Electrical circuit and trim panel

• US 5,484,186 A
• Filed: 02/02/1994
• Issued: 01/16/1996
• Est. Priority Date: 04/28/1992
• Status: Expired due to Term

• Current Assignee: Prince (Wellman Holdings, Inc.)
• Original Assignee: Prince (Wellman Holdings, Inc.)
• Inventors: Garvelink, Lee, Van Vuren, Rick A., Ramon, Alex C., Van Order, Kim L., De Jong, Jerry M.
• Primary Examiner(s): KRAMER, DEAN J
• Application Number:
  US08/190,595
• Time in Patent Office: 713 Days
• Field of Search: 296/39.1, 296/146.7, 296/152, 296/214, 296/97.1, 296/97.2, 296/97.5, 439/34, 439/36, 439/404, 439/405, 439/723, 439/724
• US Class Current: 296/97.5
• CPC Class Codes: B60R 16/0207 Wire harnesses
• CPC Class Codes: Y10T 29/49185 of terminal
• CPC Class Codes: Y10T 29/49202 including oppositely facing end orienting

Abstract

An electrical system for vehicle panels is disclosed which includes a plurality of conductors and electrical accessories for connection to the panel. The electrical accessories include insulation displacement contacts for connection with conductors in the panel. In one embodiment, the panel includes a plurality of conductive layers providing an electrical bus for the panel. In another embodiment, the conductors are formed in the panel between two dielectric layers.

Claims

1. A decorative vehicle trim panel assembly, comprising:

a panel adapted to be mounted to a vehicle, said panel having at least one aperture formed therein;

at least one panel conductor carried on said panel and fixed to said panel to extend across at least a portion of said at least one aperture, said at least one panel conductor adapted to be connected to the vehicle'"'"'s electrical system; and

an electrical accessory adapted to be carried on said panel, said electrical accessory including at least one accessory conductor and at least one insulation displacement contact coupled to said accessory conductor, said at least one insulation displacement contact being connected to said at least one panel conductor through said at least one aperture.

2. The decorative vehicle trim panel assembly as defined in claim 1 wherein said electrical accessory includes a lamp receptacle, said lamp receptacle including at least one contact coupled to said at least one accessory conductor.

3. The decorative vehicle trim panel assembly as defined in claim 2 wherein said electrical accessory further includes a switch, a first terminal of said switch coupled to said at least one lamp contact and a second terminal of said switch connected to said at least one insulation displacement contact whereby said switch selectively connects said first terminal to said second terminal to control operation of said electrical accessory.

4. The decorative vehicle trim panel assembly as defined in claim 3, wherein said electrical accessory further includes a housing, and wherein said lamp receptacle and said switch are positioned within said housing.

5. The decorative vehicle trim panel assembly as defined in claim 4 wherein said vehicle accessory further includes a connector and said switch includes at least one switch contact, said connector is supported within said housing and including one of said at least one lamp contact and one of said at least one switch contact.

6. The decorative vehicle trim panel assembly as defined in claim 1, wherein said at least one panel conductor includes a plurality of panel conductors providing a multi-conductor electrical bus for said panel.

7. The decorative vehicle trim panel assembly as defined in claim 6 wherein said plurality of conductors are provided in a ribbon cable.

8. The decorative vehicle trim panel assembly as defined in claim 6 wherein said electrical accessory is a lamp assembly.

9. The decorative vehicle trim panel assembly as defined in claim 6 wherein said electrical accessory is in an overhead console.

10. The decorative vehicle trim panel assembly as defined in claim 1 wherein said panel is a vehicle headliner.

11. The decorative vehicle trim panel assembly as defined in claim 1 further including at least one panel conductor connected to the vehicle electrical system and at least one electrical system connector adapted to be connected to said at least one panel conductor, said electrical system connector including a first insulation displacement contact adapted to connect to said at least one panel conductor whereby said electrical system connector insulation displacement contact is connected to said at least one panel conductor to connect said at least one panel conductor to the vehicle electrical system.

12. The decorative vehicle trim panel assembly as defined in claim 11 wherein said electrical accessory includes at least one accessory conductor, and wherein said at least one electrical system connector includes a second insulation displacement contact adapted to connect to said accessory conductor.

13. The decorative vehicle trim panel assembly as defined in claim 1, wherein said vehicle accessory is a center high-mounted stop-lamp including at least one lamp, said at least one stop lamp including at least one insulation displacement contact.

14. The decorative vehicle trim panel assembly as defined in claim 13, wherein said center high mounted stop lamp includes two lamp assemblies positioned within a common housing, wherein said housing is adapted to be mounted to said panel.

15. The decorative vehicle trim panel assembly as defined in claim 14, wherein each of said lamp assemblies include at least one insulation displacement contact whereby said lamps are connected to said panel conductor.

16. The decorative vehicle trim panel assembly as defined in claim 1, wherein said accessory is a vehicle visor assembly.

17. The decorative vehicle trim panel assembly as defined in claim 16, wherein said visor assembly includes a bracket including means for supporting a visor pivot rod on said bracket, and said bracket including means for connecting at least one visor electrical conductor connected to a vanity mirror lamp to at least one panel electrical conductor on said vehicle panel.

18. The decorative vehicle trim panel assembly as defined in claim 16, wherein said connecting means includes an electrical connector adapted to connect with said at least one panel electrical conductor and said at least one accessory electrical conductor.

19. The decorative vehicle trim panel assembly as defined in claim 16, further including a mounting cap.

20. The decorative vehicle trim panel assembly as defined in claim 19, further including means for assembling said bracket to said mounting cap such that the vehicle panel is positioned between said bracket and said mounting cap.

21. The decorative vehicle trim panel assembly as defined in claim 20, wherein said mounting cap includes means for securing the conductor in said connector when said bracket is assembled to said mounting cap.

22. The decorative vehicle trim panel assembly as defined in claim 21, wherein said at least one insulation displacement contact is fixedly secured to a surface of said bracket.

23. The decorative vehicle trim panel assembly as defined in claim 1, wherein said at least one insulation displacement contact is fixedly secured to a surface of said electrical accessory.

24. A decorative vehicle trim panel assembly comprising:

a panel adapted to be mounted to a vehicle;

at least one panel conductor carried on said panel, said at least one panel conductor adapted to be connected to the vehicle'"'"'s electrical system;

an electrical accessory adapted to be carried on said panel, said electrical accessory including at least one accessory conductor and at least one insulation displacement contact coupled to said accessory conductor, said at least one insulation displacement contact being connected to said at least one panel conductor; and

at least one panel conductor connected to the vehicle electrical system and at least one electrical system connector adapted to be connected to said at least one panel conductor, said electrical system connector including a first insulation displacement contact adapted to connect to said at least one panel conductor whereby said electrical system connector insulation displacement contact is connected to said at least one panel conductor to connect said at least one panel conductor to the vehicle electrical system,

wherein said electrical accessory includes at least one accessory conductor, and wherein said at least one electrical system connector includes a second insulation displacement contact adapted to connect to said accessory conductor, and

wherein said at least one electrical system connector includes first and second arms extending from a shoulder, said first and second arms extending substantially in parallel, said first and second arms including a respective one of said first and second insulation displacement contacts, respectively, for receiving said accessory conductor and said panel conductor, respectively.

25. The decorative vehicle trim panel assembly as defined in claim 24, further including a female contact connected to an end of said accessory conductor, whereby said female contact is adapted to engage said electrical system connector.

26. The decorative vehicle trim panel assembly as defined in claim 25, wherein said accessory is a vehicle visor assembly.

27. The decorative vehicle trim panel assembly as defined in claim 26, wherein said visor assembly includes a bracket including means for supporting a visor pivot rod on said bracket, and said bracket including means for connecting at least one visor electrical conductor connected to a vanity mirror lamp to at least one panel electrical conductor on said vehicle panel.

28. The decorative vehicle trim panel assembly as defined in claim 26, wherein said connecting means includes an electrical connector adapted to connect with said at least one panel electrical conductor and said at least one accessory electrical conductor.

29. The decorative vehicle trim panel assembly as defined in claim 26, further including a mounting cap.

30. The decorative vehicle trim panel assembly as defined in claim 29, further including means for assembling said bracket to said mounting cap such that the vehicle panel is positioned between said bracket and said mounting cap.

31. The decorative vehicle trim panel assembly as defined in claim 30, wherein said mounting cap includes means for securing the conductor in said connector when said bracket is assembled to said mounting cap.

32. The decorative vehicle trim panel assembly as defined in claim 24, wherein said at least one accessory conductor includes a plurality of accessory conductors and said at least one panel conductor includes a plurality of panel conductors, the number of panel conductors at least equal to the number of accessory conductors, and wherein the number of electrical system connectors is equal to the number of panel conductors.

33. A vehicle panel assembly comprising:

a panel including a first outer layer, a second outer layer, and at least three electrically conductive layers between said outer layers; and

an electrical accessory adapted to be assembled to said panel, said electrical accessory including at least one electrical conductor adapted to be connected to at least one of said electrically conductive layers, whereby said electrical accessory is connected to said one electrically conductive layer at any location on said panel by cutting an aperture in said panel to access said electrically conductive layers.

34. The vehicle panel assembly as defined in claim 33, wherein said electrically conductive layers of said panel are separated by dielectric layers.

35. The vehicle panel assembly as defined in claim 34 wherein said electrical accessory includes a mounting plate and a base, wherein said mounting plate is positioned on one side of said panel aperture and said base is positioned on another side of said panel and connected to said mounting plate to assemble said electrical accessory to said panel.

36. The vehicle panel assembly as defined in claim 33 and further including a second electrical accessory adapted to be assembled to said panel, said second electrical accessory including at least one electrical conductor adapted to be connected to at least one of said electrically conductive layers, whereby said second electrical accessory is connected to the at least one electrically conductive layer at any location on said panel by cutting a second aperture in said panel to access said electrically conductive layers.

37. The vehicle panel assembly as defined in claim 36, wherein a third one of said electrically conductive layers is connected to, and provides an electrical ground to, said electrical accessories.

38. A method of providing a vehicle panel including electrical accessories comprising the steps of:

forming a vehicle panel including at least three electrical conductors therein;

forming at least one aperture in said vehicle panel to expose said at least three conductors in said panel, said at least one aperture adapted to receive a vehicle accessory; and

mounting said vehicle accessory in said aperture in said panel such that said vehicle accessory connects to said at least one of said conductors.

39. The method as defined in claim 38, wherein said step of mounting said vehicle accessory includes a step of positioning an accessory on one surface of said panel and positioning a mounting means on another side of said panel, and securing said accessory to said mounting means.

40. The method as defined in claim 38, further including the step of connecting said conductors to said vehicle electrical system.

41. A method of providing a vehicle panel including electrical accessories comprising the steps of:

forming a vehicle panel including at least three electrical conductors therein;

assembling a plurality of layers in said panel, wherein more than one of said layers are electrically conductive;

forming at least one aperture in said vehicle panel to expose said conductors in said panel, said at least one aperture adapted to receive a vehicle accessory; and

mounting said vehicle accessory in said aperture in said panel such that said vehicle accessory connects to said at least one of said conductors.

42. A method of providing a vehicle panel including electrical accessories comprising the steps of:

forming a vehicle panel including at least three electrical conductors therein;

assembling a plurality of conductive strips extending through said panel between a layer of said panel;

forming at least one aperture in said vehicle panel to expose said conductors in said panel, said at least one aperture adapted to receive a vehicle accessory; and

mounting said vehicle accessory in said aperture in said panel such that said vehicle accessory connects to said at least one of said conductors.

43. A decorative vehicle trim panel assembly, comprising:

a panel adapted to be mounted to a vehicle;

at least one panel conductor carried on said panel, said at least one panel conductor adapted to be connected to the vehicle'"'"'s electrical system; and

an electrical accessory adapted to be carried on said panel, said electrical accessory including at least one accessory conductor and at least one insulation displacement contact fixedly secured to a surface of said electrical accessory and coupled to an end of said accessory conductor to secure said end of said accessory conductor to said surface, said at least one insulation displacement contact being connected to said at least one panel conductor.

44. The decorative vehicle trim panel assembly as defined in claim 43, wherein said accessory is a vehicle visor assembly.

45. The decorative vehicle trim panel assembly as defined in claim 43, wherein said electrical accessory includes a lamp receptacle, said lamp receptacle including at least one contact coupled to said at least one accessory conductor.

46. The decorative vehicle trim panel assembly as defined in claim 43, wherein said at least one panel conductor includes a plurality of panel conductors providing a multi-conductor electrical bus for said panel.

47. The decorative vehicle trim panel assembly as defined in claim 46, wherein said plurality of conductors are provided in a ribbon cable.

48. The decorative vehicle trim panel assembly as defined in claim 46, wherein said electrical accessory is a lamp assembly.

49. The decorative vehicle trim panel assembly as defined in claim 46, wherein said electrical accessory is in an overhead console.

50. The decorative vehicle trim panel assembly as defined in claim 43, wherein said panel is a vehicle headliner.

51. The decorative vehicle trim panel assembly as defined in claim 43 and further including at least one panel conductor connected to the vehicle electrical system and at least one electrical system connector adapted to be connected to said at least one panel conductor, said electrical system connector including a first insulation displacement contact adapted to connect to said at least one panel conductor whereby said electrical system connector insulation displacement contact is connected to said at least one panel conductor to connect said at least one panel conductor to the vehicle electrical system.

52. The decorative vehicle trim panel assembly as defined in claim 43, wherein said vehicle accessory is a center high-mounted stop-lamp including at least one lamp, said at least one stop lamp including at least one insulation displacement contact.

53. A decorative vehicle trim panel assembly, comprising:

a panel adapted to be mounted to a vehicle;

at least one panel conductor carried on said panel, said at least one panel conductor adapted to be connected to the vehicle'"'"'s electrical system; and

an electrical accessory adapted to be carried on said panel, said electrical accessory including at least one accessory conductor and at least one insulation displacement contact fixedly secured to a surface of said electrical accessory and coupled to said accessory conductor, said at least one insulation displacement contact being connected to said at least one panel conductor,

wherein said panel has at least one aperture formed therein, said at least one panel conductor is fixed to said panel across said at least one aperture, and said at least one insulation displacement contact being connected to said at least one panel conductor through said at least one aperture.

54. A decorative vehicle trim panel assembly, comprising:

a panel adapted to be mounted to a vehicle;

at least one panel conductor carried on said panel, said at least one panel conductor adapted to be connected to the vehicle'"'"'s electrical system; and

a vehicle visor assembly adapted to be carried on said panel, said vehicle visor assembly including at least one accessory conductor, and at least one insulation displacement contact fixedly secured to a surface of said vehicle visor assembly and coupled to an end of said accessory conductor to secure said end of said accessory conductor to said surface, said at least one insulation displacement contact being connected to said at least one panel conductor.

55. The decorative vehicle trim panel assembly as defined in claim 54, wherein said panel is a vehicle headliner.

56. The decorative vehicle trim panel assembly as defined in claim 55, wherein said visor assembly includes a bracket including means for supporting a visor pivot rod on said bracket, and said bracket including means for connecting at least one visor electrical conductor connected to a vanity mirror lamp to at least one panel electrical conductor on said vehicle headliner.

57. The decorative vehicle trim panel assembly as defined in claim 55, further including a mounting cap and means for assembling said bracket to said mounting cap such that the vehicle headliner is positioned between said bracket and said mounting cap.

58. The decorative vehicle trim panel assembly as defined in claim 57, wherein said mounting cap includes means for securing the conductor in said connector when said bracket is assembled to said mounting cap.

59. A decorative vehicle trim panel assembly comprising:

a vehicle headliner adapted to be mounted to a vehicle;

at least one panel conductor carried on said vehicle headliner, said at least one panel conductor adapted to be connected to the vehicle'"'"'s electrical system; and

a vehicle visor assembly adapted to be carried on said vehicle headliner, said vehicle visor assembly including at least one accessory conductor and at least one insulation displacement contact fixedly secured to a surface of said vehicle visor assembly and coupled to said accessory conductor, said at least one insulation displacement contact being connected to said at least one panel conductor, wherein said visor assembly includes;

a bracket including means for supporting a visor pivot rod on said bracket, and said bracket including means for connecting at least one visor electrical conductor connected to a vanity mirror lamp to at least one panel electrical conductor on said vehicle headliner, wherein said at least one insulation displacement contact is fixedly secured to a surface of said bracket, and

a mounting cap and means for assembling said bracket to said mounting cap such that the vehicle headliner is positioned between said bracket and said mounting cap, wherein said mounting cap includes means for securing the conductor in said connector when said bracket is assembled to said mounting cap.

60. A vehicle panel assembly comprising:

a panel including a first outer layer, a second outer layer, and at least two electrically conductive layers between said outer layers;

a first electrical accessory adapted to be assembled to said panel, said first electrical accessory including at least one electrical conductor adapted to be connected to a first one of said conductive layers, whereby said first electrical accessory is connected to said first one of said conductive layers at any location on said panel by cutting an aperture in said panel to access said electrical conductive layers; and

a second electrical accessory adapted to be assembled to said panel, said second electrical accessory including at least one electrical conductor adapted to be connected to a second one of said conductive layers, whereby said second electrical accessory is connected to said second one of said conductive layers at any location on said panel by cutting an aperture in said panel to access said electrical conductive layers,

wherein said first one of said electrically conductive layers selectively provides power to said first electrical accessory, and said second electrically conductive layer selectively provides power to said second electrical accessory.

61. The vehicle panel assembly as defined in claim 60, wherein said electrically conductive layers of said panel are separated by dielectric layers.

62. The vehicle panel assembly as defined in claim 61, wherein said at least two electrically conductive layers further include a third electrically conductive layer.

63. The vehicle panel assembly as defined in claim 62, wherein said third electrically conductive layer is connected to, and provides an electrical ground to, said first and second vehicle accessories.

64. A method of providing a vehicle panel including electrical accessories comprising the steps of:

forming a vehicle panel including at least two electrical conductors therein, said at least two electrical conductors including a first electrical conductor for selectively providing power to a first vehicle accessory and a second electrical conductor for selectively providing power to a second vehicle accessory independently from the power selectively provided by said first electrical conductor to said first vehicle accessory;

forming a first aperture in said vehicle panel to expose said first electrical conductor in said vehicle panel, said first aperture adapted to receive said first vehicle accessory;

mounting said first vehicle accessory in said first aperture in said vehicle panel such that said first vehicle accessory connects to said exposed first electrical conductor;

forming a second aperture in said vehicle panel to expose said second electrical conductor in said vehicle panel, said second aperture adapted to receive said second vehicle accessory; and

mounting said second vehicle accessory in said second aperture in said vehicle panel such that said second vehicle accessory connects to said exposed second electrical conductor.