AUTOMOTIVE ELECTRICAL CONNECTOR SYSTEM AND METHOD OF ASSEMBLING SAME

• US 20090023334A1
• Filed: 06/17/2008
• Published: 01/22/2009
• Est. Priority Date: 07/17/2007
• Status: Active Grant

• Current Assignee: Lear Corporation
• Original Assignee: Lear Corporation
• Inventors: Puschkat, Peter
• Granted Patent: US 7,708,596 B2
• Time in Patent Office: Days
• US Class Current: 439/590
• CPC Class Codes: H01H 2085/0555 Input terminal connected to a plurality of output terminals, e.g. multielectrode
• CPC Class Codes: H01H 2085/208 specially adapted for vehicles
• CPC Class Codes: H01H 85/044 General constructions or structure of low voltage fuses, i.e. below 1000 V, or of fuses where the applicable voltage is not specified H01H85/046 - H01H85/048 take precedence
• CPC Class Codes: H01H 85/2045 Mounting means or insulating parts of the base, e.g. covers, casings
• CPC Class Codes: H01H 85/205 Electric connections to contacts on the base
• CPC Class Codes: H01R 13/68 with built-in fuse
• CPC Class Codes: H01R 2201/26 for vehicles
• CPC Class Codes: H01R 9/2458 Electrical interconnections between terminal blocks
• CPC Class Codes: Y10T 29/53243 Multiple, independent conductors

Abstract

Different configurations of power distribution boxes are assembled from a common set of components. A housing may receive any of several bus assemblies having taps of differing configurations. A fuse holder that protects portions of a bus assembly inserted into the housing is attached with the housing.

Claims

1. An electrical connector for a wiring harness of an automotive vehicle comprising:

an electrical bus having a row of contacts selected from the group including input tap, first output tap, and second output tap, wherein at least one of the taps has a configuration that is different than the other taps; and

a housing including a row of slots configured to receive the row of contacts, wherein at least one of the slots is configured to receive any of the contacts selected from the group including input tap, first output tap, and second output tap.

2. The electrical connector of claim 1 further comprising a fuse holder configured to surround the electrical bus and attach with the housing.

3. The electrical connector of claim 2 wherein the electrical bus further includes a jumper tap to provide a contact patch for a jumper cable.

4. The electrical connector of claim 3 wherein the fuse holder is further configured to permit at least a portion of the jumper tap to pass through the fuse holder.

5. The electrical connector of claim 4 wherein the fuse holder includes a snap feature, further comprising a removable cap configured to cover the jumper tap and attach with the snap feature of the fuse holder.

6. The electrical connector of claim 2 wherein the fuse holder includes a fixation feature for attaching the fuse holder with the automotive vehicle.

7. The electrical connector of claim 1 wherein the electrical bus further includes an additional row of contacts selected from the group including first output tap and second output tap and wherein the first output tap has a configuration that is different than the second output tap.

8. The electrical connector of claim 7 further comprising an additional housing including a row of slots configured to receive the additional row of contacts wherein at least one of the slots is configured to receive any of the contacts selected from the group including first output tap and second output tap.

9. The electrical connector of claim 2 further comprising a bracket including a fixation feature for attaching the bracket to the automotive vehicle wherein the bracket is configured to attach with the fuse holder.

10. The electrical connector of claim 1 wherein the taps each have a width and wherein the width of the at least one tap having a configuration different than the other taps is different than the width of the other taps.

11. The electrical connector of claim 1 wherein the taps each have a cross section and wherein the cross section of the at least one tap having a configuration different than the other taps is different than the cross section of the other taps.

12. An electrical connector for a wiring harness of an automotive vehicle comprising:

an electrical bus having a row of contacts selected from the group including mega contact and mini contact, wherein each of the contacts has an insertion portion and wherein the insertion portion of the mega contact is different than the insertion portion of the mini contact; and

a housing including a row of openings configured to receive the insertion portions of the row of contacts, wherein at least one of the openings is configured to receive the insertion portion of any of the contacts selected from the group including mega contact and mini contact.

13. The electrical connector of claim 12 wherein the insertion portions have a shape and wherein the shape of the insertion portion of the mega contact is different than the shape of the insertion portion of the mini contact.

14. The electrical connector of claim 12 wherein the insertion portions have a cross section and wherein the cross section of the insertion portion of the mega contact is different than the cross section of the insertion portion of the mini contact.

15. The electrical connector of claim 12 wherein the insertion portions have a thickness and wherein the thickness of the insertion portion of the mega contact is different than the thickness of the insertion portion of the mini contact.

16. The electrical connector of claim 12 further comprising a fuse holder configured to surround the electrical bus and attach with the housing.

17. The electrical connector of claim 16 wherein the electrical bus further includes a jumper tap to provide a contact patch for a jumper cable.

18. The electrical connector of claim 17 wherein the fuse holder is further configured to permit at least a portion of the jumper tap to pass through the fuse holder.

19. A method of assembling an electrical connector for a wiring harness of an automotive vehicle, the method comprising:

selecting an electrical bus having a row of contacts wherein the contacts are selected from the group including input tap, first output tap, and second output tap, wherein each of the taps has a cross section and wherein the cross section of at least one of the taps is different than the cross section of the other taps; and

inserting the row of contacts of the electrical bus into a row of openings of a housing configured to receive the row of contacts, wherein at least one of the openings is configured to receive any of the contacts selected from the group including input tap, first output tap, and second output tap.

20. The method of claim 19 further comprising attaching a fuse holder configured to surround the electrical bus with the housing.