Abstract:
A power distribution block assembly that includes an insulative body, at least one common electrically-conductive power bus member, a plurality of connector elements, and a sealed cover is disclosed. A U-shaped bus member includes a pluarlity of terminal blades extending therefrom, and plurality of separate connector elements connect the terminal blades to input side terminals of removable circuit elements, such as fuse elements or circuit breakers. Load side terminals of the fuse elements are received in load side connectors housed in passages in the body.

Description:
BACKGROUND OF THE INVENTION 
     1.) Field of the Invention 
     The invention relates to power distribution blocks in general. In particular, the invention relates to a fuse block having a common power bus. 
     2.) Related Art 
     Power distribution blocks are commonly used in the art to collect a plurality of circuit elements, such as fuses, in one central location. 
     Several fuse blocks are presently available as snap-together modules that form a multifused panel. These snap-together modules are excessively large when a large number of fuses are to be held in the block. The modules also involve costly, labor intensive, assembly. 
     Existing fuse block designs also commonly require the user to individually wire each circuit within the block for power input. When it is desired to power more than one circuit with the same power source, a jumper is installed for this purpose. These multiple wiring procedures, and the installation of a jumper, are costly, labor intensive and time consuming to the user. In addition, added circuits require the use of larger gauge wiring in order to handle the additional amp load. The use of larger gauge wire is costly, difficult to handle, and requires more panel space to mount the fuse block. 
     Another problem with existing designs is the inability to protect the fuse block components from contamination, especially from liquids. Although “splash covers” are available for some existing designs, these covers are in the form of additional components that must be bolted in place. This type of splash cover poses certain disadvantages in that it requires additional panel space to be secured, and presents an additional labor cost for installation. 
     U.S. Pat. No. 4,944,691 to Morach discloses a holder for removable circuit elements. The holder includes a metal bus bar having a plurality of fuse holders formed integrally therewith. Output terminals are provided which extend laterally from the bus bar. A cover member is provided that includes openings in the top for the insertion of fuses. 
     U.S. Pat. No. 4,599,679 to Baader discloses a fuse bus bar assembly that includes a bus bar formed as two separate components that are stacked on top of each other. The bus bar components include oppositely bent tangs that cooperate to receive fuse terminals for electrical connection therewith. A cover member is provided that includes a plurality openings for the receipt of fuses. This construction requires rather precise formation and assembly in order for the tangs to properly receive and mate with the fuse terminals. If one tang is misformed or damaged, it may be necessary to replace the entire bus bar component. In addition, the housing and cover do not serve to effectively isolate the circuit elements or fuses from contaminants. 
     U.S. Pat. No. 5,438,310 to Ikari discloses a fuse box formed by a plurality of separate components that are mechanically attached to each other. This construction is overly complex, costly to manufacture and assembly and less compact when compared to the unitary block body of the present invention. 
     U.S. Pat. No. 4,842,534 to Mobley et al. discloses a fuse/bus bar assembly having a plurality of (female) terminal members attached thereto. The physical attachment of the terminal members to the bus bar represents an increase in cost and labor over the construction of the present invention. 
     OBJECTS AND SUMMARY 
     It is an object of the present invention to provide a compact power distribution block that does not require the assembly of separate modules. 
     It is also an object of the present invention to provide a power distribution block that requires only a single power input connection to provide power to multiple circuits or circuit components. It is a further object to provide a construction wherein separate groups of circuit elements within the same unitary power block can be supplied with power from separate power sources. 
     It is yet a further object of the present invention to isolate the circuit elements within the distribution block and protect them from contamination, especially from splashed liquids. 
     These and other objects are achieved by providing a power distribution block assembly including an insulative body, at least one electrically-conductive bus member having a longitudinally-extending base and a plurality of terminal blades extending from the base, the base defining a site for electrical connection to a power source, the terminal blades defining a plurality of sites for electrical connection to a plurality of removable circuit elements, and a plurality of connector elements contained within said body, each of the connector elements being configured to electrically couple a terminal blade of the bus with a terminal of each of the removable circuit elements. 
    
    
     BRIEF DESCRIPTION OF THE DRAWING FIGURES 
     FIG. 1 is an exploded perspective view of a power distribution block constructed according to an embodiment of the present invention. 
     FIG. 2 is a bottom perspective view of a power distribution block of one embodiment of the present invention. 
     FIG. 3 is a perspective view of a power bus bar constructed according to the principles of the present invention. 
     FIG. 4 is a bottom perspective view of a power distribution block body constructed according to the present invention. 
     FIG. 5 is a top perspective view of the power distribution block body of FIG.  4 . 
     FIG. 6 is a partial top view of the power distribution block of FIG. 5 having a plurality of connector elements housed therein, and an associated removable circuit element. 
     FIG. 6A is a partial view of an alternative embodiment of a removable circuit element. 
     FIG. 7 is a perspective view of the power bus bar of FIG. 3 in combination with electrical connector elements. 
     FIG. 8 is a perspective view of a female connector element utilized in connection with the present invention. 
     FIG. 9 is a perspective view of the tray element illustrated in FIG.  1 . 
     FIG. 10 is a perspective view of a power distribution block body as shown in FIG. 1, in combination with a female fuse clip locking member constructed according to the present invention. 
     FIG. 11 is a perspective view of a power distribution block with an attached tethered cover constructed according to the present invention. 
     FIG. 11A is a detailed perspective view of a portion of the cover member of FIG.  11 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Certain components of a power distribution block assembly  1  according to the present invention are illustrated generally in FIG.  1 . An insulative body  5  receives a tray member  15 . A “splash-proof” cover  10  is mounted to the body  5  to enclose the interior thereof. 
     The insulative body  5  is preferably constructed as a unitary member. The term “unitary” is intended to means a one-piece monolithic member. The body  5  can be constructed from any suitable material. One preferred material is a strong, heat resistant, chemical resistant plastic. 
     The body  5  may have one or more mounting flanges  125 , each having an aperture  127 , with a threaded insert  130  disposed therein (FIG. 5) for receiving a suitable fastener (not shown). The body  5  is also provided with an upstanding sidewall  115  and an interior compartment  120 . 
     As illustrated in FIG. 2, one or more electrically-conductive bus members  30 ,  35  are inserted into the bottom of the insulative body  5 . The power distribution block assembly  1  may include a plurality of electrically-conductive bus members  30 ,  35 , each having a means of connecting to a power source. One such means is a threaded stud  40 , although it is possible to use other types of connectors. If there are more than one conductive bus members  30 ,  35 , they are separated from each other by a gap or an electrically-insulative spacer element  37 . Through the use of separate conductive bus members  30 ,  35 , it is possible to provide power to the power distribution block assembly  1  from a plurality of different sources. 
     For example, in vehicular applications it is often advantageous to provide power to certain circuit elements from a power source (e.g., a battery) at all times, and to provide power to other circuit elements only at certain times, e.g., when the ignition system of the vehicle is activated. While the embodiment illustrated in FIG. 2 shows a 12-pole bus  30  in combination with a 4-pole bus  35 , it should be understood that the number of poles provided on each of the bus members  30 ,  35  can vary widely depending upon the requirements of the particular system being powered. By way of example, 4, 6, 8, 10, 12, 16, 20 and 24-pole configurations are also possible. Also, more than two bus members may be utilized. Alternatively, a single bus bar member may be utilized. 
     Details of a representative bus member  45  constructed according to the present invention are illustrated in FIG.  3 . Bus bar members  30 ,  35  may be constructed in the manner described below with respect to representative bus bar  45 . The bus member  45  is made of any suitable electrically conductive material. Preferably, the material is capable of carrying relatively high currents. One such suitable material is C1100 alloy, which is 99.9% pure copper with a ½ hard temper. The bus member  45  has a longitudinally extended U-shaped base  55 . One or more apertures  50  are provided in the base  55  to receive a suitable electrical connector, such as a threaded stud  40 . An aperture  50  may be located at either end of the base  55 . A stud  40  can be located at either end, thereby providing the most convenient location for connection to a power source and facilitating connection. The base  55  may optionally include one or more holes  70  through which a suitable fastener (not shown) may pass to affix the bus member  45  to the body  5 . A plurality of power output wires  25  are attached to the block assembly  1  in a manner to be described more fully below. 
     As shown in FIG. 3, the conductive bus member  45  also includes a plurality of terminal blades  60  that extend from the legs of the U-shaped base  55 . A plurality of attachment formations, preferably in the form of undercuts  65  are provided in the legs of the U-shaped base  55  at the location of each terminal blade  60 . The construction of the bus member  45  provides several advantages. For example, the terminal blades  60  permit attachment of a plurality of circuit elements, as will be described more fully below. These circuit elements may be powered by a single electrical connection to the base  55 , instead of resorting to jumpers or individual circuit wiring schemes. The bus member  45  can carry high currents with a close spacing of circuit elements without overheating, thereby providing reliability and compactness. 
     The manner in which the bus member  45  can be attached to the insulative body  5  is further explained by reference to FIG.  4 . 
     Slots  75  are provided in the bottom of body  5  to receive the terminal blades  60 . These slots  75  can be numbered to facilitate identification of the individual circuit elements attached to each blade  60 . 
     An attachment projection  80  is formed integrally with the body  5  and is located at each slot  75  to provide a snap-fit engagement with the undercuts  65  of the bus member  45 . A bus attachment beam  90  may also be provided along the bottom of the body  5 . Optionally, holes  85  can be provided in the beam  90 . Holes  85  correspond with optional fastener holes  70  in the base  55  of the bus member  45  and accept suitable fasteners (not shown) for providing an added means of securing the bus member  45  to the body  5 . 
     The body  5  further includes a pair of integrally formed parallel legs  95 . Legs  95  define a plurality of open chambers  100  which permit the passage of connector elements, as will be more fully explained below. 
     The other side of the body  5  is described by reference to FIG.  5 . Located within the interior compartment  120  are a plurality of passageways  140  for the receipt of a load side terminal of a removable circuit element. A plurality of pockets  150  are also provided within the interior compartment  120 . Pockets  150  house a plurality of connector elements  155  (FIGS.  6  and  7 ). Terminal blade slots  75  extend from the bottom of body  5  and are in communication with the bottom of pockets  150 . 
     As illustrated in FIGS. 6 and 7, a separate connector element  155  is located in each pocket  150 . Terminal blades  60  extend up into pockets  150  through slot openings  75 . Each connector element  155  fits over a terminal blade  60  in a manner best illustrated in FIG.  7 . Connector element  155  are formed of any suitable material, such as stainless steel. An input side terminal  178  of a removable circuit element  177  can then be received between the spring fingers  160  of the connector element  155  and the terminal blade  60 . In this manner a direct electrical connection is made between terminal  178  and terminal blade  60 . Connector element  155  is not intended to be a current-carrying element. 
     A load-side female connector  165  is received within each of the passageways  140 . See FIG. 8. A load-side terminal  179  can be received between two bent over contacts  175  of the female connector  165 . A pair of locking members  170  project laterally from the female connector  165  and rest upon ledges  145  formed within pockets  140 . This construction prevents the female connector  165  from passing through the bottom of open chambers  100 . A plurality of retention tabs  167 ,  169  are provided at the lower end connector element  165  which receive and retain the output power wires W in a manner common in the art. 
     The female terminal connector  165  illustrated in FIG. 8 is similar to a “Packard” type connecting terminal. However, the present invention is not dependent upon the specific type of load-side connector utilized. Numerous connector designs are possible for connection to the load side terminal  179 . 
     In one embodiment, removable circuit element  177  can comprise a fuse element. Numerous types of fuse elements can be utilized. By way of example, an ATC™ type fuse (available from Cooper Industries-Bussman Division) may be effectively utilized with the power distribution block of the present invention. 
     In an alternative embodiment, the removable circuit element(s) may comprise a circuit breaker element  177 A which is schematically illustrated in FIG.  6 A. 
     As best illustrated in FIGS. 1 and 9, a tray  15  may also be located within the interior compartment  120  of body  5 . Tray  15  is preferably formed of an insulative material similar to that of body  5 . Tray  15  is provided with a plurality of retaining projections  185  that are received with a snap-fit in a plurality of corresponding retaining apertures  135  in the body  5  (FIG.  5 ). Proper insertion of the tray  15  within the internal compartment  120  can be insured by providing at least one retaining projection  185  which mates with a corresponding retaining aperture  135  only when tray  15  is properly oriented relative to the body  5 . 
     The tray  15  is provided with a plurality of openings  190  which receive the removable circuit elements  177 . The openings  190  may be numbered so as to correspond with the numbering of terminal blade slots  75 , through facilitating identification of the circuits and circuit elements  177 . 
     Openings  190  also include enlarged area  195  which permits the insertion of a removal tool (not shown) to withdraw load side connector  165 . 
     By this construction, tray  15  guides and organizes the removable circuit elements  177 . Tray  15  also serves to enclose and retain box connectors  155  and female connectors  165 . 
     In an alternative embodiment, the power distribution block assembly  1  may include an additional means for securing the female connector elements  165 . One possible supplemental locking member  200  is illustrated in FIG.  10 . Locking member  200  can be formed of any suitable material, such as an insulative material similar to that of body  5 . Locking member  200  includes a plurality of bosses  205  that are adapted to fit within corresponding slot head recessed openings  105  formed in side surfaces  110  of legs  95 . Locking projections  207  also fit within the slotted recessed openings  105 . Locking projections  207  include a snap-fit tounges  210  that retain the locking member  200  once it is inserted into the openings  105 . Locking projections  207  are configured to engage an engagement portion or shelf  180  formed on the female connector  165  (FIG.  8 ). Therefore, locking member  200  acts to further retain female connectors  165  within the open chambers  100 . 
     Another aspect of the present invention involves providing a cover member  10  which effectively seals off the interior compartment  120  of the body  5 , thereby preventing contamination of the circuit elements  177  and electrical connections housed therein. Cover member  10  can be formed of any suitable material, such as an insulative material similar to that of body  5 . 
     As best illustrated in FIGS. 1 and 11, cover  10  may include a plurality of retaining projections  13  that are received with a snap-fit in corresponding retaining apertures  16  provided within body  5 . Cover  10  may also have an integral tether  11 . Tether  11  has an aperture  12  located at an end thereof for receiving a suitable fastener F. By this construction, the cover is prevented from being lost or dropped when removed. Cover member  10  may further be provided with side walls in the form of a U-shaped channel  14 . The U-shaped channel  14  is constructed to receive upstanding sidewall  115  of the body  5  therein. This arrangement forms an effective seal between the cover  10  and sidewall  115  that effectively excludes contaminants from the interior compartment  120 , especially splashed liquids. Although not specifically illustrated, cover  10  may also include means to further facilitate grasping and removal, such as tabs, projections recesses, etc. 
     Only preferred embodiments of the invention are specifically illustrated and described herein. It should be appreciated that numerous modifications and variations of the present invention are possible in light of the present disclosure, such modifications and variations being encompassed within the scope of the appended claims without departing from the spirit and scope of the present invention.