Abstract:
A thin, lightweight electrical connector box utilizing fewer components due to a construction in which air, instead of insulator boards, is used as the insulating material between the ECU, other electrical components, and an internal circuit contained within the electrical connector box. Externally facing connector modules are sandwiched between a lower case and un upper case. Mounting posts are formed on each end of connector modules to fixedly secure two ends of an ECU baseboard through insertion into opposing holes formed therein. The ECU baseboard is supported by connector modules within the region between the lower case and the upper case.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
   The present disclosure relates to subject matter contained in priority Japanese Application No. 2004-109282, filed on Apr. 1, 2004, which is herein expressly incorporated by reference in its entirety. 
   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates to an electrical connector box including an improved structure for the internal support of an electronic control unit (ECU). 
   2. Description of Related Art 
   Japanese Kokai Patent 2002-84630 is an example of a prior art electrical connector box constructed to enclose an electronic control unit within a case.  FIG. 7  illustrates electrical connector box  1  which is described by JP 2002-84630. As  FIG. 7  illustrates, multiple bus bars  4  and insulator boards  5  are oriented in a stacked configuration within a case formed by upper case  2  and lower case  3 , each bus bar  4  having been press blanked from a sheet of electrically conductive metal. Insulator board  6  is located between ECU  7  and bus bars  4 . 
   Locating insulator board  6  between ECU  7  and bus bars  4  and other devices, however, increases the number of required components as well as the size and weight of electrical connector box  1 . 
   In automotive applications where the electrical connector box is placed within the instrument panel opposing the front passenger seat facing the passenger&#39;s knees, it is preferable that space be provided between the instrument panel and the electrical connector box to provide a crush zone to lessen the force of impact should the passenger happen to strike the instrument panel as a result of sudden braking. 
   SUMMARY OF THE INVENTION 
   In consideration of the shortcomings of the prior art, the present invention includes a thin, lightweight electrical connector box utilizing fewer components in which insulator boards are not positioned between the ECU, internal circuits, and other electrical components and devices, and in which air is employed as part of the insulating structure. 
   An aspect of the present invention provides an electrical connector box including a lower case and an opposing upper case; a plurality of component modules provided between the lower case and the upper case, wherein at least one of the modules faces the exterior of the connector box; a plurality of ECU baseboard mounting posts provided on the modules facing the upper case; and a plurality of attaching elements provided on an ECU baseboard, the attaching elements configured for connection to respective mounting posts so that the modules support the ECU baseboard between the lower case and the upper case. Further, the plurality of component modules may include a connector module, a fuse module, and a relay module. Additionally, the mounting posts may be provided facing the perimeter of the upper case; and the attaching elements may be provided on the perimeter of the ECU baseboard and facing the mounting posts. 
   In a further aspect of the present invention, the electrical connector box may further include an ECU connector, into which terminals connected to ECU conductors project, extending from the perimeter of the ECU baseboard, the ECU connector being positioned in a concave portion formed within the connector module to form a structure that joins, locates, and externally exposes the connector module and ECU connector receptacle on the side of the case. Further, wherein the relay module is positioned within the central portion of the lower case, the relay module including a plurality of relays having conductors welded on an insulator board or mounted to a printed baseboard; the connector module and the fuse module are positioned along the perimeter of the relay module; the ECU baseboard, supported by the connector module and/or the fuse module, is positioned between the relay module and the upper case; and wherein electronic components mounted to the ECU baseboard extend toward the relay module and into spaces between the relays mounted thereto. 
   Further, the electrical connector box may further include a wire conductor internal circuit block positioned within the lower case; wherein the relay module is positioned over the internal circuit block; the connector module and the fuse module are positioned around the perimeter of the relay module at externally facing positions; the ECU is positioned over the relay module; and the upper case is positioned over the ECU. 
   In a further aspect of the present invention, the upper case and the lower case are substantially square shaped. Further, the electrical connector box may further include frame supports provided at the comers of the lower case, the frame supports configured to join to the lower case to the upper case. The assembled case may be substantially square shaped with an overall thin cross section. Further, the case may include an air insulation space provided between internal circuits and electrical components in said case. 
   Because the construction of the present invention supports and positions the ECU at a specific height through at least one of the connector, fuse, or relay modules within the case, space is provided between the other electrical components and internal circuits as a region of air insulation, thus eliminating the need to use conventionally employed insulator boards. This structure thus reduces the number of components while allowing the construction of a lighter electrical connector box that is thinner in cross section. 
   Also, because the ECU baseboard mounting posts are provided on at least one of the connector, fuse, or relay modules facing the perimeter surfaces of the upper case, the attaching elements on the ECU baseboard need only be connected to the mounting posts to secure the ECU within the case, thus providing a simple support structure for the ECU. 
   An ECU connector, into which terminals connected to ECU conductors project, extends from the perimeter of the ECU baseboard and includes a concave portion formed in the connector module, thus forming a structure that joins, locates, and externally exposes the connector module and ECU connector receptacle at the side of the case. 
   This structure is able to dependably locate and secure the ECU because the ECU connector receptacle, which extends from the perimeter of the ECU base board, joins to the concave portion formed in the connector module. In addition, the electrical connector box can be made having a thinner cross section due to the ECU connector receptacle being joined to the connector module in a vertically stacked orientation. Moreover, due to the ECU connector receptacle being located at an externally exposed location at the side of the case, the simple insertion of the appropriate connector into the ECU connector receptacle is all that is required to connect the terminals in the receptacle to the ECU conductors. Furthermore, making this connection from the side of the electrical connector box prevents the upward or downward extension of connectors, and thus allows the electrical connector box to have a thinner cross section. 
   It is preferable that the relay module be located within the central portion of the lower case and be equipped with multiple relays whose conductors are welded on an insulator board, or with multiple relays mounted to a printed baseboard. The connector module and fuse module are located along the perimeter of the relay module, and the ECU baseboard, which is supported by the connector module and or fuse module on the upper case side, is located between the relay module and upper case. Furthermore, it is preferable that the electronic components mounted to the ECU baseboard extend downward toward the relay module into the spaces between the relays mounted to the relay module. 
   Because this structure positions the relay module within the area surrounded by the connector module and or fuse module which are located along the outer perimeter of the case, the relays need not project from the external surface of the case, thus allowing the electrical connector box to be made to thinner cross section. Also, the electronic components attached to the ECU baseboard are provided on the side of the ECU facing the relay module, and extend into the space between the relays projecting from the insulator board of the relay module, thereby allowing the gap between the relay module insulator board and ECU baseboard to be made smaller, and the electrical connector box to be made in a thinner cross section. 
   It is preferable that the wire conductor internal circuit block be placed within the lower case, the relay module be placed over the internal circuit block, the connector module and fuse module be placed around the perimeter of the relay module at externally exposed positions, the ECU be placed over the relay module, and the upper case be placed over the ECU. It is further preferable that the upper and lower case be of approximately square shape with the upper case joining the lower case through frame supports provided at the four corners of the lower case, and that the assembled case be of approximately square shape and have an overall thin cross section. 
   Because the construction of the present invention locates the relay module within the central region of the case, and because the fuse module and connector module surround the perimeter of the relay module while being externally exposed from the side of the case, the relay receptacles, fuse receptacles, and connector receptacles need not be located on top of the upper case nor on the bottom of the lower case. Therefore, the absence of electrical components on the upper and lower surfaces of the case allow the electrical connector box to be made in thinner cross section. 
   Additionally, in a case in which the electrical connector box is provided in a vehicle at a location in front of a passenger, the thin cross section of the electrical connector box provides a greater amount of space between the connector box and the instrument panel, thereby allowing the instrument panel to crush inward to a greater extent should the passenger strike the panel, and thus reducing the shock of collision to provide enhanced protection for the passenger. 
   Further, because the relay module is located between the ECU and internal circuit block, if the ECU were to become dislodged and fall from its secured position on the upper surface of the connector module and/or fuse module, the ECU would remain insulated from the internal circuit block by the relay module. 
   As noted in the previous descriptions, because the electrical connector box invention provides a structure through which the ECU is supported by at least one among a connector module, fuse module, or relay module at a specific height within the case, an air insulation space can be provided between the internal circuits and the other electrical components in the case, and the conventionally used insulating boards can be eliminated. This structure thus reduces the size and thickness of the electrical connector box while reducing the number of components used in its construction. Moreover, the ECU can be simply installed and secured within the case by joining the attaching parts on the ECU baseboard to the ECU mounting posts provided on the upper case side of at least one among the connector module, fuse module, or relay module. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The above, and other objects, features and advantages of the present invention will be made apparent from the following description of the preferred embodiments, given as nonlimiting examples, with reference to the accompanying drawings in which: 
       FIG. 1  is a perspective view of an electrical connector box according to an embodiment of the present invention; 
       FIG. 2  is a cross sectional view of the ECU installation structure of the embodiment of  FIG. 1 ; 
       FIG. 3  is a top plan view of the internal circuit block of the embodiment of  FIG. 1 ; 
       FIG. 4  is a cross sectional plan view of the electrical connector box of the embodiment of  FIG. 1 ; 
       FIG. 5  is a cross sectional view through line A—A in  FIG. 4  of the electrical connector box of the embodiment of  FIG. 1 ; 
       FIG. 6  is a schematic circuit diagram of the relay module, fuse module, internal circuit block, and connector modules of the embodiment of  FIG. 1 ; and 
       FIG. 7  is an example of the prior art. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   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 is taken with the drawings making apparent to those skilled in the art how the forms of the present invention may be embodied in practice. 
   The following will describe preferred embodiments of the invention with reference to the drawings.  FIGS. 1 through 6  describe an embodiment of the present invention in the form of electrical connector box  10  which includes internal circuit block  20  provided in the upper side of lower case  11 , relay module  30  provided in the top part of internal circuit block  20  at the central portion of the case, fuse module  40  and connector modules  50  and  51  provided at locations peripheral to relay module  30 , ECU (electronic control unit)  60  provided above relay module  30 , and upper case  12  which covers the components. 
   Initially, the location and construction of ECU  60  will be described. ECU  60  is supported from below by connector modules  50  and  51  which are located on the respective right and left sides of connector box  10 . Multiple connector receptacles  52  and  53  are respectively formed within connector modules  50  and  51 , and are positioned between lower case  11  and upper case  12 , exposed at the sides to the exterior of the connector box  10 . Also, ECU connector  63  of ECU  60  mounts to cutout portion  55  which is provided on the upper side of connector module  50 . 
   As illustrated in  FIGS. 1 and 2 , connector modules  50  and  51  include posts  57 , formed at the ends thereof, which extend toward the upper case, and also include ribs  58  formed in proximity to posts  57  in the region along the edge of ECU baseboard  61 . 
   Apertures  66 , which serve as attaching elements, are formed in ECU baseboard  61  of ECU  60  at locations opposing posts  57  of connector modules  50  and  51  , and ECU connector  63 , which extends outward from and beneath the edge of ECU baseboard  61 , fits into cutout portion  55  formed in connector module  50 . The insertion of posts  57  of connector modules  50  and  51  into apertures  66  on ECU  60  results in ECU connector  63  being joined to cutout portion  55  in connector module  50 , and ECU connector  63  and connector receptacles  52  of connector module  50  being externally exposed on the side of the case. 
   Pressure tabs  15  extend from specific points on the lower surface of upper case  12 . When upper case  12  is placed over ECU  60 , pressure tabs  15  press ECU baseboard  61  against connector modules  50  and  51 , and posts  57  of connector modules  50  and  51  are permanently inserted into apertures  66  in ECU baseboard  61  to locate ECU  60  with respect to connector modules  50  and  51 . 
   With ECU  60  secured in position on connector modules  50  and  51 , electrical components  62 , which have been soldered to the lower side of ECU baseboard  61 , project into the space between relays  33  which are mounted to insulator board  31  of relay module  30 . Posts  57  of connector modules  50  and  51  may also be provided on fuse module  40  which is located at the perimeter of ECU  60 . 
   The following will explain the connecting structures between internal circuit block  20 , relay module  30 , fuse module  40 , connector modules  50  and  51 , and ECU  60 . Wires ‘w’, which are the electrical conductors of internal circuit block  20 , are positioned within open bottomed box shaped case  21 , and are arranged on the underside of the top part of the case. As shown in  FIG. 3 , multiple terminal slots  23 ,  24  and  25  are formed in top plate  22  of case  21  at points in proximity to relay module  30 , fuse module  40 , and connector modules  50  and  51 . Each connecting terminal  43  and  54  of bus bar  20  (of relay module  30 ), fuse module  40 , and connector modules  50  and  51  passes through terminal slot  23 ,  24 , or  25  and connects to wires ‘w’ inside of case  21 . Female connector block  26  extends upward from the peripheral part of case  21  not occupied by fuse module  40  and connector modules  50  and  51 , and connects to male connectors  65  on ECU  60  to connect wires ‘w’ to the ECU conductors. Four L-shaped locating posts  27  are provided on the upper surface of the central region of top plate  22  to position the four corners of insulator plate  31  of relay module  30 . In addition, insulator plate  28  is provided beneath internal circuit block  20 . 
   Relay module  30  is located over the central portion of internal circuit block  20 . Bus bars  32 , which are press blanked from conductive sheet metal to required shapes, are fixedly provided on the upper surface of insulator plate  31 ; and relays  33 , whose terminal parts are welded to bus bars  32 , are also fixedly attached to insulator board  31 . 
   As illustrated in  FIG. 4 , electrical power is supplied to relay module  30  through input bus bar  32   a . Terminal end  32   a - 1  of input bus bar  32   a  extends into connector receptacle  56  which forms the power input portion of connector module  50 , and connects to a power terminal to be inserted therein. The other end of input bus bar  32   a  is soldered to the input terminals of relays  33 . Regarding the output side of relay module  30 , output bus bar  32   b , which connects to fuses  44  of fuse module  40 , extends horizontally from the edge of insulator plate  31 , and the tips of friction tabs  32   b - 1  extend into fuse receptacles  41  of fuse module  40  to make friction connection to the input terminals of fuses  44 . The portion of output bus bar  32   c  that does not connect to fuses  44  extends beneath insulator board  31 , through terminal slots  23  formed in case  21  of internal circuit block  20 , to make friction connection to wires ‘w’ of the internal circuit block. Relay module  30  may also include a printed circuit board on which multiple relays are mounted. 
   Fuse module  40  is located on the forward facing surface of electrical connector box  10  (the lower part of the connector box as shown in  FIG. 4 ) and contains two horizontal rows of fuse receptacles  41  that are externally exposed on the side of the connector box between lower case  11  and upper case  12 . The upper and lower fuse receptacle rows are mutually offset in the horizontal direction so as not to align vertically. 
   Bus bar  42  connects to the input terminals of fuses  44  within fuse receptacles  41 . As shown in  FIG. 5 , One end of bus bar  42  is formed as friction tab  42   a  that makes frictional connection with the fuse  44  terminal, and the other end  42   b  extends toward connector module  50  on the right side of electrical connector box  10 . Connecting part  42   b  is resistance welded to connector part  32   a - 2 , which branches off from relay module  30 , to form welded joint  45 . Therefore, attaching an electrical power connector to receptacle  56 , which is the power input part of connector module  50 , results in the supply of electrical power to both relay module  30  and fuse module  40 . In addition, the input terminals of the fuses  44  that do not connect to bus bar  42  connect to friction tabs  32   b  of bus bar  32   b  which extend from relay module  30 . As shown in  FIG. 5 , L-shaped connector terminals  43 , each having two ends formed as friction connecting parts, connect to the output terminals of fuse  44 . One end, which is end  43   a , extends into fuse receptacle  41 , and the other end, which is end  43   b , bends downward and passes through terminal slot  24  into case  21  of internal circuit block  20  to make connection to wires ‘w’. 
   Connector receptacles  52  and  53 , which are parts of connector module  50  and  51 , respectively, are externally exposed on the side of the connector box between lower case  11  and upper case  12 . Connector receptacle  56  is formed as the electrical power input portion of connector module  50  (module  50  being positioned on the right side) and is externally exposed on the side of the connector box. 
   Connectors  54 , which join to the terminals within the connector inserted into connector receptacles  52  and  53 , are all formed in an “L” shape. One end of each connector is formed as male tab  54   a  that extends into connector receptacle  52  and  53  for connection to the terminal in the mating connector, and the other end is formed as friction connector  54   b  that bends downward and extends through a terminal slot  25 , which is provided in case  21  of internal circuit block  20 , for connection to wire ‘w’ of the internal circuit. 
     FIG. 6  is a schematic circuit diagram of relay module  30 , fuse module  40 , and connector modules  50  and  51 . Power circuit  70 , which supplies power to the load side, forms a connection between the power input part and connector modules  50  and  51  through relay module  30 , fuse module  40 , and internal circuit block  20 . Control circuit  71 , which provides a control function for power circuit  70 , connects the power input part to connector modules  50  and  51  through relay module  30  and internal circuit block  20 . Also, additional circuit  72  is connected to the power input part through welded joint  45  without going through relay  33  of relay module  30 , and thus makes connection to connector modules  50  and  51  directly through fuse module  40  and internal circuit block  20 . 
   As illustrated in  FIG. 1 , female connector  65  projects from the lower edge of ECU baseboard  61  at the rear side of electrical connector box  10 . Connector  65  joins to male connector  26 , thereby joining respective terminals within each connector to connect wires ‘w’ in the internal circuit to the conductors of ECU  60 , and thus supply electrical power to ECU  60 . One end of contact terminals  64  connects to the conductors of ECU  60 , and the other end extends into ECU connector  63  for connection to terminals of the connector to be inserted into ECU connector  63 . 
   Frame supports  13  extend from the four corners of the floor plate of approximately square shaped lower case  11 , and lower case  11  joins to approximately square shaped upper case  12  through frame supports  13 . Fuse module  40  is located on the forward facing side of the assembly between lower case  11  and upper case  12 , and connector modules  50  and  51  are located on the right and left sides, respectively at 90-degree angles to fuse module  40 . Fuses are inserted into fuse module  40  in a direction 90 degrees to relays  33  which extend upward from the top surface of insulator board  31 , as do the connectors that are inserted into the receptacles of connector modules  50  and  51 . Frame supports  13  are L-shaped structures incorporating guide channels  14  formed in both ends, thereby providing a mechanism that guides the sliding insertion of the ends of each module into guide channels  14 . 
   The following will describe the procedure through which electrical connector box  10  is assembled. Insulator board  28  and internal circuit block  20  are initially installed into lower case  11  from the top. Next, terminal end  32   a - 1  of relay module  30  input bus bar  32   a  is placed into connector receptacle  56  of connector module  50 , friction tabs  32   b - 1  of output bus bar  32   b  are placed into fuse receptacle  41  of fuse module  40 , and connector part  32   a - 2  of input bus bar  32   a  and connector part  42   b  of fuse module  40  bus bar  42  in fuse module  40 , which mutually overlap, are joined through resistance welding. This single assembly of relay module  30 , fuse module  40 , and connector modules  50  and  51  is then placed onto internal circuit block  20 . At this stage, the connector terminal of each module and bus bar friction tabs are inserted through the terminal slots in case  21  of internal circuit block  20 , and frictionally connected to wires ‘w’ to form the internal circuit. The ECU is then placed on top of the modules, and female connector  65  is joined to male connector  26  of internal circuit block  20  to make connection between wires ‘w’ of the internal circuit and the ECU  60  conductors. Also, ECU connector  63  is joined to cutout portion  55  in connector module  50 . Lastly, upper case  12  is placed over the assembly and connected to lower case  1  through frame supports  13 . 
   This structure uses connector modules  50  and  51  to support the right and left edges of ECU  60  at a desired height, therefore providing space between ECU  60  and relay module  30  and mutually insulating the two components with air without the need for insulator boards used by prior art structures. This structure reduces weight, requires fewer components, and results in electrical connector box  10  having a thinner cross section. 
   In addition, this structure provides mounting posts  57 , which are formed on connector modules  50  and  51  and extend upward toward upper case  12 , for insertion into apertures  66  in the ECU baseboard, thus providing for the simple installation and securing of ECU  60  within the case. In addition, because electronic components  62  attached to ECU baseboard  61  extend into the space occupied by relays  33  which extend from insulator board  31 , the gap between insulator board  31  of relay module  30  and ECU baseboard  61  is reduced, thus allowing electrical connector box  10  to be made to thinner cross section. 
   In particular, in an application where electrical connector box  10  is installed at a location in front of a passenger in an automobile, the reduced thickness of connector box  10  allows more space between connector box  10  and the instrument panel, thereby allowing the instrument panel to crush in to a greater extent should the passenger strike the panel due to sudden braking or like occurrence, thus reducing the shock of collision and providing enhanced protection for the passenger. 
   Moreover, while this embodiment describes the ECU as being supported from beneath by the connector modules, a structure may be employed wherein the fuse module and/or relay module support the ECU. 
   Although the invention has been described with reference to an exemplary embodiment, it is understood that the words that have been used 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 invention in its aspects. Although the invention has been described with reference to particular means, materials and embodiments, the invention is not intended to be limited to the particulars disclosed. Rather, the invention extends to all functionally equivalent structures, methods, and uses such as are within the scope of the appended claims.