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Electrical junction box for a vehicle

Imported: 24 Feb '17 | Published: 06 Jan '04

Koji Kasai, Nobuchika Kobayashi, Yuuji Saka

USPTO - Utility Patents

Abstract

The present invention provides an electrical junction box suitable for connection, for example, to a wire harness in a vehicle such as an automobile. The box is adapted to provide electrical connection to a plurality of electrical connectors, a plurality of fuses and a plurality of relays, the box having a casing, a connector circuit having a plurality of first bus bars, a fuse circuit discrete from the connector circuit and having a plurality of second bus bars and a relay circuit discrete from the connector circuit and having a plurality of third bus bars. At least one of the second and at least one of the third bus bars are welded to respective ones of the first bus bars at welding portions which are received in a protection structure which presses them towards each other. The protection structure clamps the joined welding portions so that the risk of disconnection of the welded connection is reduced or avoided.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described by way of non-limitative example with reference to the accompanying drawings. In the drawings:

FIG. 1 is a schematic exploded perspective view showing a junction box of a first embodiment of the present invention.

FIG. 2 is a sectional view showing a state in which the junction box of FIG. 1 has been assembled.

FIG. 3 is a sectional view, showing the junction box of FIG. 2, taken along a line perpendicular to FIG.

2.

FIG. 4 is a schematic perspective view of a connector module of the box of FIG. 1 viewed from the underside thereof.

FIG. 5 is a schematic view showing fuse connection bus bars.

FIG. 6 is a schematic view showing a relay connection bus bar.

FIG. 7 is a sectional view showing in more detail a port of the junction box as seen in FIG.

2.

FIGS. 8A and 8B are sectional views showing the insertion of a welded connection into a protection structure by press fitting.

FIG. 9 is a sectional plan view showing welded connections inserted into the protection structures by press fitting.

FIGS. 10A and 10B are sectional views each showing a modification of the protection structure.

FIG. 11A is a plan view showing a junction box of another embodiment of the present invention.

FIG. 11B is a bottom view showing the junction box of another embodiment of the present invention.

FIG. 12 is an exploded perspective view showing a conventional junction box.

Claims

1. An electrical junction box comprising:

2. An electrical junction box according to claim 1 wherein said welding portions of said at least one of said welded connections are inserted in said protection structure in a press-fit manner.

3. An electrical junction box according to claim 1 wherein said protection structure includes a widening guide portion that guides said welding portions into said protection structure during assembly.

4. An electrical junction box according to claim 1 wherein said protection structure is integral with said casing.

5. An electrical junction box according to claim 1 wherein said fuse circuit insulation substrate and said relay circuit insulation substrate are discrete from each other, whereby said fuse circuit and said relay circuit constitute separate modules in said junction box.

6. An electrical junction box according to claim 1 wherein said fuse circuit insulation substrate and said relay circuit insulation substrate are combined as a unitary common substrate carrying said second bus bars and said third bus bars, whereby said fuse circuit and said relay circuit constitute a combined module in said junction box.

7. An electrical junction box according to claim 1, wherein said casing comprises upper and lower ease parts which are respectively molded synthetic resin members, at least one of said upper and lower case parts comprising connector sockets that receive electrical connectors in use.

8. An electrical junction box according to claim 1 wherein the welding portions at each said welding connection are joined by one of ultrasonic welding, resistance welding, laser welding and gas welding.

9. A vehicle in which an electrical junction box according to claim 1 is mounted.