Electric junction box for an automotive vehicle

• US 5,995,380 A
• Filed: 05/12/1998
• Issued: 11/30/1999
• Est. Priority Date: 05/12/1998
• Status: Expired due to Fees

• Current Assignee: Lear Automotive Dearborn, Incorporated (Lear Corporation)
• Original Assignee: Lear Automotive Dearborn, Incorporated (Lear Corporation)
• Inventors: Eakins, Bert W., Maue, H. Winston
• Primary Examiner(s): Picard, Leo P.
• Assistant Examiner(s): Gandhi, Jayprakash N.
• Application Number:
  US09/076,269
• Time in Patent Office: 567 Days
• Field of Search: 361/736, 361/748-751, 361/752, 361/784, 361/796, 361/826, 361/827, 174/250, 174/254, 29/841, 29/855, 29/856, 264/272.17, 439/76.2, 439/949, 439/931
• US Class Current: 361/826
• CPC Class Codes: B60R 16/0238 Electrical distribution centers
• CPC Class Codes: H05K 1/095 for polymer thick films, i.e. having a permanent organic polymeric binder
• CPC Class Codes: H05K 1/119 Details of rigid insulating substrates therefor, e.g. three-dimensional details H05K1/117 takes precedence
• CPC Class Codes: H05K 1/144 Stacked arrangements of planar printed circuit boards
• CPC Class Codes: H05K 2201/0187 with regions of different dielectrics in the same layer, e.g. in a printed capacitor for locally changing the dielectric properties
• CPC Class Codes: H05K 2201/09045 Locally raised area or protrusion of insulating substrate
• CPC Class Codes: H05K 2201/09118 Moulded substrate
• CPC Class Codes: H05K 2201/0999 Circuit printed on or in housing, e.g. housing as PCB; Circuit printed on the case of a component; PCB affixed to housing
• CPC Class Codes: H05K 2201/1059 Connections made by press-fit insertion
• CPC Class Codes: H05K 2201/10651 Component having two leads, e.g. resistor, capacitor
• CPC Class Codes: H05K 2203/0113 Female die used for patterning or transferring, e.g. temporary substrate having recessed pattern
• CPC Class Codes: H05K 3/182 characterised by the patterning method
• CPC Class Codes: H05K 3/368 parallel to each other H05K3/361 takes precedence
• CPC Class Codes: Y10S 439/949 Junction box with busbar for plug-socket type interconnection with receptacle

Abstract

An electrical junction box has a first insulating polymeric portion and a second polymeric portion defining multiple electrically conductive circuits. The circuits are at least partially separated by the first insulating polymeric portion and at least some of the circuits electrically connect together wire harness connector portions. A further aspect of the present invention junction box causes a section of the first insulating polymeric portion to concurrently act as a segment of an outer protective cover for the junction box.

Claims

1. An electrical junction box comprising:

a first wire harness connector portion;

a second wire harness connector portion;

a first insulating polymeric portion; and

a second polymeric portion defining multiple electrically conductive circuits, said circuits being at least partially separated by said first insulating polymeric portion, at least some of said circuits electrically connecting together said first and second wire harness connector portions.

2. The junction box of claim 1 wherein said first wire harness connector portion is a section of said second polymeric portion integrally formed with at least some of said circuits.

3. The junction box of claim 2 wherein said first wire harness connector portion includes multiple elongated male blades extending beyond said first insulating polymeric portion.

4. The junction box of claim 1 further comprising a protective housing, said first and second polymeric portions being located in said housing and defining a circuit board, said electrically conductive circuits being located on opposite faces of said circuit board.

5. The junction box of claim 4 further comprising transversely oriented conductors electrically connecting together at least some of said electrically conductive circuits located on said opposite faces of said circuit board.

6. The junction box of claim 1 wherein a section of said first insulating polymeric portion defines at least a segment of a protective cover for said junction box.

7. The junction box of claim 1 further comprising at least one sharply angled step located in said first and second polymeric portions.

8. The junction box of claim 1 further comprising at least a first of said circuits crossing over a second of said circuits in a transversely offset manner with said first insulating polymeric portion disposed between said circuits at the cross over.

9. The junction box of claim 1 wherein said second polymeric portion is plated with a conductive metallic material.

10. The junction box of claim 1 wherein said second polymeric portion is made from a conductive polymeric resin.

11. The junction box of claim 1 wherein an electronic component is mounted and electrically connected to at least one of said electrically conductive circuits.

12. The junction box of claim 1 further comprising a fuse connector portion of said second polymeric portion integrally formed as part of at least some of said circuits, a fuse mounted and electrically connected to said fuse connector portion.

13. An automotive vehicle power distribution system comprising:

a first wire harness;

an electronic component; and

a power distribution box including an internal member having raised segments which provide a layer for conducting electricity and said internal member having depressed segments between said raised segments which electrically insulate said raised segments from each other;

said first wire harness being electrically connected to said power distribution box;

said electronic component being electrically connected to said power distribution box;

said raised segments conducting electricity between said first wire harness and said electronic component when energized, wherein said raised segments, said depressed segments and said insulator are polymeric.

14. The power distribution system of claim 13 wherein said internal member further includes an insulator located between said raised segments.

15. The power distribution system of claim 13 further comprising a metallic plating defining said layer for conducting electricity.

16. The power distribution system of claim 13 wherein said electronic component is mounted on said internal member.

17. The power distribution system of claim 13 further comprising electrically conductive male blades extending substantially perpendicularly from said raised segments, each of said male blades extending from said respective raised segments as a single piece.

18. An automotive vehicle electrical junction box comprising:

a housing;

a first wire harness connector portion;

a second wire harness connector portion;

an insulating polymeric portion; and

electrically conductive circuits being at least partially separated by said insulating polymeric portion, at least some of said circuits electrically connecting together said first and second wire harness connector portions;

at least a section of said insulating polymeric portion defining a circuit board removably spaced inside of said housing and including said insulating polymeric portion and said conductive circuits; and

an electrically conductive blade extending completely through a passageway of said circuit board.

19. The junction box of claim 18 further comprising a second set of electrically conductive circuits located on a layer offset from and substantially parallel to said circuit board, said blade being attached to and projecting substantially perpendicular from one of said second set of circuits, said blade being electrically insulated from said circuits of said circuit board.

20. The junction box of claim 18 wherein said electrically conductive blade is made from a polymeric material.

21. The junction box of claim 18, further comprising:

multiple electrical components being electrically connected to said electrically conductive circuits.

22. An automotive vehicle electrical junction box comprising:

a housing;

a wire harness connector portion;

a set of electrical circuits located in said housing suitable for supplying electricity to said wire harness connector portion; and

a female connector integrally formed as part of at least one of said electrical circuits, wherein at least an internal portion of said female connector is made from a polymeric material.

23. The junction box of claim 22 wherein said at least one of said electrical circuits is secured to said housing.

24. The junction box of claim 22 further comprising a male blade removably insertable in said female connector.