An intermediate terminal for an electrical connection box

Abstract: In order to provide an intermediate terminal for an electrical connection box with an enhanced degree of freedom in terms of a tab inserting direction, an intermediate terminal having a column with hollow end portions and connecting spring portions (5g-5j;3b,3c) projecting inwardly into the hollow interior of the end portions so as to allow the insertion and fitting of a tab (1a,2a) at each end portion, wherein the connecting spring portions (5g-5j;3b,3c) at at least one end portion are provided such that a tab (1a,2a) can be inserted and fitted in at least two different rotational orientations with respect to the longitudinal axis of the column.

Description: DETAILED DESCRIPTION OF THE INVENTION The present invention relates to an intermediate terminal for an electrical connection box and, particularly to an intermediate terminal into which a tab of a busbar mounted in an electrical connection box and a tab of a functional part such as a fuse or a relay are inserted to establish the electrical connection between the busbar and the functional part. Especially, it is designed to mount an intermediate terminal in the electrical connection box independently of a direction in which the tab of the relay or of like mating part is inserted. An electrical connection box used to connect a wiring harness for an automotive vehicle with a variety of wiring devices is adapted to realize a rational and economical junction connection of the wiring by concentrating points of junction connection on one location. A variety of types of such electrical connection boxes are being developed for different types of vehicles and for different purposes while the wiring harness is made more compact. In the above junction box, there are mounted intermediate terminals 3, 3 for connecting, for example, tabs la, la of a fuse 1 and tabs 2a, 2a of a busbar or like device mounted in the junction box as shown in FIG. 6(A). A variety of intermediate terminals 3 having different structures have been proposed. Most of them are directional in the vertical direction and the forward/backward direction, i.e. the shape of the terminals differs at its top and bottom and at its front side and rear side, respectively. For example, as shown in FIGS. 7(A) and 7(B), the structure of the intermediate terminal 3 has such a shape. An intermediate terminal 3 formerly proposed by the present inventors and shown in FIGS. 8(A) and 8(B) is non-directional, i.e. has the same structure at its top and bottom and at its front and back, respectively (Japanese Unexamined Utility Model Publication No. 5-79889). The intermediate terminal 3 shown in FIGS. 8(A) and 8(B) has generally the shape of a rectangular column. At the front and the rear ends of the intermediate terminal 3, respectively, pairs of arcuate connecting spring portions 3b, 3b and 3c, 3c project inwardly from its front and rear surfaces 3a, 3a, forming a clearance between each pair so that the tabs 1a or 2a can be inserted at will from top or bottom. Generally, the tab 1a of the fuse 1 is inserted into the clearance between the connecting spring portions 3b and 3b at the top end of the intermediate terminal 3, whereas the tab 2a of the busbar or like device is inserted into the clearance between the connecting spring portions 3c and 3c at the bottom end thereof. However, only the upper and lower ends of the intermediate terminal are identical in that terminals can be inserted from any end. Accordingly, if the tab 1a is mounted in a different direction (e.g. turned about its axis by 90°), the intermediate terminal 3 has to be mounted in the junction box so that the tab 1a can be inserted thereinto. Then, the intermediate terminal 3 cannot be used unless the tab 1a of the fuse 1 and the tab 2a of the busbar or like device extend in the same direction as shown in FIG. 6(A). Accordingly, in the case where the tabs 2a, 2a of the busbars or like devices are opposed each other, and thus turned by 90°, as shown in FIG. 6(B), such a problem arises where the tabs 2a, 2a can be inserted into the ends of the intermediate terminals 3, 3, but the tabs 1a, 1a of the fuses 1 cannot be inserted into the other ends of the intermediate terminals 3, 3. Further, in the case where 10 to 30 fuses 1 are mounted in the electrical connection box, twice as many intermediate terminals, namely, 20 to 60 intermediate terminals are required. In this case, even if the respective tabs 1a and 2a extend in the same direction, when one fuse 1' is mounted in a different direction (rotated by 90°) as shown in FIG. 9, the intermediate terminals 3 to be connected with this fuse 1 need to be turned in conformity with the mounting direction of this fuse 1'. This makes the construction of an apparatus for automatically inserting the intermediate terminal 3 complicated, thereby leading to an increased production cost. If the fuses 1 are mounted in the same direction in order to avoid this problem, a design of an internal circuitry of the electrical connection box is subject to more limitation. The invention is developed to solve the above problems, and an object thereof is to provide a more versatile intermediate terminal. The above object is accomplished by the invention defined in claim 1. The tab (which could be seen as a rotationally directional connection terminal) which is typically a tab with a rectangular cross section can be inserted in at least one end portion in at least two different rotational orientations. Accordingly, if the tabs (connection terminals) to be inserted into the other end portions are aligned in one rotational direction, the connection terminals to be inserted into the one end portion need not be aligned. Conclusively, the inventive intermediate terminals can be used for this type of connection without being turned about their longitudinal axes. Preferably, two receiving portions for receiving connection terminals at a different rotational orientation are formed. If both end portions are provided with two receiving portions, the above type of connection can be made even without aligning the intermediate terminals with respect to their up/down orientation. Preferably, the two receiving portions intersect at a right angle. In a preferred embodiment, the column has a generally rectangular cross section, and the connecting spring portions are provided at each side of the column. This embodiment is easy to manufacture. Preferably, the connecting spring portions have an arcuate cross section and define two receiving portions. It is particularly preferred that the connecting spring portions are formed throughout the entire longitudinal extension of the column. Namely, the intermediate terminal is now particularly easy to manufacture, e.g. by bending and folding a plate. According to another preferred embodiment, the column has a cross-like cross section defining four wings, wherein each two opposing wings define a receiving portion and wherein the connecting spring portions are formed at the sides of the wings. This embodiment allows easy and smooth insertion of the connection terminals. The intermediate terminal is easy to manufacture if the column is entirely hollow, particularly if also the connecting spring portions are formed over the entire length. If the column has generally a square shape, and the cross-section of its interior is point symmetrical, the intermediate terminal is easy to handle, particularly by an automatic connecting apparatus. In other words, since two intersecting tab receiving portions are formed in one intermediate terminal, the intermediate terminals can be mounted in the electrical connection box in the same direction independently of inserting directions of tabs. Further, even if a tab of a fuse or like device and a tab of a busbar or like device extend in different directions, i.e., their extending directions are displaced by 90°, the respective tabs can be inserted into the intermediate terminal. These and other objects, features and advantages of the present invention will become more apparent upon a reading of the following detailed description and accompanying drawings in which: FIG. 1 is a perspective view of an intermediate terminal as a first embodiment according to the invention, FIG. 2 is a plan view of the intermediate terminal, FIG. 3(A) is a perspective view showing a relationship of a fuse, intermediate terminals and busbars or like devices, FIG. 3(B) is a perspective view showing the tabs of busbars opposed to each other, FIG. 4 is a plan view showing mounting directions of fuses in an electrical connection box, FIG. 5 is a perspective view of an intermediate terminal as a second embodiment, FIG. 6(A) is a perspective view showing a relationship of a fuse, prior art intermediate terminals and busbars or like devices, FIG. 6(B) is a perspective view opposed to each other, FIGS. 7(A) and 7(B) are a perspective view and a side view of a prior art intermediate terminal, respectively, FIG. 8(A) is a perspective view of another prior art intermediate terminal, FIG. 8(B) is a perspective view partially in section showing an essential portion of the intermediate terminal shown in FIG. 8(A), and FIG. 9 is a plan view showing mounting directions of fuses in a prior art electrical connection box. It should be appreciated that no detailed description is given to elements having the same construction and operation as the prior art shown in FIGS. 6 to 9 by identifying them by like reference numerals. A intermediate terminal 5 as a first embodiment has the form of a substantially square column of a conductive material (e.g. metal) as indicated by phantom line in FIGS. 1 and 2. Specifically, the intermediate terminal 5 is formed into the substantially square column by folding a metal plate having a width W corresponding to a height of the intermediate terminal 5 four times by generally the same length L at an angle of 90°, placing a finishing end 5b over the outer surface of a starting end 5a, and connecting the ends 5a and 5b. Therefore, four surfaces 5c, 5d, 5e and 5f of the intermediate terminal 5 have generally the same shape. Arcuate connecting spring portions 5g, 5h, 5i and 5j projecting semicircularly inwardly extend throughout the entire longitudinal extension of the terminal 5 in the lateral center of the surfaces 5c to 5f, respectively. Accordingly, clearances g for permitting insertion of a tab 1a of a fuse 1 or a tab 2a of a busbar or like device are formed between the inner surfaces of the connecting spring portions 5g and 5h, 5h and 5i, 5i and 5j, 5j and 5g and are, thus, positioned at four corners defined by the surfaces 5c and 5d, 5d and 5e, 5e and 5f, 5f and 5c, respectively. In other words, there are formed first and second tab receiving portions 10 and 20 which extend through and intersect at a longitudinal axis A at a right angle. The inner surfaces of the connecting spring portions 5g and 5h at one diagonal end of the square terminal 5 and 5i and 5j at the opposite diagonal end are respectively opposed to each other with the first tab receiving portion 10 therebetween. The inner surfaces of the connecting spring portions 5g and 5j at one diagonal end of the square terminal 5 and 5h and 5i at the opposite diagonal end are opposed to each other with the second tab receiving portion 20 therebetween. In FIGS. 1 and 2, the first and second tab receiving portions 10 and 20 extend along lines L1 and L2, respectively. The intermediate terminals 5 can be mounted in the same direction in one electrical connection box 30 as shown in FIG. 3(A), independently of whether the tabs 2a of each busbar mounted in the electrical connection box 30 extend along the longitudinal or lateral direction orthogonally thereto and are inserted into a lower part of either the first or second tab receiving portion 10 or 20. Further, the tabs 1a of relays 1A, 1B and 1C to be connected with the intermediate terminals 5 thus connected with the tabs 2a of the busbars mounted in the electrical connection box 30 can be inserted into upper parts of the first or second tab receiving portions 10 or 20 independently of whether the tabs 1a extend along the longitudinal or lateral direction. In other words, the tabs can be connected by means of the intermediate terminals 5 mounted in the same direction in the electrical connection box 30 both when the tabs 1a, 1a of the fuses 1 and the tabs 2a, 2a of the busbars 2 to be inserted into the first or second tab receiving portions 10 or 20 extend in the same direction as shown in FIG. 3(A) and as in fuses 1A, 1A of FIG. 4, and when the tabs 1a, 1a of the fuses 1 and the tabs 2a, 2a of the busbars 2 extend in different directions as shown in FIG. 3(B) and as in fuses 1B, 1C of FIG. 4. Specifically, when the tabs 1a, 1a of the fuse 1 and the tabs 2a, 2a of the busbars 2 extend in the same direction as shown in FIG. 3(A), if the intermediate terminals 5 are mounted from above such that the tabs 2a, 2a are inserted into the lower parts thereof, the tabs 2a, 2a are tightly held between the connecting spring portions 5g and 5h, 5i and 5j (or 5g and 5j, 5h and 5i) as shown in FIG. 2. Thereafter, when the tabs 1a, 1a of the fuse 1 are inserted from above into the upper parts of the respective intermediate terminals 5, 5, the tabs 1a, 1a are tightly held between the same connecting spring portions 5g and 5h, 5i and 5j (or 5g and 5j, 5h and 5i) as the tabs 2a, 2a of the busbars 2. On the other hand, when the tabs 2a, 2a of the busbars are opposed to each other as shown in FIG. 3(B) and therefore extend in the different direction from the tabs 1a, 1a of the fuse 1 (see the fuse 1B in FIG. 4), if the intermediate terminals 5, 5 are mounted from above regardless of the direction thereof such that the tabs 2a, 2a are inserted into the lower parts thereof, the tabs 2a, 2a are tightly held between the connecting spring portions 5g and 5h, 5i and 5j (or 5g and 5j, 5h and 5i) as shown in FIG. 2. Thereafter, when the tabs 1a, 1a of the fuse 1 are inserted from above into the upper parts of the respective intermediate terminals 5, 5, the tabs 1a, 1a are tightly held between the connecting spring portions 5g and 5j, 5h and 5i (or 5g and 5h, 5i and 5j) differently from the tabs 2a, 2a of the busbars. Further, even when the tabs 1a, 1a of the fuse 1 extend in the same direction as the tabs 2a, 2a of the busbars as with the fuse 1A of FIG. 4, but the fuse 1 is mounted in the different direction (rotated by 90°) as the fuse 1C of FIG. 4, if the intermediate terminals 5, 5 are mounted from above regardless of the direction thereof such that the tabs 2a, 2a are inserted into the lower parts thereof, the tabs 2a, 2a are tightly held between the connecting spring portions 5g and 5h, 5i and 5j (or 5g and 5j, 5h and 5i) as shown in FIG. 2. Thereafter, when the tabs 1a, 1a of the fuse 1 are inserted from above into the upper parts of the respective intermediate terminals 5, 5, the tabs 1a, 1a are tightly held between the same connecting spring portions 5g and 5h, 5i and 5j (or 5g and 5j, 5h and 5i) as the tabs 2a, 2a of the busbars. As described above, the tabs 1a, 1a and 2a, 2a can be inserted into the intermediate terminals 5, 5 even if the tabs 1a, 1a of the fuse 1 extend in the direction displaced by e.g. 90° from the tabs 2a, 2a of the busbars. Accordingly, even if the fuses 1 are mounted in different directions (rotated by 90°) in the electrical connection box, the intermediate terminals 5, 5 need not be aligned in conformity with the mounting directions of the fuses 1. Thus, the automatic intermediate terminal inserting apparatus is allowed to have a simple construction, thereby reducing a production cost. Further, since it is not necessary to mount the fuses 1 in the same direction, a design of an internal circuitry of the electrical connection box is subject to less limitation. Furthermore, the tabs 1a, 1a of the fuse 1 and the tabs 2a, 2a of the busbar may even be inserted into clearances between apexes of the facing arcuate connecting spring portions 5g and 5i, 5h and 5j as indicated by dashed line in FIG. 2. However, the tabs must have a specified width. To the contrary, if the tabs are inserted into the tab receiving portions, they must not have a specified width, but a specified thickness. FIG. 5 shows an intermediate terminal 3A as a second embodiment which employs the basic construction of the prior art intermediate terminal 3 shown in FIG. 8. The intermediate terminal 3A looks as if it were formed by cutting away one side surface 3d shown in FIG. 8(A) from the intermediate terminal 3, and joining four such intermediate terminals 3 to have a cross-like cross section by bringing the cut edges into abutment. In reality, the intermediate terminal 3a is formed by bending and embossing a metal plate similar to the intermediate terminal 5. The intermediate terminal 3A is in the form of a cross-like column. Surfaces 3e to 3h face each other. In the intermediate terminal 3A as the second embodiment, there are also formed two tab receiving portions, namely a first tab receiving portion 10' and a second tab receiving portion 20' which intersect at right angles. Accordingly, if the intermediate terminals 3A are mounted in the same direction in the electrical connection box, the tabs of the busbars can be connected with the corresponding tabs of the relays by means of the intermediate terminals independently of whether the tabs extend in the longitudinal or lateral direction. As is clear from the above description, in the inventive intermediate terminals, the connecting spring portions are formed on the side surfaces of the rectangular column which surfaces are point-symmetrical with respect to a middle point of two intersecting directions. Accordingly, even if a tab of a fuse or like device and a tab of a busbar or like device extend in different directions, i.e., their extending directions are displaced by e.g. 90°, the respective tabs can be inserted into the same intermediate terminal. Therefore, even if fuses or like devices are mounted in different directions in the electrical connection box (rotated by 90°), the intermediate terminals need not be aligned in accordance with the mounting direction of the fuses. This makes the construction of an automatic intermediate terminal inserting apparatus simple, thereby reducing a production cost. Further, since it is not necessary to mount the fuses or like devices in the same direction, a design of an internal circuitry of the electrical connection box is subject to less limitation. LIST OF REFERENCE 1 Fuse 1a Tab 2 Busbar 2a Tab 5 Intermediate Terminal 5c to 5f Surface 5g to 5j Connecting Spring Portion 10 First Tab Receiving portion 20 Second Tab Receiving Portion A Longitudinal Axis g Clearance

Claims: A tab connection intermediate terminal (5; 3) for an electrical connection with a substantially planar tab (1a; 2a), the tab connection intermediate terminal (5; 3) having a column with hollow end portions and connecting spring portions (5g-5j;3b,3c) projecting inwardly into the hollow interior of the end portions so as to allow the insertion and fitting of the tab (1a,2a) at each end portion, wherein the connecting spring portions (5g-5j;3b,3c) at at least one end portion are provided such that a tab (1a,2a) is insertable and fittable in at least two different rotational orientations (L1; L2) with respect to the longitudinal axis (A) of the column, the two different rotational orientations (L 1 ;L 2 ) being arranged at an angle of less then 180°. A tab connection intermediate terminal according to claim 1, wherein two receiving portions (10, 20; 10', 20') are defined between adjacent connecting spring portions (5g-5j; 3b, 3c) for receiving connection terminals (1a, 2a) at a different rotational orientation are formed by the interior of at least one end portion of the column. A tab connection intermediate terminal according to claim 2, wherein the two receiving portions (10,20;10'20') intersect at a right angle. A tab connection intermediate terminal according to any of the preceding claims, wherein the column has a generally rectangular cross section and wherein the connecting spring portions (5g-5j) are formed at each side of the column. A tab connection intermediate terminal according to claim 4, wherein the connecting spring portions (5g-5j) have an arcuate cross section and define two receiving portions (10, 20). A tab connection intermediate terminal according to claim 4 or 5, wherein the connecting spring portions (5g-5j) are formed throughout the entire longitudinal extension of the column. A tab connection intermediate terminal according to any of claims 1 to 3, wherein the column has a cross-like cross section defining four wings (3,3,3,3), wherein each two opposing wings define a receiving portion (10',20') and wherein the connecting spring portions (3b,3c) are formed at the sides of the wings (3,3,3,3). A tab connection intermediate terminal according to any of the preceding claims, wherein the column is hollow throughout its entire longitudinal extension. A tab connection intermediate terminal according to any of the preceding claims, wherein the column has a generally square shape and wherein the cross-section of its interior is point-symmetrical with respect to its longitudinal axis (A).

Inventors: GOTO HIDEKI, OKA YOSHITO, GOTO, HIDEKI, OKA, YOSHITO, Goto, Hideki, c/o Sumitomo Wiring Systems, Ltd., OKA, YOSHITO, C/O SUMITOMO WIRING SYSTEMS, LTD.
Applicants: SUMITOMO WIRING SYSTEMS, SUMITOMO WIRING SYSTEMS, LTD.
Application year: 1995
Main classification: H01R13
IPC codes: H01R13, H02G3, H01H11, H01H85, H01R31