Embodiments of the invention generally relate to packaging circuit components in modules. More specifically, embodiments of the invention relate to packaging circuit protection devices into modules to ease installation and replacement
Electrical components or systems are often coupled with circuit protection devices such as fuses and relays in order to protect the wiring of the electrical components. The circuit protection devices regulate and limit the amount of current provided to the wiring of the electrical components either by breaking a connection, detouring, buffering, or consuming the excess power. Objects utilizing a large amount of electrical components, for example, vehicles often also utilize a large amount of circuit protection devices to protect the large and often complex electrical system. Integrating the circuit protection devices into the electrical system is often a daunting task. Each circuit protection device requires specific placement and wiring. Placing a circuit protection device in the wrong location or placing the wrong type of circuit protection device in a location can damage a number of electrical components or even the entire electrical system.
Circuit boards containing one or more electrical components may be precisely configured in an arrangement that provides the necessary connections, power, and grounding for both the electrical components and corresponding circuit protection devices. If the arrangement of the electrical components changes, however, the circuit board configuration may need to be redesigned. Replacing the circuit protection devices may also require the resoldering of connections and can disrupt a number of components also contained on the circuit board.
In one embodiment, the invention provides a modularized circuit component. The modularized circuit component includes a device having an identifying feature, an electrical terminal, and at least one of a mechanical plug and a mechanical receptacle. The modularized circuit component further includes a support block having an identifying feature that is substantially the same as the identifying feature of the device, at least one of a mechanical plug and a mechanical receptacle to interface with the at least one of a mechanical plug and a mechanical receptacle of the device, and an electrical terminal configured to interface with a circuit board. The identifying feature of the device and of the support block may comprise a texture, a color, a shape, or the like. In some embodiments, the device included in the modularized circuit component is a circuit protection device such as a fuse or a relay.
In another embodiment, the invention provides a circuit module that includes a circuit board; a plurality of devices, each device having an identifying feature, an electrical terminal, and a mechanical plug; a plurality of support blocks, each support block having an identifying feature, a mechanical receptacle to receive at least one plug of at least one device, and an electrical terminal configured to interface with the circuit board, where each electrical terminal of each support block is substantially identical to one another, and where at least some of the identifying features of the plurality of support blocks are substantially the same as at least some of the identifying features of at least some of the plurality of devices. The identifying features of the plurality of devices and of the plurality of support blocks may comprise a texture, a color, a shape, or the like. In some embodiments, the plurality of devices consists of circuit protection devices such as fuses or relays.
In another embodiment, the invention provides a method of assembling a circuit module. The method includes providing a circuit board; providing a plurality of devices, each device having an identifying feature, an electrical terminal, and a mechanical interface; providing a plurality of support blocks, each support block having an identifying feature, a mechanical interface to interact with at least one plug of at least one mechanical interface of at least one of the plurality of devices, and an electrical terminal configured to interface with the circuit board, where each electrical terminal of each support block is substantially identical to one another, and where at least some of the identifying features of the plurality of support blocks are substantially the same as at least some of the identifying features of at least some of the plurality of devices; associating each of the plurality of devices with a support block; and associating each of the support blocks with the circuit board.
In yet another embodiment, the invention provides a system for controlling electrical connections. The system includes a circuit board; and a circuit protection module having an identifying feature and configured to interface with the circuit board and to interface with a circuit protection device having an identifying feature, where the identifying feature of the circuit protection device is the same as the identifying feature of the circuit protection module. The identifying feature of the circuit protection device and of the circuit protection module may comprise a texture, a color, a shape, or the like. In some embodiments, the circuit protection module further includes one or more terminals configured to interface with the circuit board through a pin and paste connection and may also include a mechanical key also configured to interface with the circuit board.
In another embodiment, the invention provides a junction box module. The junction box module includes a circuit protection module having a support block with one or more terminals and a housing with an identifying feature and containing a circuit protection device having an identifying feature, where the identifying feature of the circuit protection device is the same as the identifying feature of the housing; and a circuit board configured to interface with the one or more terminals of the support block. The circuit board included in the junction box module may be configured to provide power to the circuit protection module. The circuit protection device may also be configured to be removable from the circuit protection component.
In yet another embodiment of the invention, a method of assembling a circuit protection module is provided. The method includes means for attaching a circuit protection device having an identifying feature to a support block having an identifying feature and one or more terminals where the identifying feature of the support block is the same as the identifying feature of the circuit protection device; and means for attaching the one or more terminals of the support block to a circuit board. In some embodiments, the circuit protection device further includes a mechanical interface.
Additional objects and aspects of embodiments of the invention are illustrated in the drawings and provided in the subsequent description.
In the drawings:
Before embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of the examples set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or carried out in a variety of applications and in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “mounted,” “connected,” and “coupled” are used broadly and encompass both direct and indirect mounting, connecting, and coupling. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
The housing 12 may have an identifying feature that allows different types of circuit protection devices to be identified. For example, the housing 12 of fuses of with certain amperage may be a particular color. The housing 12 may incorporate a texture, a size, a shape, a symbol, or any combination thereof, that identifies a type of circuit protection device 10. The identifying feature may provide a quick reference for determining the type of circuit protection device included in an electrical system and may also provide an easy replacement safeguard to ensure the correct circuit protection device is inserted in the correct location. For example, red fuses should be replaced with red fuses. The housing 12 of the circuit protection device may also shield the conductor or similar circuitry from dust, debris, or physical forces that may cause the circuitry to break or malfunction.
The circuit protection device 10 may also include one or more electrical terminals. The circuit protection device illustrated in
In some embodiments, the terminals 14 and 16 are configured to perform as mechanical keys or plugs. Mechanical keys restrict the connection of components that are not configured to be connected. For example, a fuse of a given amperage may be required at a specific receptacle of the circuit board. Placing a fuse with any other amperage may result in possible damage to an electrical component. The receptacle of the circuit board may be configured to accept only mechanical keys of a physical terminal configuration that corresponds to the required circuit protection device. The terminals of different types of circuit protection devices, such as fuses with different amperages, may have unique configurations that limit the placement of the circuit protection device 10. The terminals 14 and 16 of different types of circuit protection devices may be constructed of various materials, may be positioned in various alignments, and may include additional ribs, notches, or other physical alterations in order to distinguish one type of circuit protection device 10 from another. Alternatively, the circuit protection device 10 may include a separate mechanical key or physical appendage or rib (not shown) that does not operate as a terminal but limits the connectability of the circuit protection device. The shape or configuration of the circuit protection device 10 itself may also act as a mechanical key. Only receptacles with mechanical receptacles configured to accept the physical configuration of the mechanical key or plug may be able to connect to the circuit protection device 10.
In some embodiments, the circuit protection device 10 is contained within a circuit protection module or modularized circuit component 20, as illustrated in
Similar to the housing 12 of the circuit protection device 10, the housing 22 of the circuit protection module 20 may have identifying features. As previously described, the housing 22 may have a texture, shape, size, symbol, or any combination thereof. In some embodiments, the identifying feature of the housing 22 of the circuit protection module 20 may match the identifying feature of the circuit protection device 10 contained in the circuit protection module 20. Matching identifying features may include, but are not limited to, identical or corresponding colors, shapes, textures, or symbols. By matching the identifying features, even when the circuit protection device 10 is removed from the circuit protection module 20, an individual can determine what type of circuit protection device 10 to insert into the module 20.
The housing 22 may further provide support and shielding from dust, debris, and physical movement. In some embodiments, the housing 22 is a plastic module. The housing 22 may also be configured (with cooling fins and other known features (not shown)) to act as a heat sink and dissipate heat created by the circuit protection device 10.
The circuit protection module 20 may also contain one or more terminals 24, 26, 28, and 30. The circuit protection module 20 illustrated in
The terminals 24, 26, 28, and 30 may be configured to attach to a circuit board. The terminals 24, 26, 28, and 30 may be wave soldered to a circuit board by threading or inserting the terminals into, and possibly through, the circuit board. The terminals 24, 26, 28, and 30 may also be surface mounted on a circuit board using gull wings that melt when heated. The melted gull wings solder the terminals 24, 26, 28, and 30 to the circuit board. Alternatively, the terminals may be attached to a circuit board through a pin and paste method. The pin and paste method involves inserting terminals into the circuit board where the length of the terminal legs is about the same length as the thickness or depth of the receptacles of the circuit board. The top of the circuit board may contain solder that when heated flows into the receptacles of the circuit board and around the inserted terminals. Upon surrounding the inserted terminals, the solder forms a connection between the inserted terminals and the receptacles of the circuit board. The terminals may also be selective-soldered, hand-soldered, laser-welded, glued, press-fit or the like to the circuit board or other substrate material configured to define an electrical circuit.
The housing 22 with the attached terminals 24, 26, 28 and 30 may rest on a support block 32. The support block 32 provides a foundation for the circuit protection module 20. The support block 32 may rest on top of a circuit board or other interface connectable to the module 20. As described for the housing 22, the support block 32 may also contain an identifying feature such as a color, size, shape, texture, symbol, or combination thereof. Similar to the housing 22, the identifying feature of the support block 32 may match the identifying feature of the housing 22 and/or the circuit protection device 10. The support block 32 may also be configured (with cooling fins and other known features) to act as a heat sink for the circuit protection device 10. In some embodiments, the housing 22 is made from a metallic material and the support block 32 may be configured to electrically isolate the housing 22 from the circuit board and terminals 24, 26, 28, and 30. The support block 32 may also be configured to absorb or insulate any heat generated by the circuit protection device 10. The support block 32 may also protect other components also connected to the circuit board from experiencing interference from heat or energy generated by the circuit protection device 10.
In some embodiments, the support block 32 and housing 22 may be incorporated into one part. The support block 32 may be also be configured to provide terminal receptacles for the circuit protection device 10 as previously described for the housing 22.
In some embodiments, the terminals 56, 58, 60, and 62 of the circuit protection module 50 are identical to the terminals 24, 26, 28, and 30 of the circuit protection module 20. The terminals may be identical to allow the circuit protection modules 20 and 50 to be moved and positioned in various locations on a circuit board.
The modular construction of the circuit protection modules 20 and 50 also allow circuit protection devices such as fuses and relays, which often require replacement, to be quickly and efficiently replaced without replacing the entire module. The reusability of the module and the safe-guards provided by the module help reduce costs and provide preventive measures for limiting time and cost spent repairing electric systems due to improper installation or replacement of circuit protection devices.
It should be understood that other packaged electrical devices may be used in place of circuit protection devices. The circuit protection device 10 and 52 may be replaced by other packaged electrical components such as gates, buffers, inverters, or the like that may need to be replaced, relocated, removed, or added to a circuit board.
It should also be understood that in some embodiments, the mechanical plug may be configured on the circuit protection module 20 rather than on the circuit protection device 10. The circuit protection device 10 may similarly include the mechanical receptacle rather than the circuit protection module 20.
Various features and aspects of the invention are set forth in the following claims.