Abstract:
In one aspect of the present invention, a power distribution bus bar that includes a first conductive bus bar configured to receive power from a power source. A plurality of stamped finger-like clamping members are integrally formed to the first conductive bus bar and configured to distribute power to a secondary high power bus bar within a power distribution box. The plurality of stamped finger-like clamping members apply a compression force to the secondary high power bus bar for securing the secondary high power bus bar within the power distribution box.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    Not Applicable 
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not Applicable 
       REFERENCE TO A SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTING COMPACT DISC APPENDIX 
       [0003]    Not Applicable 
       BACKGROUND OF THE INVENTION 
       [0004]    1. Field of the Invention 
         [0005]    This invention relates in general to a vehicle power distribution box, and more specifically, to a serviceable power distribution module of the power distribution box. 
         [0006]    2. Background of Related Art 
         [0007]    A vehicle power distribution box is typically a relay block connected to a vehicle power source such as a battery for distributing power to various components of the vehicle. The power distribution box typically includes a casing having an open and closeable serviceable region. Power-supply conduits are typically routed through the bottom of the power distribution box and are connected to a bus bar in the casing via bolts. Power is distributed from the bus bar wires. Terminals connected to the ends of the wires are secured in the bottom of the box and are positioned in spaced relation to output terminals for electrical connection to the output terminals. Fuses or relays used to electrically connect the input terminals and output terminals are serviceable from the top of the power distribution box for electrically connecting the input power terminals to the output power terminals. Typically, high power connections, for example connections from the battery, require a terminal bolt-fastening operation. Such an operation creates assembly and servicing inefficiencies. 
       BRIEF SUMMARY OF THE INVENTION 
       [0008]    The present invention has the advantage of providing a serviceable connection to a high power distribution module within the power distribution box. Each of the components within the module are detachable from one another minimizing the use of threaded fasteners thereby increasing assembly efficiency and service efficiency. 
         [0009]    In one aspect of the present invention, a power distribution bus bar that includes a first conductive bus bar configured to receive power from a power source. A plurality of stamped finger-like clamping members are integrally formed to the first conductive bus bar and configured to distribute power to a secondary high power bus bar within a power distribution box. The plurality of stamped finger-like clamping members apply a compression force to the secondary high power bus bar for securing the secondary high power bus bar within the power distribution box. 
         [0010]    In yet another aspect of the present invention, a power distribution box is provided for distributing power from a power source to vehicle electrical components. The power distribution box includes a power distribution box housing and a fastenerless detachable high power bus bar that includes a plurality of high-current fastenerless terminals for distributing power to output devices. The plurality of high-current fastenerless terminals each have an integrated fuse for terminating power across a respective high-current fastenerless terminal during a power overload condition. A plurality of housing connectors is inserted within the housing configured to electrically couple the plurality of high-current fastenerless terminals to an output device conduit. A power distribution box busbar receives power from the power source. The power distribution busbar includes a plurality of stamped finger-like clamping members for distributing power to the detachable high power bus bar. The plurality of stamped finger-like clamping members secures the detachable high power bus bar within the power distribution box. 
         [0011]    Various objects and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the preferred embodiment, when read in light of the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  is a plan view of a vehicle engine compartment of the present invention. 
           [0013]      FIG. 2  illustrates a perspective view of a power distribution box of the present invention. 
           [0014]      FIG. 3  illustrates a perspective view of a power distribution module of the present invention. 
           [0015]      FIG. 4  illustrates an exploded view of the power distribution module of the present invention. 
           [0016]      FIG. 5  illustrates a perspective view of a detachable high power bus bar of the present invention. 
           [0017]      FIG. 6  illustrates a perspective view of a power distribution bus bar of the present invention. 
           [0018]      FIG. 7  illustrates a side view of the detachable high power bus bar of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0019]    Referring now to the drawings, there is illustrated in  FIG. 1  a vehicle  10  having a power distribution box (PDB)  12 . The PDB  12  distributes power provided by a vehicle&#39;s power source, such as a vehicle battery, shown generally at  14 . 
         [0020]    The vehicle power source  14  is electrically connected to the PDB  12  via a power source conduit  16 . The PDB  12  distributes power to various electrical devices within the engine compartment and throughout the vehicle  10 . Examples of such electrical devices for which power may be provided from the PDB  12  include, but are not limited to, an alternator  18 , an electric assist steering motor  20 , and a smart power distribution junction box  22 . 
         [0021]      FIG. 2  illustrates a perspective view of the PDB  12 . The PDB  12  includes a plastic, non-conductive housing  24 . Electrical conduits are routed through the bottom of the housing  24  for coupling to terminals disposed within the housing  24 . Respective input and output terminals disposed within the housing  24  are electrically connected to one another via a fusing device such as a relay or a fuse (not shown). The PDB  12  includes a plurality of mounting sockets  26  disposed in its upper surface  28 . Respective female input terminals and female output terminals are secured within the mounting sockets  26 . A respective fuse or relay is mounted within a respective set of mounting sockets  26  for distributing power from a respective input terminal to a respective output terminal. 
         [0022]    The PDB  12  further includes a power distribution module  30 . The power distribution module  30  is a detachable modular electronic device for receiving high input power from the vehicle battery  14  (shown in  FIG. 1 ) and for distributing high power to a plurality of output devices. The power distribution module  30  is secured to the PDB  12  by a plurality of stamped finger-like clamping members  31  which will be discussed in detail below. The plurality of stamped finger-like clamping members  31  provides a fastenerless connection between the PDB  12  and the power distribution module  30 . The substantial portion of the electrical connections to the power distribution module  30  is secured by fastenerless connections. Providing fastenerless connections to the power distribution module  30  reduces the assembly inefficiencies and service inefficiencies. 
         [0023]    Referring now to both  FIGS. 3 and 4 , the power distribution module  30  includes a module housing  34  made of a non-conductive material such as plastic. A conductive stud  36  is secured to the module housing  34 . The conductive stud  36  may be secured to the module housing  34  as part of an insert mold operation or the module housing  34  may include a slot for capturing the conductive stud  36  to the module housing  34 . 
         [0024]    A detachable high power bus bar  38  having a plurality of conductive terminals is secured to the module housing  34  via locating studs  39  which will be discussed in detail below. Alternatively, the detachable high power bus bar  38  may be secured to the PDB by a method other than the locating studs. 
         [0025]      FIG. 5  illustrates an enlarged view of the detachable high power bus bar  38 . The detachable high power bus bar  38  is preferably formed by a stamping operation. The detachable high power bus bar  38  includes a main body portion  43  and the plurality of conductive terminals. The main body portion  43  is formed at a substantially right angle to the plurality of conductive terminals for seating against the module housing  34  (shown in  FIG. 3 ). A first high-current fastenerless terminal  46  distributes power received from the plurality of finger-like clamp members  31  to one of the output devices shown in  FIG. 1 . The first high-current fastenerless terminal  46  includes a fuse  48  integrated within the second high-current fastenerless terminal  46  for protection against a power overload condition. A second high-current terminal  50  distributes the power received from the second high-current fastenerless terminal  44  to the alternator  18  (shown in  FIG. 1 ). The second high-current terminal  50  includes a fuse  52  integrated within the second high-current terminal  50  for protecting against a power overload condition. Alternatively, the detachable high power bus bar  38  may include additional high-current fastenerless terminals for distributing power to other various output devices. In addition, the first and second high-current fastenerless terminals  46  and  50  include apertures  53  for locating and securing the respective terminals on the module housing  34  to the locating studs  39 . 
         [0026]    Referring again to  FIGS. 3 and 4 , the second high-current terminal  50  of the detachable high power bus bar  38  includes an aperture  54  for receiving the conductive stud  36 . A nut  56  secures a high power output conduit  58  to the third high-current terminal  48  and conductive stud  36  for distributing power from the power source  14  to the alternator  18  via the PDB  12  (shown in  FIG. 1 ). The locating studs  39  of the module housing  34  are aligned with the apertures  53  of the plurality of terminals for locating and securing the plurality of high current terminals of the detachable high power bus bar  38  to the modular housing  34 . The module housing  34  may also include locating guides  59  for locating the plurality of terminals of the detachable high power bus bar  38  within the module housing  34  during assembly. 
         [0027]    A first plastic housing connector  60  is inserted within the module housing  34  for coupling the first high-current fastenerless terminal  46  to the power source conduit  16 . The first plastic housing connector  60  utilizes a snap-fit connection for securing the first plastic housing connector  60  to the module housing  34 . The plastic housing connector  60  includes a first terminal receiving end  62  for coupling to the first high-current fastenerless terminal  46 . The first plastic housing connector  60  further includes a second terminal receiving end  64  configured to be coupled to the power source conduit  16 . Alternatively, an additional plastic housing connector may be inserted within the housing for coupling additional respective high current fastenerless terminals to respective output device conduits. Moreover the plastic housing connector may include a plurality of receiving slots for accommodating a plurality of high-current fastenerless terminals. 
         [0028]      FIG. 6  illustrates a perspective view of a power distribution bus bar  70  including the plurality of finger-like clamp members  31 . The plurality of finger-like clamp members  31  are segregated into sets of finger-like clamp members. As shown in  FIG. 6 , the power distribution bus bar  70  includes a first set  72  and a second set  74 . Alternatively, the power distribution bus bar  70  may include additional sets to secure the detachable high power bus bar  38  to the power distribution bus bar  70 . Each respective set of finger-like clamp members include a plurality finger-like members, preferably formed from a stamping operation, although other processes may be used to form the plurality of finger-like members. A respective set of finger-like members includes an upper group of finger-like members  76  and an opposing lower group of finger-like members  78 . Each of the finger-like members have an arcuate shape and are resilient for allowing the detachable high power bus bar  38  to be disposed between the upper group of finger-like members  76  and the lower group of finger-like members  78 . Preferably each respective finger-like member of the upper group  76  alternates with a respective finger-like member of the lower group  78  for forming a respective clamping member which allows an equal force to be exerted on the attaching power bus bar  38  as it is inserted between the upper group  76  and lower group  78 . The resiliency of the each respective finger-like member exerts a restorative force against the detachable high power bus bar  38  thereby holding the detachable high power bus bar  38  in compression between the first group  76  and the second group  78 . 
         [0029]      FIG. 7  illustrates a side view detachable high power bus bar  38  coupled to the power distribution bus bar  70 . A clamping section  80  of the detachable high power bus bar  38  is inserted between the upper group  76  and the lower group  78  of a respective finger-like clamp member. A compression force is exerted on the detachable power bus bar  38  by the upper group  76  and lower group  78  for securing the detachable power bus bar  38  therebetween. In addition the secured connection between the plurality of finger-like clamping members provides a tight electrical connection that minimizes arcing across the two electrical distribution devices. This slip fit connection between the power distribution bus bar  70  and the detachable high power bus bar  38  eliminates the use of fasteners which reduces the overall cost of the electrical distribution system. 
         [0030]    The fastenerless connections provide for increased assembly efficiency and service efficiency while providing a secure attachment between the high power coupling devices. As a result, the power source conduit and output device conduits may be easily detached from the power distribution module. Moreover, the power distribution module may be easily serviced if parts require changing since module itself is easily removable from the PDB in addition to the components being easily serviceable from the housing of the power distribution module. 
         [0031]    In accordance with the provisions of the patent statutes, the principle and mode of operation of this invention have been explained and illustrated in its preferred embodiment. However, it must be understood that this invention may be practiced otherwise than as specifically explained and illustrated without departing from its spirit or scope.