Patent Description:
Components such as fuses, relays, diodes, and the like, are used in automobiles to provide a connection between the battery and various components, such as the starter, generator, and so forth. Fuses may be provided in a fuse assembly that may be connected to the automobile battery. Such an assembly is shown in e.g. <CIT>. The fuses may be individually inserted frictionally into a pair of projections, which are provided by a terminal. The terminal is held fixed by upper and lower press-fit layers. An upper housing of a housing assembly defines apertures, wherein the projections extend into the apertures so that an operator may place a fuse into the pair of projections. However, power distribution assemblies including multiple components and multi-part housings are expensive to manufacture and assemble, and lack scalable customization to meet the needs of smaller applications.

In view of the foregoing, it would be advantageous to provide a sealed modular power distribution apparatus that allows greater flexibility to meet the needs of smaller applications that may not have the volume to justify customizing an entire fuse box. Additionally, it would be advantageous to provide interchangeable modules that are sealed to a housing assembly and configured to receive terminals through openings formed through a base wall of the housing assembly to directly connect the terminals to one or more components (e.g., fuses, relays, circuit breakers, diodes, etc.) within the housing assembly.

One exemplary approach in accordance with the present disclosure may include an apparatus having a module extending into an interior cavity of a housing assembly through an opening formed in a base section of the housing assembly, the module including a component grid. The apparatus may further include a mechanical sealing element disposed along a surface of the module to provide a seal between the module and the base section defining the opening.

Another exemplary approach in accordance with the present disclosure may include a modular power distribution apparatus having a housing assembly including a base section coupled to a cover, and a set of modules extending into an interior cavity of the housing assembly through one or more openings formed in the base section. Each of the set of modules may include a component grid disposed at a first end. The modular power distribution apparatus may further include a mechanical sealing element disposed along one or more sidewalls of each of the set of modules to provide a seal between each of the set of modules and the base section defining each of the one or more openings.

Another exemplary approach in accordance with the present disclosure may include a modular power system having a housing assembly including a base section and a cover. The base section may include a base wall including a plurality of openings, and an inner wall extending substantially perpendicularly from the base wall, wherein the inner wall is releasably coupled to the cover. The modular power system may further include a plurality of modules extending into an interior cavity of the housing assembly through the plurality of openings of the base wall. Each of the set of modules may include a component grid disposed at a first end, and a mechanical sealing element disposed along one or more sidewalls of each of the set of modules, the mechanical sealing element in contact with the base wall.

The drawings are merely representations, not intended to portray specific parameters of the disclosure. The drawings are intended to depict typical embodiments of the disclosure, and therefore should not be considered as limiting in scope. In the drawings, like numbering represents like elements.

Furthermore, certain elements in some of the figures may be omitted, or illustrated not-to-scale, for illustrative clarity. Cross-sectional views may be in the form of "slices", or "near-sighted" cross-sectional views, omitting certain background lines otherwise visible in a "true" cross-sectional view, for illustrative clarity. Furthermore, for clarity, some reference numbers may be omitted in certain drawings.

An apparatus, a modular power distribution apparatus, and a modular power system in accordance with the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which embodiments of the system and method are shown. The apparatus, modular power distribution apparatus, and modular power system, however, may be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the system and method to those skilled in the art.

For the sake of convenience and clarity, terms such as "top," "bottom," "upper," "lower," "vertical," "horizontal," "lateral," and "longitudinal" will be used herein to describe the relative placement and orientation of these components and their constituent parts, each with respect to the geometry and orientation of a sensor apparatus and/or housing assembly as they appear in <FIG>. Said terminology will include the words specifically mentioned, derivatives thereof, and words of similar import.

As used herein, an element or operation recited in the singular and proceeded with the word "a" or "an" should be understood as not excluding plural elements or operations, unless such exclusion is explicitly recited.

As stated above, approaches herein provide for customized power distribution using a sealed modular apparatus. In one approach, an apparatus may include a module extending into an interior cavity of a housing assembly through an opening formed in a base section of the housing assembly. The module may include a component grid at one end for receiving one or more components (e.g., fuses, relays, circuit breakers, diodes, etc.), and a wiring alignment cover at an opposite end operable with a terminal. The apparatus may further include a mechanical sealing element disposed along one or more surfaces of the module to provide a seal between the module and the base section defining the opening. In another approach, a plurality of modules may be disposed within a plurality of openings formed in the base section. In another approach, the apparatus may include a bracket configured to releasably connect the base section and the cover.

Referring to <FIG>, an exemplary embodiment of a modular power distribution apparatus/system (hereinafter, apparatus <NUM>) in accordance with the present disclosure is shown. The exemplary apparatus <NUM> includes a housing assembly <NUM> having a base section <NUM> coupled to a cover <NUM>, the cover <NUM> removably connected to the base section <NUM> and covering the circuit protection components therein. The cover <NUM> can be removed, for example, to replace an opened fuse or to inspect the power distribution grid. The cover <NUM> includes a seal that prevents dust, moisture and other contaminants from reaching the circuit protection devices.

In one embodiment, the cover <NUM> can snap-fit to the base section <NUM> and/or include one or more latching mechanisms to secure the cover to the housing releasably, as will be further described herein. In an alternative embodiment, the cover <NUM> is threaded onto the base section <NUM> and can include a spring seal that provides a tensile force against the cover <NUM>, which tends to hold the cover in a tight, threaded relationship with the housing even when the vehicle is moving and creating vibrations that could otherwise loosen the cover <NUM>. The spring mechanism can also provide a seal between the cover <NUM> and the base section <NUM>. Although not specifically illustrated, the cover <NUM> may also include means to further facilitate grasping and removal, such as tabs, projections, recesses, etc..

The base section <NUM> may include a set of interlocking features <NUM> for mounting multiple housing assemblies together, as well as one or more mounting apertures <NUM>. In some embodiments, the housing assembly <NUM> may be made of an insulating material, such as plastic, which is molded to form a demonstrated shape. In some embodiments, the base section <NUM> and the cover <NUM> can be made of the same or different materials, such as an insulating plastic, e.g., nylon, glass-filled nylon, polyester and polycarbonate.

As shown, the apparatus <NUM> further includes one or more brackets <NUM> coupled to a pin <NUM> (<FIG>) of the base section <NUM>, wherein the brackets <NUM> are configured to releasably connect the base section <NUM> to the cover <NUM>. In one embodiment, the brackets <NUM> pivot about an axis defined by the pin <NUM> to move a top section <NUM> of each bracket <NUM> towards/away from the cover <NUM>. When the cover is not in use, for example as shown in <FIG>, the brackets <NUM> may rotate and extend away from the cover <NUM>. Then, as the cover <NUM> is positioned onto the base section <NUM>, a first set of support structures <NUM> of the cover <NUM> are positioned atop and generally align with a second set of support structures <NUM> of the base section <NUM>. The first set of support structures <NUM> and the second set of support structures <NUM> extend perpendicularly from an end wall surface <NUM> of the cover <NUM> and an end wall surface <NUM> of the base section <NUM>, respectively. Furthermore, as shown, a cross-brace <NUM> extends between the first set of support structures <NUM> of the cover <NUM> and includes a tab <NUM> configured to engage a protrusion <NUM> of the top section <NUM> of each bracket <NUM> to secure the cover <NUM> to the base section <NUM>.

As further shown in <FIG>, the apparatus <NUM> may further include a sealing strip <NUM> positioned between the cover <NUM> and the base section <NUM> to provide a seal therebetween. In one embodiment, the sealing strip <NUM> is an elastomer configured as a plurality of ridges and groves to provide a mechanical seal between an upper rim <NUM> of the base section <NUM> and a lower shoulder <NUM> of the cover <NUM>.

Referring now to <FIG>, a set of interchangeable modules operable with the housing assembly <NUM> will be described in greater detail. Unlike a unitary one-piece monolithic insulative housing assembly and power distribution block, the apparatus <NUM> of the present disclosure includes one or more modules 70A-B, which provide customizable electrical connections. The modules 70A-B allow a snap-together assembly with the base section <NUM> of the housing assembly <NUM> to accommodate different bussed or non-bussed configurations and, therefore, provide a wide variety of pole variations for a specific application. It will be appreciated that although <FIG> demonstrate a pair of modules 70A-B extending through a corresponding pair of openings, the apparatus <NUM> is scalable, and therefore may accommodate a greater number of modules and openings in other embodiments.

In one embodiment, the apparatus <NUM> includes one or more modules 70A-B extending into an interior cavity <NUM> of the housing assembly <NUM> though one or more corresponding openings 76A-B formed in the base section <NUM> of the housing assembly <NUM>. As shown, the base section <NUM> includes a base wall <NUM> having openings 76A-B formed therein, the openings 76A-B configured to receive the modules 70A-B. The openings 76A-B may be separated by a framing element <NUM> and include a first ledge <NUM> for engaging a flange <NUM> that extends laterally from a sidewall <NUM> of each module 70A-B. Each of the openings 76A-B may further define a second ledge <NUM> for engaging a mechanical sealing element <NUM> disposed along one or more sidewalls of the modules 70A-B. As shown, when positioned within the openings 76A-B, the first ledge <NUM> is in abutment with the flange <NUM>, the second ledge <NUM> is in abutment with the mechanical sealing element <NUM>, and the modules 70A-B are substantially planar with a surface <NUM> within the interior cavity <NUM>.

Referring now to <FIG>, the modules 70A-B will be described in greater detail. As shown, each module 70A-B includes the mechanical sealing element <NUM> disposed along the sidewall <NUM> to provide a seal between the modules 70A-B and the base section <NUM> defining respective openings 76A-B. In one embodiment, the mechanical sealing element <NUM> includes a gasket <NUM> (e.g., an elastomer) in contact with a ridge <NUM>, wherein the gasket <NUM> and the ridge <NUM> extend perpendicularly from each side of the modules 70A-B to form a perimeter around each of the modules 70A-B. As shown, the gasket <NUM> is positioned between the ridge <NUM> and the second ledge <NUM> of each opening 76A-B to form a seal therebetween.

In exemplary embodiments, as more clearly demonstrated in <FIG>, each the modules 70A-B includes a component grid <NUM> disposed at a first end <NUM> thereof. As shown, the component grid <NUM> may be coupled to each module 70A-B and positioned within the openings 76A-B such that the component grid <NUM> is exposed to the interior cavity <NUM> of the base section <NUM> and is substantially planar with the surface <NUM>. In exemplary embodiments, the component grid <NUM> may include a matrix of apertures that form a plurality of footprints for a plurality of components, such as fuses or circuit protection devices (overcurrent or overvoltage), that are plugged into the component grid <NUM> of the apparatus <NUM>.

The apertures in the component grid <NUM> can form a plurality of the same types of fuses. Alternatively, the apertures form different footprints for different types of component footprints. In one embodiment, the apertures of the component grid <NUM> form footprints for a plurality of male blade type fuses, such as MINI® fuses. In another embodiment, the apertures may form footprints for female cartridge fuses (e.g., JCASE™ fuses provided by the assignee of the present disclosure) or larger type fuses (e.g., ATO® fuses or MAXI® fuses, both provided by the assignee of the present disclosure). Components may be micro-relays, while other components may be ISO/power relays. The apparatus <NUM> is accordingly not limited to fuse operation.

The fuses and other components are illustrated for automotive uses, such as for cars, trucks, motorcycles, boats, wave-runners, all-terrain vehicles and other types of sports vehicles or others listed above. However, the teachings of the present disclosure and the benefits and advantages of the apparatus <NUM> are not limited to vehicle type applications.

In various embodiments, the modules 70A-B may be bussed and/or unbussed. For example, one or more of the modules 70A-B may operate without a bussing element (e.g., a bus bar). The elimination of internal bussing may allow greater circuitry customization using direct wire-to-component connections. In one embodiment, unbussed modules may accommodate one or more of the following component configurations: (<NUM>) MINI®; (<NUM>) ATO®; (<NUM>) MAXI®; (<NUM>) JCASE™; (<NUM>) ISO form C MINI® relay and (<NUM>) ATO®; (<NUM>) ISO power relay; (<NUM>) ISO micro form A and (<NUM>) ATO®, (<NUM>) MAXI® and (<NUM>) ATO®; (<NUM>) Delphi® Metri-Pack <NUM> series form C relays and (<NUM>) Delphi® Metri-Pack <NUM> series form A terminals; and (<NUM>) Delphi® Metri-Pack <NUM> series form A terminals and (<NUM>) MINI®.

In other embodiments, one or more of the modules 70A-B include a bussing element, such as a bus bar, connected thereto. For example, bussed modules may accommodate one or more of the following component configurations: (<NUM>) MINI®; <NUM> ATO®; (<NUM>) JCASE™; (<NUM>) ISO power relay form A and (<NUM>) MAXI®; (<NUM>) ISO MINI® form C and (<NUM>) ATO®; (<NUM>) ISO power relay form A and (<NUM>) JCASE™; (<NUM>) Delphi® Metri-Pack <NUM> series form C terminals and (<NUM>) series form A terminals; and (<NUM>) Delphi® Metri-Pack <NUM> series form A terminals and (<NUM>) MINI®. The bus bar may be made of any suitable electrically conductive material, for example, a material capable of carrying relatively high currents. One such suitable material is C1100 alloy, which is <NUM>% pure copper with ½ hard temper. In another embodiment, the bus bar includes one or more heat sinks.

As shown in <FIG> and <FIG>, to secure the modules 70A-B within the openings 76A-B, each of the modules 70A-B includes one or more module fasteners <NUM> that releasably connect to corresponding elements (not shown) along the interior of the openings 76A-B. In one embodiment, each module fastener <NUM> may be a snap-fit connector having a retaining projection <NUM> that is received in a sidewall aperture of the openings 76A-B. In one embodiment, the snap-fit connector includes one or more tongues extending beneath leading edges of adjacent sections and received in complementary slots (not shown) inside grooves of mating sections along the sidewalls of openings 76A-B so that the mating ends of adjacent sections slightly overlap one another and form a secure, structurally stable fit with one another. In one embodiment, the module fasteners <NUM> provide a secure resistance fit that facilitates assembly and disassembly of the modules 70A-B by hand and without employing tools.

Referring again to <FIG>, <FIG>, and <FIG>, a wiring alignment cover attached to each module 70A-B will be described in greater detail. As shown, each of the modules 70A-B is coupled with a wiring alignment cover <NUM> at a second end <NUM> thereof, the wiring alignment cover <NUM> disposed external to the base section <NUM>. In exemplary embodiments, the wiring alignment cover <NUM> may be a terminal position assurance lock (TPA), which provides secondary locking protection of wire leads (not shown) inserted through a plurality of openings <NUM> therein, which are substantially aligned with a plurality of openings <NUM> (<FIG>) in the modules 70A-B. Module 70B of <FIG> is shown without the wiring alignment cover <NUM> for the sake of explanation.

The wiring alignment cover <NUM> may snap onto the bottom of the modules 70A-B after wires are installed, and do not interfere with any cable seals. As shown, the wiring alignment cover <NUM> is secured to each of the modules 70A-B via one or more alignment cover fasteners <NUM> disposed along a sidewall of the modules 70A-B, wherein the alignment cover fasteners <NUM> are configured to releasably connect the wiring alignment cover <NUM> and each of the modules 70A-B. In one embodiment, each alignment cover fastener <NUM> is a snap-fit connector having a retaining projection that is received in an aperture <NUM>.

Although not shown, a plurality of terminals may be coupled to the modules 70A-B at the second end <NUM>, so that the terminals extend through the modules 70A-B via the plurality of openings 76A-B and directly connect to the components of the component grid <NUM> through the base wall <NUM> of the base section <NUM>. Alternatively, the modules 70A-B may additionally receive any combination of cable seals and/or cavity plugs in addition to the terminals. In one embodiment, the terminals may include a male blade-type fuse (e.g., a MINI® fuse), which includes a pair of blade terminals, each of which press fits into one of the fuse mounting terminals. For each fuse, one of the terminals may connect to a trace that extends to a load within the vehicle. Other terminals may connects electrically to a trace that extends to a common electrical connection.

In an exemplary embodiment, the modules 70A-N are operable with terminals utilizing internationally standardized male blade sizes, allowing for flexibility in design. For example, blade sizes may range from <NUM> to <NUM> with current capability ranging from <NUM> to <NUM> amps. The terminals may be designed to be compatible with processing techniques such as automated pull-to-seat and push-to-seat assembly, dual-stage crimping, load cell crimp inspection and automated part identification and orientation. The terminals may be sealed to reduce exposure to extreme temperatures, chemicals, and abrasion.

In some embodiments, the terminals may be mounting terminals (e.g., having a tuning fork like configuration) that may or may not be soldered (e.g., wave soldered) to a printed circuit board (PCB). In an alternative embodiment, the terminals are surface-mounted to the PCB. In such case, the terminals do not extend through the PCB.

The PCB provides the circuit routing between the fuses and terminal connections. The PCB includes traces that run from the fuse mounting terminals to the connector terminals, stud connectors, etc. The PCB may be made of FR-<NUM> material but can alternatively be ceramic if a more rigid material is needed. The PCB can be single or multilayered and is customized as desired by the customer. The PCB can provide a wider trace that serves as a buss bar or common connection for the fuse mounting terminals and connector terminals.

The PCB can also hold other types of circuit protection, such as overvoltage protection in the form of medal oxide varistors ("MOVs"), diodes, and thyristors. The overvoltage protection devices can be used for example to protect low operating voltage or signal level devices placed in the automobile. The overvoltage protection devices can be mounted on a same side of the PCB as the fuses or be located on the opposite or bottom side of the PCB.

In view of the foregoing, at least the following advantages are achieved by the embodiments disclosed herein. It is an advantage to enable customization through modularity of the various power distribution modules. Whether using non-feed-through terminals, feed-through terminals, screw cover, snap-on cover, bolt-on cover, screw base, snap-on base, bolt-on base, the modules have the same mounting footprint so that customers can switch out modules without changing the mounting configuration. It is another advantage of the present disclosure to provide a modular power distribution apparatus for vehicles, which is relatively easy to manufacture and install. It is still another advantage of the present disclosure to provide a power distribution module for vehicles, which provides relatively high component and circuit density. It is yet another advantage of the present disclosure to provide a power distribution module for vehicles, which has a feed-through configuration that further increases the amount of components and/or circuitry allowable in a same footprint capacity. It is still a further advantage of the present disclosure to provide a ready way to manufacture different module housings via a same mold. Further still, it is an advantage of the present disclosure to provide a modular power distribution apparatus having a standardized mounting hole pattern so that customers can interchange modules without reconfiguring the customer's mounting apparatus. Moreover, it is an advantage of the present disclosure to provide power distribution modules that are sealed effectively from the outside to prevent contaminants from reaching the interior of the housing assembly.

Claim 1:
An apparatus (<NUM>), comprising:
a module (70A, 70B) extending into an interior cavity (<NUM>) of a housing assembly (<NUM>) through an opening of a plurality of openings (76A, 76B) formed in a base section (<NUM>) of the housing assembly (<NUM>), the module (70A, 70B) including a component grid (<NUM>); and
a mechanical sealing element (<NUM>) disposed along a surface (<NUM>) of the module (70A, 70B) to provide a seal between the module (70A, 70B) and the base section (<NUM>) defining the opening, wherein the plurality of openings (76A, 76B) are separated by a framing element (<NUM>) extending across the interior cavity (<NUM>),
wherein the mechanical sealing element (<NUM>) comprises a gasket (<NUM>) in abutment with a ridge (<NUM>), the ridge (<NUM>) extending from the surface of the module (70A, 70B).