Branch junction box

• US 5,902,138 A
• Filed: 02/14/1996
• Issued: 05/11/1999
• Est. Priority Date: 02/14/1995
• Status: Expired due to Term

• Current Assignee: Sumitomo Wiring Systems Limited (Sumitomo Corporation)
• Original Assignee: Sumitomo Wiring Systems Limited (Sumitomo Corporation)
• Inventors: Murakami, Koji
• Primary Examiner(s): Abrams, Neil
• Assistant Examiner(s): WITTELS, DANIEL NMN
• Application Number:
  US08/599,953
• Time in Patent Office: 1,182 Days
• Field of Search: 439/77, 439/76.1, 439/76.2
• US Class Current: 439/76.2
• CPC Class Codes: H01R 12/59 for flexible printed circuits, flat or ribbon cables or like structures
• CPC Class Codes: H01R 31/08 Short-circuiting members for bridging contacts in a counterpart
• CPC Class Codes: H01R 9/2466 using a planar conductive structure, e.g. printed circuit board
• CPC Class Codes: H05K 1/0263 High current adaptations, e.g. printed high current conductors or using auxiliary non-printed means; Fine and coarse circuit patterns on one circuit board H05K1/0293 takes precedence
• CPC Class Codes: H05K 1/0284 Details of three-dimensional rigid printed circuit boards H05K1/119 takes precedence; shaping of the substrate H05K3/0014
• CPC Class Codes: H05K 1/0393 Flexible materials H05K1/038 takes precedence; specific organic compositions are classified in H05K1/0313 and subgroups
• CPC Class Codes: H05K 2201/0352 Differences between the conductors of different layers of a multilayer
• CPC Class Codes: H05K 2201/09045 Locally raised area or protrusion of insulating substrate
• CPC Class Codes: H05K 2201/091 Locally and permanently deformed areas including dielectric material
• CPC Class Codes: H05K 2201/09118 Moulded substrate
• CPC Class Codes: H05K 2201/10272 Busbars, i.e. thick metal bars mounted on the printed circuit board [PCB] as high-current conductors
• CPC Class Codes: H05K 2201/10583 Cylindrically shaped component; Fixing means therefore
• CPC Class Codes: H05K 2201/10651 Component having two leads, e.g. resistor, capacitor
• CPC Class Codes: H05K 2203/167 Using mechanical means for positioning, alignment or registration, e.g. using rod-in-hole alignment
• CPC Class Codes: H05K 3/0058 Laminating printed circuit boards onto other substrates, e.g. metallic substrates H05K1/0281 takes precedence
• CPC Class Codes: H05K 3/202 using self-supporting metal foil pattern
• CPC Class Codes: H05K 3/306 Lead-in-hole components, e.g. affixing or retention before soldering, spacing means H05K3/32 takes precedence
• CPC Class Codes: H05K 3/4084 by deforming at least one of the conductive layers

Abstract

A branch junction box containing a flexible printed circuit sheet includes circuit terminals and other parts which are easily mounted. A first insulation plate is provided on one of its faces, with a plurality of printed circuit terminals vertically fixed therethrough. On its other face, the first insulation plate carries a flexible printed circuit sheet, the printed circuit of which is electrically connected to the circuit terminals. The surface of the insulating plate facing the circuit terminals may be provided with bus bar wiring patterns and corresponding bus bar terminals. These circuit terminals and bus bar terminals are branch-connected to wiring harnesses in a proper and reliable way through connectors formed in the casing of the box.

Claims

1. A system for connecting wiring harnesses comprising

a first flexible sheet including a printed circuit thereon, a plurality of first circuit terminals for connection to said wiring harnesses, each of said first circuit terminals having a first end and a second end, a first insulating plate having a first surface facing said sheet, a second surface on said first insulating plate opposite said first surface;

a retainer for securing said sheet to said first insulating plate comprising a plurality of first path holes extending through said first insulating plate and said sheet in a direction substantially perpendicular to a plane of said first plate and said sheet, each of said first circuit terminals extending through one of said first path holes;

a connection between said first end and said printed circuit, said second end adapted for connection to one of said wiring harnesses;

a first bus bar wiring pattern on said second surface, said first pattern having at least one first bus bar terminal which projects from said second surface.

2. The system of claim 1 wherein said first insulating plate and said sheet are provided with a plurality of second path holes extending therethrough in a direction substantially perpendicular thereto, said first bus bar terminal passing through one of said second path holes and projecting from said first surface.

3. The system of claim 2 wherein said first bus bar terminal projects substantially perpendicularly from said first surface.

4. The system of claim 1 wherein said first insulating plate carries a protruding element on at least one of said first surface and said second surface, at least one of said first sheet and said first bus bar pattern has a hole corresponding to said protruding elements, said elements fitted into said hole, thereby fixing said first sheet and/or said first bus bar pattern to said first insulating plate.

5. The system of claim 1 wherein at least one of said first surface and said second surface is provided with a fixing device for holding electronic components.

6. The system of claim 1 wherein at least one of said first surface and said second surface is provided with a fixing device for holding electronic components.

7. The system of claim 1 wherein said first bus bar terminal projects substantially perpendicularly from said second surface.

8. A branch junction box having an upper case, a lower case, and the system of claim 1 therebetween, said upper case having connector housings for receiving said first circuit terminals.

9. A branch junction box having an upper case, a lower case, and the system of claim 1 therebetween, said upper case having connector housings for receiving said first circuit terminals and said first bus bar terminals, said lower case comprising holes for receiving additional bus bar terminals for external connection.

10. A system for connecting wiring harnesses comprising

a first sheet including a printed circuit thereon, a plurality of first circuit terminals for connection to said wiring harnesses, each of said first circuit terminals having a first end and a second end, a first insulating plate having a first surface facing said sheet, a second surface on said first insulating plate opposite said first surface;

a retainer for securing said sheet to said first insulating plate comprising a plurality of first path holes extending through said first insulating plate and said sheet in a direction substantially perpendicular to a plane of said first plate and said sheet, each of said first circuit terminals extending through one of said first path holes;

a connection between said first end and said printed circuit, said second end adapted for connection to one of said wiring harnesses;

each of said first circuit terminals has a head end and a leg end, said head end having a larger diameter than said leg end, each of said first path holes having a stepped axial cross section complementary to one of said first circuit terminals.

11. The system of claim 10 wherein each of said first path holes has a head portion adjacent said first surface and a leg portion adjacent said second surface.

12. The system of claim 11 wherein said leg end is in electrical contact with said printed circuit.

13. The system of claim 12 wherein said leg end is affixed to said printed circuit by electrically conductive material.

14. The system of claim 10 wherein each of said first circuit terminals has a flange on said head end, said flange being substantially parallel to said plane, whereby said head end is supported.

15. A system for connecting wiring harnesses comprising

a first sheet including a printed circuit thereon, a plurality of first circuit terminals for connection to said wiring harnesses, each of said first circuit terminals having a first end and a second end, a first insulating plate having a first surface facing said sheet, a second surface on said first insulating plate opposite said first surface;

a retainer for securing said sheet to said first insulating plate comprising a plurality of first path holes extending through said first insulating plate and said sheet in a direction substantially perpendicular to a plane of said first plate and said sheet, each of said first circuit terminals extending through one of said first path holes;

a connection between said first end and said printed circuit, said second end adapted for connection to one of said wiring harnesses;

a first bus bar wiring pattern on said second surface, said first pattern having at least one first bus bar terminal which projects from said second surface;

a second insulating plate on said first bus bar pattern and carrying a second said sheet, said second sheet being provided with a second bus bar pattern having corresponding second circuit terminals and second bus bar terminals, said second plate having a plurality of third path holes and fourth path holes, said first circuit terminals passing through said third path holes and said first bus bar terminals passing through said fourth path holes, at least one of said first circuit terminals and said first bus bar terminals projecting outwardly of said second insulating plate.