Battery-mounted power distribution module

• US 5,643,693 A
• Filed: 10/30/1995
• Issued: 07/01/1997
• Est. Priority Date: 10/30/1995
• Status: Expired due to Term

• Current Assignee: Yazaki Corporation
• Original Assignee: Yazaki Corporation
• Inventors: Stern, Eric J., Hill, Mark G.
• Primary Examiner(s): KALAFUT, STEPHEN J
• Application Number:
  US08/550,367
• Time in Patent Office: 610 Days
• Field of Search: 429/7, 429/65, 429/121, 429/123
• US Class Current: 429/121
• CPC Class Codes: H01H 2085/025 Structural association with a binding post of a storage battery
• CPC Class Codes: H01H 85/205 Electric connections to contacts on the base
• CPC Class Codes: H01M 50/202 Casings or frames around the primary casing of a single cell or a single battery
• CPC Class Codes: H01M 50/244 Secondary casings; Racks; Suspension devices; Carrying devices; Holders characterised by their mounting method
• CPC Class Codes: H01M 50/249 specially adapted for aircraft or vehicles, e.g. cars or trains constructional details of batteries specially adapted for electric vehicles B60L50/64
• CPC Class Codes: H01M 50/296 characterised by terminals of battery packs terminals of batteries H01M50/543
• CPC Class Codes: H01M 50/298 characterised by the wiring of battery packs
• CPC Class Codes: H01M 50/50 Current conducting connections for cells or batteries
• CPC Class Codes: H01M 50/581 in response to temperature
• CPC Class Codes: H01M 50/583 in response to current, e.g. fuses
• CPC Class Codes: H01M 50/588 outside the batteries, e.g. incorrect connections of terminals or busbars
• CPC Class Codes: H01M 50/591 Covers
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

An electrical power distribution module for use with an automotive vehicle electrical system is adapted to be mounted on the top surface of a standard automotive lead-acid storage battery and connect with a battery terminal extending therefrom. The power distribution module includes a battery post connecting assembly for housing a terminal connector for making electrical connections with the battery terminal and alternator and starter cables, a fuse block for receiving a plurality of fuses associated with separate vehicle electrical circuits, and a harness guide channel for routing a plurality of wires which connect the fuses with their associated circuits. The power distribution module is mounted to lay flat on top of the battery'"'"'s upper surface with the battery terminal extending upwardly into the module to be engaged by the battery terminal connector. The module does not extend substantially above the highest point of the battery terminal, nor does it extend laterally substantially outside of the battery perimeter. A cover is attached to the power distribution module and has hinged sections which may be opened to provide access to the battery terminal connector and the fuse receptacles.

Claims

1. An electrical power distribution module for mounting to a vehicle battery having a substantially horizontal top surface and a battery terminal projecting from the top surface, the power distribution unit comprising:

a battery terminal connector for making electrical contact with the battery terminal and a plurality of fuse receptacles electrically connected with the battery terminal connector by a bus bar, characterized in that the power distribution module is adapted to be mounted in overlying relation to the battery top surface.

2. A power distribution module according to claim 1 characterized in that when mounted to the battery the power distribution module lies essentially within the lateral boundaries of the battery top surface.

3. A power distribution module according to claim 1 wherein the bus bar lies in a substantially horizontal plane.

4. A power distribution module according to claim 1 further including means for electrically connecting a starter cable with the battery terminal connector and an alternator cable with the bus bar.

5. A power distribution module according to claim 4 further including means for mounting a fuse between the alternator cable and the bus bar.

6. A power distribution module according to claim 1 wherein the fuse receptacles lie in a horizontal row substantially parallel with the battery top surface and are oriented such that fuses may be inserted horizontally therein.

7. A power distribution module according to claim 1 further including a wire harness guide channel for routing a plurality of wires connected with the fuse receptacles over the battery top surface.

8. A power distribution module according to claim 1 further including a cover having at least first and second separately openable hinged portions, the first hinged portion providing access to the battery terminal connector and the second hinged portion providing access to the fuse receptacles.

16. A power distribution module according to claim 1 wherein the battery terminal connector, the fuse receptacles, and the bus bar do not project above a highest point of the battery terminal.

9. An electrical power distribution module for mounting to an automotive vehicle battery having a battery terminal with portions projecting therefrom, the power distribution module comprising:

a battery terminal connector for making electrical contact with the battery terminal and a plurality of fuse receptacles electrically connected to the battery terminal connector by a bus bar, characterized in that the power distribution module when mounted to the battery encloses the portions of the battery terminal projecting from the battery.

10. An electrical power distribution module adapted to be mounted above an automotive vehicle battery having a battery terminal projecting upward from a substantially horizontal top surface of the battery, the power distribution module comprising:

a battery connecting block positioned over the battery terminal and having a battery terminal connector for making electrical connection with the battery terminal, means for electrically connecting a starter cable and an alternator cable to the power distribution module, and fuse mounting means for mounting a main fuse in electrical connection between the alternator cable and the power distribution module;

a fuse block adapted to lie in a substantially horizontal plane above the battery top surface and having a plurality of horizontally oriented fuse receptacles and a bus bar electrically connecting the fuse receptacles with the battery terminal connector, the bus bar lying in a substantially horizontal plane;

a wire harness guide channel for routing a plurality of wires connected with the fuse receptacles over the battery top surface; and

a cover for covering the battery connecting block, the fuse block, and the wire harness guide channel and having at least first and second separately openable hinged portions, the first hinged portion openable to allow access to the battery terminal connector and the second hinged portion openable to allow access to the fuse receptacles.

11. A battery-mounted, fuse-protected, automotive power distribution module comprising:

a housing of electrically non-conductive material having respective internal spaces for a battery terminal connector, a distribution bus bar and a plurality of fuses;

a battery terminal connector in the battery terminal connector space;

a bus bar disposed in the bus bar space and electrically connected to the battery terminal connector; and

means for mounting the module in overlying relation to an automotive battery with a terminal of the battery extending upwardly into the battery terminal connector.

12. A battery-mounted, fuse-protected automotive power distribution module as defined in claim 11 wherein said housing includes a first cover portion for providing access to the battery terminal connector space.

13. A battery-mounted, fuse-protected automotive power distribution module as defined in claim 11 wherein said housing includes a second cover portion for providing access to said fuse space.

14. A battery-mounted, fuse-protected automotive power distribution module as defined in claim 11 further including a plurality of fuses mounted within said fuse space and means for electrically connecting said fuses to said distribution bus bar.

15. A battery-mounted, fuse-protected automotive power distribution module as defined in claim 11 wherein said means for mounting the module comprises a plurality of threaded clamping rods extending in mutually parallel relation through a portion of said housing, and threaded nuts engaging the end portions of said rods.