Patent Publication Number: US-9407038-B2

Title: Electrical distribution center

Description:
TECHNICAL FIELD OF THE INVENTION 
     The invention generally relates to electrical distribution center that may be configured for use in a vehicle, and more particularly relates to an electrical distribution center having a plurality of slides and a single lever configured to secure a connector body to a base. 
     BACKGROUND OF THE INVENTION 
     Electrical connector assemblies, such as a simple electrical connector or a multi-functional electrical distribution center, are widely used. The electrical distribution centers are generally a central junction box or block system designed as a stand-alone assembly. The electrical connectors typically electrically connect at least two wire harnesses together and thus house a plurality of connected male and female terminals. The distribution centers perform a similar function as the electrical connectors, but may also house various fuses, relays and other electrical devices in a central location. Electrical distribution centers not only reduce cost by consolidating various functions and/or electrical connections into one block, but the centers also reduce the number of cut and spliced leads which increases reliability. Such electrical distribution centers include provisions for electrically connecting a power source and electrical devices housed in the junction block to electrical wiring harness connectors for supplying power and control signals to various electrical systems. 
     In many electrical distribution center applications, such as that used in the engine compartment of a vehicle, disclosed in U.S. Pat. No. 5,715,135, to Brussalis, the entire disclosure of which is hereby incorporated by reference, devices such as fuses and relays of the electrical distribution centers are accessible from the top with bases protruding from a bottom side. Unfortunately, due to this orientation, access to the connectors is often difficult for mating (connecting) and unmating (disconnecting). In many cases, the electrical distribution center has to be flipped upside down, the connectors assembled, and the entire assembly with protruding wire harnesses flipped again into a final position. 
     Known electrical distribution centers, such as that disclosed in Brussalis, typically mount the fuses, relays and electrical devices to a top side of an upper electrical distribution panel. A plurality of double ended terminals is engaged to and extends through a tray located below the panel. A top end of each terminal projects through a respective slot of the upper panel for engagement to the fuse, relay or electrical device. A bottom end of the male terminal projects downward through respective slots of yet a second lower tray for electrical engagement to terminals locked into at least one electrical connector body which is engaged to a lower support structure of the distribution center. Unfortunately, the panel, trays and connector bodies are all held together by a plurality of threaded fasteners which is costly to manufacture and requires special tools for assembly and maintenance purposes. 
     Known improvements to this conventional distribution assembly are described in U.S. Pat. No. 5,788,529 to Borzi issued 4 Aug. 1988, U.S. Pat. No. 6,739,889, to Daggett, issued 25 May 2004, and U.S. Pat. No. 7,094,081 to Senk, et al. issued 22 Aug. 2006. In Borzi and Daggett, the distribution assembly is not flipped when assembling internal connectors and does not require the use of threaded fasteners or bolts thus does not need special assembly tools to secure various connector bodies of the distribution assembly together. Instead, an engagement mechanism or leverage device having four independent cam levers applies a normal force when the cam levers are rotated to connect the distribution assembly. Simultaneous rotation of the four levers also produces a moment which is countered by various structural and alignment features incorporated into this known distribution assembly to maintain alignment of the terminals during connecting. In Senk, the engagement mechanism has two independent cam levers that apply a normal force when rotated to connect the distribution assembly. 
     The subject matter discussed in the background section should not be assumed to be prior art merely as a result of its mention in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also be inventions. 
     BRIEF SUMMARY OF THE INVENTION 
     The inventors recognized the problems created by the prior art electrical distribution centers of requiring packaging space to be allocated on both ends of the electrical distribution center for the levers. The inventors also recognized that separate levers on each end of the electrical distribution center restricts where the electrical distribution center can be mounted in the vehicle while meeting ergonomic requirements to operate the levers. The inventors further recognized the potential for misalignment between the connectors or the connector bodies of the electrical distribution center caused when the levers are engaged separately from each other. 
     Described herein are solutions for an electrical distribution center having a single lever configured to apply a normal force when rotated to connect the electrical distribution center. The single lever is located centrally in the electrical distribution center. The single lever does not require packaging space to be allocated on both ends to accommodate movement of the lever. Because the electrical distribution center has a single lever, the likelihood of misalignment caused by engaging a plurality of levers separately is reduced. The single lever may also be mounted to the electrical distribution center either laterally or longitudinally, providing greater flexibility for mounting locations in the vehicle that can meet ergonomic requirements. 
     In accordance with one embodiment of this invention, an electrical distribution center configured for use in a motor vehicle is provided. The electrical distribution center includes a connector body, a base, a first and second slide, and a slide lever. The connector body has a first side wall spaced apart from a second side wall and an electrically conductive first terminal that is rigidly engaged to the connector body. The base has an electrically conductive second terminal rigidly engaged to the base. The second terminal is constructed and arranged to electrically connect with the first terminal. The base defines a first stud and a second stud that are constructed and arranged to mechanically connect with the connector body. The base further includes an electrical connector that is configured be attached to a mating connector of a wire harness. The first slide is slideably supported within a first channel that is defined by the first side wall. The first slide is spaced inwardly from the first side wall and defines a first dog-leg shaped slot configured to engage the first stud. The a second slide slideably supported within a second channel defined by the second side wall and spaced inwardly from the second side wall and defining a second dog-leg shaped slot configured to engage the second stud. The slide lever is pivotally connected to the first and second side walls of the connector body, the first slide, and the second slide. The slide lever has a first arm connected by a handle to a second arm that is spaced apart from the first arm. The first arm extends between the first slide and the first side wall and the second arm extending between the second slide and the second side wall. The slide lever is operable to simultaneously slideably move the first and second dog-leg shaped slots with respect to the first and second stud, thereby connecting the connector body with the base. 
     The base may include a plurality of first studs and a plurality of second studs. The first slide may include a plurality of first slots and the second slide may include a plurality of second slots. 
     The connector body may define a rectangular shape that has a major axis and a minor axis. The first and second slides may be disposed substantially parallel to the major axis or the minor axis. 
     Further features 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 THE SEVERAL VIEWS OF THE DRAWING 
       The present invention will now be described, by way of example with reference to the accompanying drawings, in which: 
         FIG. 1  is an exploded perspective view of an electrical distribution center in accordance with one embodiment; 
         FIG. 2  is a perspective view of a connector body the electrical distribution center of  FIG. 1  disconnected from a base in accordance with one embodiment; 
         FIG. 3  is a partial cut-away side view of the electrical distribution center shown in  FIG. 2  in accordance with one embodiment; 
         FIG. 4  is a perspective view of the connector body the electrical distribution center of  FIG. 1  connected to the base with a slide lever in an open position in accordance with one embodiment; 
         FIG. 5  is a partial cut-away side view of the electrical distribution center shown in  FIG. 4  in accordance with one embodiment; 
         FIG. 6  is a perspective view of the connector body the electrical distribution center of  FIG. 1  connected to the base with a slide lever in a locked position in accordance with one embodiment; and 
         FIG. 7  is a partial cut-away side view of the electrical distribution center shown in  FIG. 6  in accordance with one embodiment. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The electrical distribution center described herein utilizes a single lever to make the connection in the vehicle from the wire harness electrical connectors to the electrical distribution center. It has a single slide lever that drives a pair of slides which engage studs on the base thereby pulling the electrical center downward onto the electrical connectors. This configuration allows the electrical center to be mounted in one of multiple orientations while still maintaining ergonomic requirements for operating the lever. 
     Referring to the various figures wherein like numerals refer to like elements throughout the several views, the exploded assembly view of  FIG. 1  illustrates a non-limiting example of an electrical distribution center  10 . The electrical distribution center  10  includes a base  12 , a connector body  14 , and a cover  16  attached to the connector body  14 . The cover  16  is configured for covering and protecting relays, fuses, and control modules (not shown) within the connector body  14 . The cover  16  attaches to the connector body  14  by means of several locking tangs  18  that lock the cover  16  to the connector body  14 . 
     The base  12  includes an electrical connector (not shown) that is configured be attached to a mating connector (not shown) of a wire harness (not shown). The electrical connector also includes electrical terminals (not shown) that are configured to engage electrical terminals (not shown) included in the connector body  14 . The base  12  defines an unthreaded first stud  22  and a corresponding unthreaded second stud on the opposite side of the base  12  (not shown due to the perspective of the drawing). Each stud  22  may be characterized as a boss or cylindrical protuberance extending from the sides of the base  12 . The base  12  may define a plurality of first studs  22  and a plurality of second studs. The connector body  14  is configured to connect with the base  12 , thus establishing electrical connection between the electrical terminals in the connector body  14  and the electrical terminals in the base  12 . 
     The connector body  14  includes a first side wall  24  spaced apart from the connector body  14  and defining a first channel  26  between the connector body  14  and the first side wall  24 . A first slide  28  is inserted into the first channel  26  and is slidably supported in the first channel  26  and is spaced inwardly from the first side wall  24 . The connector body  14  also includes a second slide  30  that is similarly slidably supported in a second channel  32  defined between a second side wall  34  and the connector body  14  on the opposite side of the connector body  14  from the first side wall  24 . The second slide  30  is spaced inwardly from the second side wall  34 . The first and second channels  26 ,  32  are molded as part of the connector body  14 . The first and second channels  26 ,  32  support the first and second slides  28 ,  30  respectively, but in a position spaced away from the first and second side walls  24 ,  34  respectively of the connector body  14 . 
     The first slide  28  includes a first dog-legged shaped connecting slot  36  that is adapted to receive the first stud  22  of the base  12 . The second slide  30  also includes a second dog-legged shaped connecting slot  38  that is adapted to receive the second stud of the base  12 . A slide lever  40  is pivotally interconnected with the connector body  14  and each of the first and second slides  28 ,  30 , and is operable to move the first and second slides  28 ,  30 , with respect to the connector body  14  to facilitate connecting the connector body  14  with the base  12 . 
     The slide lever  40  has a first arm  42  and a spaced apart second arm  44  attached to a central handle portion  46  that is configured to be gripped by an operator. The free ends  48  of the first and second arm  42 ,  44 , that is the ends not attached to the central handle portion  46 , define a forked shape having an arm slot  50  between the tines of the fork shape. The first and second slides  28 ,  30  are disposed in the arm slots  50  of the first and second arms  42 ,  44  respectively. The free ends  48  of the first arm  42  and the second arm  44  each defines a pair of pivot pins  52  that pivotally engage an opening  54  in the first and second side walls  24 ,  34  and an opening in the side of the connector body (not shown). The pivot pins  52  and the openings in the connector body  14  allow the slide lever  40  to pivot in relation to the connector body  14 . Each pivot pin  52  may be substantially equidistant from each end of each side wall  24 ,  34 . As used herein, substantially equidistant means±10 millimeters of absolutely equidistant. 
       FIG. 2  illustrates the electrical distribution center  10  in an assembled condition with the slide lever  40  in the open position. With the slide lever  40  in the open position, a portion of the first and second slides  28 ,  30  protrude from the first and second channels  26 ,  32 . 
       FIG. 3  illustrates a partial cutaway view of the electrical distribution center  10  as illustrated in  FIG. 2  wherein the first side wall  24  and the outside tine of the first arm  42  are removed. As shown in  FIG. 3 , the first arm  42  defines a slide pin  56 . The slide pin  56  has a tapered surface to facilitate engagement with the first slide  28  during assembly. The first slide  28  defines U-shaped slide pin slot  58  that is sized to receive the heads of the pivot pins  52 . Without subscribing to any particular theory of operation, the slide pin  56  interfaces with the slide pin slot  58  so that as the lever pivots about the pivot pin, the slide pin  56  pushes the first slide  28  longitudinally, that is along the longitudinal axis X, within the first channel  26 . The second arm  44  likewise defines a similar slide pin that interfaces with a similar U-shaped slide pin slot to push the second slide  30  longitudinally within the second channel  32 . The slide lever  40  and first and second slides  28 ,  30  are configured so that the first and second slides  28 ,  30  move substantially simultaneously within the first and second channels  26 ,  32 . As used herein, substantially simultaneously means that the first and second slides begin and end movement within 250 milliseconds of each other and the movement of one slide is within ±5 millimeters of the other. As can be best seen in  FIG. 3 , the first connecting slot  36  defines a dog-leg shape that has an open end  60  or mouth that is configured to allow entry of the first stud  22  into the first connecting slot  36  when the connector body  14  is mated to the base  12 . The first connecting slot  36  defines a “knee”  62  whereat the slot curves to a closed end  64  wherein the first stud  22  is retained when the first slide  28  is moved by the slide lever  40  to the locked position. The axis of the closed end  64  of the slot defines an angle relative to the open end  60  of the slot that is generally greater than 90 degrees and preferably about 106 degrees. 
       FIG. 4  illustrates an example of the electrical distribution center  10  wherein the connector body  14  is placed on the base  12  and the slide lever  40  is in the open position. 
       FIG. 5  illustrates a partial cutaway view of the electrical distribution center  10  as illustrated in  FIG. 4  wherein the first side wall  24  and the outside tine of the first arm  42  are removed. As shown in  FIG. 5 , each of the first studs  22  is at a beginning point in the open end  60  of each of the first connecting slots  36 . As the first slide  28  moves, it draws the first stud  22  from a beginning point at the mouth of the slot to an ending point at or near the opposite end of the first connecting slot  36 . This action, which is essentially a camming action, draws the base  12  tighter against the connector body  14  and retains it in this tight relationship. 
       FIG. 6  illustrates an example of the electrical distribution center  10  wherein the slide lever  40  is in a closed position and the connector body  14  is tightly secured to the base  12 . As shown the non-limiting example of  FIG. 6 , the slide lever  40  has moved the first and second slides  28 ,  30  so that they no longer protrude from the first and second channels  26 ,  32 . 
       FIG. 7  illustrates a partial cutaway view of the electrical distribution center  10  as illustrated in  FIG. 5  wherein the first side wall  24  and the outside tine of the first arm  42  are removed. As shown in  FIG. 7 , each of the first studs  22  is at an ending point in the closed end  64  of each of the first connecting slots  36  after the slide lever  40  has moved the first slide  28  relative to the first studs  22 . 
     The second slide  30 , second stud, and second arm  44  contain all of the features of the first slide  28 , first stud  22 , and first arm  42  illustrated in  FIGS. 3, 5, and 7 . The second slide  30  functions similarly and substantially simultaneously with the first slide  28 . 
     The first and second arms  42 ,  44  each terminate in a tip segment. The first and second arms  42 ,  44  each include an abutment disposed adjacent the tip segment, wherein the abutment extends outwardly from the tip segment relative to an imaginary axis running the length of each arm. In other words, the tip segment is narrower than the portion of the arm having the abutment. 
     Each channel defines a support slot that is sized to provide clearance to the tip segment, but not the abutment, so that the tip segment passes through the support slot until the abutment abuts the channel. The support slot may be viewed as an interruption in the channel. 
     The connector body  14  defines a deflection slot adjacent the support slot. The deflection slot is contiguous with the support slot. The purpose of the deflection slot is to allow the side walls of the connector body  14  to deflect outwardly when the slide lever  40  is connected to the first and second slides  28 ,  30  during assembly. 
     The electrical distribution center  10  may define a rectangular shape having a major axis and a minor axis. The first and second slides  28 ,  30  may be disposed substantially parallel to the major axis X (longitudinally) or alternatively may be disposed substantially parallel to the minor axis Y (laterally). As used herein, substantially parallel is ±15° of absolutely parallel. Thus, being able to mount the slides laterally or longitudinally may provide greater flexibility for finding mounting locations in the vehicle for the electrical distribution center  10  that can meet ergonomic requirements for an operator operating the slide lever  40 . 
     The component pieces of the electrical distribution center  10  including the connector body  14 , base  12 , first and second slides  28 ,  30 , and slide lever  40  are made from a suitable injection molded plastic, such as polyamide (PA, NYLON), polybutylene terephthalate (PBT), or polypropylene (PP). 
     Accordingly, an electrical distribution center  10  is provided. The connector body  14  may be attached to the base  12  of the electrical distribution center  10  by operating a single slide lever  40 . The single slide lever  40  does not require packaging space to be allocated on both ends of the electrical distribution center  10  to accommodate movement of the slide lever  40 . Because the electrical distribution center  10  has a single slide lever  40 , the likelihood of misalignment caused by engaging a plurality of levers separately is reduced. The single slide lever  40  may also be mounted to the electrical distribution center  10  either laterally or longitudinally, providing greater flexibility for mounting locations in the vehicle that can meet ergonomic requirements. 
     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. Moreover, the use of the terms first, second, etc. does not denote any order of importance, but rather the terms first, second, etc. are used to distinguish one element from another. Furthermore, the use of the terms a, an, etc. do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.