A support structure for connecting sections of wire harnesses

Abstract: A structure for securing electrical contact between connecting sections of a wire harness includes a wall with a hole therethrough and a projection having a hollow. The projection extends from a rim of the hole and the hollow is in communication therewith. There is a cover which closes the end of the projection remote from the rim. There is a plurality of connecting sections on one or more wire harnesses and an insulative cap is placed thereover. The hollow is adapted to receive the cap and connection sections and an opening is provided in the cover. This permits introduction of a resilient cap, which will secure the connecting sections within the hollow and allows otherwise trapped air to escape readily through the opening. This simplifies both production and assembly.

Description: The present Invention is directed to a support structure for making secure electrical contact between connecting sections of wire harnesses, particularly those used in automotive vehicles such as cars and trucks. BACKGROUND OF THE INVENTION A prior art device of the general type referred to herein is shown in Figure 4. Connection box 11 is provided with projection 12 extending from bottom wall 11a thereof. Connecting sections 13a of main line 13 are inserted into the hollow portion of projection 12. Support hook 14 holds connecting sections 13a within the hollow and prevents them from falling out. However, this configuration suffers from certain defects. During assembly, connecting sections 13a are inserted into the interior of projection 12. However, since the connecting sections are hidden inside the projection, it cannot be determined if connecting sections 13a have been pushed too far in and are impacting against the inner wall of the projection. Alternatively, if connecting sections 13a have not been inserted far enough, this also cannot be determined readily by observation. The result of the latter will be unstable contacts. In US-A-4 839 473 which is considered to represent the closest prior art, a waterproof electrical splice enclosure is disclosed. The electrical splice enclosure secures electrical contact between connection sections of a wire harness having a plurality of connecting sections and comprises an insulative cap on said connecting sections. SUMMARY OF THE INVENTION The present Invention is intended to overcome the foregoing deficiencies of the prior art and provide a connection box wherein the connecting sections of the wire harness can be inserted readily and reliably into the hollow projection. This is achieved with a structure, according to claim 1. The inventive structure for securing electrical contact between connecting sections of the wire harness has a wall with a hole therethrough. A projection with a hollow therein extends from the rim of the hole and communicates therewith. A cover closes the end of the projection remote from the rim. There is also provided a wire harness having a plurality of connecting sections with an insulative cap placed thereover. The combination of the cap and connecting sections is inserted into the hollow which is provided with an opening through its cover. Preferably, the projection extends inwardly of the structure and is of circular cross section. Also, the opening is desirably circular. It is also preferred that the cap is resilient and is slightly larger in diameter than the internal diameter of the hollow. Thus, when the cap is inserted into the hollow, it bears against the inner wall thereof and is secured, along with the contact sections, therein. Advantageously, the cap is waterproof. BRIEF DESCRIPTION OF THE DRAWINGS In the accompanying drawings, constituting a part hereof, and in which like reference characters indicate like parts, Figure 1 is a perspective view of a connection box in accordance with the present Invention; Figure 2 is a view, similar to that of Figure 1, partly in section along line A-A; Figure 3 is an enlarged view, partly in section, showing the cap and wire harnesses within the projection; and Figure 4 is a view, partly in section, of a prior art connection box. DETAILED DESCRIPTION OF THE INVENTION As shown in Figures 1 to 3, connection box 1 is provided with projection 2 upstanding from bottom wall 1a. Connection sections 3a of main lines 3 of the wire harnesses are encased by resilient cap 4. As particularly shown in Figure 3, cap 4 and sections 3a are forced into the hollow of projection 2. The resilience of cap 4 enables it to bear against the inner walls of projection 2, thereby securing the cap and the connection sections therein. This structure provides a number of important advantages. The opening in the cover of the projection permits the assembler to observe the cap and connection sections of the wire harness as they are being installed. In this way, it can be assured that the cap and sections are inserted properly. Undue forcing and insufficient insertion are thereby eliminated. Moreover, since the cap may be resilient, this characteristic permits it to grip the inside of the projection and thereby be retained therein. This eliminates the need for the hook used in the prior art. The opening in the cover performs a further function. Since the cap will fit snugly within the hollow, the opening provides a ready exit for air which would otherwise be trapped therein. In addition, by making the cap waterproof, the connection sections are further protected. The projection can be formed integrally with the bottom wall of the connection box, thereby simplifying both the construction and the assembly thereof. If the opening is circular, it can be more easily formed. Also, it is possible to form the connecting sections efficiently by the use of resistance welding. Although only a limited number of aspects of the present Invention have been expressly disclosed, such modifications as would be apparent to the person of ordinary skill may be made without departing from the scope or spirit thereof. For example, there are other processes to connect the connection sections and they may be used in place of resistance welding. While it is desirable to form the bottom wall of the connection box integrally with the projection, it is also feasible to have these two elements as separate members adhered together. The present Invention teaches that the projection has a circular cross section. However, other hollow cross sections are possible, so long as an opening is provided in the cover and the degree of insertion of the connection sections can be readily ascertained. Although the Invention has been expressly disclosed with regard to one embodiment, it is, nonetheless, to be broadly construed, and not to be limited except by the character of the claims appended hereto.

Claims: A structure for securing electrical contact between connecting sections (3a) of a wire harness comprising a wire harness having a plurality of said connecting sections (3a), and an insulative cap (4) on said connecting sections (3a), characterised by a wall (1a) of said structure with a hole therethrough, a projection (2) having a hollow, said projection (2) extending from a rim of said hole with said hollow in communication therewith, a cover closing an end of said projection (2) remote from said rim, said hollow being adapted to receive said cap (4) and said connecting sections (3a), there being an opening (2a) in said cover. The structure of claim 1 wherein said projection (2) extends inwardly of said structure. The structure of claim 1 wherein said projection (2) is substantially circular in cross section parallel to said wall (1a). The structure of claim 1 wherein said opening (2a) is circular. The structure of claim 1 wherein said cap (4) is resilient and has an outer diameter greater than that of said hollow whereby, when said cap (4) is inserted into said hollow, an outer surface of said cap bears (4) against an inner surface of said projection (2). The structure of claim 5 wherein said cap (4) is waterproof. The structure of claim 1 wherein said projection (2) is substantially perpendicular to said wall (1a). The structure of claim 1 wherein said projection (2) is integral with said structure. The structure of claim 1 wherein said wall is a bottom wall of said structure. The structure of claim 1 wherein said connecting sections (3a) are resistance welded.

Inventors: KAWAGUCHI KIYOFUMI, KAWAGUCHI, KIYOFUMI, Kawaguchi, Kiyofumi Sumitomo Wiring Systems, Ltd.
Applicants: SUMITOMO WIRING SYSTEMS, SUMITOMO WIRING SYSTEMS, LTD.
Application year: 1999
Main classification: H01R4
IPC codes: H02G3, H01R4