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FIELD OF THE INVENTION
This invention relates to a method and to an apparatus for selectively
connecting electrical circuits and components, and more particularly to a
method and to an apparatus for fuseably protecting and for selectively
distributing electrical power to these circuits and components.
BACKGROUND OF THE INVENTION
Electrical circuit connection and power distribution assemblies, commonly
referred to as "junction boxes," are used within automobiles to provide a
convenient physical and electrical interface for the selective connection
between the various automobile electrical circuits and between these
circuits and various components, such as fuses and relays. Importantly,
these automobile junction boxes also allow for the relatively efficient
"troubleshooting" of these circuits by providing efficient access to the
circuitry as well as providing an efficient and selective coupling and
distribution of electrical power to these circuits and components. While
prior junction boxes provided such a desired circuit, component, and
electrical power distributive and connective interface, they suffered from
several drawbacks.
Particularly, due to the complexity and the number of the various
automobile circuits and components, prior junction boxes included and
required the formation of a multi-dimensional, non-uniform, and relatively
complicated stamped metal fret circuit pattern which required a relatively
large amount of time to create, was "statically" designed to operate only
with a unique circuit and component configuration, and was not capable of
being easily and dynamically modified. Typically, a new junction box
design was required for each new model of automobile that was produced and
for each model that was electrically modified from one year to the next,
thereby adding to the overall cost and complexity of modifying and
creating new automobile designs.
There is therefore a need for a new and improved junction box which may be
utilized by a wide variety of automobiles having different types, numbers,
and arrangements of electrical circuits and components, thereby reducing
the overall automobile production cost.
SUMMARY OF THE INVENTION
It is a first object of the invention to provide an assembly which
overcomes some or all of the previously delineated drawbacks associated
with prior electrical junction box assemblies.
It is a second object of the invention to provide an assembly which may be
used within a wide variety of automobiles.
It is a third object of the invention to provide a relatively efficient and
relatively cost effective method of manufacturing and/or creating
electrical connection and power distribution assemblies, and certain
terminal members contained within these assemblies.
According to a first aspect of the present invention, an electrical
connection and power distribution assembly is provided. The assembly
includes a dynamically configurable array of substantially identical
terminal members which cooperatively allow for the selective connection by
and between the various circuits and components of an automobile.
According to a second aspect of the present invention, an electrical
connection and power distribution assembly is provided. The assembly
includes a plurality of substantially identical terminal members, each of
the terminal members having a distributed plurality of circuit connection
portions. The terminal members are adapted to be arranged in an array of a
selected size. Electrical connections are made by and between the various
arrayed terminal members, and by and between the various automobile
circuits and terminal members, thereby selectively providing a desired
circuit connection and power distribution configuration.
According to a third aspect of the present invention, an electrical
connection and power distribution assembly is provided. The assembly
includes a plurality of substantially identical terminal members, each of
the terminal members including a generally thin conductive body having a
plurality of integrally formed and evenly spaced conductive blades
projecting from the body in a first direction and a plurality of
integrally formed and evenly spaced conductive receptacles which are
linearly coextensive to the blades and which project from the body in a
second direction; and a dielectric plate having a plurality of reception
slot apertures, each of the reception slot apertures receiving a unique
one of the plurality of blades.
According to a fourth aspect of the present invention, a method for
distributing electrical power to a circuit is provided. The method
includes the steps of providing a plurality of terminals each having a
conductive lead frame and multiple termination portions integrally formed
with the lead frame; coupling one of the multiple termination portions of
a first of the plurality of terminals to the circuit; coupling one of the
multiple termination portions of a second of the plurality of terminals to
a source of electrical power; and selectively connecting the first and
second of the plurality of terminals, thereby providing and distributing
electrical power to the circuit.
These and other features, advantages, and objects of the invention will
become apparent by reference to the following specification and by
reference to the following drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective, fragmented, and unassembled view of an electrical
connection and power distribution assembly made in accordance with the
teachings of the preferred embodiment of the invention;
FIG. 2 is a perspective assembled view of a single portion of the assembly
shown in FIG. 1;
FIG. 3 is sectional view of the portion shown in FIG. 2 taken along view
line 3--3;
FIG. 4 is an unassembled perspective view of one of the terminal members
shown in FIG. 1 illustrating the connection of the terminal member to a
typical fuse, terminal member connector, and heat sink member;
FIG. 5 is a side view of a terminal member made in accordance with an
alternate embodiment of the invention;
FIG. 6 is an end view of the terminal member shown in FIG. 5;
FIG. 7 is perspective view of one of the terminal members shown in FIG. 1
illustrating the creation of two electrical circuits from this terminal
member;
FIGS. 8(a) and 8(b) are two typical electrical circuits used within a
typical junction box;
FIGS. 9(a) and 9(b) respectively and without limitation illustrate one
electrical terminal member configuration which selectively produces the
electrical circuits shown in FIGS. 8(a) and 8(b);
FIG. 10 is a top view of a nested terminal member configuration made in
accordance with the teachings of an alternate embodiment of the invention;
FIG. 11 is a perspective view of a terminal member made in accordance with
the teachings of another alternate embodiment of the invention;
FIG. 12 is a perspective view of a terminal roll made in accordance with
the teachings of the preferred embodiment of the invention;
FIG. 13 is a perspective view of a terminal member made in accordance with
the teachings of yet another alternate embodiment of the invention; and
FIG. 14 is a top view of an alternate terminal nesting arrangement.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE INVENTION
Referring now to FIGS. 1-4, there is shown an electrical connection and
power distribution assembly 10 made in accordance with the teachings of
the preferred embodiment of the invention. As shown, assembly 10 includes
an array of substantially identical electrically conductive terminal
members 12, 14, each having a relatively thin electrically conductive body
or "lead frame" 16 including a plurality of integrally formed, evenly
spaced, substantially identical, relatively thin, and electrically
conductive blades 18-40, and electrically conductive receptacles 42-64.
Blades 18-40 and receptacles 42-64 are integrally formed on opposed
surfaces of the body 16, are mutually and linearly coextensive with the
body 16, and respectively project from body 16 in opposite directions.
Particularly, each receptacle 42-64 is paired with a unique one of the
blades 18-40 and surfaces 41 and 43 are co-planar with body 16. In an
alternate terminal embodiment, shown best in FIGS. 5 and 6, blades 18-40
and receptacles 42-64 orthogonally project in opposed directions from body
16. Alternatively, body 16 is substantially eliminated from the terminals
shown in FIGS. 5 and 6 and portions 42 and 18 are directly connected.
Further, as shown best in FIG. 13, terminal 290 may be formed by a folding
a metal member 300 and by placing a series of each of the substantially
rectangular conductive receptacles 304 on one of the side surfaces 302 of
the member 300 and forming a series of conductive blades 306 which connect
to a unique one of the receptacles 304 disposed upon surface 302. The
folding of member 300, in the foregoing manner, increases the electrical
conductivity of the terminal 290 over that provided by thinner terminal
designs, such as those shown in FIG. 1.
Assembly 10 further includes at least one dielectric board or surface 66
having a plurality of substantially identical slotted apertures 68 which
are adapted to frictionally receive a unique one of the blades 18-40 and
to allow the received blades 18-40 to pass through the board 66.
Particularly, the width of each of the slots 68 is slightly smaller than
the width of flange 70 which is integrally formed upon each blade 18-40.
Each flange 70 is adapted to pass through board 66 and to substantially
prevent the undesired detachment of the blades 18-40 from the board 66.
Circuit assemblies or automobile "harnesses" 99, 101, each having a
plurality of conductive busses or circuits 103, which traverse through an
automobile and connect to the various electrical components of an
automobile, each have a portion which is selectively stacked beneath board
66. Each stacked circuit assembly portion 99, 101 is separated by a
dielectric surface 105 which may be integrally formed upon one surface of
assembly 99 which contacts assembly 101. Blades 18-40, after traversing
through board 66, selectively, physically, and electrically connect to
these busses 103 of circuit assemblies 99, 101 by soldering or other
conventional electrical connection methodologies.
Assembly 10 also includes a generally hollow cover 72 having substantially
identical flexible and resilient fasteners 74 which are integrally formed
on opposed longitudinal ends of the cover 72, which each have a flexible
and resilient hook portion 76, and which are each adapted to be
frictionally inserted into a unique slotted aperture 78 resident within
and through board 66. Particularly, each hook portion 76 is adapted to
pass through board 66 and to engage the under surface 67 of board 66 in
order to substantially prevent the undesired detachment of cover 72 from
board 66. Further, each cover 72 includes a pair of substantially similar
flexible and resilient members 80, 82 on a first side portion. Each member
80, 82 includes a flexible and resilient respective hook portion 84, 86
and each member 80, 82 is adapted to be frictionally inserted through a
unique slotted aperture 88 in the board 66. Hook portions 84, 86 contact
surface 67 and cooperate with portions 76 to substantially prevent the
detachment of cover 72 from its placement upon board 66. Each cover 72
further includes a pair of substantially similar slots 90 on a second side
surface 97. As shown best in FIG. 3, each portion 90 is adapted to
selectively, frictionally, and removably receive a unique one of the
members 80, 82, thereby physically coupling two adjacent covers 72.
Further, each cover includes a plurality of top surface slotted apertures
92 which allow for communication into the hollow interior of cover 72.
As best shown in FIG. 1, each cover 72 is adapted to contain two linearly
coextensive terminals 12, 14 which are secured to board 66 in the
previously described manner. It should be realized that each cover 72 may
be of a different shape and size from that shown in the Figures and that
each cover 72 may be adapted to contain different numbers of members 12,
14 other than that shown in the Figures. One of the advantages of this
invention is that assembly 10 may be created or configured to have a
selectable number of members 12 and 14, thereby being adapted for use in a
wide variety of automobiles having varying numbers, types, and
arrangements of circuits and components. Each of these members 12, 14 is
therefore a "building block" which may be selectively added to other
substantially identical "building blocks" to form a junction assembly 10
of a desired size and configuration. Each slotted aperture 92 overlays a
unique one of the receptacles 42-64 of each of the terminals 12, 14 and
selectively and frictionally receives and allows one conductive terminal
94 of a protective fuse 93 or other type of electrical component, such as
"dummy fuse" 95 or a relay to be selectively and removably inserted into a
selected one of the receptacles 42-64 of a selected one of the terminal
members 12, 14.
As shown, each receptacle 42-64 includes substantially identical,
resilient, and opposed slotted ridges 96, 98 which cooperatively,
resiliently, and removably fix and position the received terminal 94 into
engagement with body 16 of a respective member 12, 14. In this manner,
electrical power or an electrical signal which is applied to the terminal
12, 14 is applied and conducted to retained terminal 94. Each terminal
member 12, 14 further includes substantially identical flange members 91,
107 integrally formed with body 16, orthoganally projecting in opposite
directions away from body 16, and formed on opposite side surfaces of each
of the blades 18-40. Flanges 91, 107 engage surface 69 of board 66 as the
blades 18-40 pass through respective board apertures 68 and cooperatively
position the longitudinal axis of symmetry of each blade 18-40 at a
substantial right angle with respect to the planar board surface.
Terminals 12, 14 may be selectively, physically, and electrically connected
by the use of an electrically conductive connector 100 which is adapted to
be soldered to each terminals 12, 14 or to frictionally receive one unique
end portion 102 of each terminal in each integrally formed slot 104, 106.
Terminals 12, 14 may also be physically and electrically connected by
conductive circuit trace 108 appearing and/or integrally formed upon a
circuit assembly 110 to which blades 18-40 may be selectively coupled.
Trace 108 may be connected to a conventional "heat sink" allowing heat to
be dispersed from the connected terminal assembly 12, 14. Alternatively, a
conventional "heat sink" device 117 may be selectively attached to the
blades 18-40 and coupled to a "heat sink" bus 108 in order to cool blades
18-40 and substantially prevent thermal malfunction. Circuit assembly 110
may also include an electrical power bus 111 which is electrically coupled
to a source of electrical power 113 and which is selectively coupled to
one or more of the blades 1840. The selective connection of the some or
all of the blades 18-40 to the bus 111 allows electrical power to be
"sourced", provided, and/or distributed to one or more of the terminal
members 12, 14 and to the various components which are resident within the
receptacles 42-64. Importantly, the use of multiple terminating blades
18-40 allows the assembly 10 to "spread out" the current thereby
substantially ensuring that the net electrical power "drop", and
concomitant resistive heat loss at each blade bus contacting interface
remain relatively low. Hence, the blades 18-40 are not readily susceptible
to heat or thermal fatigue or malfunction. As shown best in FIG. 7, the
physical and electrical continuity of each terminal 12, 14 may also be
selectively broken, cut, or severed in order to form two or more
physically and electrically distinct circuits 112, 114.
Assembly 10 therefore may be "dynamically" configured to meet the
electrical connection and power distribution needs of a wide variety of
automobiles. First, a designer may dynamically adjust the size of assembly
10 by merely adding or removing "building block" terminals 12, 14.
Secondly, the designer may dynamically configure and/or reconfigure the
electrical circuit and component connections by selectively coupling
certain blades 18-40 to certain circuit assemblies 99, 101, 110; by
selectively disconnecting certain blades 18-40 from certain circuit
assemblies 99, 101, 110; by selectively severing some portions of each or
one of the terminals 12, 14; by selectively connecting some of the
terminals 12, 14; and by selectively placing and/or removing certain
components 93, 95 from certain of the receptacles 4264. Assembly 10
therefore represents a "toolkit" having an array of "parts" which allow
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