Abstract:
An electrical distribution center assembly includes a housing having a connector shroud. The shroud defines a shroud cavity adapted for receiving a mating electrical connector body. A blade stabilizer is formed integral with the shroud in a first position within the shroud cavity. The blade stabilizer has blade apertures formed therein. Bladed terminals extend from the housing into the blade apertures. In this position, the blade stabilizer protects the terminal blades from being bent away from a terminal axis. The blade stabilizer is movable to a second position to enable female terminals of the mating electrical connector to electrically connect to the blade terminals.

Description:
This application claims benefit of priority from U.S. Provisional Patent Application No. 61/348428, filed May 26, 2010. 
    
    
     TECHNICAL FIELD OF INVENTION 
     The invention relates generally to electrical distribution centers and more specifically to electrical distribution centers having at least one male terminal therewithin. Still more particularly, the present invention relates to electrical distribution centers of the aforesaid type incorporating a terminal stabilizer. 
     BACKGROUND OF INVENTION 
     Electrical distribution centers are widely used in vehicles. An electrical distribution center can package various fuses, relays and other electrical devices in a central location. Such electrical distribution centers include provisions for electrically connecting a power source and electrical devices housed in the electrical distribution center to electrical wiring harness connectors for supplying power and control signals to various electrical systems of the vehicle. Examples of electrical distribution centers may be found in U.S. Pat. No. 5,715,135 granted to Brussalis et al., U.S. Pat. No. 5,788,529 granted to Borzi et al., U.S. Pat. No. 6,220,876 granted to Avila et al., U.S. Pat. No. 6,739,889 granted to Daggett et al., and U.S. Pat. No. 7,635,212 granted to Seidler. 
     A known electrical distribution center that incorporates a connector shroud includes a non-movable floor that sits at the base of the male blade terminals to provide some level of blade dimensional stabilization prior to mating with a wiring harness connector. For additional blade stabilization and protection from damage prior to connector mating, a second piece, a blade stabilizer, is mounted to the shroud using flex locks to capture the terminals near the tips. As the connector is mated to the electrical distribution center in the vehicle, the second piece is pushed out of its flex locks and toward the connector floor near the base of the terminals. The design incorporating only a shroud with a floor at the base of the terminals does not provide optimal protection or terminal alignment, but is one piece and thus the less expensive alternative. The design incorporating the shroud having a non-movable floor and a second piece blade stabilizer requires two separate plastic pieces as well as the necessary labor and equipment to assemble them together, but provides much greater levels of pre-vehicle assembly protection and blade alignment to the product. 
     SUMMARY OF THE INVENTION 
     The present invention can enable a multifunctional connector shroud design employing a movable blade stabilizer that is molded into the overall shroud. Such a stabilizer can aid in providing the level of pre-vehicle assembly protection and alignment achieved with currently known connector shrouds incorporating loose piece blade stabilizers. The present invention can also aid in enabling lower cost blade stabilization and protection by eliminating the need for additional assembly of a loose piece blade stabilizer to an electrical distribution center assembly housing. 
     The invention can further enable a stabilizer wall that is molded into a shroud cavity at a male terminal tip position. And, by using either integral flexible springs or breakable tabs to attach the stabilizer wall to the shroud walls, the stabilizer is adapted and configured to enable a mating connector body to push the stabilizer wall to the floor of the connector shroud as the connector is inserted into the shroud during vehicle assembly. The male terminal base or a separate stand-off may be configured to function as a positive stop for the stabilizer wall. 
     The invention can further enable an electrical distribution center assembly including a housing assembly including first and second housing members which define an accommodation space therein; a connector shroud formed in the first housing member, the shroud having side walls defining a shroud cavity therein for receiving a mating plug connector, the shroud cavity communicating with the accommodation space; an electrical bus disposed in the accommodation space; a bladed terminal electrically contacting the electrical bus, the terminal including an elongated blade projecting along a terminal axis to a tip located in the shroud cavity; a terminal stabilizer formed integrally as a part of the first housing member and including a rigid stabilizer wall and an attachment portion, the stabilizer wall located within the shroud cavity and having a blade aperture formed therein, the attachment portion extending between the stabilizer wall and the side walls of the shroud for supporting the stabilizer wall in a terminal alignment position, wherein the tip of the terminal is received in the blade aperture, whereby the blade stabilizer protects the blade from being bent away from the terminal axis by a force applied to the blade in a direction orthogonal to the terminal axis. 
     In a preferred embodiment, the stabilizer wall is movable from the terminal alignment position to a seated position when at least a predetermined level of force is applied to the stabilizer wall in a direction parallel to the terminal axis. In the seated position stabilizer wall is closer to the electrical bus than when it is in the terminal alignment position. In the seated position, the blade of the bladed terminal is exposed for mating with a female terminal of the plug connector. 
     The invention can further aid in providing an electrical distribution center assembly including a housing assembly including a first housing member attached to a second housing member, the first housing member including a connector shroud and terminal stabilizer wall, the connector shroud defining a shroud cavity therein which has an opening for receiving a mating plug connector, the terminal stabilizer wall being integrally formed with the connector shroud in a terminal alignment position and defining a blade aperture extending therethrough; an electrical bus disposed in the housing assembly; and a male terminal having a base portion electrically contacting the electrical bus and a contact portion extending into the shroud cavity for mating with a female terminal of the plug connector, the contact portion projecting into the blade aperture, whereby the contact portion is stabilized within the shroud cavity. 
     The invention can further aid in providing an electrical distribution center assembly including a housing assembly including a first and a second housing member, the first housing member being of unitary construction and including an outer wall of the housing assembly, a connector shroud, and a terminal stabilizer, the shroud defining a shroud cavity therein for receiving a mating plug connector; a circuit board disposed in the body of the housing; and a blade stabilizer formed integrally with the shroud, the blade stabilizer including a blade stabilizer wall disposed within the shroud cavity and a blade stabilizer support for releasably supporting the blade stabilizer wall at a terminal alignment position, the blade stabilizer wall having a blade aperture formed therein at a location aligned with a terminal axis; a male terminal projecting along the terminal axis from the circuit board into the blade aperture, wherein when the blade stabilizer wall is in the terminal alignment position a void for protecting the male terminal exists and is defined axially between the blade stabilizer wall and the circuit board. 
     Further features, uses and advantages of the invention will appear more clearly on a reading of the following detailed description of the preferred embodiment of the invention, which is given by way of non-limiting example only and with reference to the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       This invention will be further described with reference to the accompanying drawings in which: 
         FIG. 1  is a bottom view of a lower housing of an electrical distribution center assembly in accordance with an embodiment of the present invention. 
         FIG. 2  is a side view of a housing of an electrical distribution center assembly and a mating connector assembly in accordance with an embodiment of the present invention. 
         FIG. 3  is a perspective view of an aspect of an electrical distribution center assembly of the present invention. 
         FIG. 4  is another perspective view of an aspect of an electrical distribution center assembly of the present invention. 
         FIG. 5  is a side section view of an electrical distribution center assembly in accordance with an embodiment of the present invention. 
         FIG. 6  depicts a detail of  FIG. 5 . 
         FIG. 7  is a side section view of an electrical distribution center assembly and an electrical connector assembly in a partially mated position in accordance with an embodiment of the present invention. 
         FIG. 8  depicts a detail of  FIG. 7 . 
         FIG. 9  is a side section view of an electrical distribution center assembly and a mating connector assembly in a fully mated position in accordance with an embodiment of the present invention. 
         FIG. 10  depicts a detail of  FIG. 9 . 
         FIG. 11  is a bottom view of a lower housing of an electrical distribution center assembly in accordance with an alternate embodiment of the present invention. 
         FIG. 12  is a perspective view of an aspect of an electrical distribution center assembly in accordance with an alternate embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF INVENTION 
     Referring to  FIGS. 1-10  an electrical distribution center assembly  10  in accordance with a preferred embodiment of the present invention includes a housing  12  and an accommodation space  14  defined by housing  12 . Housing  12  is formed from a semi-shell shaped lower housing  16  and an upper housing  18  attached to lower housing  16 . A printed circuit board  20  is disposed in accommodation space  14 . Alternatively, another type of electrical bus, such as a routed wire plate, may be used instead of or in addition to printed circuit board  20 . Lower housing  16  includes a connector shroud  22 . A plurality of male blade terminals  24  extend from printed circuit board  20  into a shroud cavity  26  defined by connector shroud  22 . A male blade stabilizer  28  is integrally molded with connector shroud  22  in a terminal alignment position  30  within shroud cavity  26 , whereby the tips  32  of male blade terminals  24  are received in respective blade apertures  34  formed in a stabilizer wall  36  of blade stabilizer  28 . In this position blade stabilizer  28  protects the blades  38  of the male blade terminals  24  from being bent away from the terminal axis  40  by a force applied to the blade  38  in a direction orthogonal to the terminal axis  40 . Connector shroud  22  is adapted and configured for mating with a plug electrical connector  42 . During mating of plug electrical connector  42  with electrical distribution center assembly  10 , at least a predetermined level of force applied to blade stabilizer  28  in a direction parallel to terminal axis  40  causes stabilizer wall  36  to move toward circuit board  20  to a seated position  44  with respect to male terminal  24  enabling plug electrical connector  42  to be received in shroud cavity  26  and fully mated with electrical distribution center assembly  10 . 
     Referring to  FIGS. 1 ,  3 , and  4 , an electrical distribution center assembly  10  in accordance with a preferred embodiment of the present invention includes lower housing  16  and connector shroud  22  formed in lower housing  16 . Connector shroud  22  is defined, at least in part, by shroud walls  46  extending outward from an outer facing wall  48  of lower housing  16 . Shroud walls  46  define shroud cavity  26  having an opening  50 . Blade stabilizer  28  is disposed in shroud cavity  26 . Blade stabilizer  28  includes stabilizer wall  36  extending across shroud cavity  26  orthogonal to shroud walls  46 . A plurality of blade apertures  34  extend through stabilizer wall  36  in parallel with terminal axis  40  (as shown on  FIG. 6 ). Blade stabilizer  28  further includes a plurality of flexible springs  52  that attach stabilizer wall  36  to shroud walls  46 . Preferably, flexible springs  52  extend from periphery  54  of stabilizer wall  36  to one or more spring mount  56  (one shown on  FIGS. 3 and 4 ) formed in shroud walls  46 . A gap  57  is formed between periphery  54  of stabilizer wall  36  and side walls  46  of the shroud  22 . Alternatively, at least one flexible spring may extend between other portions of a lower housing and a stabilizer wall. 
     In a preferred embodiment, blade stabilizer wall  36 , plurality of flexible springs  52 , spring mount  56 , and shroud walls  46  are all integrally formed together with lower housing  16 . Preferably, blade stabilizer wall  36 , plurality of flexible springs  52 , spring mount  56 , and shroud walls  46  are integrally formed together with lower housing  16  in a plastic molding process. 
     Referring to  FIGS. 3 and 4 , blade stabilizer  28  is shown as it is initially formed in terminal alignment position  30  with respect to male terminals  24 . Flexible springs  52  extend from stabilizer wall  36  to spring mount  56  supporting stabilizer wall  36  in terminal alignment position  30  within shroud cavity  26  of connector shroud  22 . As shown on  FIG. 4 , when blade stabilizer  28  is in terminal alignment position  30 , tips  32  of respective male blade terminals  24  extend into respective one of blade apertures  34 , whereby blade stabilizer  28  protects the blades  38  of terminals  24  from being bent away from terminal axis  40  by a force applied to the blades  38  in a direction orthogonal to terminal axis  40 . 
       FIG. 2  illustrates an electrical connection assembly  11  including a plug electrical connector  42  mated with electrical distribution center assembly  10 . 
     Referring to  FIGS. 5 and 6 , electrical distribution center assembly  10  includes lower housing  16  attached to upper housing  18 . Lower housing  16  and upper housing  18  define an accommodation space  14 . Printed circuit board  20  is disposed in accommodation space  14 . Shroud walls  46  extend outward from face  48  of lower housing  16 . Flexible springs  52  extend between shroud walls  46  and stabilizer wall  36  support blade stabilizer  28  in terminal alignment position  30 . Male blade terminals  24  are electrically connected to conductive circuit traces (not shown) on printed circuit board  20 . Male blade terminals  24  each have a base  58  connected to printed circuit board  20  and an elongated bladed portion  38  which extends from base  58  in parallel to terminal axis  40  to tip  32  disposed in shroud cavity  26 . Each tip  32  is received in a respective one of the plurality of blade apertures  34 . As shown on  FIG. 6 , blade apertures  34  extend between an inner face  60  of stabilizer wall  36  to an outer face  62  of stabilizer wall  36 . Blade apertures  34  each have an enlarged opening  64  in inner face  60  of stabilizer wall  36  to facilitate assembly. As shown on  FIG. 5 , when blade stabilizer  28  is in terminal alignment position  30 , a void  66  for protecting male terminals  24  exists and is defined axially between blade stabilizer wall  36  and circuit board  20 . 
     Referring to  FIGS. 7 and 8 , electrical distribution center assembly  10  is shown with blade stabilizer  28  in terminal alignment position  30 . Plug connector  42  includes female terminals  68  constructed and arranged for mating with male blade terminals  24  when plug connector  42  is inserted into cavity  26  of connector shroud  22 . In a pre-mating position as shown on  FIGS. 7 and 8 , a forward end  70  of plug connector  42  is received in opening  50  of shroud cavity  26 . A forward face  72  of plug connector  42  contacts outer face  62  of stabilizer wall  36 . During mating of plug connector  42  with electrical distribution center assembly  10 , plug connector  42  is inserted into shroud cavity  26  using at least a predetermined level of force parallel with terminal axis  40  causing springs  52  to flex, thereby enabling stabilizer wall  36  to move from terminal alignment position  30  to seated position  44 . 
     Referring to  FIGS. 9 and 10 , plug connector  42  is fully mated with electrical distribution center assembly  10  forming electrical connection assembly  11 . In this configuration, plug connector  42  is fully received in shroud cavity  26  and female terminal  68  electrically contacts blade  38  of bladed terminal  28 . Blade stabilizer  28  is in seated position  44 , where it is positioned closer to circuit board  20  than when it is in the terminal alignment position  30 . A positive stop  74  extending from side wall  46  of connector shroud  22  supports blade stabilizer  28  in seated position  44 . Alternatively, terminal base  58  may be adapted and configured to be larger than blade aperture  34  so that terminal base  58  may serve as a positive stop for supporting blade stabilizer  28  in seated position  44 . Blade  38  of terminal  24  is received in female terminal  68 . 
     Referring to  FIGS. 11 and 12 , an alternate embodiment of an electrical distribution center assembly  110  in accordance with the present invention is similar to electrical distribution center assembly  10  shown in  FIGS. 1-10  except that it includes a blade stabilizer  128  having a stabilizer wall  136  that is integrally attached to a shroud wall  146  by at least one breakable tab  176  instead of by at least one flexible spring. At least one breakable tab  176  is adapted and configured to break when at least a predetermined level of force is applied to stabilizer wall  136  in a direction parallel to a terminal axis  140 , enabling stabilizer wall  136  to move from a terminal alignment position  130  to a seated position  144  which is closer to a circuit board  120  than the alignment position  130 . At least one breakable tab  176  may alternatively include a narrowed portion or notch  178  for serving as break point. A lock (not shown) may be used for retaining stabilizer wall  136  in seated position  144  to prevent stabilizer wall from falling off if a mating connector is removed. In a preferred embodiment, blade stabilizer wall  136 , breakable tab  176 , and shroud walls  146  are integrally formed together with lower housing  116 . Preferably, blade stabilizer wall  136 , breakable tab  176 , and shroud walls  146  are integrally formed together with lower housing  116  in a plastic molding process. 
     While this invention has been described in terms of the preferred embodiments thereof, it is not intended to be so limited, but rather only to the extent set forth in the claims that follow.