Abstract:
An integrated power distribution box includes an upper level assembly with a printed circuit board including at least one electrical component, a lower housing configured to receive at least a portion of the printed circuit board, an intermediate housing configured to be coupled with at least one fuse, a master fuse electrically coupled to the printed circuit board, and a lower level assembly including at least one connector corresponding to at least one of the master fuse, the at least one electrical component, and the at least one fuse.

Description:
BACKGROUND 
       [0001]    The present disclosure relates to power distribution boxes, including power distribution boxes that can be used, for example, to support a plurality of electrical components within a vehicle or a device. 
       SUMMARY 
       [0002]    The present disclosure includes a power distribution box. In an embodiment, a power distribution box includes a first housing and a second housing. The first housing may include a first connection element, and the second housing may include a second connection element that is configured for engagement with the first connection element. In an embodiment, the first and second connection elements are configured to retain the first housing relative to the second housing, and the first and second elements may be configured to electrically connect the first housing and the second housing. 
         [0003]    Various aspects of this invention will become apparent to those skilled in the art from the following detailed description of an embodiment of the present disclosure, when read in light of the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0004]      FIG. 1  is an exploded perspective view of portions of an embodiment of a power distribution box in accordance with teachings of the present disclosure. 
           [0005]      FIG. 2  is a partial cross-sectional perspective view of portions of an embodiment of a power distribution box in accordance with teachings of the present disclosure. 
           [0006]      FIG. 3  is a partial cross-sectional perspective view of portions of an embodiment of a power distribution box in accordance with teachings of the present disclosure. 
           [0007]      FIG. 4  is a bottom view of an embodiment of a first housing of a power distribution box in accordance with teachings of the present disclosure. 
           [0008]      FIG. 5  is a perspective view of portions of an embodiment of a power distribution box in accordance with teachings of the present disclosure. 
           [0009]      FIG. 6  is a perspective view of portions of an embodiment of a power distribution box in accordance with teachings of the present disclosure. 
           [0010]      FIGS. 7A-7D  are partial perspective views of portions of an embodiment of a power distribution box and a vehicle in accordance with teachings of the present disclosure. 
       
    
    
     DETAILED DESCRIPTION 
       [0011]    Reference will now be made in detail to embodiments of the present disclosure, examples of which are described herein and illustrated in the accompanying drawings. While the invention will be described in conjunction with embodiments, it will be understood that they are not intended to limit the invention to these embodiments. On the contrary, the invention is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the invention as defined by appended claims. 
         [0012]    Power distribution box  10  may be used to support a plurality of electrical components, such as, for example, within a portion of a vehicle  92  (see, e.g.,  FIG. 7A ). It should be appreciated, however, that power distribution box  10  may be used in any appropriate environment and for any desired purpose. 
         [0013]    Referring to the drawings,  FIG. 1  generally illustrates an exploded view of an embodiment of a first housing  20  of a power distribution box  10 . First housing  20  may include relays  22 , a relay housing  24 , a circuit board  26 , electrical components  28  connected to circuit board  26 , a fuse housing  30 , fuses  32 , and/or a fuse cover  34 . As generally illustrated in  FIGS. 1 and 2 , first housing  20  may include a bus bar  40  that may be connected, physically and/or electrically, to circuit board  26 . Bus bar  40  may be configured to receive electrical power from second housing  60  and/or may be configured to distribute electrical power to circuit board  26  and/or other electrical components  28 . Bus bar  40  may also be referred to herein as a circuit board bus bar. Bus bar  40  may include a generally vertical portion or projection  42  that may extend (e.g., downwardly) toward second housing  60 . Vertical portion  42  may include a first connection element  50 . In embodiments, vertical portion  42  and/or first connection element  50  may be disposed generally in or about a corner of first housing  20 . In embodiments, bus bar  40 , vertical portion  42 , and/or first connection element may be formed as a single unitary element. 
         [0014]    As generally illustrated in  FIG. 2 , power distribution box  10  may include first housing  20  and a second housing  60  that may be configured to be assembled together. In embodiments, an assembled configuration of first housing  20  and second housing  60  may include a cover  34  disposed between relay housing  24 , circuit board  26 , and/or fuse housing  30  on one side and second housing  60  on the other side. A top/exterior side  24 A of relay housing  24  may include connecting areas or portions configured for connection with wiring harness connectors  100  (e.g., as generally illustrated in  FIG. 7C ). 
         [0015]    In embodiments, second housing  60  may include a bus bar, such as a pre-fuse bus bar  62 . Bus bar  62  may include a vertical portion  64  and/or a horizontal portion  66 . Horizontal portion  66  may include projections, which may extend generally horizontally for connection with pre-fuses  68 . Vertical portion  64  may be connected to horizontal portion  66  and may extend generally vertically upward toward first housing  20 . Bus bar  62  may be configured to be electrically connected, for example, with a vehicle battery  70 , which may be via one or more pre-fuses  68 . Pre-fuses  68  may be connected to a power source, such as a vehicle battery  70 , via one or more cables and/or wires  72  or other forms of connectors. In embodiments, pre-fuses  68  may be configured to regulate electrical power incoming to power distribution box  10  from a battery  70 . In embodiments, second housing  60  may include a second connection element  80  that may be connected to and/or formed with vertical portion  64  of bus bar  62 . 
         [0016]    In embodiments, first connection element  50  and/or second connection element  80  may include one or more of a variety of shapes, sizes, and/or configurations. First connection element  50  and second connection element  80  may be configured to cooperate and/or engage with each other. For example, and without limitation, second connection element  80  may be configured as a female connection element, which may include being configured to receive some or all of first connection element  50  and/or vertical portion  42 , and first connection element  50  may be configured as a male connection element, which may include being configured as a blade-type connector that may extend toward second connection element  80 . Second connection element  80  may be configured as a receptacle for a blade-type connector. In other embodiments, first connection element  50  may be configured as a post-type connector and second connection element  80  may be configured to receive a post-type connector. In embodiments, at least one of first and second connection elements  50 ,  80  may include a resilient portion. For example, and without limitation, second connection element  80  may include resilient portion  90  that may be configured to be deflected upon insertion of first connection element  50 . In embodiments, after first connection element  50  has been substantially inserted, resilient portion  90  may apply a spring force to first connection element  50  to retain first connection element  50  relative to second connection element  80 . In other embodiments, first connection element  50  may be configured as a female connection element, and second connection element  80  may be configured as a male connection element. In embodiments, first and second connection elements  50 ,  80  may not include a male-female connection, and may comprise various other forms or features for connection or attachment. 
         [0017]    In embodiments, as generally illustrated in  FIGS. 2 and 3 , second connection element  80  may be configured to extend outwardly (e.g., vertically upward) from second housing  60  and into at least a portion of first housing  20 . Second connection element  80  may include an insulating portion  82  that may electrically insulate at least a portion of second connection element  80 . Insulating portion  82  may comprise electrically insulating material, such as plastic. Insulating portion  82  may include a shape that generally corresponds to an aperture  34 A of cover  34  and/or a recess  30 A of fuse housing  30 , such that insulating portion  82  may extend into and/or through recess  30 A and/or aperture  34 A. In embodiments, insulating portion  82  may extend farther outward from second housing  60  than an electrically conducting portion  88  of second connection element  80  (e.g., insulating portion may extend into fuse housing recess  30 A, but electrically conductive portion may only extend into cover aperture  34 A). Insulating portion  82  may include an aperture  84  configured to receive a portion of first connection element  50 . In embodiments, insulating portion  82  may include a cross-sectional area that corresponds to the cross-sectional area of recess  30 A and/or aperture  34 A. For example, and without limitation, insulating portion  82  may include a smaller cross-sectional area than aperture  84 , but may include a cross-sectional area that is substantially the same as or slightly larger than the cross-sectional area of fuse housing recess  30 A, which may correspond to an interference fit. 
         [0018]    In embodiments, such as generally illustrated in  FIGS. 2-4 , bus bar  40  and/or first connection element  50  may extend through circuit board  26  and/or fuse housing  30 . Cover aperture  34 A may be aligned with first connection element  50  so that first connection element  50  is exposed to the exterior when first and second housings  20 ,  60  are not assembled together (e.g., as generally shown in  FIG. 4 ). In embodiments, second connection element  80  may extend from second housing  60  and at least partially extend into fuse housing recess  30 A and/or cover aperture  34 A. 
         [0019]    In embodiments, such as generally illustrated in  FIG. 5 , second connection element  80  may be welded to and/or otherwise permanently connected to bus bar  62 . A configuration of second connection element  80  may depend on or relate to an intended use environment of second housing  60 , such as an intended vehicle application, which may include a vehicle-specific configuration of first housing  20  (see, e.g., vehicle portion  92  in  FIG. 7A ). As described above, first connection element  50  of first housing  20  may include one or more of a variety of configurations, and those configurations may depend on an intended use or application. Second connection element  80  may be configured to complement the configuration of first connection element  50 , which may permit second housing  60  to otherwise remain substantially the same for several different use environments (e.g., vehicles). In other embodiments, as generally illustrated in  FIG. 6 , second connection element  80  may be integrally formed with bus bar  62  and/or may include a single configuration that may be compatible with multiple configurations of first connection element  50 . 
         [0020]    In embodiments, first connection element  50  and second connection element  80  may be configured to provide an electrical connection between first housing  20  and second housing  60 , such as between bus bar  40  and bus bar  62 . For example, and without limitation, first and second connection elements  50 ,  80  may comprise one or more electrically conductive materials. In embodiments, first and second connection elements  50 ,  80  may be configured to provide the sole electrical connection between first and second housings  20 ,  60 , which may include providing circuit board  26  with its sole source of electrical power. An electrical connection provided by first and second connection elements  50 ,  80  between first and second housings  20 ,  60  may not include (e.g., may be independent of) wires or cables. Electrical connections including wires often require fastening and unfastening of the wires with the assistance of tools (e.g., screwdrivers, wrenches, pliers, etc.) during assembly or disassembly. An electrical connection without wires or cables may simplify assembly and disassembly, which may allow the connection to be made and/or to be disconnected manually (e.g., without any tools). 
         [0021]    In embodiments, first and second connection elements  50 ,  80  may, additionally or alternatively, be configured to physically retain first housing  20  and second housing  60  relative to each other. As described above, first and second connection elements  50 ,  80  may be configured as corresponding male and female connectors. Such male and female connectors may be configured such that they generally prevent substantial relative movement between first and second housings  20 ,  60  in a least one direction. For example, if first connection element  50  is configured as a male connector and is inserted into second element, which is configured as a female connector, first and second connection elements  50 ,  80  may prevent substantial relative horizontal movement between first and second housings  20 ,  60 . 
         [0022]    Additionally or alternatively, embodiments of first connection element  50  and/or second connection element  80  may include a vertically retaining feature. For example, and without limitation, first connection element  50  may include a clip  52  configured to selectively engage an aperture or recess  86  of second connection element  80 . Clip  52  may be configured to deflect and/or rotate in and out of recess  86 . Clip  52  may comprise a resilient material that may cause clip  52  to be biased into recess  86 . Clip  52  may prevent relative vertical movement between first and second housings  20 ,  60 . In embodiments, clip  52  may be configured for manual operation, which may include being configured such that clip  52  may be rotated in and out of recess  86  without any tools. In embodiments, second connection element  80  may include clip  52  and clip  52  may selectively engage first connection element  50 . 
         [0023]    In embodiments, first connection element  50  and second connection element  80  may be the only elements that positively physically retain first and second housings  20 ,  60  relative to each other. When engaged, first and second connection elements  50 ,  80  may provide a sufficient retaining force to substantially maintain the assembled positions of first and second housings  20 ,  60  during expected operating conditions and/or in an expected operating environment (e.g., operation of a vehicle). While first housing  20  and/or second housing  60  may include other physical retaining elements, such as tabs  74 , that may passively limit relative movement, such retaining elements may not be configured for positive engagement. Such passive retaining elements may not include movable parts and may not be actuated, moved, and/or directly interacted with by an operator during assembly or disassembly. In embodiments, first and second connection elements  50 ,  80  may provide the only electrical connection and the sole positive physical connection between first and second housings  20 ,  60 . Such a single electrical and physical connection arrangement may significantly simplify assembly and disassembly because the first and second housings  20 ,  60  may be disconnected from each other via only one connection. Often, in conventional designs, several physical connections must be disengaged, sometimes simultaneously and/or with the assistance of tools, to disconnect a power distribution box  10  or portions of a power distribution box  10  from a mounting position (e.g., in a vehicle  92 ). Additionally, in conventional designs, several electrical connections may also need to be disconnected, usually with tools, to disconnect a first housing  20  of power distribution box  10 . In embodiments, first connection element  50  may be configured as a single projection from first housing  20  that corresponds to second connection element  80 , which may be configured as a single projection from second housing  60  and include insulating portion  82  and/or electrically conductive portion  88 . In embodiments, first and second connection elements  50 ,  80  may be disposed in corresponding corners of first and second housings  20 ,  60 , respectively. 
         [0024]    Simplified assembly may be particularly advantageous during initial assembly (e.g., on an assembly line), so that assembly time for assembly personnel and/or assembly equipment (e.g., a robot) can be reduced and/or minimized. In embodiments, second housing  60  may be configured to be mounted in a mounting location  94 , which may include in an engine compartment of a vehicle  92 . For example, and without limitation, second housing  60  may include mounting portions  76 . Simplified disassembly may be particularly advantageous during maintenance, so that an operator/repair technician can quickly and manually (e.g., without tools) remove first housing  20  from a mounting location  94 . 
         [0025]    As generally illustrated in  FIGS. 7A-7B , a method of assembly for a power distribution box  10  may include disposing second housing  60  near a mounting location  94  and then disposing second housing  60  at mounting location  94 . Second housing  60  may be fastened to the mounting location  94  via one or more fasteners  96 . As generally illustrated in  FIG. 7C , first housing  20  may then be disposed generally above or over second housing  20 , which may include aligning first connection element  50  and second connection element  80 . 
         [0026]    As generally illustrated in  FIGS. 7C and 7D , first housing  20  may be moved (e.g., by applying a substantially vertically downward/perpendicular force) toward second housing  60  until first connection element  50  and second connection element  80  are fully engaged (e.g., as generally shown in  FIGS. 2 ,  3 ,  5 , and  6 ). As described above, engagement of first and second connection elements  50 ,  80  may provide the only electrical connection and/or the only positive physical connection necessary between first and second housing  20 ,  60 . Also as described above, such a method of assembly may be accomplished manually by an operator/repair technician without the use of tools. Wiring harness connectors  100  may then be connected to first housing  20 , which may include moving wiring harness connectors  100  vertically downward toward first housing  20 . Various circuits routed to power distribution box  10  by wiring harness connectors  100  may receive power from power distribution box  10 , electrically interact with relays  22  and  32 , and/or be interconnected via circuit board  26 . 
         [0027]    In embodiments, first housing  20  may be disassembled from second housing  60  via a method corresponding to the assembly method described above. As an initial step, an operator may disengage first and second connection elements  50 ,  80 , and may immediately thereafter (e.g., without disconnecting any other elements) remove first housing  20  from contact and/or connection with second housing  60  (e.g., second housing  60  may remain mounted to vehicle  92 ). Such disassembly may be accomplished manually, independently of tools. 
         [0028]    In embodiments, first housing  20  may remain substantially stationary during assembly and/or disassembly. In such embodiments, assembly may include second housing  60  being moved toward first housing (e.g., by a substantially vertical/perpendicular force applied by an operator) to engage first and second connection elements  50 ,  80 . Disassembly may include an operator disconnecting first and second connection elements  50 ,  80 , and removing second housing  60  from any contact with first housing  20 . 
         [0029]    The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and various modifications and variations are possible in light of the above teaching. It should be understood that references to a single element are also intended to include embodiments that may include more than one of that element or zero of that element. It should also be understood that references to directions, such as vertical  64 , horizontal  62 , top, bottom, are provided for illustrative purposes only are not intended to limit the scope of the disclosure. For example, and without limitation, although first and second housings  20 ,  60  have been described as being assembled vertically/perpendicularly, embodiments of the present disclosure may include assembling first and second housings  20 ,  60  horizontally (which may be perpendicularly), or at an angle with respect to the vertical  64  and/or horizontal  62  directions, depending on the positioning of second housing  60 . 
         [0030]    The embodiments were chosen and described in order to explain the principles of the invention and its practical application, to thereby enable others skilled in the art to utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims and their equivalents.