Kind Code |
A1 |
Darr; Christopher J. |
March 12, 2009 |
POWER DISTRIBUTION BUS BAR
Abstract
In one aspect of the present invention, a power distribution bus
bar that includes a first conductive bus bar configured to receive
power from a power source. A plurality of stamped finger-like
clamping members are integrally formed to the first conductive bus
bar and configured to distribute power to a secondary high power
bus bar within a power distribution box. The plurality of stamped
finger-like clamping members apply a compression force to the
secondary high power bus bar for securing the secondary high power
bus bar within the power distribution box.
Inventors: |
Darr; Christopher J.;
(Livonia, MI) |
Correspondence
Address: |
MACMILLAN, SOBANSKI & TODD, LLC
ONE MARITIME PLAZA-FIFTH FLOOR, 720 WATER STREET
TOLEDO
OH
43604
US
|
Family ID: |
40365525 |
Appl. No.: |
11/853146 |
Filed: |
September 11, 2007 |
Current U.S.
Class: |
361/626 |
Current CPC
Class: |
H01R 13/11 20130101;
H01R 9/226 20130101; H01R 13/05 20130101 |
Class at
Publication: |
361/626 |
International
Class: |
H02B 1/26 20060101
H02B001/26 |
Claims
1. A power distribution bus bar comprising: a first conductive bus
bar configured to receive power from a power source; a plurality of
clamping members integrally formed to the first conductive bus bar
and configured to distribute power to a second conductive bus bar
within a power distribution box, wherein the plurality of clamping
members are formed as sets of clamping members, each set of
clamping members includes a first group of clamping members and a
second group of clamping members, and each respective clamping
member of the first group alternates with a respective clamping
member of the second group for applying a compression force to the
second conductive bus bar for securing the second conductive bus
bar within the power distribution box.
2. (canceled)
3. The power distribution bus bar of claim 1 wherein each set of
clamping members includes at least four respective clamping
members.
4. The power distribution bus bar of claim 1 wherein each of the
clamping members is arcuate shaped.
5. (canceled)
6. A power distribution box for distributing power from a power
source to vehicle electrical components, the power distribution box
comprising: a power distribution box housing; a detachable bus bar
disposed within the power distribution box housing, the detachable
bus bar including a plurality of fastenerless terminals for
distributing power to output devices, the plurality of fastenerless
terminals each having an integrated fuse for terminating power
across a respective fastenerless terminal during a power overload
condition; a plurality of housing connectors inserted within the
power distribution box housing configured to electrically couple
the plurality of fastenerless terminals to an output device
conduit; and a power distribution box bus bar for receiving power
from the power source, the power distribution bus bar includes a
plurality of like clamping members for distributing power to the
detachable bus bar, wherein the plurality of stamped finger like
clamping members secure the detachable bus bar within the power
distribution box housing.
7. The power distribution box of claim 6 wherein the housing
further comprises an electrically conductive stud that is
configured for attachment to an output conduit, wherein the
detachable bus bar further comprises a terminal having an aperture
for receiving the conductive stud, the terminal providing power to
the output conduit via the conductive stud.
8. The power distribution box of claim 7 wherein the conductive
stud is configured to secure the output conduit to the detachable
bus bar.
9. The power distribution box of claim 7 wherein the conductive
stud is configured to provide power to an alternator.
10. The power distribution box of claim 6 further comprising a
module housing configured to support the detachable bus bar,
wherein the module housing is configured to be inserted within the
power distribution box housing.
11. The power distribution box of claim 10 wherein the plurality of
housing connectors are detachable from the module housing.
12. (canceled)
13. The power distribution box of claim 6 wherein the module
housing includes locating studs for locating the plurality of
terminals of the bus bar on the module housing.
14. The power distribution box of claim 6 wherein the module
housing includes locating guides for locating the bus bar within
the module housing.
15. The power distribution box of claim 6 wherein the detachable
bus bar further includes a main body portion, wherein the main body
portion extends at substantially a right angle to the plurality of
fastenerless terminals for seating against the module housing.
16. A power distribution box for distributing power from a power
source to vehicle electrical components, the power distribution box
comprising: a power distribution box housing; a first bus bar
disposed within the power distribution box housing, the first bus
bar including a plurality of terminals for distributing power to
output devices, the plurality of terminals each having an
integrated fuse for terminating power across a respective terminal
during a power overload condition; a plurality of housing
connectors inserted within the power distribution box housing
configured to electrically couple the plurality of terminals to an
output device conduit; and a second bus bar for receiving power
from the power source, the second bus bar including a plurality of
clamping members for distributing power to the first bus bar,
wherein the plurality of clamping members secure the first bus bar
within the power distribution box housing.
17. The power distribution box of claim 16 wherein the plurality of
terminals are fastenerless terminals.
18. The power distribution box of claim 17 wherein the first bus
bar includes a fastening terminal having an aperture, and wherein
an electrically conductive stud is integrated within the power
distribution box housing and is configured for attachment to an
output conduit, wherein the conductive stud is electrically
inserted through the aperture for electrically coupling the output
conduit to the fastening terminal.
19. The power distribution box of claim 17 further comprising a
module housing configured to support the first bus bar, wherein the
module housing is configured to be inserted within the power
distribution box housing, wherein the plurality of housing
connectors are detachable from the module housing.
20. The power distribution box of claim 16 wherein the plurality of
clamping members are formed as sets of clamping members, each set
of clamping members includes a first group of clamping members and
a second group of clamping members, each respective clamping member
of the first group alternates with a respective clamping member of
the second group, wherein each of the sets of clamping members
apply a compression force to the first bus bar for securing the
first bus bar within the power distribution box.
21. The power distribution box of claim 16 further comprising a
module housing configured to support the first bus bar, wherein the
module housing is configured to be inserted within the power
distribution box housing.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
REFERENCE TO A SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM
LISTING COMPACT DISC APPENDIX
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] This invention relates in general to a vehicle power
distribution box, and more specifically, to a serviceable power
distribution module of the power distribution box.
[0006] 2. Background of Related Art
[0007] A vehicle power distribution box is typically a relay block
connected to a vehicle power source such as a battery for
distributing power to various components of the vehicle. The power
distribution box typically includes a casing having an open and
closeable serviceable region. Power-supply conduits are typically
routed through the bottom of the power distribution box and are
connected to a bus bar in the casing via bolts. Power is
distributed from the bus bar wires. Terminals connected to the ends
of the wires are secured in the bottom of the box and are
positioned in spaced relation to output terminals for electrical
connection to the output terminals. Fuses or relays used to
electrically connect the input terminals and output terminals are
serviceable from the top of the power distribution box for
electrically connecting the input power terminals to the output
power terminals. Typically, high power connections, for example
connections from the battery, require a terminal bolt-fastening
operation. Such an operation creates assembly and servicing
inefficiencies.
BRIEF SUMMARY OF THE INVENTION
[0008] The present invention has the advantage of providing a
serviceable connection to a high power distribution module within
the power distribution box. Each of the components within the
module are detachable from one another minimizing the use of
threaded fasteners thereby increasing assembly efficiency and
service efficiency.
[0009] In one aspect of the present invention, a power distribution
bus bar that includes a first conductive bus bar configured to
receive power from a power source. A plurality of stamped
finger-like clamping members are integrally formed to the first
conductive bus bar and configured to distribute power to a
secondary high power bus bar within a power distribution box. The
plurality of stamped finger-like clamping members apply a
compression force to the secondary high power bus bar for securing
the secondary high power bus bar within the power distribution
box.
[0010] In yet another aspect of the present invention, a power
distribution box is provided for distributing power from a power
source to vehicle electrical components. The power distribution box
includes a power distribution box housing and a fastenerless
detachable high power bus bar that includes a plurality of
high-current fastenerless terminals for distributing power to
output devices. The plurality of high-current fastenerless
terminals each have an integrated fuse for terminating power across
a respective high-current fastenerless terminal during a power
overload condition. A plurality of housing connectors is inserted
within the housing configured to electrically couple the plurality
of high-current fastenerless terminals to an output device conduit.
A power distribution box busbar receives power from the power
source. The power distribution busbar includes a plurality of
stamped finger-like clamping members for distributing power to the
detachable high power bus bar. The plurality of stamped finger-like
clamping members secures the detachable high power bus bar within
the power distribution box.
[0011] Various objects and advantages of this invention will become
apparent to those skilled in the art from the following detailed
description of the preferred embodiment, when read in light of the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 is a plan view of a vehicle engine compartment of the
present invention.
[0013] FIG. 2 illustrates a perspective view of a power
distribution box of the present invention.
[0014] FIG. 3 illustrates a perspective view of a power
distribution module of the present invention.
[0015] FIG. 4 illustrates an exploded view of the power
distribution module of the present invention.
[0016] FIG. 5 illustrates a perspective view of a detachable high
power bus bar of the present invention.
[0017] FIG. 6 illustrates a perspective view of a power
distribution bus bar of the present invention.
[0018] FIG. 7 illustrates a side view of the detachable high power
bus bar of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0019] Referring now to the drawings, there is illustrated in FIG.
1 a vehicle 10 having a power distribution box (PDB) 12. The PDB 12
distributes power provided by a vehicle's power source, such as a
vehicle battery, shown generally at 14.
[0020] The vehicle power source 14 is electrically connected to the
PDB 12 via a power source conduit 16. The PDB 12 distributes power
to various electrical devices within the engine compartment and
throughout the vehicle 10. Examples of such electrical devices for
which power may be provided from the PDB 12 include, but are not
limited to, an alternator 18, an electric assist steering motor 20,
and a smart power distribution junction box 22.
[0021] FIG. 2 illustrates a perspective view of the PDB 12. The PDB
12 includes a plastic, non-conductive housing 24. Electrical
conduits are routed through the bottom of the housing 24 for
coupling to terminals disposed within the housing 24. Respective
input and output terminals disposed within the housing 24 are
electrically connected to one another via a fusing device such as a
relay or a fuse (not shown). The PDB 12 includes a plurality of
mounting sockets 26 disposed in its upper surface 28. Respective
female input terminals and female output terminals are secured
within the mounting sockets 26. A respective fuse or relay is
mounted within a respective set of mounting sockets 26 for
distributing power from a respective input terminal to a respective
output terminal.
[0022] The PDB 12 further includes a power distribution module 30.
The power distribution module 30 is a detachable modular electronic
device for receiving high input power from the vehicle battery 14
(shown in FIG. 1) and for distributing high power to a plurality of
output devices. The power distribution module 30 is secured to the
PDB 12 by a plurality of stamped finger-like clamping members 31
which will be discussed in detail below. The plurality of stamped
finger-like clamping members 31 provides a fastenerless connection
between the PDB 12 and the power distribution module 30. The
substantial portion of the electrical connections to the power
distribution module 30 is secured by fastenerless connections.
Providing fastenerless connections to the power distribution module
30 reduces the assembly inefficiencies and service
inefficiencies.
[0023] Referring now to both FIGS. 3 and 4, the power distribution
module 30 includes a module housing 34 made of a non-conductive
material such as plastic. A conductive stud 36 is secured to the
module housing 34. The conductive stud 36 may be secured to the
module housing 34 as part of an insert mold operation or the module
housing 34 may include a slot for capturing the conductive stud 36
to the module housing 34.
[0024] A detachable high power bus bar 38 having a plurality of
conductive terminals is secured to the module housing 34 via
locating studs 39 which will be discussed in detail below.
Alternatively, the detachable high power bus bar 38 may be secured
to the PDB by a method other than the locating studs.
[0025] FIG. 5 illustrates an enlarged view of the detachable high
power bus bar 38. The detachable high power bus bar 38 is
preferably formed by a stamping operation. The detachable high
power bus bar 38 includes a main body portion 43 and the plurality
of conductive terminals. The main body portion 43 is formed at a
substantially right angle to the plurality of conductive terminals
for seating against the module housing 34 (shown in FIG. 3). A
first high-current fastenerless terminal 46 distributes power
received from the plurality of finger-like clamp members 31 to one
of the output devices shown in FIG. 1. The first high-current
fastenerless terminal 46 includes a fuse 48 integrated within the
second high-current fastenerless terminal 46 for protection against
a power overload condition. A second high-current terminal 50
distributes the power received from the second high-current
fastenerless terminal 44 to the alternator 18 (shown in FIG. 1).
The second high-current terminal 50 includes a fuse 52 integrated
within the second high-current terminal 50 for protecting against a
power overload condition. Alternatively, the detachable high power
bus bar 38 may include additional high-current fastenerless
terminals for distributing power to other various output devices.
In addition, the first and second high-current fastenerless
terminals 46 and 50 include apertures 53 for locating and securing
the respective terminals on the module housing 34 to the locating
studs 39.
[0026] Referring again to FIGS. 3 and 4, the second high-current
terminal 50 of the detachable high power bus bar 38 includes an
aperture 54 for receiving the conductive stud 36. A nut 56 secures
a high power output conduit 58 to the third high-current terminal
48 and conductive stud 36 for distributing power from the power
source 14 to the alternator 18 via the PDB 12 (shown in FIG. 1).
The locating studs 39 of the module housing 34 are aligned with the
apertures 53 of the plurality of terminals for locating and
securing the plurality of high current terminals of the detachable
high power bus bar 38 to the modular housing 34. The module housing
34 may also include locating guides 59 for locating the plurality
of terminals of the detachable high power bus bar 38 within the
module housing 34 during assembly.
[0027] A first plastic housing connector 60 is inserted within the
module housing 34 for coupling the first high-current fastenerless
terminal 46 to the power source conduit 16. The first plastic
housing connector 60 utilizes a snap-fit connection for securing
the first plastic housing connector 60 to the module housing 34.
The plastic housing connector 60 includes a first terminal
receiving end 62 for coupling to the first high-current
fastenerless terminal 46. The first plastic housing connector 60
further includes a second terminal receiving end 64 configured to
be coupled to the power source conduit 16. Alternatively, an
additional plastic housing connector may be inserted within the
housing for coupling additional respective high current
fastenerless terminals to respective output device conduits.
Moreover the plastic housing connector may include a plurality of
receiving slots for accommodating a plurality of high-current
fastenerless terminals.
[0028] FIG. 6 illustrates a perspective view of a power
distribution bus bar 70 including the plurality of finger-like
clamp members 31. The plurality of finger-like clamp members 31 are
segregated into sets of finger-like clamp members. As shown in FIG.
6, the power distribution bus bar 70 includes a first set 72 and a
second set 74. Alternatively, the power distribution bus bar 70 may
include additional sets to secure the detachable high power bus bar
38 to the power distribution bus bar 70. Each respective set of
finger-like clamp members include a plurality finger-like members,
preferably formed from a stamping operation, although other
processes may be used to form the plurality of finger-like members.
A respective set of finger-like members includes an upper group of
finger-like members 76 and an opposing lower group of finger-like
members 78. Each of the finger-like members have an arcuate shape
and are resilient for allowing the detachable high power bus bar 38
to be disposed between the upper group of finger-like members 76
and the lower group of finger-like members 78. Preferably each
respective finger-like member of the upper group 76 alternates with
a respective finger-like member of the lower group 78 for forming a
respective clamping member which allows an equal force to be
exerted on the attaching power bus bar 38 as it is inserted between
the upper group 76 and lower group 78. The resiliency of the each
respective finger-like member exerts a restorative force against
the detachable high power bus bar 38 thereby holding the detachable
high power bus bar 38 in compression between the first group 76 and
the second group 78.
[0029] FIG. 7 illustrates a side view detachable high power bus bar
38 coupled to the power distribution bus bar 70. A clamping section
80 of the detachable high power bus bar 38 is inserted between the
upper group 76 and the lower group 78 of a respective finger-like
clamp member. A compression force is exerted on the detachable
power bus bar 38 by the upper group 76 and lower group 78 for
securing the detachable power bus bar 38 therebetween. In addition
the secured connection between the plurality of finger-like
clamping members provides a tight electrical connection that
minimizes arcing across the two electrical distribution devices.
This slip fit connection between the power distribution bus bar 70
and the detachable high power bus bar 38 eliminates the use of
fasteners which reduces the overall cost of the electrical
distribution system.
[0030] The fastenerless connections provide for increased assembly
efficiency and service efficiency while providing a secure
attachment between the high power coupling devices. As a result,
the power source conduit and output device conduits may be easily
detached from the power distribution module. Moreover, the power
distribution module may be easily serviced if parts require
changing since module itself is easily removable from the PDB in
addition to the components being easily serviceable from the
housing of the power distribution module.
[0031] In accordance with the provisions of the patent statutes,
the principle and mode of operation of this invention have been
explained and illustrated in its preferred embodiment. However, it
must be understood that this invention may be practiced otherwise
than as specifically explained and illustrated without departing
from its spirit or scope.
* * * * *