Abstract:
A power distribution module utilizes a planar substrate having an array of repeating slots configured to accept two types of relays, one having four terminals and the other having five terminals. Both relays can mate with the slots of the substrate in a variety of orientations, including reverse orientations wherein the relay terminal footprint can be rotated 180 degrees and still mate with a corresponding, yet shifted, slot footprint.

Description:
TECHNICAL FIELD 
     This invention relates to power distribution modules and more particularly to power distribution modules having plug-in sockets for ISO relays. 
     BACKGROUND OF THE INVENTION 
     U.S. Pat. No. 5,023,752 granted to Gary C. Detter et al Jun. 11, 1991 discloses an electrical power distribution center that supports electronic and electrical devices including a number of relay devices that are controlled by electrical signals to position contacts for supplying power from a power source to auxiliary electrical systems of an electrical supply system for an automobile or other vehicle. The relay devices have four blade terminals in a unique pattern consisting of three parallel blade terminals in a triangular pattern and a fourth blade terminal perpendicularly arranged at the base of the triangle. The socket pattern for receiving the four blades of the relay terminal is shown in FIG. 1 of the &#39;752 patent and in FIG. 1 of U.S. Pat. No. 4,995,818 granted to Tetsuro Saimoto Feb. 26, 1991 for a bus bar interlayer connector structure in a junction box. 
     The power distribution center and the junction box disclosed in the above patents are designed for a specific vehicle. Consequently each must be redesigned and retooled for other vehicles, or even related vehicles. 
     SUMMARY OF THE INVENTION 
     The object of this invention is to provide a power distribution module for the relays that are very versatile so that the same module can be used in a number of vehicles by repositioning the relays. The power distribution module utilizes a planar substrate having an array of slots configured to accept, preferably, two types of relays, one having four terminals and the other having five terminals. Both relays can mate with the slots of the substrate in a variety of orientations, including reverse orientations wherein the relay terminal footprint can be rotated 180 degrees and still mate with a corresponding, yet shifted, slot footprint. 
     The planar substrate of the module is divided into three portions being two end portions and a middle portion or repeating cell. Each end portion has an end slot centered laterally along the substrate. Each cell has a first sub-cell and a mirror image second sub-cell. Each sub-cell has three longitudinal rows of slots. The outer rows, or first and third rows each have a pair of co-linear slots, and the middle or second row has a lateral slot and a longitudinal slot. All slots are appropriately spaced forming a variety of slot footprints to mate with the footprint (i.e. four terminal configuration) of the terminals of the relays. 
     A feature of the invention is that the same relay can be plugged into the power distribution module in a number of different positions to perform different functions for different vehicle applications. 
     Another feature of the invention is the reduction of varying module designs between vehicle applications, thereby reducing manufacturing costs. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The presently preferred embodiments of the invention are disclosed in the following description and accompanying drawings wherein 
     FIG. 1 is a perspective view of a power distribution module according to the invention; 
     FIG. 2 is a plan view of a substrate of the power distribution module; 
     FIG. 3 is a perspective view of a small relay; 
     FIG. 4 is a perspective view of a second embodiment of the power distribution module; 
     FIG. 5 is a perspective view of a large relay; 
     FIG. 6 is a perspective view of a third embodiment of the power distribution module; and 
     FIG. 7 is a perspective view of a fourth embodiment of the power distribution module. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring now to the Figures, a power distribution module  10  comprises an electrically non-conductive housing or elongated planar substrate  12  having a series of equally proportioned slots  14 . Mating with any number of the slots is a small standard ISO relay  16  having a four terminal configuration  18  and/or a large standard ISO relay  20  having the same four terminal configuration  18  plus an additional auxiliary terminal  22 . The substrate  12  can be divided into generally three different quadrants being a first end portion  24 , an opposite end portion  26  and at least one cell  28  disposed there-between. Each cell  28  has two mirror imaged sub-cells  30 ,  32  aligned back to back from one another. As best shown in FIG. 2, the present invention preferably has a first cell  28  and an identical second cell  29  aligned so that the second sub-cell  32  of the first cell  28  is located adjacent to the first sub-cell  30  of the second cell  29 . 
     Defined by and extending longitudianlly along the elongated planar substrate  12  is a first, second and third row  34 ,  36 ,  38  of slots  14 . The second row  36  is substantially centered between the first and third rows  34 ,  38 . The first and second end slots  40 ,  42  are located at respective ends of the second row  36 . Each sub-cell  30 ,  32  has a co-linear slot pair  44  in both the first row  34  and the third row  38 . The slot pair  44  in the first row  34  is aligned axially or longitudinally to the slot pair  44  in the third row  38 . The adjacent ends of the slots within the slot pair  44  are separated from each other by a common distance  46 . Moreover, the slot pair  44  of the second sub-cell  32  of the first cell  28  is separated from the slot pair  44  of the first sub-cell  30  of the second cell  29  within the corresponding rows  34 ,  38  by the same distance  46 . 
     The second row  36  of each sub-cell  30 ,  32  has a lateral slot  48  and a longitudinal slot  50  separated in a longitudinal direction and disposed perpendicular to one-another. Sub-cell  30  is aligned longitudinally and back-to-back with sub-cell  32  so that the longitudinal slot  50  of the first sub-cell  30  is adjacent to the longitudinal slot  50  of the second sub-cell  32  of the same cell and separated therefrom by the distance  46 . Wherein each slot  14  is sized by a common dimensional width  51  and a length  52 , the lateral slots  48  of the first sub-cell  30  of the first cell  28  is separated from the adjacent end slot  40  by a relay position shift length  53  which equals the length  52 , plus the distance  46 , and minus the width  51 . Accordingly, the lateral slot  48  of the second sub-cell  32  of the second cell  29  is separated from the second end slot  42  by the shift length  53 , and the side edge of the lateral slot  48  of the second sub-cell  32  of the first cell  28  is separated from the adjacent side edge of the lateral slot  48  of the first sub-cell  30  of the second cell  29  by the shift length  53 . These separations permit mating of the small and large relays  16 ,  20  to the slots  14  across cell boundaries. The orientation of the first and second cells  28 ,  29  repeats when additional cells are added between end portions  24 ,  26 . 
     Referring to FIGS. 2,  3  and  5 , the four terminal configuration  18  of the small and large relay  16 ,  20  each have a first terminal, a second terminal, a third terminal, and a fourth terminal  54 ,  56 ,  58 ,  60 , which project substantially downward from the relays  16 ,  20  and into the slots  14  of the substrate  12 . The first, second and third terminals  54 ,  56 ,  58  are parallel to one-another and are orientated to form a triangular shape. In assembly, the first terminal  54  is engaged or mated within a longitudinal slot  50  of the second row  36  of the substrate  12 , regardless of the orientation of the relays  16 ,  20  to the substrate  12 . However, depending upon the orientation of the relays  16 ,  20  the second terminal  26  may be mated to one of the slots of the co-linear slot pairs  44  in the first row  34 , or in the third row  38 . Likewise, the third terminal  38  may be mated to one of the slots  14  of the co-linear slot pair  44  of the alternate or remaining outside row, being the third row  38  or the first row  34 . 
     The fourth terminal  60  is positioned perpendicular to the first terminal  54  near and outside of the base of the triangle. Fourth terminal  60  mates with any one of; the first end slot  40 , the second end slots  42 , and the lateral slots  48  within the second row  36  of the substrate  12 . The fourth terminal  60  is located near the opposite edge of the relay  16  or relay  20  from the first terminal  54 . The space between the first terminal  54  and the fourth terminal  60  is substantially equal to the shift length  53 , plus the width  62 , plus the space between the lateral slot  48  and the longitudinal slot  50  of the second row  36  of any sub-cell, as best shown in FIGS. 2 and 3. The distance between the second and third terminals  56 ,  58  is equal to the space between the slot pairs  44  of the first and third rows  34 ,  38  of the substrate  12 . The large relay  20  has the four terminal configuration  18  plus an auxiliary or fifth terminal  61  which is adjacent to and co-linear with terminal  54  and is separated therefrom by the distance  46 . 
     Referring to FIG. 4, a second embodiment of module  10 ′ is illustrated, wherein a maximum of three small relays  16  can mate with the substrate  12  at any one time. Because the small relay  16  can be rotated 180° and still have the capability to mate with the slots  14  of the substrate  12 , relay  16  can be orientated onto the substrate  12  in eight different positions. As best shown in FIGS. 6 and 7, a third and fourth embodiment is illustrated wherein the large relay  20  is capable of mating with the substrate  12  in four different positions. This also accounts for the ability to reverse or rotate the relay  20  by 180°. A maximum of two large relays  20  can mate to the substrate  12  at any one time. Module  10 ″ of the third embodiment shows the fifth terminal  61  mated to the longitudinal slots  50  of the first sub-cells  30 , and module  10 ′″ of the fourth embodiment shows the fifth terminal  61  mated to the longitudinal slots of the second sub-cells  32 . Moreover, any variety of small and large relays  16 ,  20  can mate with the substrate  12  at any one time, as best shown in the first embodiment of FIG.  1 . It is this large variety of relay orientations that provides flexibility in the power distribution module  10  thereby eliminating design changes between vehicle applications. 
     Although the preferred embodiments of the present invention have been disclosed, various changes and modifications may be made thereto by one skilled in the art without departing from the scope and spirit of the invention as set forth in the appended claims. It is also understood that the terms used herein are merely descriptive, rather than limiting, and that various changes may be made without departing from the scope and spirit of the invention.