Patent Description:
Vehicles are equipped with a variety of electrically powered equipment. These electrically powered devices may be controlled by an electrical box known as a power distribution module (PDM). PDMs are installed in applications to ensure circuits are protected, controlled, and/or sensed. PDMs provide centralized, safe power distribution for many applications, and may include fuses, relays, circuit breakers, and other components.

The environment within a vehicle presents a challenge for the PDM, as the ingress of water and other contaminants must be strictly protected. Manufacturing a PDM that has both IP67 (total protection from dust and protected from temporary liquid immersion) and IP69K (proven to resist ingress of high temperature and pressure wash) Ingress Protection ratings is challenging because the components are accessed during maintenance, and thus cannot be permanently sealed within the hard-wired box of the PDM.

One of those components may be a relay, which is an electrically operated switch. An ISO relay is one which adheres to a standard pattern for its electrical terminals that has been spelled out by the International Standards Organization (ISO). ISO micro relays are used in automotive switching applications such as for lamps and motors. ISO-style relays also generally plug into their end application via sockets, such as a PDM. Housing an ISO micro relay in a PDM is not difficult but providing a PDM that satisfies the IP67/IP69K Ingress Protection ratings is challenging.

<CIT> states in its abstract: 'A routed wire electrical center adapter for coupling electrical components having varying terminal footprints with standard electrical center components having a standard terminal footprint through an adapter element within the electrical center including application specific electrical elements for receiving, on a first element end, electrical terminals of a first footprint, and for receiving, on a second element end opposing the first element end, electrical terminals of a second footprint. The first footprint is selected from a wide range of footprints as specified in an application. The second footprint is a standard footprint across a broad range of electrical center applications.

This Summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended as an aid in determining the scope of the claimed subject matter.

An exemplary embodiment of an electrical box in accordance with the present disclosure may include a housing with a relay socket. The relay socket consists of a first, second, and third blade sockets, and first, second, and third terminal seats. The second blade socket is adjacent and parallel to the first blade socket. The third blade socket is orthogonal to the first blade socket and adjacent to the second blade socket. The relay socket is adapted to accept an ISO micro relay. The first terminal seat, adapted to receive a first terminal, is located in a center position of the first blade socket. The second terminal seat, adapted to receive a second terminal, is located in a center position of the second blade socket. The third terminal seat, adapted to receive a third terminal, is located in one end of the third blade socket.

An exemplary embodiment of a relay socket in accordance with the present disclosure may include first, second, and third blade sockets and first, second, and third terminal seats. The first blade socket is adapted to receive a first blade of an ISO micro relay and has a first edge and a second edge. The second blade socket, adjacent and parallel to the first blade socket, is adapted to receive a second blade of the ISO micro relay and has a third edge and a fourth edge, the third edge being proximate the first edge and the fourth edge being proximate the second edge. The third blade socket, adjacent and parallel to the second blade socket, is adapted to receive a third blade of the ISO micro relay and has a fifth edge and a sixth edge, the fifth edge being proximate the third edge and the sixth edge being proximate the fourth edge. The first terminal seat, adapted to receive a first terminal, is located at the first edge of the first blade socket. The second terminal seat, adapted to receive a second terminal, is located at the fourth edge of the second blade socket. The third terminal seat, adapted to receive a third terminal, is located at the fifth edge of the third blade socket.

An exemplary embodiment of a housing for use in an electrical box in accordance with the present disclosure may include a component side and a terminal side and also includes a relay socket which is adapted to receive an ISO micro relay. The relay socket includes first, second, and third cross-shaped openings. The first cross-shaped opening is adapted to receive a first blade of the ISO micro relay on the component side and a first terminal on the terminal side. The second cross-shaped opening is adapted to receive a second blade of the ISO micro relay on the component side and a second terminal on the terminal side. The third cross-shaped opening is adapted to receive a third blade of the ISO micro relay on the component side and a third terminal on the terminal side. The second cross-shaped opening is identical to the third cross-shaped opening.

A novel electrical box design, suitable for ISO Micro relays, is disclosed herein. The electrical box is adapted to support IP67 and IP69K Ingress Protection ratings. The housing of the electrical box is molded with blade sockets that correspond to blade positions of the ISO micro relays. The housing is also molded with terminal seats and cylindrical openings which vary, depending on the blade socket, enabling terminals of different sizes, orientations, and positions relative to the respective blades, to be easily inserted into the back of the housing. The resulting position of the terminals ensures that electrical connections to the ISO micro relay are made and ingress protection of components inside the electrical box is ensured.

For the sake of convenience and clarity, terms such as "top", "bottom", "upper", "lower", "vertical", "horizontal", "lateral", "transverse", "radial", "inner", "outer", "left", and "right" may be used herein to describe the relative placement and orientation of the features and components of the electrical box, each with respect to the geometry and orientation of other features and components of the electrical box appearing in the perspective, exploded perspective, and cross-sectional views provided herein. Said terminology is not intended to be limiting and includes the words specifically mentioned, derivatives therein, and words of similar import.

<FIG> is a representative perspective illustration of a relay <NUM>, according to the prior art. The relay <NUM> is one which adheres to a standard pattern for its electrical terminals that has been spelled out by the International Standards Organization (ISO), and thus may be thought of as an ISO relay. Further, because the relay is somewhat smaller than standard relays, this type of relay is known as an ISO micro relay. ISO micro relays <NUM> are standard off-the-shelf components with five blades 104a-e (collectively, "blades <NUM>"). The ISO micro relay <NUM> establishes a connection to a circuit by being plugged into a socket. As one example, the socket may be part of an electrical box, enabling a connection to be established between the ISO micro relay and a switching application.

The blades <NUM> of the ISO micro relay <NUM> are oriented in a particular configuration. Two of the blades 104a and 104b are oriented in one way (top of the relay and horizontally disposed, in the view of <FIG>) while the remaining three blades 104c, 104d, and 104e are orientated in another way (bottom of the relay and vertically disposed, in the view of <FIG>), which is orthogonal to the blades 104a and 104b. The blades 104a and 104b are also a different size (w<NUM>) than the blades 104c, 104d, and 104e (w<NUM>), with w<NUM> > w<NUM>. Further, the blades 104a and 104b are spaced a distance, d<NUM>, apart, while the spacing between blades 104c and 104d and blades 104d and 104e are a distance, d<NUM>, apart, with d<NUM> being smaller than d<NUM>. The blades are all approximately the same length, l.

The ISO micro relay <NUM> terminates in a socket to create an electrical connection to the device or circuit being supported by the relay, where the socket further holds the relay in place. For products that are water-resistant or protected against complete temporary water submersion, the pass-through socket housing the ISO micro relay would be sealed. The layout of the ISO micro relay <NUM>, where the blades <NUM> are oriented in a close configuration, however, does not enable the sealing of the socket housing.

<FIG>are representative illustrations of an electrical box <NUM>, according to exemplary embodiments. <FIG> is an exploded perspective view of the electrical box; <FIG> is a perspective view of the electrical box showing the component side of the housing; and <FIG>is a bottom view of the electrical box showing the terminal side of the housing. As will be shown, the novel electrical box <NUM> supports ISO micro relays, such as the ISO micro relay <NUM> of <FIG> and provides IP67 and IP69K protection against ingress of water or other contaminants into the electrical box, thus protecting all components within the electrical box.

The housing <NUM> of the electrical box <NUM> has two opposing sides, a component side of housing 218a (<FIG> and <FIG>) and a terminal side of housing 218b <FIG>both of which are shown and described in greater detail herein. Four ISO micro relays <NUM> (<FIG>) are shown, with a relay socket capable of receiving a fifth ISO micro relay. The number of relays shown in the electrical box <NUM> is not meant to be limiting. The relays <NUM> and fuses <NUM> are seated in the component side of housing 218a and power cables <NUM> and terminals <NUM> are connected to the terminal side of housing 218b. A cover <NUM> fits over the housing <NUM> to protect the relays <NUM> and fuses <NUM>. A seal <NUM> disposed between the cover <NUM> and the housing <NUM> provides additional protection against ingress of water/contaminants. Latches 220a and 220b (collectively, "latches <NUM>") are fastened on either side of the cover <NUM> and also engage with the housing <NUM>. The latches <NUM> secure the cover <NUM> to the housing <NUM>. As this disclosure concerns the relays <NUM> and not the fuses <NUM>, no further discussion is included about the fuses.

The electrical box <NUM> is designed to provide electrical connection between the relays <NUM> and external components by way of the power cable <NUM> and terminals <NUM>. Since the relays <NUM> each include five blades <NUM> (<FIG>), there are five dedicated terminals <NUM> associated with each relay, one for each blade. The relays <NUM> are inserted into dedicated sockets in the component side of housing 218a. The terminals <NUM> are connected to the terminal side of housing 218b such that they establish a connection to respective relays <NUM> through the housing <NUM>. Once power is delivered to the electrical box <NUM> through the power cable <NUM>, an electrical connection is established between the relays <NUM> and respective terminals <NUM>.

A relay socket for receiving an ISO micro relay is illustrated on both sides of the housing <NUM>. Relay socket 206a is featured on the component side of housing 218a (<FIG>) and relay socket 206b is featured on the terminal side of housing 218b <FIG>(collectively, "relay socket <NUM>"). The relay <NUM> of <FIG> may fit in the relay socket <NUM>, for example. Thus, the relay socket <NUM> is to be connected to five terminals <NUM>, one for each blade of the ISO micro relay, to establish an electrical connection between the relay and circuitry connected to the electrical box <NUM>.

Though the electrical box <NUM> is designed with the relays <NUM> and terminals <NUM> in mind, the relays and terminals are not part of the electrical box. Instead, both the relays <NUM> and terminals <NUM> are standard, off-the-shelf parts purchased by customers who utilize the electrical box <NUM>. To understand the challenges of designing the electrical box <NUM> to be IP67- and IP69K-compliant, a better understanding of the terminals <NUM> is warranted.

<FIG> are representative drawings of the terminal <NUM>, according to the prior art. In <FIG>, the terminal <NUM> is attached to one blade <NUM> of the ISO micro relay <NUM> (<FIG>). The terminal <NUM> features a device cable <NUM> and a rubber seal <NUM>, along with a three-part connector consisting of a socket interface <NUM>, a wire crimp area <NUM>, and a seal crimp area <NUM>. The socket interface <NUM> includes clips 306a and 306b (collectively, "clips <NUM>"), which are the parts of the terminal <NUM> that will mate with the blade <NUM>. Alternatively, the terminal <NUM> may be attached to components other than blades, such as busbars or other electrically conductive elements.

The clips <NUM> are spring-tensioned to be initially touching one another before attachment to something. When pushed against an edge of the blade <NUM>, the two clips <NUM> separate just enough that the blade fits between the two clips. The terminal <NUM> thus becomes fixably attached to the blade <NUM>. This attachment allows an electrical connection to be established between the ISO micro relay <NUM> and the terminal <NUM>. One clip 306a slides against one side of the blade <NUM> while the other clip 306b slides against the other side of the blade. The spring tension causes the clip <NUM> to remain connected to the blade <NUM> until the terminal <NUM> is removed from the blade.

The clips <NUM> of the socket interface <NUM>, as well as the wire crimp area <NUM> and seal crimp area <NUM> are made of an electrically conductive material. When power is delivered to the electrical box <NUM>, a current will pass through the blade <NUM> to the clips <NUM>, through the socket interface <NUM>, the wire crimp area <NUM>, the seal crimp area <NUM>, and through the wiring inside the device cable <NUM>, and vice-versa. Thus, the terminal <NUM> facilitates flow of electrical current between the ISO micro relay <NUM> and whatever device/circuit the device cable <NUM> is connected to.

The rubber seal <NUM> of the terminal <NUM> has a diameter, d<NUM> (<FIG>), while the socket interface <NUM> has a width, w<NUM> (<FIG>). The diameter, d<NUM>, of the rubber seal <NUM> is larger than the width, w<NUM>, of the socket interface <NUM>, the width, w<NUM>, of the wire crimp area <NUM>, and the width, w<NUM>,of the seal crimp area. Thus, the diameter, d<NUM>, of the rubber seal <NUM> is the widest part of the terminal <NUM>. To support different applications, the terminal <NUM> is available in different sizes. As will be shown, the electrical box <NUM> supports terminals <NUM> of two different sizes for connection to the ISO micro relay <NUM>.

At the electrical box <NUM>, two clips <NUM> for each blade <NUM> are disposed on the terminal side of housing 218b, where the relays <NUM> are plugged into the relay socket 206a on the component side of housing 218a. Though not fully visible in <FIG>, each of the terminals <NUM> ends at the relay socket 206b of the electrical box <NUM>. Thus, when the relay <NUM> is inserted into the relay socket <NUM>, each blade <NUM> automatically fits into the two clips <NUM> of its respective terminal <NUM>, for a total of five terminals. Further, each terminal <NUM> includes a rubber seal <NUM>, which is the widest part of the terminal. Thus, each terminal <NUM> will need a space greater than the diameter, d<NUM>, of the rubber seal <NUM> in the relay socket 206b.

<FIG> and <FIG> are representative illustrations of the relay socket portion of an electrical box <NUM>, according to the prior art. <FIG> is a top view of a relay socket <NUM> that is part of the prior art electrical box <NUM> while <FIG> shows relative placement of elements of the relay socket <NUM>. The relay socket <NUM> includes five blade sockets 404a-e (collectively, "blade sockets <NUM>"), for receiving five blades of an ISO micro relay, such as the ISO micro relay <NUM> (<FIG>).

To receive the ISO micro relay <NUM>, the blade sockets <NUM> are oriented in a particular configuration. Two of the blade sockets 404a and 404b are oriented in one way (top of the relay socket <NUM> and horizontally disposed, in the illustrated views). The remaining three blade sockets 404c, 404d, and 404e are orientated in another way (bottom of the relay socket <NUM> and vertically disposed, in the illustrated views), with the blade sockets 404c, 404d, and 404e being orthogonal to the blade sockets 404a and 404b. The blade sockets 404a and 404b are of a first size (w<NUM>), to correspond with the size, w<NUM>, of blades 104a and 104b (<FIG>); the blade sockets 404c, 404d, and 404e are of a different size (w<NUM>), to correspond with the size, w<NUM>, of blades 104c, 104d, and 104e, with w<NUM> > w<NUM>. The blade sockets 404a and 404b are spaced a distance, d<NUM>, apart, corresponding to the distance, d<NUM>, between blades 104a and 104b; the spacing between blade sockets 404c and 404d (d<NUM>) correspond with the distance between blades 104c and 104d; and the spacing between blade sockets 404d and 404e (also d<NUM>) correspond with the distances between blades 104d and 104e, with d<NUM> < d<NUM>. Further, though shown in two dimensions, each blade socket <NUM> has a depth sufficient to receive the length, l, of respective blades. Thus, the blade sockets <NUM> are sized to accept respective blades <NUM> of the ISO micro relay <NUM>.

The relay <NUM>, once inserted into the relay socket <NUM>, connects with terminals on the other side of the prior art electrical box <NUM> (not shown). <FIG> feature blade location indicators (patterned with upward diagonal stripes) (collectively, "blade location indicators <NUM>") and clip location indicators (patterned with downward diagonal stripes) (collectively, "clip location indicators <NUM>"). The blade location indicators <NUM> and the clip location indicators <NUM> illustrate how blades and terminals are seated into the respective blade sockets <NUM>. The blade location indicators <NUM> show that each blade essentially "fills" the respective blade sockets <NUM>. The blades <NUM> of the ISO micro relay <NUM> plug into the front of the relay socket <NUM> of the prior art electrical box <NUM> while the clips, such as the clips <NUM> of the terminal <NUM> (<FIG>) plug into the back of the relay socket. <FIG> thus indicates relative placement of the terminals <NUM> and the blades <NUM> once the ISO micro relay <NUM> is inserted into the relay socket <NUM> of the prior art electrical box <NUM>.

Thus, for blade socket 404a, blade location indicator 414a and clip location indicators 416a and 416b are shown; for blade socket 404b, blade location indicator 414b and clip location indicators 416c and 416d are shown. A position indicator <NUM> (disposed vertically in <FIG>) indicates that clip location indicators 416a-416d line up in the same plane with one another.

For blade socket 404c, blade location indicator 414c and clip location indicators 416e and 416f are shown; for blade socket 404d, blade location indicator 414d and clip location indicators <NUM> and <NUM> are shown; for blade socket 404e, blade location indicator 414e and clip location indicators 416i and 416j are shown. A position indicator <NUM> (disposed horizontally in <FIG>) indicates that clip position indicators 414e-414j line up in the same plane with one another.

The position indicators <NUM> and <NUM> thus show the typical "centered" location for where the clips, and thus terminals, are usually located (on the other side of the prior art electrical box <NUM>). The position indicator <NUM> show that the clip location indicators 416a-d are in the same plane. Recall from the ISO micro relay <NUM> (<FIG>) that the blades <NUM> are not all the same size. Blades 104a and 104b are a first width, w<NUM>, while blades 104c, 104d, and 104e are a second width, w<NUM>, with w<NUM> < w<NUM>. Thus, it is possible to join the blades 104a and 104b with terminals <NUM> that are a first size, while blades 104c, 104d, and 104e are joined with terminals that are a second, smaller size. Recall that the rubber seal <NUM> of the terminal <NUM> (<FIG>) has a diameter, d<NUM>, which is as wide or wider than any other component of the terminal. Thus, the rubber seal <NUM> governs the ability to successfully connect a terminal <NUM> to each blade of the ISO micro relay <NUM> into the relay socket <NUM> of the prior art electrical box <NUM>.

Recall that the terminal <NUM> is a standard, off-the-shelf part available for purchase by a customer, where that customer also purchases the prior art electrical box <NUM>. The customer may populate the prior art electrical box <NUM> with fewer relays and fuses than the electrical box supports. With respect to the relays, for example, the customer purchases the number of relays needed for the particular application, then purchases five terminals for each relay obtained, one terminal for each blade. Because two of the blades of each relay have larger dimensions than the remaining three blades, the customer would purchase two terminals of one size, and three terminals of a different, smaller size for each relay. Thus, the relays support terminals of two different sizes. And the corresponding rubber seals for each terminal are sized differently, with the larger terminal having a rubber seal that is larger than the smaller terminal. For this reason, <FIG> shows two different sizes of rubber seals.

<FIG> illustrates how the rubber seal of the terminal <NUM> fits, relative to each blade socket <NUM>. Blade sockets 404a and 404b including rubber seal location indicators 422a and 422b, respectively (collectively, "rubber seal location indicators <NUM>"). Blade sockets 404c, 404d, and 404e include rubber seal location indicators 424a, 424b, and 424c (collectively, "rubber seal location indicators <NUM>"). Rubber seal location indicators <NUM> are larger than rubber seal location indicators <NUM>. Thus, the blade <NUM> is inserted into the blade socket <NUM> on the component side of the prior art electrical box <NUM>, while the clips <NUM> and the rubber seals <NUM> of the terminals <NUM>, one for each blade <NUM>, are "below" or "behind" the blade socket <NUM> on the terminal side of the prior art electrical box.

Further, clip location indicators 416b (for blade socket 404a) and 416c (for blade socket 404b) are spaced apart enough to fit the larger rubber seal around each terminal, as rubber seal location indicators 422a and 422b are not touching one another. The distance, d<NUM>, between blade location indicators 414a and 414b is thus large enough to support the larger rubber seal.

However, this is not true for blade sockets 404c-e, even though they are to be fit with terminals having the smaller rubber seals. The position indicator <NUM> shows that the clip location indicators 416e-416j are in the same plane. But clip location indicator 416i (for blade socket 404e) is very close to clip location indicator <NUM> (for blade socket 404d) and clip location indicator <NUM> (for blade socket 404d) is very close to clip location indicator 416f (for blade socket 404c). Thus, the terminals <NUM> that are to be connected on the backside of the prior art electrical box <NUM> for three of the blade socket 404c-e will be too close together to include even the smaller rubber seal around each terminal.

Returning to <FIG> and <FIG>the novel electrical box <NUM> has a relay socket design that is different from what is shown in <FIG> and <FIG>, according to exemplary embodiments. Based on the layout of its relay socket, as shown and described below, the novel electrical box <NUM> is able to provide IP67 and IP69K protection against ingress of water into the electrical box, thus sealing and protecting the ISO micro relays within the electrical box.

<FIG> are representative drawings of the component side of the electrical box <NUM> of <FIG> and <FIG>, according to exemplary embodiments. <FIG> and <FIG> are close-up views of the electrical box <NUM> of <FIG> and <FIG>, according to exemplary embodiments, with the relay socket 206a (component side of housing 218a) being shown in more detail. <FIG> is a head-on view of a terminal arrangement <NUM> supported by the electrical box <NUM>, in exemplary embodiments. <FIG> includes terminal seats while <FIG> shows the actual terminals. Five blade sockets 504a-e are shown, one for each blade of the ISO micro relay (collectively, "blade sockets <NUM>"). For the ISO micro relay <NUM> (<FIG>), blade 104a fits in blade socket 504a, blade 104b fits in blade socket 504b, blade 104c fits in blade socket 504c, blade 104d fits in blade socket 504d, and blade 104e fits in blade socket 504e.

To receive the ISO micro relay <NUM>, the blade sockets <NUM> are oriented in a particular configuration. Two of the blade sockets 504a and 504b are oriented in one way (top of the relay socket 206a and horizontally disposed, in the illustrated views). The remaining three blade sockets 504c, 504d, and 504e are orientated in another way (bottom of the relay socket 206a and vertically disposed, in the illustrated views), with the blade sockets 504c, 504d, and 504e being orthogonal to the blade sockets 504a and 504b. The blade sockets 504a and 504b are of a first size (w<NUM>), to correspond with the size, w<NUM>, of blades 104a and 104b (<FIG>); the blade sockets 504c, 504d, and 504e are of a different size (w<NUM>), to correspond with the size, w<NUM>, of blades 104c, 104d, and 104e, with w<NUM> > w<NUM>. The blade sockets 504a and 504b are spaced a distance, d<NUM>, apart, corresponding to the distance, d<NUM>, between blades 104a and 104b; the spacing between blade sockets 504c and 504d (d<NUM>) correspond with the distance between blades 104c and 104d; and the spacing between blade sockets 504d and 504e (also d<NUM>) correspond with the distances between blades 104d and 104e, with d<NUM> < d<NUM>. Further, though shown in two dimensions, each blade socket <NUM> has a depth sufficient to receive the length, l, of respective blades. Thus, the blade sockets <NUM> are sized to accept respective blades <NUM> of the ISO micro relay <NUM>. In exemplary embodiments, the blades <NUM> of the ISO micro relay <NUM> essentially "fill" the respective blade sockets <NUM>.

The blades <NUM> of the ISO micro relay <NUM> plug into the front of the relay socket 206a of the novel electrical box <NUM> while the terminals, including clips, are located in back of the relay socket. Once inserted into the relay socket 206a, the ISO micro relay <NUM> connects with the terminals. Terminal seats 506a-e (shown as white crosses) (collectively, "terminal seats <NUM>") illustrate the relative position of terminals "behind" respective blade sockets <NUM>. Recall that the terminals <NUM> are purchased by customers separate from purchasing the electrical box <NUM>. If an ISO micro relay <NUM> is to be installed into the electrical box <NUM>, the customer will purchase five terminals <NUM> for each ISO micro relay being installed. The terminal seats <NUM> thus indicate placement of terminals, such as the terminals <NUM> (<FIG>) relative to the blade sockets <NUM> once the ISO micro relay <NUM> is inserted into the relay socket 206a of the novel electrical box <NUM>.

Thus, for blade socket 504a, terminal seat 506a is shown; for blade socket 504b, terminal seat 506b is shown. A position indicator <NUM> (disposed vertically in <FIG>) indicates that the terminal seats 506a and 506b line up in the same plane with one another.

For blade socket 504c, terminal seat 506c is shown; for blade socket 504d, terminal seat 506d is shown; for blade socket 504e, terminal seat 506e is shown. A position indicator <NUM> (disposed horizontally in <FIG>) indicates that terminal seats 506c and 506e line up in the same plane with one another. However, a second position indicator <NUM> (disposed horizontally in <FIG>) indicates that terminal seat 506d is in a different plane than terminal seats 506c and 506e. In contrast to the prior art relay socket <NUM> (<FIG>), the relay socket 206a has an "off-centered" layout or geometry which allows standard terminals and wire seals to be used in the electrical box <NUM>, in exemplary embodiments. Further, in exemplary embodiments, the positioning of the terminals ensures that the electrical box <NUM> supports the IP67 and IP69K ingress protection protocols.

In exemplary embodiments, the housing of the electrical box <NUM> is molded to have openings for fitting the blade of the ISO micro relay (on the component side) and the terminal (on the terminal side). These openings may be characterized as being "cross-shaped", the cross consisting of two intersecting bars, the first bar being disposed in one orientation and the second bar being disposed in another, right-angle orientation, such that the two bars are perpendicular to one another. Thus, in exemplary embodiments, the component side of housing 218a is molded such that resulting "cross-shaped openings" are formed in the housing for both the blades and their respective terminals. Because of the size and orientation of both the blades and the terminals, as well as the relative position of the terminals behind respective blade sockets, the cross-shaped openings vary somewhat, in some embodiments.

As viewed from the illustrations of <FIG> and <FIG>, the cross-shaped openings for blade sockets 504a and 504b, for example, have a horizontal portion sized to accept the larger blades (104a and 104b) and a vertical portion sized to accept larger terminals in a first orientation, each resulting in a first cross-shape. Blade sockets 504c and 504e have vertical portions sized to accept the smaller blades (104c and 104e) and a horizontal portions sized to accept smaller terminals in a second orientation, each resulting in a second cross-shape. Blade socket 504d has a vertical portion sized to accept a smaller blade (104d) and a horizontal portion sized to accept a larger terminal in the second orientation, resulting in a third cross-shape. Further, since the terminal part is oriented at one edge of the blade socket, the cross-shape of blade sockets 504c and 504e looks somewhat like a small letter "t" while the cross-shape of blade socket 504d looks like an upside down small letter "t", given that the terminal part is at the opposing edge, with the vertical part of the cross being fatter for the blade socket 504d. In exemplary embodiments, the molding of the housing <NUM> thus facilitates the placement of the off-the shelf ISO micro relay and terminal components into the electrical box <NUM>.

In an exemplary embodiment, the novel electrical box <NUM> allows for standard terminal terminals and rubber seals to be installed in offset blade sockets. In <FIG>, the terminals are visible through the openings of respective blade sockets <NUM>. Terminal 508a is visible in blade socket 504a; terminal 508b is visible in blade socket 504b; terminal 508c is visible in blade socket 504c; terminal 508d is visible in blade socket 504d; and terminal 508e is visible in blade socket 504e (collectively, "terminals <NUM>"). In exemplary embodiments, terminals 508c and 508d are of a smaller size than terminals 508a, 508b, and 508d. Further, in exemplary embodiments, the terminals 508a and 508b are in a first orientation while terminals 508c, 508d, and 508e are in a second orientation, the second orientation being orthogonal to the first orientation.

Each of the terminals <NUM> features two clips. Terminal 508a includes clips 510a and 510b; terminal 508b includes clips 510c and 510d; terminal 508c includes clips 510e and 510f; terminal 508d includes clips <NUM> and <NUM>; and terminal 508e includes clips 510i and 510j (collectively, "clips <NUM>"). When respective blades <NUM> are inserted in the terminals <NUM>, the clips <NUM> will move slightly to receive the blades. Viewed from the illustration of <FIG>, when blade 104a of ISO micro relay <NUM> (<FIG>) is inserted in blade socket 504a, the clip 510a of the terminal 508a will move upward slightly, while the clip 510b will move downward slightly. When blade 104b is inserted in blade socket 504b, the clip 510c of the terminal 508b will move upward slightly, while the clip 510d will move downward slightly. When blade 104c is inserted into blade socket 504c, the clip 510e of the terminal 508c will move slightly to the right, while the clip 510f will move slightly to the left. When blade 104d is inserted into blade socket 504d, the clip <NUM> of the terminal 508d will move slightly to the right, while the clip <NUM> will move slightly to the left. When blade 104e is inserted in blade socket 504e, the clip 510i of the terminal 508e will move slightly to the right, while the clip 510j will move slightly to the left. The spring tension of each pair of clips <NUM> will maintain a connection to the respective blades <NUM>, thus ensuring that the terminals <NUM> are electrically connected to the blades.

In the head-on view of the terminal arrangement <NUM> (<FIG>), the five terminals <NUM> are shown, with respective clips <NUM>, as before. The terminal arrangement <NUM> is from the component side of the electrical box, with the electrical box not shown. The terminal seats <NUM> (<FIG>) are arranged to accommodate the terminals <NUM>, in exemplary embodiments, with the terminals 508a and 508b arranged in one direction (with respective clips <NUM> to be attached above and below respective blades) and the terminals 508c, 508d, and 508e are arranged at right angles to terminals 508a and 508b (with respective clips <NUM> to be attached to the left and right of respective blades). Further, the terminal arrangement <NUM> shows that the terminals 508c and 508e are smaller than terminals 508a, 508b, and 508d.

The terminal arrangement <NUM> also shows rubber seals for each terminal, with the rubber seals being "behind" the clips <NUM>. Rubber seals 512a, 512b, and 512d are a first size, with rubber seals 512c and 512e being a second, smaller size (collectively, "rubber seals <NUM>"). The arrangement of the terminal seats <NUM> (<FIG>), as well as the attachment of terminals to respective blades (<FIG>), with some terminals being attached to the center of the blade and some not, ensures that the rubber seals <NUM> do not touch one another.

Recall that the rubber seal <NUM> of the terminal <NUM> (<FIG>) has a diameter, d<NUM>, while the socket interface <NUM> has a width, w<NUM> (<FIG>), with the diameter, d<NUM>, being larger than the width, w<NUM>, and thus the widest part of the terminal <NUM>. This is true even for terminals of different sizes. In the head-on view terminal arrangement <NUM> of <FIG>, though they are "behind" the respective terminals <NUM>, the rubber seals <NUM> are each visible, as the diameter of each rubber seal is larger than that of the other components of each terminal. This is true whether a smaller rubber seal (e.g., 512c and 512e) or a larger rubber seal (e.g., 512a, 512b, and 512d) is used. In exemplary embodiments, the novel approach to terminal alignment shown in <FIG> allows a sealed connection to be made between each blade <NUM> of the ISO micro relay <NUM> and each terminal <NUM>. In exemplary embodiments, the terminals <NUM> can be installed into and removed from the electrical box <NUM> with industry standard methods.

<FIG> and <FIG> are representative drawings of the terminal side of housing 218b of the electrical box <NUM>, according to exemplary embodiments. The illustrations show how the "offset" configuration of the relay socket 206a (component side of housing 218a) of <FIG> and <FIG> allows space for each terminal to have a standard seal in the relay socket 206b (terminal side of housing 218b). The novel configuration thus facilitates placement of the terminals, including the rubber seals, in the relay sockets of the electrical box <NUM>, according to exemplary embodiments, such that IP67 and IP69K ingress protection is obtained.

In exemplary embodiments, the terminal side of the relay socket 206b features elements that mate with the ISO micro relay <NUM> once inserted into the blade sockets <NUM> on the component side of the relay socket 206a. Blade socket locations 604a-e (collectively, "blade socket locations <NUM>") are indicated as the backside locations of respective blade sockets 504a-e in <FIG> and <FIG> and are the locations where terminals, such as terminals <NUM>, are disposed. Accordingly, in blade socket location 604a, an insulated wire 606a surrounded by a rubber seal 608a, is shown. The insulated wire 606a and rubber seal 608a are both part of a terminal, such as terminal <NUM> (<FIG>), which connect to blade 104a of ISO micro relay <NUM> (<FIG>) once the relay is inserted into the relay socket 206a. Similarly, blade socket location 604b features insulated wire 606b surrounded by rubber seal 608b; blade socket location 604c features insulated wire 606c surrounded by rubber seal 608c; blade socket location 604d features insulated wire 606d surrounded by rubber seal 608d; and blade socket location 604e features insulated wire 606e surrounded by rubber seal 608e (collectively, "insulated wires <NUM>" and "rubber seals <NUM>").

In exemplary embodiments, the blade socket locations 604a, 604b, and 604d are larger than the blade socket locations 604c and 604e. This corresponds to the terminals 508a, 508b, and 508d being larger in size than the terminals 508c and 508d (<FIG>). Although the orientation of terminals 508a and 508b are orthogonal to the orientation of terminals 508c, 508d, and 508e, this is not evident on the terminal side of the relay socket 206b.

In exemplary embodiments, between the blade socket locations 604e and 604d, there is a space, s; similarly, between the blade socket locations 604d and 604c, there is a space, s. The space, s, ensures that there is sufficient spacing so that respective rubber seals <NUM> do not overlap one another. Once the terminals are in place in the electrical box, the rubber seals <NUM> fit tightly against the housing of the electrical box <NUM>, in exemplary embodiments. When the ISO micro relay <NUM> is installed in the relay socket 206a, the pair of clips of each terminal will become attached to the respective relay blades. In exemplary embodiments, the tight fitting of the rubber seals <NUM> of the terminals <NUM> provides a seal against the housing of the electrical box <NUM>, preventing water or contaminants from entering the electrical box. In exemplary embodiments, the electrical box <NUM> satisfies both IP67 (total protection from dust and protected from temporary liquid immersion) and IP69K (proven to resist ingress of high temperature and pressure wash) Ingress Protection ratings with the novel arrangement of the relay socket.

<FIG> is a second terminal side view of the electrical box <NUM>, again featuring the relay socket 206b. In this view, blade location indicators 614a-e (collectively, "blade location indicators <NUM>") for the ISO micro relay <NUM> are shown. Blade location indicators 614a and 614b, for the blade socket locations 604a and 604b, respectively, indicate that respective terminals are positioned in the middle of the blade socket location. The insulated wire 606a, for example, is disposed in the center of the blade location indicator 614a, and the rubber seal 608a is also disposed such that its center is in the center of the blade location indicator and its circumferential edges are equidistant from the left and right edges of the blade location indicator. The same is true for the insulated wire 606b and rubber seal 608b, both are positioned in the middle of the blade location indicator 614b.

In exemplary embodiments, the blade location indicators 614c, 614d, and 614e show that the terminals are not positioned in the middle of the blade socket locations but are each in offset positions relative to the blade sockets. Insulated wire 606c and rubber seal 608c, for example, are disposed at one end of the blade location indicator 614c (to the end closer to blade location indicator 614b). Similarly, insulated wire 606e and rubber seal 608e are disposed at one end of the blade location indicator 614c (to the end closer to blade location indicator 614b). Thus, in exemplary embodiments, terminals connect at the top, not at the center, of the blades 104c and 104e. Insulated wire 606d and rubber seal 608d, on the other hand, are disposed at the other end of the blade location indicator 614d (end that is farther away from blade location indicator 614b). Thus, in exemplary embodiments, a terminal connects at the bottom, not the center, of the blade 104d. In this manner, all blades <NUM> of the ISO micro relay <NUM> are connected to terminals and the rubber seals <NUM> are able to be positioned flush against the housing of the electrical box <NUM>, ensuring that the electrical box satisfies IP67 and IP69K ingress protection ratings.

<FIG> and <FIG> are representative drawings of an ISO micro relay <NUM> connected to terminals, where the terminals are arranged as they would be in the electrical box <NUM>, according to exemplary embodiments. <FIG> shows a perspective view of the ISO micro relay <NUM> without housing while <FIG> shows a side view of the ISO micro relay <NUM> within the housing <NUM> of the electrical box <NUM>. The ISO micro relay <NUM> includes blades 704a-e, arranged just as with the ISO micro relay <NUM> (<FIG>). Terminal 706a connects to blade 704a; terminal 706b connects to blade 704b; terminal 706c connects to blade 704c; terminal 706d connects to blade 704d; and terminal 706e connects to blade 704e (collectively, "blades <NUM>" and "terminals <NUM>").

In exemplary embodiments, terminal 706a is positioned so that it connects to the center of blade 704a; similarly, terminal 706b is positioned so that it connects to the center of blade 704b. By contrast, terminal 706c is positioned so that it connects to the top of blade 704c; similarly, terminal 706e is positioned so that it connects to the top of blade 704e. Finally, terminal 706d is positioned so that it connects to the bottom of blade 704d. Further, terminals 706c and 706e are smaller than terminals 706a, 706b, and 706d. These arrangements are consistent with the illustrations and descriptions of <FIG>, <FIG>, <FIG> and <FIG>, above. By using smaller terminals for blades 704c and 704e and by staggering the connection location of terminals 706c, 706d, and 706e, the rubber seals of all five terminals <NUM> are able to fit flush against the electrical box so as to provide the desired ingress/egress protection.

Blades 704a, 704b and 704c are visible in the side view of <FIG> and are connected to terminals 706a, 706b, and 706c, respectively. Rubber seal 714a of terminal 706a fits into cylindrical opening 710a of the housing <NUM> of the electrical box <NUM>; rubber seal 714b of terminal 706b fits into cylindrical opening 710b of the housing; and rubber seal 714c of terminal 706c fits into the cylindrical opening 710c of the housing (collectively, "cylindrical openings <NUM>" and "rubber seals <NUM>"). Clips 708a and 708b of terminal 706a are shown on either side of blade 704a (collectively, "clips <NUM>").

In exemplary embodiments, the cylindrical openings <NUM> are sized in a telescoping manner such that the smallest part of each terminal <NUM> (the clips <NUM>) fit into a smaller portion of the cylinder, and the rubber seals <NUM> fit into a larger portion of the cylinder. In exemplary embodiments, the size of the cylindrical openings <NUM> vary, depending on the size of the terminals <NUM>. Thus, the cylindrical opening 710a and 710b are sized to fit respective larger terminals 706a and 706b while the cylindrical openings 710c are sized to fit a smaller terminal 706c. In exemplary embodiments, the diameter of each rubber seal <NUM> fills the space of respective cylindrical opening <NUM> of the housing <NUM> and forms a secure, water- and air-tight connection. In exemplary embodiments, the abutting of the rubber seals <NUM> against the cylindrical openings <NUM> of the housing <NUM> ensure that the electrical box <NUM> satisfies IP67 and IP69K ingress protection ratings, as water and other contaminants are not able to get past the rubber seals. Thus, in exemplary embodiments, the blades <NUM> and the clips <NUM> of the terminals <NUM> will not get wet or otherwise contaminated.

Thus, a novel electrical box features Ingress Protection ratings of IP67 and IP69K, in exemplary embodiments. The housing of the electrical box is designed such that the rubber seals of each terminal fit snugly into cylindrical spaces of the housing. The electrical box is able to house and support ISO micro relays having five terminals, as shown and described above.

Claim 1:
An electrical box (<NUM>) comprising:
a housing (<NUM>) comprising a relay socket (206b), the relay socket (206b)comprising:
a first blade socket;
a second blade socket adjacent and parallel to the first blade socket;
a third blade socket orthogonal to the first blade socket, wherein the third blade socket is adjacent to the second blade socket, wherein the relay socket (206b) is adapted to accept an International Standards Organization (ISO) micro relay;
a first terminal seat disposed in a center position of the first blade socket, wherein the first terminal seat is adapted to receive a first terminal;
a second terminal seat disposed in a center position of the second blade socket, wherein the second terminal seat is adapted to receive a second terminal;
a third terminal seat disposed in a first end of the third blade socket, wherein the third terminal seat is adapted to receive the third terminal,
a fourth blade socket orthogonal to the first blade socket;
a fifth blade socket orthogonal to the first blade socket, wherein the fourth blade socket and the fifth blade socket are adjacent to the second blade socket, with the fourth blade socket being between the third blade socket and the fifth blade socket,
a fourth terminal seat disposed at a second end of the fourth blade socket,
a fifth terminal seat disposed at a third end of the fifth blade socket, wherein the first end and the third end are in a first plane and the second end is in a second plane,
a first cylindrical opening of a first size adapted to receive the first terminal;
a second cylindrical opening of the first size adapted to receive the second terminal; and
a third cylindrical opening of a second size adapted to receive the third terminal, wherein the second size is smaller than the first size.