Abstract:
A power distribution module for a personal recreational vehicle includes a housing and a cover. The housing defines an interior and includes a wall having an array of receptacle openings. The receptacle openings are adapted to receive and secure electrical components inside the housing. A distribution harness includes a plurality of electrical conductors and is coupled to the housing wherein the electrical conductors are in electrical communication with the electrical components inside the housing. The power distribution module can optionally include a decal to assist quick and accurate placement of the electrical components during the manufacturing process. A method for producing a personal recreational vehicle having a standardized housing over a range of models. The housing includes a component arrangement guide for locating and installing electrical components.

Description:
PRIORITY CLAIM 
     This application constitutes a continuation of co-pending, commonly-owned U.S. patent application Ser. No. 11/427,280 filed Jun. 28, 2006 entitled, “POWER DISTRIBUTION MODULE FOR PERSONAL RECREATIONAL VEHICLE,” which is a continuation of co-pending commonly-owned U.S. patent application Ser. No. 10/283,427 entitled “POWER DISTRIBUTION MODULE FOR PERSONAL RECREATIONAL VEHICLE,” filed on Oct. 29, 2002. 
    
    
     FIELD OF THE INVENTION 
     The invention relates generally to personal recreational vehicles, and more particularly to a power distribution module for use with engines that power personal recreational vehicles. 
     BACKGROUND OF THE INVENTION 
     Personal recreational vehicles, such as snowmobiles and ATV&#39;s, are used by millions of people for sport and fun. To illustrate, snowmobiling is a sport enjoyed by individuals of all ages and walks of life. Although interest in snowmobiling has traditionally been considerable, in recent years the sport has seen its popularity soar. For example, according to the International Snowmobile Manufacturers Association, about 82,000 snowmobiles were sold in the United States in 1992. By 1997, that number topped 170,000 units. 
     Similarly, the number of Americans driving off-road vehicles such as ATV&#39;s increased from 19.4 million in 1983 to 27.9 million in 1995. The increase in use of personal recreational vehicles is partly due to technological advancements of the equipment, advances that have made use safer and easier for persons of differing levels of ability. 
     For example, snowmobiles have become more comfortable, responsive and maneuverable, resulting in a more pleasing and exciting riding experience for the driver. One advancement of particular importance is the improvement in the maneuverability and stability of snowmobiles. As these characteristics have advanced, a greater number of individuals have been drawn to the sport. The industry has kept pace with the growth in the sport by expanding the number of models available across a range of prices. ATVs have seen similar types of changes and improvements. 
     The growing popularity of personal recreational vehicles puts an increased demand on manufacturers to reduce cost of the vehicles. One way manufacturers can reduce cost is to standardize components, both within and across a product line. Standardization reduces manufacturing cycle time as well as cost. 
     All personal recreational vehicles include some type of power distribution system for routing and control of power and signals throughout the vehicle. The power distribution system usually includes a fuse box, with individual fuses blowing when the fuse rated power is exceeded. Other components such as diodes and relays are housed in other locations. 
     For the reasons stated, it is desirable to devise a means by which the power distribution module can be easily standardized for manufacturing. Additionally, it is also desirable to have a power distribution module that includes components other than fuses. 
     SUMMARY OF THE INVENTION 
     Against this backdrop, the invention has been created. One aspect of the present invention is directed to a power distribution module for a personal recreational vehicle. The power distribution module includes a housing defining an interior and including a component attachment portion and a cover. The housing further includes a plurality of receptacle openings in a wall in the component attachment portion, and the receptacle openings are spaced-apart and adapted for receiving and securing electrical components within the housing. The power distribution module further includes a distribution harness having a plurality of electrical conductors, wherein the electrical conductors electrically cooperate with the receptacle openings to connect to the electrical components, and the conductors are adapted to distribute power. 
     Another aspect of the present invention is directed to a personal recreational vehicle having an electrical distribution system for distributing electrical signals and power. The electrical distribution system includes a power distribution module, wherein at least a portion of the electrical signals and power passes through the power distribution module. The power distribution module includes a housing having a plurality of receptacle openings in a wall, and the receptacle openings are spaced-apart in an array and adapted for receiving electrical components. The power distribution module also includes a distribution harness having a plurality of electrical conductors, and the electrical conductors electrically cooperate with the receptacle openings for receiving electrical components. 
     Another aspect of the invention is directed to a power distribution system for a personal recreational vehicle including a distribution harness for distributing power and electrical signals adapted to be connected to electrical components; and means for connecting the distribution harness to the electrical components. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  depicts an ATV incorporating an example embodiment of the power distribution module of the present invention. 
         FIG. 2  is a perspective view of an example of an embodiment of a power distribution module of the present invention. 
         FIG. 3  is a perspective view from the opposite side of the power distribution module of  FIG. 2 . 
         FIG. 4  is an elevational view of the cover for a power distribution module shown in  FIGS. 2 and 3 . 
         FIG. 5  is a top view of the cover of  FIG. 4 . 
         FIG. 6  is a bottom view of the cover of  FIG. 4 . 
         FIG. 7  is an elevational view of the power distribution module shown in  FIGS. 2 and 3 . 
         FIG. 8  is a top view of the power distribution module of  FIG. 7 . 
         FIG. 9  is a bottom view of the power distribution module of  FIG. 7 . 
         FIG. 10  is an end view of the component attachment module of  FIG. 7 . 
         FIG. 11  is a schematic of a decal indicating the layout of electrical components for use in a power distribution module having a 4 by 10 array of receptacle openings in accordance with an example embodiment of the present invention. 
         FIG. 12  is a section view of an example embodiment of a catch and latch assembly in the open position for use as a one-handed opening mechanism according to the present invention. 
         FIG. 13  is a section view of an example embodiment of a catch and latch assembly in the open position for use as a one-handed closed mechanism according to the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     In general, the present disclosure discusses a power distribution module for use in a vehicle. The power distribution module tile is capable of being made water-resistant and opens and closes using a one-handed operation, and includes other desirable properties. 
       FIG. 1  depicts an ATV  100  with a steering mechanism  102  that controls the orientation of a set of front wheels  106  via a steering shaft  104 . The steering shaft  104  couples the steering mechanism  102  with the front wheels  106  via tie rods (not shown) that connect the steering shaft  104  to the suspension system (not shown) of the front wheels  106 . The details regarding the coupling of the steering shaft  104  and the suspension system for the wheels  106  vary from ATV to ATV and are known and are not the focus of the present invention. Therefore, they are not discussed further. As the steering mechanism  102  is turned, the front wheels  106  also turn, thereby controlling the direction in which the ATV  100  moves. An engine  108  is mounted toward the front of the chassis of the ATV  100 . The engine provides power to the drive train (not shown) of the ATV  100 . The details of the drive train vary from ATV to ATV, but according to the present invention, the ATV will have a power distribution module  110  to control the flow of power and electrical signals. The power distribution module will typically be located on a portion of the frame of the ATV near the engine compartment. However, the location can vary depending on the ATV. Similarly, the power distribution module of the present disclosure can be used on a snowmobile, and its use and placement are dictated by considerations similar to those in using the power distribution in an ATV. 
     Referring generally to  FIGS. 2-10 , an example of an embodiment of a power distribution module  210  of the present invention is shown. Power distribution module  210  is adapted for housing and securing electrical components to protect them from inclement operating conditions. Power distribution module  210  includes a housing  220 , the housing  220  defining an interior, and a distribution harness  260 . The housing  220  includes a component attachment portion  230  adapted to receive and hold electrical components (not shown). Electrical components are held in place in receptacle openings  232  in a wall  231  of the housing  220 . The receptacle openings  232  are spaced apart and adapted to receive and secure electrical components within the housing, as will be discussed further. 
     In the example embodiment shown, the housing  220  includes a component attachment portion  230  and a removable cover  250 . Preferably, when the cover  250  is removably secured to the component attachment portion  230  of the housing  220 , a waterproof seal is formed, keeping the electrical components protected in the interior of the housing  220  free from condensation or other aqueous materials, such as oil or mud, that can cause the electrical components to have a shortened life or fail. One of skill in the art will recognize that many modifications could be made to make the housing waterproof, such as a lip and a gasket. 
     A latch  252  on the cover  250  may engage with a catch  240  on the component attachment portion  230  to removably secure the cover  250  in place. An advantage of the example embodiment shown is that a user can remove the cover  250  from the component attachment portion  230  using only one hand, as will be discussed further below, by disengaging each latch  252  from its catch  240 . This is especially helpful when accessing the power distribution module  210 , which may not be easily accessible. This allows for easy access to the electrical components in the event that one needs to be replaced, since the power distribution module  210  is typically located in a small and cluttered space. The cover  250  also can be seated in place by engaging one or more stops  238  protruding from an outer surface  237  of the component attachment portion  230 . When the cover  250  is secured to the component attachment portion  230 , the electrical components in the interior are protected from the elements. Optionally, one or more mounting brackets  244  can be included on the housing  220  for connecting to a complementary mating portion (not shown) located on the ATV frame to releasably secure the power distribution module  210 . 
     Referring to  FIGS. 12-13 , shown is an exemplary embodiment of a latch  252  and catch  240  arrangement that allows for one-handed removal and placement of the cover  250  on the component attachment portion  230 , such as that shown in FIGS.  1 - 2 . Catch  240  includes a distal end  281  and a proximal end  282 . Proximal end  282  of catch  240  is attached to the cover  250 . Proximal end  282  includes an arcuate section  283  that forms a pocket  284  between depending section  285  of catch  240  and the cover  250 . Pocket  284  holds a sealing member  285 , for example, a gasket or O-ring. Distal end  281  of catch  240  includes an engagement member  286 . Catch  240  also includes a resilient portion  287  that allows the distal end  281  of catch  240  to move towards and away from the cover  250 . The resilient portion  287  biases the catch  240  into an engagement position away from the cover  250  when there is no force applied to catch  240 . Catch  240  also includes a finger engagement portion  288 . Force F 1  applied to the finger engagement portion  288  moved the distal end  281  of the catch  240  towards the cover  250 . Catch  240  includes a flange member  290  extending from the wall of the component attachment portion  230 . The flange member  290  includes a distal portion  291  located away from the component attachment portion  230 . A protruding shoulder  292  projects from the distal end  291  of the flange member  290 , forming a catch receiving area  293  there between. Latch  252  also includes an arcuate section  294  for receiving into the pocket  284  of catch  240 . 
       FIG. 12  shows the cover  250  and component attachment portion  230  with the cover  250  disengaged.  FIG. 13  shows the cover  250  engaged with the component attachment portion  230 , whereby a watertight seal is formed. Beginning from the disengaged position, cover  250  is engaged with the component attachment portion  230  by inserting the distal end  281  of the catch  240  into the catch receiving area  293  of the latch  252 . As the catch  240  moves into the engagement position with the latch  252 , a ramp  289  engages the upper end  296  of the shoulder  292 , creating an inward force F 1  that moves the distal end  281  of the catch  240  towards the cover  250 . The catch  240  is moved into the catch receiving area  293  until the engagement member  286  of the catch  240  clears the lower end  295  of the shoulder  292 , removing the inward force F 1  from the distal end  281  of the catch  240 . Upon removal of the force, the resilient portion  287  of the catch  240  returns the catch  240  to the unbiased position and the engagement member  286  of the catch  240  engages the lower end  295  of the shoulder  292 , securing the cover  250  onto the component attachment portion  230 . A watertight seal is formed by the sealing member  285  being compressed into the pocket  284  by the arcuate section  294  of the latch  252 . Preferably, the pocket  284  runs around the entire periphery of the cover  250 , and the sealing member  285  is made from one piece of material, minimizing the chance that leak points exist. Compression of the sealing member  285  also creates a compressive force that holds the engagement member  286  against the lower end  295  of the shoulder  292 , creating an interference fit that keeps the cover  250  secured. 
     Referring to  FIGS. 1-2  &amp;  12 - 13 , to remove the cover  250  from the component attachment portion  230  via a one-handed operation, a force F 2  is applied to the finger engagement portion  288  ˜f each catch  240 , moving each catch  240  towards the cover  250  until the engagement member  286  clears the shoulder  292 . The compressive force stored in the sealing member  285  then moves the cover  250  slightly away from the component attachment portion  230  and the cover  250  can be completely removed from the component attachment portion  230 , allowing access to the components. 
     Referring generally to  FIGS. 2-10 , the power distribution module  210  may be mounted to a distribution harness  260 . The distribution harness  260  includes a plurality of electrical conductors  262 , which optionally can be housed within a sheath  269  to keep the conductors  262  in a bundle. Each electrical conductor  262  optionally may include an insulating covering (not shown). Each electrical conductor  262  goes into an associated receptacle opening  232 , and is in electrical communication with an electrical component secured into receptacle openings  232  inside the housing. One or more electrical components are secured into the receptacle openings  232  in the housing  220 . The electrical components can be of any type typically used in power distribution systems, such as resistors, capacitors, diodes and fuses. 
     Referring to  FIGS. 2 and 3 , the distribution harness  260  preferably is secured to the housing  220  to keep the conductors  262  in an orderly bundle. In the example embodiment shown, a first cable tie  264  secures a first section  265  of the distribution harness  260  to a first cable tie down  234  on the component attachment portion  230  of the housing  220 , and a second cable tie  266  secures a second section  267  of the distribution harness  260  to a second cable tie down  236  on the component attachment portion  230  of the housing  220 . Optionally, a third cable tie  268  can secure conductors in the bundle at a third section  269  between the first and second sections  265 ,  267  of the distribution harness  260 . The third cable tie  268  also secures conductors or other elements in the distribution harness  260  that do not contain termination points into the receptacle openings  232 . 
     Referring to  FIG. 9 , in the example embodiment shown, the receptacle openings  232  are arranged in an array  242  of rows and columns having a regular spacing. The spacing can be selected so that the array  242  is adapted to receive and secure standardized electrical components. An advantage of having the array  242  of receptacle openings  232  with a regular spacing pattern is standardized electrical components can be located and installed easily in the power distribution module. Preferably, the array  242  spacings are identical in the transverse T and lateral L directions. More preferably, the spacing is such that the receptacle openings  232  are arranged to receive ATO™ or ATC™ specification electrical components. 
     Referring to  FIG. 11 , a component arrangement guide  300  is shown. Preferably, component arrangement guide  300  is a decal. A decal allows for easy identification and location of electrical components across product and model lines by placing the decal over the receptacle opening ( 232  as seen in  FIGS. 3 and 9 ). The electrical components can then be easily located and installed. In the example embodiment shown, component arrangement guide includes a schematic for placing fuses  302 , diodes  304 , and a relay  306  in the receptacle openings of a power distribution module. The use of the decal allows each component to be easily located and installed into its proper receptacle opening, and also allows for easy identification of a specific component location if it needs to be replaced during maintenance. 
     An advantage of the power distribution module of the present invention is that it can be used across a variety of models of personal recreational vehicle by using a standardized housing common to the models. A method of producing a plurality of personal recreational vehicle models is accomplished using the standardized power distribution module, thereby saving time and increasing product quality by allowing a reduction in inventory of parts specific to each model and also allowing for accurate placement of the electrical components during assembly. The power distribution module includes a plurality of receptacle openings passing from an interior to an exterior of the housing and is assembled into the personal recreational vehicle. By placing a component arrangement guide adjacent the receptacle openings on the interior side of the housing, the electrical components can be quickly and accurately installed. The component arrangement guide includes a schematic indicating placement of electrical components. Preferably, the component arrangement guide is a decal, which can be pre-printed with electrical components arranged for later installation. 
     When the component arrangement guide is used, the plurality of electrical components are installed into the housing into a position in the receptacle openings as indicated by the component arrangement guide. The electrical components can be installed before or after the power distribution module is placed into the personal recreational vehicle. When the electrical components and conductors are installed into the receptacle openings, each electrical component is electrically connected to an associated electrical conductor. 
     Each electrical component can be connected to its respective electrical conductor through its respective receptacle opening by a variety of techniques known in the art. 
     The preferred method of connecting is to strip any insulation off the end of the conductor to be inserted into a receptacle opening. The stripped end is inserted into its respective receptacle opening. Retention of the stripped end in the receptacle opening can be enhanced by shaping the stripped end to form fingers that will snap into one or more recesses in a sidewall of the receptacle opening, thereby locking the stripped end into the receptacle opening. If necessary, removal of the stripped end from its receptacle opening is accomplished by using an extraction tool that is inserted into the receptacle opening opposite the electrical conductor side to push the conductor out of the receptacle opening. 
     Preferably, the electrical conductors are installed before the electrical components. After each electrical conductor is inserted into its respective receptacle opening, each electrical component is inserted into its appropriate location in the power distribution module, as indicated by the component arrangement guide. Preferably, each electrical component will have male-blade terminals that are inserted into their respective receptacle openings and the terminals are held into the receptacle openings using a friction or interference fit so that the electrical components will not fall out during operation. By using a friction fit, an operator can remove a defective electrical component using only fingers and no special tool is needed. 
     It will be clear that the present invention is well adapted to attain the ends and advantages mentioned as well as those inherent therein. While presently preferred embodiments have been described for purposes of this disclosure, various changes and modifications may be made which are well within the scope of the present invention. For example, power distribution module can include receptacle openings in more than one wall of the housing. Numerous other changes may be made which will readily suggest themselves to those skilled in the art and which are encompassed in the spirit of the invention disclosed and as defined in the appended claims.