Information
-
Patent Grant
-
6447325
-
Patent Number
6,447,325
-
Date Filed
Friday, March 3, 200024 years ago
-
Date Issued
Tuesday, September 10, 200222 years ago
-
Inventors
-
Original Assignees
-
Examiners
- Sircus; Brian
- Le; Thanh-Tam
Agents
-
CPC
-
US Classifications
Field of Search
US
- 439 404
- 439 402
- 439 507
- 439 949
- 439 408
-
International Classifications
-
Abstract
A common insulating plate 16 is prepared such that a plurality of paired upper and lower electric wire fitting grooves 16b and 16d are formed straight in the insulating plate 16 at a constant pitch P1 in the transverse direction, and such that a plurality of press-fitting slits 16e are formed in the individual electric wire fitting grooves 16a and 16c at a constant pitch P2 in the longitudinal direction; compression relay terminals 17 are press-fitted in suitable positions of the individual press-fitting slits 16e: and the electric wires 15 are individually fitted in the paired upper and lower electric wire fitting grooves 16b and 16d having the compression relay terminals 17 press-fitted therein, so that the upper and lower electric wires 15 are individually compressed and connected in the upper and lower compression blades 17a and 17b of the compression relay terminals 17 so that the upper and lower electric wires 15 of the insulating plate 16 can be electrically connected.
Description
BACKGROUND OF THE INVENTION
The present invention relates to a connection structure for electric wires to be accomodated in an electric connection box.
The electric connection box to be used for branching and connecting a wire harness or the like for an automobile with a variety of electrical equipments branches and connects the electric wires rationally and economically by concentrating a branching and connecting point at one point. A variety of types have been developed for different kinds and applications of automobiles as the wire harness grows dense.
One of the aforementioned electric connection boxes is manufactured, as shown in
FIG. 9
, by punching a hoop material
6
into individual bus bars
7
A to
7
C by a press mold, by cutting and raising tab terminals
7
a
and
7
b
vertically from the pattern portion of each of the bus bars
7
A to
7
C, by stacking insulating plates
8
A to
8
C individually between the bus bars
7
A to
7
C, and by housing the stack in an upper case
9
A and a lower case
9
B of an electric connection box
9
. Here, numeral
10
designates relay terminals, and numerals
11
and
12
designate relays and fuses.
However, the wiring of each of the aforementioned bus bars
7
A to
7
C has to be complicated by folding or bending it according to the conveniences of the circuit construction. The circuit design takes a long time, and the number of designing steps increases. When only one circuit is to be changed, the wiring of another circuit has to be reconsidered to raise another problem that a quick response to the design change cannot be made.
SUMMARY OF THE INVENTION
The present invention has been conceived for solving the aforementioned problems of the prior art and has an object to provide an electric wire connection structure which can reduce the number of steps of designing a circuit drastically and can respond to a design change quickly.
In order to solve the aforementioned problems, according to the present invention, there is provided a connection structure for electric wires to be accomodated in an electric connection box, characterized: in that an insulating plate has a pair of upper and lower electric wire fitting grooves formed straight in its upper face and lower face at vertically symmetric positions such that the paired upper and lower electric wire fitting grooves are provided in plurality at a constant pitch in the widthwise direction thereof; in that press-fitting slits are formed to extend through the paired upper and lower electric wire fitting grooves and are provided in plurality at a constant pitch in the longitudinal direction of the paired upper and lower electric wire fitting grooves; in that compression relay terminals having compression blades formed at their upper and lower portions are press-fitted into suitable portions of the individual press-fitting slits; and in that the electric wires are individually fitted in the paired upper and lower electric wire fitting grooves, in which the compression relay terminals are press-fitted, so that the upper and lower electric wires are individually compressed and connected by the upper and lower compression blades of the compression relay terminals.
According to the present invention, the common insulating plate is prepared such that the paired upper and lower electric wire fitting grooves are formed straight in the plurality in the insulating plate at the constant pitch in the transverse direction, and such that the press-fitting slits are formed in the plurality in the individual electric wire fitting grooves at the constant pitch in the longitudinal direction; the compression relay terminals are press-fitted in suitable positions of the individual press-fitting slits: and the electric wires are individually fitted in the paired upper and lower electric wire fitting grooves having the compression relay terminals press-fitted therein. As a result, the upper and lower electric wires are individually compressed and connected in the upper and lower compression blades of the compression relay terminals so that the upper and lower electric wires of the insulating plate can be electrically connected.
If the construction is made such that a jumper terminal having a plurality of compression blades formed in a crosswise direction across the pitch of the electric wire fitting grooves is press-fitted in the press-fitting slits of the electric wire fitting grooves in each face of said insulating plate such that its individual compression blades are compressed and connected with the individual electric wires, as in Aspect 2, or if the construction is made such that a jumper wire is compressed and connected with the compression blades of the individual relay terminals which are press-fitted in the press-fitting slits of the electric wire fitting grooves in each face of said insulating plate, as in Aspect 3, the electric wires in the crosswise direction in each face of the insulating plate can be electrically connected by the jumper terminal or the jumper wire.
If the construction is made such that an input/output terminal having a compression blade formed is press-fitted in the press-fitting slit of the electric wire fitting groove in each face of said insulating plate so that its compression blade is compressed and connected with the electric wire, as in Aspect 4, the input/output terminal can be disposed at the position of the press-fitting slit.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1
is a perspective view of a connection structure of electric wires in an electric connection box of the present invention.
FIG. 2
is an enlarged view of the connection structure of the electric wires of FIG.
1
.
FIG. 3A
is a perspective view of an insulating plate, and
FIG. 3B
is an enlarged view of FIG.
3
A.
FIG. 4A
is a perspective view of the insulating plate having compression relay terminals press-fitted therein, and
FIG. 4B
is an enlarged view of FIG.
4
A.
FIG. 5A
is a sectional view of the insulating plate before the electric wires are compressed in the compression relay terminals, and
FIG. 5B
is a sectional view after the electric wires are compressed in the compression relay terminals.
FIG. 6A
is a perspective view of a jumper terminal, and
FIG. 6B
is a sectional view of the insulating plate when the jumper terminal is compressed on the electric wires.
FIG. 7A
is a perspective view of a connection structure of electric wire, in which jumper wires are compressed in the compression relay terminals, and
FIG. 7B
is a sectional side elevation of a compression relay terminal compressing the jumper wire.
FIG. 8A
is a perspective view of a male terminal, and
FIG. 8B
is a sectional view of the male terminal compressing the electric wire.
FIG. 9
is a perspective view of a process of the prior art for manufacturing bus bars.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the present invention will be described in detail with reference to the accompanying drawings. Here, the detail description of the same construction and functions as those of the prior art will be omitted by designating them by the common reference numerals.
In an upper case
9
A and a lower case
9
B of an electric connection box
9
, as shown in
FIGS. 1 and 2
, there is accomodated a block
14
in which a signal portion and a low current region are wired by electric wires
15
, separately of a block
13
in which a high current region is wired by bus bars
7
(A to C).
In vertically symmetric positions of the upper face
16
a
and the lower face
16
c
of an insulating plate
16
of the aforementioned block
14
, as shown in detail in
FIG. 3
, there are formed straight a pair of upper and lower electric wire fitting grooves
16
b
and
16
d.
These paired upper and lower electric wire fitting grooves
16
b
and
16
d
are provided in plurality at a constant pitch P
1
in their transverse direction.
On the other hand, there are formed press-fitting slits
16
e
which extend through the paired upper and lower electric wire fitting grooves
16
b
and
16
d
. These press-fitting slits
16
e
are formed in plurality at a constant pitch P
2
in the longitudinal direction of the paired upper and lower electric wire fitting grooves
16
b
and
16
d.
The aforementioned insulating plate
16
is prefabricated and standardized to the maximum number and the largest length of the electric wire fitting grooves
16
b
and
16
d
and is cut out for use from the standardized one in accordance with the necessary number and length of the electric wire fitting grooves
16
b
and
16
d.
On the other hand, there are provided a compression relay terminal
17
which is provided compression blades
17
a
and
17
b
at its upper and lower portions. This compression relay terminal
17
is press-fitted downward into the electric wire fitting grooves
16
b
and
16
d
of the aforementioned insulating plate
16
. At the two side portions of the compression relay terminal
17
, individually, there are formed retained pawls
17
c
which are to be retained on the two side portions of the press-fitting slits
16
e
thereby to prevent the compression relay terminal
17
from coming out.
The aforementioned compression relay terminals
17
are press-fitted in the suitable ones of the press-fitted slits
16
e
which are required for the circuit construction by the electric wires
15
, as shown in FIG.
4
.
As shown in
FIG. 5
, morever, the upper and lower electric wires
15
are individually inserted into the paired upper and lower electric wire fitting grooves
16
b
and
16
d
having the press-filled compression relay terminals
17
so that they are individually compressed and connected by the upper and lower compression blades
17
a
and
17
b
of the compression relay terminals
17
.
As shown in
FIGS. 1 and 2
, the electric wires
15
to be inserted into the individual electric wire fitting grooves
16
b
and
16
d
of the aforementioned insulating plate
16
are given different lengths, and a male terminal
18
and a female terminal
19
for external input/output are individually attached to the two ends of each electric wire
15
. Moreover, the male terminal
18
and the female terminal
19
can be disposed at arbitrary positions according to the length of the electric wire
15
by raising
18
and
19
individually.
In the aforementioned construction: the paired upper and lower electric wire fitting grooves
16
b
and
16
d
are formed straight in the insulating plate
16
at the constant pitch P
1
in the transverse direction; the press-fitting slits
16
e
are formed in the individual electric wire fitting grooves
16
b
and
16
d
at the constant pitch P
2
in the longitudinal direction; the compression relay terminals
17
are press-fitted in suitable positions of the individual press-fitting slits
16
e
: and the electric wires
15
are individually fitted in the paired upper and lower electric wire fitting grooves
16
b
and
16
d
having the compression relay terminals
17
press-fitted therein. As a result, the upper and lower electric wires
15
are individually compressed and connected in the upper and lower compression blades
17
a
and
17
b
of the compression relay terminals
17
so that the upper and lower electric wires
15
of the insulating plate
16
can be electrically connected.
Thus, the insulating plate
16
can be cut out for use according to the numbers and lengths of the necessary electric wire fitting grooves
16
b
and
16
d
in accordance with the different electric connection boxes
9
for different kinds and grades of automobiles so that it can be made common (or standardized) to reduce the fabrication cost of the insulating plate
16
.
On the other hand, the electric wires
15
to be fitted in the electric wire fitting grooves
16
b
and
16
d
of the insulating plate
16
are given different lengths so that the external input/output terminals
18
and
19
at the two ends of the electric wires
15
can be disposed at arbitrary positions. At the same time, the upper and lower electric wires
15
are compressed and connected by the upper and lower compression blades
17
a
and
17
b
of the compression relay terminals
17
which are press-fitted in suitable positions of the press-fitting slits
16
e
, so that they can be electrically connected in the insulating plate
16
. As a result, the number of steps of designing the circuit can be drastically reduced, and a slight change in the circuit can be made merely by changing the lengths of the electric wires
15
and the positions of the compression relay terminals
17
thereby to respond the design change promptly.
Especially in the electric connection box
9
, the high current region is given a wiring structure similar to that of the bus bars
7
(A to C) of the prior art, and the signal portion and the low current region are given the aforementioned wiring structure by the electric wires
15
. The external input/output terminals
18
and
19
can be disposed at the arbitrary positions to make the arrangement of the insulating plate
16
flexible in the electric connection box
9
and the arranging design feasible.
As shown in
FIG. 6
, a jumper terminal
20
having a plurality of compression blades
20
a
formed in the crosswise direction across the pitch P
1
of the electric wire fitting grooves
16
b
and
16
d
of the aforementioned insulating plate
16
, and the individual compression blades
20
a
of the jumper terminal
20
are press-fitted in the press-fitting slits
16
e
of the electric wire fitting grooves
16
b
and
16
d
in the individual faces
16
a
and
16
c
of the insulating plate
16
. Then, the individual compression blades
20
a
are compressed and connected with the individual electric wires
15
.
By the jumper terminal
20
, therefore, the crosswise electric wires
15
in the individual faces
16
a
and
16
c
of the insulating plate
16
can be electrically connected so that the compression relay terminals
17
can be made smaller and lighter than those of the case, in which the crosswise electric wires are connected by forming the compression blades on the left and right sides of the compression relay terminals
17
, thereby to narrower the electric wire pitch P
1
.
As shown in
FIG. 7
, on the other hand, short jumper wires (electric wires)
21
are provided and are compressed and connected at their two ends with the compression blades
17
a
and
17
b
of the individual compression relay terminals
17
which are press-fitted in the press-fitting slits
16
e
of the electric wire fitting grooves
16
b
and
16
d
in the individual faces
16
a
and
16
c
of the insulating plate
16
. As in
FIG. 6
, too, the crosswise electric wires
15
in the individual faces
16
a
and
16
c
of the insulating plate
16
can be connected.
As shown in
FIG. 8
, moreover, an input/output male terminal
22
having a compressed blade
22
a
formed at its lower portion is provided and is press-fitted at its compression blade
22
a
in the press-fitting slit
16
e
of the electric wire fitting groove
16
b
or
16
d
in each face
16
a
or
16
c
of the insulating plate
16
. Then, the compression blade
22
a
is compressed and connected with the electric wire
15
. Thus, the male terminal
22
can be disposed at the position of the press-fitting slit
16
e.
According to the present invention, as apparent from the foregoing description: the common insulating plate is prepared such that the paired upper and lower electric wire fitting grooves are formed straight in the plurality in the insulating plate at the constant pitch in the transverse direction, and such that the press-fitting slits are formed in the plurality in the individual electric wire fitting grooves at the constant pitch in the longitudinal direction; the compression relay terminals are press-fitted in suitable positions of the individual press-fitting slits: and the electric wires are individually fitted in the paired upper and lower electric wire fitting grooves having the compression relay terminals press-fitted therein. As a result, the upper and lower electric wires are individually compressed and connected in the upper and lower compression blades of the compression relay terminals so that the upper and lower electric wires of the insulating plate can be electrically connected.
Thus, the insulating plate can be cut out for use according to the numbers and lengths of the necessary electric wire fitting grooves in accordance with the different electric connection boxes for different kinds and grades of automobiles so that it can be made common (or standardized) to reduce the fabrication cost.
On the other hand, the electric wires to be fitted in the electric wire fitting grooves of the insulating plate are given different lengths so that the external input/output terminals at the two ends of the electric wires can be disposed at arbitrary positions. At the same time, the upper and lower electric wires are compressed and connected by the upper and lower compression blades of the compression relay terminals which are press-fitted in suitable positions of the press-fitting slits, so that they can be electrically connected in the insulating plate. As a result, the number of steps of designing the circuit can be drastically reduced, and a slight change in the circuit can be made merely by changing the positions of the compression relay terminals thereby to respond the design change promptly.
Especially in the electric connection box, the high current region is given a wiring structure similar to that of the bus bars of the prior art, and the signal portion and the low current region are given the aforementioned wiring structure by the electric wires. The external input/output terminals can be disposed at the arbitrary positions to make the arrangement of the insulating plate flexible in the electric connection box and the arranging design feasible.
If the construction is made such that the jumper terminal is press-fitted in the press-fitting slits to compress and connect its compression blade on the electric wires, as in Aspect 2, or such that the jumper wire is compressed and connected in the compression blades of the compression relay terminals press-fitted in the press-fitting slits, as in Aspect 3, the crosswise electric wires can be electrically connected in the individual faces of the insulating plate by the jumper terminal or the jumper wire.
As a result, the compression relay terminals can be made smaller and lighter than those of the case, in which the crosswise electric wires are connected by forming the compression blades on the left and right sides of the compression relay terminals, thereby to narrower the electric wire pitch.
If the input/output terminals are press-fitted in the press-fitting slits and are compressed and connected at their compression blades with the electric wires, as in Aspect 4, the input/output terminals can be disposed at the positions of the press-fitting slits.
Claims
- 1. A connection structure including electric wires to be accommodated in an electric connection box, wherein:an standardized insulating plate includes a pair of upper and lower electric wire fitting grooves formed straight in an upper face and lower face thereof at vertically symmetric positions such that the paired upper and lower electric wire fitting grooves are provided in plurality at a constant pitch in a widthwise direction thereof, and press-fitting slits are formed on the standardized insulating plate to extend through the paired upper and lower electric wire fitting grooves, the press-fitting slits provided in plurality at a constant pitch in a longitudinal direction of the paired upper and lower electric wire fitting grooves; compression relay terminals having compression blades formed at their upper and lower portions and retaining pawls that gradually extend outwardly at an intermediate position are press-fitted downwardly into press-fitting slits so that ends of the upper and lower compression blades of the terminals extend passed the upper and lower face of the insulation plate respectively; and electric wires with at least one of a male and female terminal connected to ends of the electric wires, the ends being free from the insulating plate, the electric wires are individually fitted in the paired upper and lower electric wire fitting grooves, in which said compression relay terminals are press-fitted, so that upper and lower electric wires are individually compressed and connected by the upper and lower compression blades of said compression relay terminals.
- 2. The electric wire connection structure as set forth in claim 1, whereina jumper terminal having a plurality of compression blades formed in a crosswise direction across the pitch of wire electric wire fitting grooves is press-fitted in the press-fitting slits of the electric wire fitting grooves in each face of said insulating plate such that individual compression blades thereof are compressed and connected with individual electric wires.
- 3. The electric wire connection structure as set forth in claim 1, whereina jumper wire is compressed and connected with the compression blades of the individual relay terminals which are press-fitted in the press-fitting slits of the electric wire fitting grooves in each face of said insulating plate.
- 4. The electric wire connection structure as set forth in claim 1, whereinan input/output terminal having a compression blade formed is press-fitted in the press-fitting slit of the electric wire fitting groove in each face of said insulating plate so that compression blade thereof is compressed and connected with said electric wire.
Priority Claims (1)
| Number |
Date |
Country |
Kind |
| 11-176824 |
Jun 1999 |
JP |
|
US Referenced Citations (12)
Foreign Referenced Citations (3)
| Number |
Date |
Country |
| 0 470 887 |
Jul 1992 |
FR |
| 60-35911 |
Feb 1985 |
JP |
| 6-275346 |
Jun 1994 |
JP |
