Patent Abstract:
A novel power block distribution block kit is disclosed. The blocks may use MAXI or AUG, or other types of commercially available type fuses. The present invention discloses a variably fusable power distribution block kit that permits custom configuration of the fuse to circuit relationships on a common base, and with a common cover to achieve higher circuit ratings with the same device, fuses, and component parts.

Full Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     None. 
     BACKGROUND OF THE INVENTION 
     1. Technical Field 
     The present invention relates to the technology of electrical connection design and in particular, to the technology of fuse box design and power distribution circuits. More specifically, the present Invention relates to the design of a fuse box kit of the type that would be commonly used in an automobile, boat, plane, RV, or other vehicle, where it would be desirable to variably multiply the available fuse protection for applications involving equipment having high power load requirements. 
     2. Description of Related Art 
     Most vehicles have a number of electrical components such as lights, horns, stereo radios, televisions, DVD players, amplifiers, and the like. To protect the electrical circuits of the vehicles, fuses are located in the circuit for each electrical accessory. The fuses are typically positioned in a central fuse box between the electrical supply and the accessory. The main function of the fuse is to protect the wiring circuit. The fuse contains an internal conductor which provides the electrical connection between the ends of the fuse. The conductor inside the fuse is a metallic strip that has a lower melting temperature than the wiring of the circuit. The size of the conductor is calibrated so that when the failure rating of the fuse is reached, sufficient heat will be generated to melt the conductor and break the circuit (burn the fuse). In use, if an accessory fails, the increased power demand in the circuit will exceed the failure rating of the fuse, causing the fuse to bum and separate, breaking the electrical connection. If a fuse is not used, overcurrent conditions could damage circuit elements or the electric accessory, overheat the wiring and perhaps cause a fire. The condition presents a danger to both life and property. 
     Most automobiles have two fuse panels. The engine compartment fuse panel typically contains the fuses for protection of the electrical circuits associated with the primary vehicle functions such as cooling fans, anti-lock brake pumps, and the engine control units. An interior fuse panel is usually located under the dash on the driver&#39;s side of the vehicle, and protects the electrical circuits associated with the electrical devices inside the passenger compartment. 
     Different fuse designs have different rating ranges. For example, AGU fuses (glass cylinder type) are commercially available with ratings between 5 and 60 amps. MAXI fuses (blade type) are commercially available with ratings between 20 and 80 amps. The more expensive ANL fuses (wafer type) are commercially available with ratings between 60 and 300 amps. For larger loads, circuit breakers are generally required. 
     Improvements in electronics and microchip technology have led to an enormous increase in the development and availability of high technology accessories for use in vehicles. These devices include CD players, DVD players, televisions, computers, telephones, fax machines, custom lighting, special effects devices, high powered amplifiers, other stereo system components, and other appliances configured to operate at low voltages. The number of options far exceeds the availability, capacity, and design of factory supplied electric circuits. 
     Frequently, the load requirement of a desired accessory exceeds the highest rated fuse that can fit in a factory supplied fuse panel. For example, many stereo amplifiers are rated at 2,000 or even 3,000 watts. 150 amp fuses are required for these units. As a result, the consumer must either purchase a separate fuse panel for the accessory that accommodates ANL fuses, or install a circuit breaker. 
     In addition to a lack of space of the factory supplied fuse panels, a variety of electric devices available on the market have significantly different load requirements. As a result, some accessories may require higher current circuits with higher fuse ratings, and other accessories may require lower current circuits with lower fuse ratings. Due to the difference in fuse design capacity, the consumer is required to purchase more than one additional fuse panel. 
     As a result of the above described issues, retailers will normally stock two or three different power distribution panels to accommodate the different fuse designs, as well as the different sizes of AWG gage input wires. 
     The large custom automobile market has created a special demand for additional power distribution and high current load capable circuits. These applications require solutions that not only satisfy the electric system functionality requirements, but solutions that are cosmetically enhancing. It is common in the custom automobile industry to use gold plated fuses, and fuse panels with highly decorative architecture. 
     Numerous devices have been developed for the purpose of providing additional power distribution that are cosmetically attractive. Other devices have been developed which permit fuse stacking to provide a higher fuse rating by using multiple fuses on a circuit. 
     One such device is disclosed in U.S. Pat. No. 6,457,995 B1 issued to Brooks. The device is a distributor having a positive input terminal block separated by a riser from a negative current input terminal block. 
     Another device is disclosed in U.S. Pat. No. 5,628,654 issued to Lineberry, Jr., for an accessory connector adapted for insertion Into a vehicle fuse box. The connector has a pair of fuse blade receptacles for inserting additional fuse blades, such that after removing a fuse from the fuse box, the accessory connector replaces the fuse and is then located between the fuse and the fuse box. 
     Another device is disclosed in U.S. Pat. No. 3,744,03 issued to Dipace (3 B&amp;D Products, Inc.), comprising a fuse block adapter, where a fuse is removed from a fuse clip and the fuse block adapter is inserted to allow for the fusing of an additional circuit. 
     Another device is disclosed in U.S. Pat. No. 6,457,995 B1 issued to Brooks, comprising a fuse block extender consisting of a male bus electrode and a circuit electrode positioned side by side and adapted to fit into the female electrodes of a vehicle fuse block, and of one or more accessory electrodes that connect to the bus electrode and to one or more accessories. 
     One disadvantage of these devices is that most are complex and expensive. Another disadvantage of these devices is that they are esthetically displacing, and thus unsuitable for customized vehicle applications. Another disadvantage of these devices is that they are limited by their principal configuration. Another disadvantage of these devices is that they are electrically unique, and require special knowledge to install and use. Another disadvantage of these devices is that they take up additional space to install. Another disadvantage of these devices is that they do not provide for use with higher load electrical appliances. 
     It can thus be seen that there is a need for a design of a power distribution panel that can be adapted to the various load requirements of different electrical accessories for vehicles. There is also a need for a design of a power distribution panel that can accomplish this objective while providing an esthetically enhancing architecture. 
     The fuse ratings and circuit descriptions are used for general Identification purposes only. The forgoing description is not intended to be instructive as to the use or safety of any particular fuse, circuit, or electrical accessory. Numerous variables, including the length and weight of the wiring are not considered here. The manufacturers recommendations for the individual electrical accessory should be consulted and followed. 
     BRIEF SUMMARY OF THE INVENTION 
     A primary advantage of the present invention is that it provides a power distribution panel kit that can be adapted to the various load requirements of different electrical accessories for vehicles. Another advantage of the present invention is that it allows for the use of less expensive fuses in higher load circuit designs. Another advantage of the present invention is that it accommodates an easily changeable configuration without any change to its esthetically enhancing architecture. Another advantage of the present invention is that it permits the addition of high load electric accessories, while eliminating the need to install additional power distribution blocks for higher fuse ratings. Another advantage of the present invention is that it provides for a broader range of circuit protection with a single fuse style. 
     Other advantages of the present invention will become apparent from the following descriptions, taken In connection with the accompanying drawings, wherein, by way of illustration and example, an embodiment of the present invention is disclosed. 
     In the preferred embodiment of the present invention, a fuse block system kit is disclosed having a nonconductive base. An electrically conductive input block is attached to the base, and a plurality of fuse clips are electrically connected to the input block. Opposite the input block, a plurality of single output blocks made of conductive material are removably attached to the base. A fuse clip is electrically connected to each single output block. Fuses are locatable in the fuse clips between the input block and the output blocks. A dual output block made of conductive material is attachable to the base in substitution of two single output blocks. In this manner, two single output blocks can be removed, and the dual output block substituted in their place. A pair of fuse clips is electrically connected to the dual output block. The resulting configuration doubles the fuse rating of the circuit without changing the size or appearance of the distribution block, and without changing the style of the fuse required. 
    
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) 
     The drawings constitute a part of this specification and include exemplary embodiments to the invention, which may be embodied in various forms. It is to be understood that in some instances various aspects of the Invention may be shown exaggerated or enlarged to facilitate an understanding of the invention. 
     FIG. 1 is an isometric view of a preferred embodiment of the present invention, disclosing a Variably Fusable Power Distribution Block kit adaptable for use in vehicles and particularty configured to receive fuses of the AGU type. 
     FIG. 2 is an exploded isometric view of the embodiment disclosed in FIG.  1 . 
     FIG. 3 is a top view of the embodiment of the invention disclosed in FIG.  1  and FIG.  2 . 
     FIG. 4 is a side view of the embodiment of the invention disclosed in FIGS. 1,  2 , and  3 . 
     FIG. 5 is an end view of the embodiment of the invention as disclosed In FIGS. 1 through 4, showing the receptacles ends of single output blocks. 
     FIG. 6 is a sectional side view of the embodiment of the invention as disclosed in FIG. 4, showing the members of the base connecting to input and output blocks. 
     FIG. 7 is an isometric view of a preferred embodiment of the present invention, disclosing the Variably Fusable Power Distribution Block of FIG. 1, whereas dual output blocks have been substituted for the single output blocks. 
     FIG. 8 is a top view of the embodiment of the invention disclosed in FIG.  7 . 
     FIG. 9 is an end view of the embodiment of the invention as disclosed in FIGS. 7 and 8, showing the receptacles ends of the dual output blocks. 
     FIG. 10 is an isometric view of a preferred embodiment of the present invention, disclosing a Variably Fusable Power Distribution Block kit configured to receive fuses of the MAXI type. 
     FIG. 11 is a top view of the embodiment of the invention disclosed in FIG.  10 . 
     FIG. 12 is a side view of the embodiment of the invention disclosed in FIGS. 10 and 11. 
     FIG. 13 is a top view of the basic embodiment of the present disclosure as disclosed in FIG. 1, showing a schematic of a circuit in which power from a power source is directed through an input connector on the input block, and being distributed to four fuses attached to single output blocks, defining four separate circuits. 
     FIG. 14 is a top view of the basic embodiment of the present disclosure as disclosed in FIG. 7, showing a schematic of a circuit in which power from a power source is directed through an input connector on the input block, and being distributed to four fuses attached to dual output blocks, defining two separate circuits. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The following description is presented to enable any person skilled in the art to make and use the invention, and is provided in the context of a particular application and its requirements. Various modifications to the disclosed embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the present invention. Thus, the present invention is not intended to be limited to the embodiments shown, nor to a single collection of all of the elements disclosed, but is to be accorded the widest scope consistent with the principles and features disclosed herein. 
     FIG. 1 is an isometric view of a preferred embodiment of the present invention, disclosing a variably fusable power distribution block kit adaptable for use in vehicles, and particularly configured to receive fuses of the AGU type. In this figure, it is seen that power distribution block assembly  10  generally comprises a base  20 , an input block assembly  40 , and a plurality of single output assemblies  60 . A cover  90  encloses input block assembly  40  and single output assemblies  60 . 
     FIG. 2 is an exploded view of the power distribution block assembly  10  disclosed in FIG.  1 . In this view, base  20  is shown. Base  20  is preferable made of a non-conductive material, such as plastic. Base  20  has a base front  22  and an opposite base back  24  (not visible). Base  20  has a base top  26 . In the preferred embodiment, base top  26  extends outwardly, such as in the convex configuration shown in FIG.  2 . Also in the preferred embodiment, base  20  has a raised perimeter edge  28  extending upward from base front  22 . Also in a preferred embodiment, base  20  has a plurality of slots  30  located along, or near to, raised perimeter edge  28 . One or more base mounting holes  32  pass through base  20  and provide a means for attaching base  20  to the vehicle. Another feature of the preferred embodiment is the presence of locating pegs  34  formed on, and raising upward from base front  22 . A plurality of block mounting holes  36  are located on base  20 . 
     Still referring to FIG. 2, an input block  42  made of electrically conductive material is shown located on base  20 . In the preferred embodiment, input block  42  has an outwardly extending top  44 , such as in the convex configuration shown in FIG. 2. A terminal connector  46  is threadedly connected to input block  42 . In the preferred embodiment, one or more secondary terminal connectors  48  are threadedly connected to input block  42 . In a preferred embodiment, input block  42  has an input platform  50  with a plurality of threaded platform holes  52 . 
     Still referring to FIG. 2, a plurality of single output blocks  62  made of electrically conductive material are located on base  20  opposite input block  42 . Single output blocks  62  have a threaded mounting hole  64  (not visible) located on their bottom side for attachment to base  20 . In a preferred embodiment, single output blocks  62  have an output platform  66 . Also in a preferred embodiment, single output blocks  62  have a threaded platform hole  68  on output platform  64 . An output receptacle  70  is located on the side of single output block  62  opposite platform portion  64 . A terminal connector  72  is threadedly attached on top of single output block  62 . Terminal connector  72  intersects output receptacle  70 . 
     In a preferred embodiment, threaded connectors  80  attach a plurality of electrically conductive fuse clips  82  to input platform  50  through threaded platform holes  52 . Likewise, a threaded connector  80  attaches a fuse clip  82  to each output platform  66  through threaded platform hole  68 . 
     A preferred embodiment of cover  90  is further disclosed as having a face  92  and side portions  94  extending downward from face  92 . Tabs  96  extend outward from side portions  94  for engagement with slots  30  of base  20 . In a preferred embodiment, cover  90  has an outwardly extending top  98 , such as in the convex configuration shown in FIG.  2 . 
     FIG. 3 is top view of distribution block assembly  10  in the embodiment disclosed in FIGS. 1 and 2, with a section of cover  90  shown broken away, with tabs  96  engaging slots  30 . In FIG. 3, four ( 4 ) AGU fuses  100  are shown installed between fuse clips  82  on input block assembly  40  and fuse dips  82  on single output assemblies  60 , establishing electrical connectivity between input block assembly  40  and single output assemblies  60 . 
     FIG. 4 is side view of distribution block assembly  10  in the embodiment disclosed in FIGS. 1,  2 , and  3 . In FIG. 4, it can be seen that the opening beneath outwardly extending top  98  of cover  90  provides access for variable positioning of an electrical connection from a power source to terminal connector  46 , or for connection to secondary terminal connector  48 . 
     FIG. 5 is an end view of distribution block assembly  10  in the embodiment disclosed in FIGS. 1 through 4, showing output receptacles  70  of single output blocks  62 . In this view, it is seen that the opening formed between face  92  and side portions  94  of cover  90  provides access for locating wiring electrically connected to each output receptacle  70  of each single output block  62 , thereby defining as many as four separate fuse protected circuits in the embodiment shown. 
     FIG. 6 is a sectional side view of distribution block assembly  10  in the embodiment disclosed in FIG.  4 . In this view, it can be seen that terminal connector  72  intersects output receptacle  70  providing electrical and physical connectivity to circuit wiring installed in receptacle  70 . In a preferred embodiment, threaded connector  80  attaches electrically conductive fuse clip  82  to Input platform  50  through threaded platform hole  52 . In this embodiment, threaded connector  80  passes through threaded platform hole  52  so as to attach input block  42  to base  20  through threaded block mounting holes  36 . Similarly, another threaded connector  80  attaches another fuse clip  82  to output platform  66  through threaded platform hole  68 . Also in this embodiment, threaded connector  80  passes through threaded platform hole  68  so as to attach output block  62  to base  20  through threaded block mounting holes  36 . 
     Still referring to FIG. 6, it can be seen that locating pegs  34  of base  20  can be used to locate and secure input block  42  on base  20 . Likewise, locating pegs  34  of base  20  can be used to locate and secure output block  62  on base  20 . 
     FIG. 7 is an isometric view of the preferred embodiment of distribution block assembly  10 . In this view of distribution block assembly  10 , single output assemblies  60  have been removed and replaced with dual output assemblies  110 . It is seen from FIG. 7 that the overall appearance of distribution block assembly  10  remains otherwise unchanged in appearance as compared to FIG.  1 . 
     Each dual output assembly  110  has a dual output block  112  having a single receptacle  114  which is comparatively larger than receptacle  70  in single output block  62 , and is thus capable of accommodating a larger wire size. In the preferred embodiment, fuse clip  82  is connectable to dual output block  112  with threaded connector  80 . In the preferred embodiment for use with AGU fuses, dual output block  112  also has a platform portion  116  with a pair of platform holes  118  (not visible) in spaced apart alignment with base mounting holes  32 . Each dual output assembly  110  is substituted into the position of two single output assemblies  60 , and secured to base  20  with the same threaded connectors  80 . In this configuration distribution block assembly provides two separate fuse protected circuits, each circuit having a circuit rating of approximately twice that of the individual circuits disclosed in FIG.  1 . 
     In another preferred embodiment, not shown, distribution block assembly  10  comprises a combination of two single output assemblies  60  and one dual output assembly  110 , thus providing three separate fuse protected circuits. 
     FIG. 8 is top view of distribution block assembly  10  in the embodiment disclosed in FIG. 7, with a section of cover  90  shown broken away, with tabs  96  engaging slots  30 . In FIG. 8, two (2) AGU fuses  100  are shown installed between fuse clips  82  on input block assembly  40  and fuse clips  82  on each dual output assembly  110 , establishing electrical connectivity protected by two fuses between input block assembly  40  and output block assembly  110 . By dividing the current between the two fuses  100 , the fuse rating of the circuit is essentially doubled, without using larger fuses. 
     FIG. 9 is an end view of distribution block assembly  10  In the embodiment disclosed in FIG. 7, showing output receptacles  114  of dual output assemblies  110 . In this view, it is seen that the larger opening of receptacles  114  are provided to receive the larger gage wiring associated with the higher rated circuit. 
     FIG. 10 is an isometric view of another preferred embodiment of distribution block assembly  10 . In this embodiment, power distribution block assembly  10  is configured to receive fuses  100  of the MAXI type. 
     OPERATION OF THE INVENTION 
     In the preferred embodiment of the present invention a power distribution block assembly  10  is generally comprised of a base  20 , an input block assembly  40 , and a plurality of single output assemblies  60 . A cover  90  encloses input block assembly  40  and single output assemblies  60 . Fuses  100  are removably installed between fuse clips  82  on the input block assembly  40  and fuse clips  82  on single output assemblies  60 . Single output assemblies  60  are removably attached to non-conductive base  20  by threaded connectors  80 . In the preferred embodiment, a threaded connector  80  connects a fuse clip  82  to a single output block  62  through a threaded platform hole  68 . In the more preferred embodiment, threaded connector  80  also connects single output block  62  to base  20  through one of the threaded block mounting holes  36 . 
     When the vehicle owner elects to connect an electrical accessory that requires more electrical power to operate than can be provided by the largest available fuse  100  that fits in power distribution block assembly  10 , the operator can remove two single input block assemblies  40  that are adjacently located, and replace them with one dual output assembly  110 . In the preferred embodiment, the same fuse dips  82 , and threaded connectors that are used for single output assembly  40  can be used to assemble and attach dual output assembly  110 . Theoretically, even fuses  100  can be used, if properly sized to accommodate the current rating requirement of the new electrical accessory. 
     FIG. 11 is a top view of the basic embodiment of the present disclosure showing a schematic for a circuit in which power from a power source  120  is directed through a circuit  122 , which is connected at a wire end to terminal connector  46  on input block assembly  40 . In this configuration, four single output assemblies  60  define four separate circuits through which electrical power from power source  120  is distributed. Each of circuits  124 ,  126 ,  128 , and  130  have a wire end located in a receptacle  70  of a single output block  60 . The current capacity of each circuit is defined by their respective fuse  100  rating for the circuit For example, the rating of circuit  124  is the amp rating of fuse  100   a , the rating of circuit  126  is the amp rating of fuse  100   b , the rating of circuit  128  is the amp rating of fuse  100   c , and rating of circuit  130  is the amp rating of fuse  100   d.    
     FIG. 12 is a top view of the embodiment disclosed in FIG. 11, whereas the vehicle owner has removed all four single output assemblies  60 , and replaced them on the same base with two dual output assemblies  110 . In this configuration, dual output assemblies  110  define two separate circuits through which electrical power from power source  120  is distributed. Each of circuits  132  and  134  have a wire end located in a receptacle  70  of a single output block  60 . The current capacity of each circuit is defined as the combined rating of the respective fuses  100  connected to dual output assembly  110 . The fuses attached to a dual block assembly should have the same amp rating. Thus, the rating of circuit  132  is the sum of the amp rating of fuses  100   a  and  100   b , and the rating of circuit  134  is the sum of the amp rating of fuses  100   c  and  100   d.    
     While this invention has been described in connection with a preferred embodiment it is not intended to limit the scope of the invention to the particular form set forth, but on the contrary, it is intended to cover such altematives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims. 
     The result from the use of the disclosed invention is that the vehicle owner can configure a circuit for amperage rating higher than the highest fuse rating otherwise available for a given fuse style. In addition, the present invention permits various such configurations, including the use of a dual output assembly in the center, or on either side of the power distribution block  10 . It is also seen from the foregoing that the present invention permits the user to avoid the cost, expense and trouble of purchasing additional power distribution blocks in many applications. It is also seen that the present invention preserves the aesthetic appeal of the device, even when reconfigured. It is also seen that the present invention allows for use of many of the same component parts in either configuration. 
     It will be appreciated by one of ordinary skill in the art that other configurations of the output blocks are possible based on this disclosure. For example, a triple output block assembly can be provided in the manner disclosed for a dual output assembly, and thus substitute in the place of three single output block assemblies. It is also recognized that numerous methods for connection and attachment of the essential elements are possible, but that the choice of such connection and attachment does not depart from the spirit and scope of the present invention.

Technology Classification (CPC): 7