Information
-
Patent Grant
-
6364670
-
Patent Number
6,364,670
-
Date Filed
Wednesday, November 18, 199825 years ago
-
Date Issued
Tuesday, April 2, 200222 years ago
-
Inventors
-
Original Assignees
-
Examiners
- Bradley; P. Austin
- Gushi; Ross
Agents
- Greer, Burns & Crain, Ltd.
-
CPC
-
US Classifications
Field of Search
US
- 439 762
- 439 761
- 439 949
- 439 67
- 439 77
-
International Classifications
-
Abstract
An electric junction box is adapted to minimize the number of necessary components. It includes a first part having a first side including a plurality of integrally formed first connectors and a second side arranged and configured to receive at least one of a fuse and/or a relay. A second part has a first side arranged and configured to receive at least one external connector and a second side having a plurality of integrally formed second connectors. At least one intermediate part is disposed between the first part and the second part. It has a first side including a plurality of integrally formed first interconnecting means for engaging the first connectors of the first part, and a second side having a plurality of integrally formed second interconnecting means for engaging the second connectors of the second part.
Description
The present invention generally relates to electrical junction boxes, and more particularly to an electrical junction box having electronics for performing various functions.
Conventionally, electrical junction boxes used in motor vehicles are generally utilized as an electrical signal distribution center for generic electronic module (GEM) which perform various necessary functions in an electrical system, such as a security function or a door chime function in an automobile or other motor vehicles, for example. The junction boxes and the GEM are normally implemented as separate units and are electrically connected together by connectors such as wiring harnesses that carry a large number of wire conductors. Often the junction boxes and the GEM may be separated by a relatively significant distance due to the physical layout of the motor vehicles that utilize these components, thereby requiring longer connectors. Consequently, these connectors complicate the electrical system of the device and also add to the overall cost of manufacture.
Therefore, it is desirable to consolidate the junction box and the GEM into a single unit, i.e., incorporate the GEM into the junction box. One problem of simply housing the GEM in the junction box is that the junction box carries high current, which creates a high thermal power density within the junction box and interferes with the proper operation of the GEM, which operates at a much lower current than the junction box. Another problem is the high material cost and manufacturing complexity involved in consolidating a large number of components of the junction box and the function electronics. This problem is compounded by the fact that the users, typically original equipment manufacturing engineers, of such a combined junction box generally desire that the junction box be packaged into a smaller and lighter assembly.
Accordingly, it is a primary objective of the present invention to provide an improved junction box adapted to incorporate function electronics into its housing.
Another object of the present invention to provide such an improved junction box which directs heat away from the function electronics.
Still another object of the present invention is to provide such an improved junction box which requires minimal number of parts.
Yet another object of the present invention is to provide such an improved junction box having molded three-dimensional electrical circuits.
Other objects and advantages will become apparent upon reading the following detailed description, in conjunction with the attached drawings, in which:
FIG. 1
is an exploded perspective view showing a top, a bottom and an intermediate parts of a junction box embodying the present invention;
FIG. 2
is an assembled perspective view of the junction box of
FIG. 1
;
FIG. 3
is an enlarged perspective view of pin structures for interconnecting the top, the intermediate and the bottom parts of the junction box of
FIG. 1
;
FIG. 4
is an enlarged view of another embodiment of a pin structure for interconnecting the top, the intermediate and the bottom parts of the junction box of
FIG. 1
;
FIG. 5
is a bottom perspective view of the junction box of FIG.
2
;
DETAILED DESCRIPTION
The present invention is directed to a junction box having molded three-dimensional electrical circuits and adapted to incorporate function electronics into the junction box. Broadly stated, the present invention is directed to an electrical junction box which is adapted to minimize the number of necessary components. It includes a first part having a first side including a plurality of integrally formed first connectors and a second side arranged and configured to receive at least one of a fuse and/or a relay. A second part has a first side arranged and configured to receive at least one external connector and a second side having a plurality of integrally formed second connectors. At least one intermediate part is disposed between the first part and the second part, and has a first side including a plurality of integrally formed first interconnecting means for engaging the first connectors of the first part, and a second side having a plurality of integrally formed second interconnector means for engaging the second connectors of the second part.
The invention is also directed to a junction box which incorporates electronics for performing various functions into its housing. It includes a first part for receiving at least one of a fuse and/or a relay, and an intermediate part configured to be mated to the first part and electrically connected to the at least one of the fuse and/or the relay. Also included is a second part which is configured to be mated to the intermediate part and adapted to electrically connect the fuse and/or the relay to a corresponding external connector via the intermediate part. The second part has a ledge integrally formed on an inside thereof and a heat sink integrally formed on an outside thereof. The electronics for performing the function are disposed between the intermediate part and the second part and thermally attached to the integral ledge, so that heat built-up on the function electronics is released through the integral heat sink.
Turning now to
FIGS. 1 and 2
, the junction box of the present invention is indicated generally at
10
and includes a fuse/relay part
12
, a connector part
14
and a routing part
16
disposed between the fuse/relay part and the connector part. The junction box
10
houses a generic electronic module (GEM)
18
which is provided between the routing part
16
and the connector part
14
.
In accordance with one important aspect of the present invention, the fuse/relay part
12
, the connector part
14
and the routing part
16
are produced generally through a process known as a molded interconnect technology (MIT), which is disclosed in detail in U.S. Pat. No. 5,407,622 to Cleveland et al. Briefly, these parts
12
,
14
,
16
are produced by first injection molding a platable resin to form desired circuit patterns, which are raised relative to a generally flat base. Then a non-platable resin is molded onto the base and around the raised circuits, thereby keeping the circuit patterns exposed. The exposed circuit patterns are then plated with copper to the desired thickness. Thus, the parts
12
,
14
,
16
of the junction box
10
are, in effect, three-dimensional electrical circuits.
The fuse/relay part
12
has a top side
20
which has a plurality of shrouds
22
configured to receive corresponding fuses
24
or relays
26
(best shown in FIG.
2
). The shrouds
22
are integrally formed on the fuse/relay part
12
during the MIT molding process. The fuses
24
and the relays
26
become electrically connected to the corresponding plurality of male connectors
28
(shown in
FIGS. 3 and 4
) protruding from the bottom side
30
of the fuse/relay part
12
, via electrical circuit
31
partially imbedded in the fuse/relay part (best shown in FIGS.
3
and
4
), when the fuses and the relays are plugged into their respective receptacles
32
on the top side
20
(best shown in FIG.
2
). Thus, the present fuse/relay part
12
advantageously incorporates all the components in a junction box typically required for receiving the fuses and the relays (i.e., a plurality of shrouds, receptacles, electrical circuits and connector pins) into a single integrated piece.
The routing part
16
is configured to be attached to the fuse/relay part
12
. Its primary function is to electrically connect the fuses and/or relays on the fuse/relay part to the connector part
14
. To this end, the routing part
16
includes a plurality of female connectors
34
on the top side
36
thereof. These female connectors
34
are configured to engage the male connectors
28
of the fuse/relay part
12
(shown in FIGS.
3
and
4
). Turning now to
FIGS. 3 and 4
, the male connectors
28
of the fuse/relay part
12
depend from the bottom side
30
thereof and engage the corresponding female connectors
34
of the routing part
16
. In one embodiment, the male connectors
28
are generally flat pins which are configured to engage the female connectors
34
having a generally U-shaped slot for receiving the male connectors (best shown in FIG.
3
). In another embodiment, the male connectors
28
are cylindrical pins which are configured to engage the generally cylindrically tube-shaped female connectors
34
(best shown in FIG.
4
).
As on the top side
36
, the bottom side
38
of the routing part
16
also includes a plurality of female connectors
40
which are configured to engage the male connectors
42
of the connector part
14
. The female connectors
40
on the bottom side
38
are directly connected to the female connectors
34
on the top side
36
through the routing part
16
(best shown in FIG.
4
), or are connected via electrical circuit
41
partially embedded in the routing part (best shown in FIG.
3
). Thus, the routing part
16
is adapted to electrically connect the fuse/relay
12
to the connector part
14
when their respective male and female connectors
28
,
34
,
40
are interconnected.
It should be noted that while the routing part
16
is shown as being a single piece in
FIG. 1
, more than one routing part can be used to electrically connect the fuse/relay
12
to the connector part
14
, if necessary. Similar to the fuse/relay part
12
, an important feature of the routing part
16
is that it incorporates multiple components, including the plurality of female connectors
34
,
40
and the electrical circuits
41
into a single integrated piece, thereby significantly simplifying the manner in which the fuse/relay part
12
is interconnected with the connector part
14
of the junction box
10
.
Referring still to
FIGS. 3 and 4
, the male connectors
42
of the connector part
14
are located on the inside
44
thereof. They are generally the same as the male connectors
28
described above with respect to the fuse/relay part
12
and correspondingly engage the female connectors
40
on the bottom side
38
of the routing part
16
. The male connectors
42
are electrically connected to a plurality of terminal pins and/or receptacles
46
on the outside
48
(best shown in
FIG. 5
) of the connector part
14
via electrical circuits
49
partially embedded within the connector part
14
during the production process employing the molded interconnect technology (MIT).
Turning now to
FIG. 5
, the terminal pins and/or receptacles
46
on the outside
48
of the connector part
14
are enclosed within several shrouds
50
. The shrouds
50
are integrally formed on the connector part
14
and serve to assist external connectors (not shown) in making electrical connection with the terminal pins and/or receptacles
46
. In accordance with an important feature of the invention, the connector part
14
is provided with a heat sink
52
which is integrally formed on the connector part during the MIT manufacturing process. The heat sink
52
has a plurality of fins
54
which are configured and adapted to release heat generated within the junction box via thermal conduction.
Turning back to
FIG. 1
, the generic electronic module (GEM)
18
is preferably implemented on a printed circuit board (PCB)
56
, but may also be provided on a flexible circuit board or a ceramic substrate, as well. The PCB
56
is disposed between the routing part
16
and the connector part
14
, and rests directly atop a ledge
58
on the inside
44
of the connector part. It should be noted that the ledge
58
is integrally formed on the connector part
14
, so that heat built-up on the PCB
56
can be channeled away to the heat sink
52
and dissipated. Electrical connections between the GEM
18
and the fuse/relay part
12
are made through a plug
60
which extends through an opening
62
in the routing part
16
. Electrical connections to the external devices (not shown), the functions of which the GEM controls, are made via a plurality of function receptacles
64
. To facilitate the connection between receptacles
64
and the external devices, the routing part
16
and the connector part
14
have cut-out sections
66
which form a generally rectangular opening
68
when these parts are put together (best shown in FIG.
2
).
From the foregoing description, it should be understood that an improved junction box has been shown and described which has many desirable attributes and advantages. Using the molded interconnect technology (MIT), the number of the basic components of the junction box has been reduced to three, including the heat sink for protecting the GEM from high thermal density inside the junction box.
While various embodiments of the present invention have been shown and described, it should be understood that other modifications, substitutions and alternatives are apparent to one of ordinary skill in the art. Such modifications, substitutions and alternatives can be made without departing from the spirit and scope of the invention, which should be determined from the appended claims.
Various features of the invention are set forth in the appended claims.
Claims
- 1. An electrical junction box adapted to minimize the number of necessary components thereof, comprising:a first part having a first side including a plurality of first connecting means formed into a single integrated piece with and protruding from said first side, and a second side arranged and configured to receive at least one of a fuse and/or a relay; a second part having a first side arranged and configured to receive at least one external connector and a second side having a plurality of second connecting means formed into a single integrated piece with and protruding from said second side of said second part; at least one intermediate part disposed between said first part and said second part and having a first side including a plurality of first interconnecting means formed into a single integrated piece with said first side of said intermediate part for engaging said first connecting means of said first part, and a second side having a plurality of second interconnecting means formed into a single integrated piece with said second side of said intermediate part for engaging said second connecting means of said second part; and, at least one generic electronic module disposed between said intermediate part and said second part.
- 2. The junction box as defined in claim 1 wherein said plurality of said first connecting means of said first part are male connectors and said plurality of said first interconnecting means of said at least one intermediate part are female connectors.
- 3. The junction box as defined in claim 1 wherein said plurality of said second connecting means of said second part are male connectors and said plurality of said second interconnecting means of said at least one intermediate part are female connectors.
- 4. The junction box as defined in claim 1 wherein said intermediate part includes an integrally formed electric circuit for electrically connecting said plurality of said first interconnecting means of said intermediate part to said plurality of said second interconnecting means of said intermediate part.
- 5. The junction box as defined in claim 1 wherein said first part is integrally formed through molded interconnect technology.
- 6. The junction box as defined in claim 1 wherein said second part is integrally formed through molded interconnect technology.
- 7. The junction box as defined in claim 1 wherein said intermediate part is integrally formed through molded interconnect technology.
- 8. The junction box as defined in claim 1 wherein said generic electronic module is electrically connected to said first part via a plug which extends through an opening in said intermediate part.
- 9. The junction box as defined in claim 1 wherein said generic electronic module is attached to a heat sink integrally formed on the first side of said second part.
- 10. The junction box as defined in claim 1 wherein said second side of said first part includes at least one integrally formed receptacle for receiving said at least one of said fuse and/or said relay.
- 11. The junction box as defined in claim 10 wherein said second side of said first part further includes at least one shroud integrally formed around said receptacle for guiding said at least one of said fuse and/or said relay into said receptacle.
- 12. The junction box as defined in claim 10 wherein said first part further includes an integrally formed electric circuit for electrically connecting said at least one receptacle formed on said second side of said first part to at least one corresponding said plurality of first connecting means formed on said first side of said first part.
- 13. The junction box as defined in claim 1 wherein said first side of said second part includes at least one integrally formed receptacle for receiving said at least one external connector.
- 14. The junction box as defined in claim 13 wherein said first side of said second part further includes at least one shroud integrally formed around said receptacle for guiding said at least one external connector into said receptacle.
- 15. The junction box as defined in claim 13 wherein said second part further includes an integrally formed electric circuit for electrically connecting said at least one receptacle formed on said first side of said second part to at least one corresponding said plurality of second connecting means formed on said second side of said second part.
- 16. The junction box as defined in claim 1 wherein said first side of said second part further includes an integrally formed heat sink.
- 17. The junction box as defined in claim 16 wherein said heat sink is a plurality of fins.
- 18. A junction box adapted to incorporate function electronics, comprising:a first part for receiving at least one of a fuse and/or a relay; an intermediate part configured to be mated to said first part and electrically connected to said at least one of said fuse and/or said relay; and a second part configured to be mated to said intermediate part and adapted to electrically connect said fuse and/or said relay to a corresponding external connector via said intermediate part, said second part having a ledge integrally formed on an inside thereof and a heat sink integrally formed on an outside thereof; wherein the function electronics are disposed between said intermediate part and said second part and thermally attached to said integral ledge, so that heat built-up on the function electronic is released through said integral heat sink.
- 19. The junction box as defined in claim 18 wherein said heat sink is a plurality of fins.
- 20. An electrical junction box adapted to be used on a motor vehicle and to minimize the number of necessary components thereof, comprising:a first part having a first side including a plurality of first connecting means formed into a single integrated piece with and protruding from said first side, and a second side arranged and configured to receive at least one of a fuse and/or a relay of the motor vehicle; a second part having a first side arranged and configured to receive at least one wiring harness of the motor vehicle, and a second side having a plurality of second connecting means formed into a single integrated piece with and protruding from said second side of said second part; at least one intermediate part disposed between said first part and said second part and having a first side including a plurality of first interconnecting means formed into a single integrated piece with said first side of said intermediate part for engaging said first connecting means of said first part, and a second side having a plurality of second interconnecting means formed into a single integrated piece with said second side of said intermediate part for engaging said second connecting means of said second part; and, at least one generic electronic module disposed between said intermediate part and said second part.
US Referenced Citations (18)