Abstract:
An electrical connector box includes a connector box case configured to guide a wire along a side of the case, a relay terminal having pinch blades on one end thereof, the pinch blades having a slot therebetween and configured to hold the wire in the slot. The connector box also includes one of a female and male connector on the other end of the relay terminal, the one of a female and male connector configured to connect to a terminal of at least a relay, a fuse and a connector. The slot is configured to be welded closed, or the pinch blades are configured to weldingly secure the wire thereto.

Description:
FIELD OF THE INVENTION 
   The present invention relates to an electrical connector box to which branch wires of an automotive wiring harness are connected, and more particularly, to an electrical connector box in which the wires connecting internal circuits do not extend downward from the connector box in loop configurations. 
   DESCRIPTION OF THE RELATED ART 
   As illustrated in  FIG. 9A , a conventional electrical connector box of the type to which the branch wires of an automotive wiring harness are attached, incorporates relay receptacles  3 , connector receptacles  4 , and fuse receptacles  5 , all of which are located on the upper side of case  2 . The connections of the internal circuits of electrical connector box  1  are formed through vertical busbars (not shown in the figure) and wires ‘w’. 
   In the known connector box, all of the circuits within electrical connector box  1  are configured in a way that would allow their connection through a vertical busbar, but the density of the various components installed within the limited space of case  2  in electrical connector box  1  makes this type of structure difficult to attain. Therefore, power distribution circuits that carry a large current flow are structured to include a vertical busbar, and other circuits are structured so as to include wires ‘w’. 
   As illustrated in  FIG. 9B , in a case where wire ‘w’ is used to connect the internal circuits of electrical connector box  1 , wire ‘w’ must be of sufficient length to allow the insertion of friction terminals  6 , which are attached to both ends of wire ‘w’, upward into terminal receptacles  2   a  from the floor of case  2 . After terminals  6  are completely inserted into receptacles  2   a , wire ‘w’ assumes a loop shape that hangs downward from case  2 . 
   The downward extending loop formed by wire ‘w’ hanging from the bottom of electrical connector box  1  poses a problem in that it can snag on other components during shipment and also when the connector box is installed to the vehicle, thus resulting in reduced assembly efficiency and the possibility of damage to the wires and connector box, a factor that can adversely affect the quality of the connector box. 
   SUMMARY OF THE INVENTION 
   The present invention, having taken the aforesaid problems into consideration, provides an improved structure for an electrical connector box in which wires do not extend downward from the connector box, thus improving both assembly efficiency and the quality of the connector box. 
   The present invention provides an electrical connector box having at least one of a relay, a fuse and a connector. The connector box has a connector box case configured to guide a wire along a side of the case, a relay terminal having pinch blades on one end thereof, the pinch blades having a slot therebetween and configured to hold the wire in the slot. Also provided is one of a female and male connector on the other end of the relay terminal, the one of a female and male connector configured to connect to a terminal of the at least one of a relay, a fuse and a connector. The slot may be configured to be welded closed, or the pinch blades may be configured to weldingly secure the wire thereto. Further, the side of the case may be an underside. 
   In one aspect of the invention, the electrical connector box may be a relay block, and the case may include a plurality of wire guides on the side of the case, the plurality of wire guides configured to guide the wire along the side of the case. Each end of the wire may be respectively connected to pinch blades of respective relay terminals. The other end of the relay terminal may be a female terminal or a male terminal configured to join the terminal of the at least one a relay, a fuse and a connector. 
   In another aspect of the invention, a busbar configured to conduct a first electrical current may be provided, wherein the wire is configured to conduct a second electrical current weaker than the first electrical current. 
   In a further aspect of the invention, the case may further include a holding cavity configured to selectively hold one of the relay terminal and a terminal connected to a wire end. 
   The present invention also provides a method for routing an electrical wire along a surface of an electrical connector box. The method includes holding the wire in a slot located between pinch blades on an end of a relay terminal, connecting one of a female and male terminal provided on the other end of the relay terminal to a terminal of at least one of a relay, a fuse and a connector, and welding the slot closed. 
   In another aspect of the invention, the method may include guiding the wire along the electrical connector box via a plurality of wire guides on the electrical connector box, wherein the electrical connector box is a relay block, and the connecting includes connecting a female terminal of the relay terminal to the terminal of the at least one of a relay, a fuse and a connector. 
   In a further aspect of the invention, the method may include conducting a first electrical current through a busbar, and conducting a second electrical current weaker than the first electrical current, through the wire. 
   An additional aspect of the invention may include selectively holding, in a holding cavity, one of the relay terminal and a terminal crimped to a wire end. 
   The present invention also provides a method for routing an electrical wire along a surface of an electrical connector box. The method includes holding the wire in a slot located between pinch blades on an end of a relay terminal, connecting one of a female and male terminal provided on the other other end of the relay terminal to the terminal of the at least one of a relay, a fuse and a connector, and welding the wire to the pinch blades. 
   Still yet another aspect of the invention may include guiding the wire along the electrical connector box via a plurality of wire guides on the electrical connector box, wherein the electrical connector box is a relay block, and the connecting includes connecting a female terminal of the relay terminal to the terminal of the at least one of a relay, a fuse and a connector. 
   Another aspect of the invention may include conducting a first electrical current through a busbar, and conducting a second electrical current weaker than the first electrical current, through the wire. 
   An aspect may still yet include selectively holding, in a holding cavity, one of the relay terminal and a terminal connected to a wire end. 
   The present invention provides a structure for an electrical connector box in which electrical wires run along the underside of the connector box case, each of the wires being forcibly inserted between pinch blades formed on one end of a relay terminal after which the slot between the tips of the pinch blades is welded closed, or after which the wire held between the pinch blades is welded to the pinch blades. Female or male connector terminals are formed on the other ends of the aforesaid relay terminals opposite to the aforesaid pinch blades, and the aforesaid female or male connector terminals are joined to the terminals of relays, fuses, and/or connectors installed to the electrical connector box. 
   The aforesaid connector box structure runs electrical wires along the underside of the connector box case and therefore prevents the wires from hanging downward outside of the case, thus eliminating the problem of the downwardly hanging electrical wires inadvertently snagging on objects during shipment or when the connector box is installed to a vehicle, and thus improving both installation efficiency and the quality of the electrical connector box. 
   The connections between the electrical wires and the male or female relay terminals that connect to relays and other electrical components are not only maintained by the pressure applied against the electrical wire by the pinch blades, but also by a weld that connects the slot between the ends of the pinch blades, or a weld that connects the wire to the pinch blades. As a result, the reliability of the connection between the wire and pinch blades is improved, and the need to install a cover over the connection is eliminated. Furthermore, the elimination of the aforesaid connection cover and downwardly hanging wires makes it possible to reduce the height of the electrical connector box. 
   The electrical connector box of the present invention incorporates a relay block with wire guides formed on the underside thereof as means of establishing the routing path of the aforesaid electrical wires. The ends of each electrical wire are forcibly inserted between the pinch blades of a relay terminal, and the opposite end of the relay terminal is formed as a female terminal that connects to the female terminals of relays, fuses, and/or connectors located in the relay block. 
   By positioning the wires along the underside of the relay block through wire guides, the aforesaid connector box structure simplifies the wire installation process and eliminates the problem of wires falling out because the wires are securely held in position after their installation to the wire guides. 
   A vertical busbar is provided within the relay block to carry large current flows, and the aforesaid electrical wires are provided to carry medium or light current flows. In other words, a circuit that carries a large current flow, such as a power distribution circuit, is structured to include a vertical busbar, and a circuit carrying a lesser amount of current is structured to include the electrical wires that run along the underside of the case. 
   Relay terminal holding cavities are provided within the aforesaid relay block and are formed to a shape also able to hold a terminal crimped to a wire end. The aforesaid holding cavities are thus able to house either a relay terminal or a crimp-type wire terminal. 
   The invention provides terminal holding cavities shaped to accept either a relay terminal connected to a wire that runs along the underside of the relay block case, or a terminal to which an external wire has been connected through a crimped joint, therefore providing a relay block case that allows one type of relay block to be wired in various configurations without the need to utilize a differently structured relay block. 
   The electrical connector box positions electric wires along the surface of the connector case to prevent wires from hanging downward into the region external to the case, thus preventing the connector box wires from snagging on other components during shipment or when being installed, and thus improving the quality of the connector box as well as the efficiency with which the connector box can be handled. Moreover, as the pinch blades of the relay terminals securely grip the electrical wires, and as the tips of the pinch blades are welded together, or the wire end is welded to the pinch blades, a more reliable electrical connection is established that eliminates the need for a protective cover to be placed over the connection. Furthermore, the need for a cover over the connector box is eliminated as there are no electric wires hanging downward from the connector box, thus allowing the connector box to have a lower profile (i.e., the box may be made thinner). 
   Furthermore, the provision of wire guides on the underside of the case, along which the wires are routed, allows for a convenient wire installation operation. Also, the problem of disconnected wires is eliminated because the wires are positioned on and secured to the case underside upon their installation thereto. Still further, the relay terminal cavities, to which are inserted relay terminals that connect to wires running along the underside of the case, are structured to also allow the insertion of terminals that are crimped to external wires, a configuration that allows the case to be adapted to various circuit structures without the need to use a different type of case. 
   Other exemplary embodiments and advantages of the present invention may be ascertained by reviewing the present disclosure and the accompanying drawings. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The present invention is further described in the detailed description which follows, in reference to the noted plurality of drawings by way of non-limiting examples of certain embodiments of the present invention, in which like numerals represent like elements throughout the several views of the drawings, and wherein: 
       FIG. 1  is a bottom plan view of the present invention; 
       FIG. 2A  is a top plan view of a relay terminal incorporating a female connector according to the present invention; 
       FIG. 2B  is a side view of the relay terminal incorporating the female connector; 
       FIG. 2C  is an end view of the relay terminal incorporating the female connector; 
       FIG. 3A  is a top plan view showing a connection between the relay terminal and the wire; 
       FIG. 3B  is a top plan view showing a second embodiment of a connection between the relay terminal and the wire; 
       FIG. 4A  is a top plan view of a relay terminal having a male terminal end; 
       FIG. 4B  is a side view that of the relay terminal of  FIG. 4A ; 
       FIG. 5  is a cross section of the part of the relay block pertaining to the invention. 
       FIG. 6  is a partial side sectional view of the relay block of the present invention. 
       FIG. 7A  is a perspective view showing a vertical busbar of the present invention; 
       FIG. 7B  is a perspective that showing a second embodiment of the vertical busbar and connecting terminal pieces of the present invention 
       FIG. 8  is a perspective view of wire guides of the present invention with a wire guided thereby. 
       FIG. 9A  is a perspective view showing a related art electrical connector box; and 
       FIG. 9B  is a partial side sectional view of the related art connector box. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to show structural details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the present invention may be embodied in practice. 
   Referring to the drawings wherein like characters represent like elements, the present invention incorporates relay block  10 , the underside thereof being illustrated in FIG.  1 . Relay block  10  is equipped with fuse receptacles  12 , relay receptacles  13 , and connector receptacles  14 . The power distribution circuit that carries a large current flow incorporates vertical busbar  15  which is inserted at a specific location on underside  11   a  of case  11 , and the circuits that carry a lesser current flow incorporate wires w 1  and w 2  that run along floor  11   a  of case  11 . 
   Relay terminals  20 ,  40  are attached to the extremities of wires w 1  and w 2 , and are inserted and secured within cavities  18  and  18 ′ of case  11 . As shown in  FIGS. 2A ,  2 B and  2 C, a pair of pinch blades  20   a  incorporating tapered tip parts  20   a - 1  form slot S at one extremity of relay terminal  20 . Female terminal  20   d  is formed on the other extremity of relay terminal  20 . Stop notch  20   c  is provided between cylindrical part  20   b , which is formed adjacent to pinch blades  20   a  and female terminal  20   d.    
   As illustrated in  FIG. 3A , wires w 1  and w 2  are connected to terminal  20  by forcibly inserting their ends into slot S between pinch blades  20   a , thereby forcing pinch blades  20   a  to cut through the insulation of wire w 1  and w 2  to make electrical contact with the core conductor of the wire. The tapered ends of pinch blades  20   a  allow for the easy insertion of the wire without the need for excessive force. 
   Once wires w 1  and w 2  are inserted, tapered tips  20   a - 1  of pinch blade  20   a  are connected through a gas welding process that forms welded part Y which closes slot S.  FIG. 3B  illustrates another type of connection in which wire w 1  or w 2  is welded to pinch blades  20   a . It is readily understood by those skilled in the art that welding processes other then gas welding, such as ultrasonic welding, electrical resistance welding, and the like may also be used. 
   Furthermore, as shown in  FIGS. 4A and 4B , a pair of pinch blades  40   a  incorporating tapered tip parts  40   a - 1  form slot S on one end of relay terminal  40 . A spade-type male terminal  40   d  is formed on the other extremity of relay terminal  40 . Stop notch  40   c  is formed between cylindrical part  40   b , which is formed adjacent to pinch blades  40   a , and male terminal  40   d . Because wire w 1  and w 2  are connected to relay terminal  40  in the same manner as previously described in relation to terminal  20 , a description of their connecting procedure is omitted herein. 
   As illustrated in  FIG. 5 , relay terminal  20 , which is connected to the ends of wire w 1  and w 2 , is inserted into cavity  18  through case underside  11   a , and secured within cavity  18  as a result of stop tab  18   a  located within stop notch  20   c  of the relay terminal  20 . Multiple pairs of pins  17  protrude outward at specific locations from case underside  11   a  to form a wire guide path that guides wires w 1  and w 2 , to which relay terminals  20  are attached, along case underside  11   a.    
   Terminals  21 , which are crimped to the ends of external wires w 3  which in turn are part of an external wiring harness, are inserted into the remaining cavities  18  and secured therein by stop tab  18   a  located within stop notch  21   c  of crimped terminal  21 . Each cavity  18  is configured to allow either the inserted attachment of relay terminal  20  or terminal  21  to which external wires w 3  are crimped. Furthermore, as the extremity of relay terminal  20  is formed as a female-type connector, it is inserted into each of cavities  18  which form relay receptacle  13  (or fuse receptacle  12 ). 
   As illustrated in  FIG. 6 , relay terminal  40 , which is connected to the ends of wire w 1  and w 2 , is inserted through case underside  11   a  into cavity  18 ′ within which stop tab  18   a ′ is formed on an internal surface, and is secured within cavity  18 ′ through stop tab  18   a ′ located within stop notch  40   c  formed within relay terminal  40 . Terminals  41 , which are crimped to the ends of wires coming in from an external wiring harness, can be inserted into the remaining cavities  18 ′ with male connector terminals  41   d  protruding into connector receptacle  14 , and secured therein by stop tab  18   a ′ located within stop notch  41   c  of terminal  41 . In other words, each cavity  18 ′ is configured to allow either the inserted attachment of relay terminal  40  or terminal  41  which is crimped to external wire w 3 . 
   Moreover, as illustrated in  FIG. 1 , the electrical power distribution circuit does not make use of electrical wire connections, but rather utilizes busbar  15  to make circuit connections. As illustrated in  FIG. 7A , busbar  15  includes contact tabs  15   a  located at uniform intervals on the busbar with each contact tab  15   a  incorporating a grip slot  15   a - 1 . Busbar  15  is inserted through case underside  11   a  into a parallel circuit fuse receptacle  12  into which contact tabs  15   a  extend to make contact with the terminals of the fuses (fuses not shown). Furthermore, the vertical busbar  15  is not only used to form the circuits that extend into the fuse receptacle  12 , but also for the high current flow power distribution circuit of relay receptacle  13  and connector receptacles. 
     FIG. 7B  illustrates a second embodiment of the vertical busbar in which beam-shaped vertical busbar  19  is installed on case underside  11   a  and connected to fuse receptacle  12  through connector pieces  30 . Grip slot  30   a  at the lower end of each connector piece  30  connects to the vertical busbar  19  while the fuse (not shown in the figure) within fuse receptacle  12  connects to grip slot  30   b  at the upper end of each connector piece  30 . 
   It is noted that the foregoing examples have been provided merely for the purpose of explanation and are in no way to be construed as limiting of the present invention. While the present invention has been described with reference to certain embodiments, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Changes may be made, within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the present invention in its aspects. Although the present invention has been described herein with reference to particular means, materials and embodiments, the present invention is not intended to be limited to the particulars disclosed herein; rather, the present invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims. 
   The present application claims priority under 35 U.S.C. §119 of Japanese Patent Application No. 2002-066442, filed on Mar. 12, 2002, the disclosure of which is expressly incorporated by reference herein in its entirety.