Power distribution assembly

Abstract

A "power distribution assembly" having: a cover selectively sealing over an opening in a housing of the power distribution assembly; the locking assembly is used for fixing the sealing cover at a fixed position; and a closure detection switch that provides a notification when the lid is opened. A readable medium may be included on the cover to provide an indication of full closure of the cover on the housing.

Description

Technical Field

[0001] The invention relates to a power distribution assembly. Background Art

[0002] The distribution box commonly used in motor vehicles usually has a cover mounted to the housing. The cover in the open position provides access to the fuse panel, fuses and relays, while the cover in the closed position eliminates the exposure of these components to moisture and debris. However, if the cover is not correctly positioned in the closed position or is not completely closed on the housing, it may happen that the components in the distribution box are exposed to moisture or debris. Some distribution boxes have provided features for locking the cover in place, but such locking features may allow the cover to be incorrectly or incompletely latched to the housing. Such incomplete latching may still allow the possibility of moisture or debris entering the distribution box. In addition, if the cover is missing, the components of the distribution box may also be exposed. Summary of the invention

[0003] One embodiment contemplates a power distribution assembly having: a housing including a wall defining an opening, the opening being configured to allow selective access to components within the housing; a cover having: a main panel sized and shaped to cover the opening; a hinge assembly located at a first end of the main panel and configured to secure the cover to the housing for pivotal movement between an open position in which the opening is accessible and a fully closed position in which the cover covers the opening and seals the opening; a closure detection switch configured to detect when the cover is closed. when the cover is not in the fully closed position relative to the shell; a diverter, which is configured to cooperate with the closure detection switch when the cover is in the fully closed position; and a CPA device, the CPA device comprising: a body, which is mounted to the cover adjacent to the second end of the main panel, is spaced apart from the first end and can be pivoted relative to the cover; a gear cam arm, which is configured to engage with the shell and pivot to move the cover to the fully closed position; and a lock, which is configured to be movable into a fixed position to fix the cover in the fully closed position.

[0004] One embodiment contemplates a power distribution assembly comprising: a housing including a wall defining an opening, the opening being configured to allow selective access to components within the housing; a cover having: a main panel sized and shaped to cover the opening; a hinge assembly located at a first end of the main panel and configured to secure the cover to the housing for pivotal movement between an open position in which the opening is accessible and a fully closed position in which the cover covers the opening and seals the opening; a CPA device comprising: a body having a A second end of the main panel is mounted adjacent to the cover, spaced apart from the first end and capable of pivoting relative to the cover; a gear cam arm, which is configured to engage with the housing and pivot to move the cover to the fully closed position; and a lock, which is configured to be movable into a fixed position to secure the cover in the fully closed position; a closure detection switch, which is configured to detect when the cover is not in the fixed position relative to the housing; and a diverter, which is configured to cooperate with the closure detection switch when the cover is in the fixed position.

[0005] An advantage of an embodiment is that the closure is assembled to the housing in only one orientation. An advantage of an embodiment is that the closure is closed using a gear cam lever of a latch, a secondary connection positive assurance (CPA) device, and an electronic verification switch that confirms that the closure is properly and completely closed. If the verification switch is not activated, a notification is sent to indicate that the closure is not completely closed. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Figure 1 is a schematic perspective view of the power distribution assembly.

[0007] Figure 2 is a schematic perspective view of the electronic verification switch assembly.

[0008] Figure 3 is a schematic side view of a portion of a housing of a power distribution assembly.

[0009] Figure 4 It is a schematic diagram of the human-machine interface. DETAILED DESCRIPTION

[0010] Figures 1 to 4 An example of a power distribution assembly 20 is shown that includes a housing 22 and a cover 24. The power distribution assembly may be employed, for example, in a motor vehicle. The housing 22 includes a pair of side walls 26, a first end wall 28, and a second end wall 30 that define an opening 31. The opening 31 is sized and shaped to be completely covered by the cover 24. The side walls 26 may be substantially mirror images of each other, and therefore only one side wall is shown in the drawings.

[0011] Mounted within the walls 26, 28, 30 is a printed circuit board (PCB) 32 that includes electronics 34 for power distribution (e.g., in a vehicle) and a plurality of fuses 36 that limit the maximum power flow to various electronic components (e.g., electrical elements in a vehicle).

[0012] The first end wall 28 includes resilient hinge pin channels 38 , each aligned with a respective one of the side walls 26 , and a groove track 40 extending along the first end wall 28 between the side walls 26 and adjacent the hinge pin channels 38 .

[0013] Each of the side walls 26 includes a gearbox structure 42 adjacent the second end wall 30, with a gearbox opening 44 adjacent the opening 31. Inside the gearbox structure 42 is a gear cam mechanism 46 configured to pull (pivot) the closure 24 into a fully closed position relative to the housing 22.

[0014] The cover 24 includes a main panel 50 that is sized and shaped to cover over and seal around the opening 31 of the housing 22. A hinge support wall 54 extends from a first end 52 of the main panel 50 in a generally normal direction. A hinge pin 56 is supported by the cover 24 near the intersection of the main panel 50 and the hinge support wall 54. The hinge pin 56 extends generally parallel to the first end wall 28, and the hinge pin is sized to align with the hinge channel 38 of the housing 22. The diameter of the hinge pin 56 is larger than the opening 58 in the hinge channel 38, thereby causing the hinge channel 38 to resiliently flex when each of the hinge pins 56 is pushed through the corresponding opening 58 and enters the corresponding hinge channel 38. This pivotally secures the cover 24 to the housing 22 for pivotal movement about the axis 57 between an open position in which the electronics 34 and fuses 36 are accessible through the opening 31 and a fully closed position in which the main panel 50 covers and seals the opening 31.

[0015] The cover 24 includes a flange 60 that is spaced apart from the main panel 50 and extends from the hinge support wall 54 generally parallel to the main panel 50. The flange 60 aligns with the groove track 40 of the housing 22 to help seal the opening 31 of the housing 22 when in the closed position, and slides into the groove track 40 when the cover is pivoted to its open position.

[0016] The cover 24 includes a readable medium (e.g., a barcode, QR code, etc.) 62 located on an outer surface 64 of the main panel 50 adjacent to the second end wall 30. The readable medium 62 can be attached to (e.g., printed on), integrally formed with (e.g., molded into, laser etched onto) or otherwise created on the outer surface 64 of the main panel 50. When the cover 24 is in the fully closed position, the readable medium can be electronically readable by a scanner.

[0017] The cover 24 includes a diverter 66 extending from an inner surface 67 of the main panel 50 , which is located on the side opposite to the outer surface 64 .

[0018] The power distribution assembly 20 includes a connection positive assurance (CPA) device 68. The CPA device 68 includes a body 70 from which a pair of gear cam arms 72 extend in a generally vertical direction. The gear cam arms 72 are pivotally mounted to the main panel 50 adjacent to a second end 74 of the main panel 50, which allows the body 70 to pivot relative to the cover 24 about a pivot axis 75. Each of the gear cam arms 72 includes a clamping engagement feature (e.g., at least one of a tooth or a cam surface) 82 that mates with a corresponding feature in a respective one of the gear cam mechanisms 46.

[0019] The body 70 includes a reader window 80 that is positioned so that when the CPA device 68 is in a fixed position, the readable medium 62 is aligned with and readable through the reader window 80 .

[0020] The CPA device 68 also includes a lever arm 76 that extends from the body 70. The twist lock 78 cooperates with the lever arm 76 to pivot with the lever arm 76 relative to the closure 24 and maintain the CPA device 68 in a fixed position. The fixed position is when the closure 24 is in a fully closed position, the body 70 pivots to hold the closure 24 in the fully closed position and the twist lock 78 rotates to maintain the closure 24 and the body 70 in these positions. The twist lock 78 can engage a slot, hole or other mechanism to be maintained by the body 70.

[0021] The printed circuit board 32 includes (or is electronically connected to) a closure detection switch 84, which may be sealed. The closure detection switch 84 is positioned to align with the shunt 66, wherein the shunt 66 can slide into the closure detection switch 84 when the cover 24 is in the fully closed position and the CPA device 68 is in the fixed position. The closure detection switch 84 and the shunt 66 can be positioned within the housing 22, or positioned outside the housing 22 and adjacent to the housing.

[0022] A human-machine interface 86 (e.g., a light located on the vehicle instrument cluster 88, an audible signal inside the vehicle, or other indicator to a human) is operatively connected (e.g., wired or wirelessly) to the closure detection switch 84 and is configured to indicate when the closure 24 is not in the fully closed position (or secured position). The human-machine interface may also include sending a wireless signal (e.g., via an over-the-air download system on the vehicle) to a remote location (e.g., a car dealership, which may relay such information to the vehicle owner).

[0023] Now refer to Figures 1 to 4 The example shown in discusses the opening and closing of the cover 24 relative to the housing 22. The twist lock 78 is rotated from the fixed position of the cover 24 to the released position, and the body 70 is pivoted about the axis 75 relative to the main panel 50 in the direction 90, thereby causing the cover 24 to move from its fully closed position. The cover 24 is then pivoted about the axis 57 to the open position, in which the opening 31 of the housing 22 is accessible to a person. This provides access to the PCB 32, the electronic device 34, and the fuse 36 through the opening 31. In the event that the shunt 66 is out of contact with the closure detection switch 84, the human-machine interface 86 is activated (e.g., a signal is transmitted to illuminate a light on the instrument cluster 88 and send an over-the-air download signal to the car dealer) to indicate that the cover 24 is not in the fully closed position (or fixed position).

[0024] The cover 24 is pivoted about the axis 57 from the open position of the cover 24 toward the closed position. As the cover 24 pivots, the gear cam arm 72 begins to slide into the corresponding gear box opening 44 and slides into contact with the gear cam mechanism 46. As the cover 24 is pulled toward the opening 31 of the housing 22, the body 70 pivots about the pivot axis 75 in the direction 92. When this occurs, the body 70 of the CPA device 68 pivots toward the main panel 50, wherein the readable medium 62 is now aligned with the reader window 80 and can be read through the reader window. If not, this provides a visual indication that the cover 24 is not properly aligned with the opening 31 of the housing 22 and is not closed on the opening. When the cover 24 reaches its fully closed position, the diverter 66 engages with the closure detection switch 84, thereby deactivating the cover open signal to the human-machine interface 86. The twist lock 78 is then rotated to secure the cover 24 in a fixed position. Alternatively, deactivation of the closure open signal to the human-machine interface 86 may occur when the twist-lock 78 is rotated to secure the closure 24 in a fixed position (rather than only when the closure 24 is in the fully closed position).

[0025] While certain embodiments of the present invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention as defined by the following claims.

Claims

1. A power distribution assembly, comprising: a housing including a wall defining an opening configured to allow selective access to components within the housing; a cover having: a main panel sized and shaped to cover the opening; a hinge assembly located at a first end of the main panel and configured to secure the cover to the housing for pivotal movement between an open position providing access to the opening and a fully closed position in which the cover overlies and seals the opening; a closure detection switch configured to detect when the cover is not in the fully closed position relative to the housing; a diverter configured to cooperate with the closure detection switch when the cover is in the fully closed position; as well as A CPA device, the CPA device comprising: a body, which is mounted to the cover adjacent to the second end of the main panel, spaced apart from the first end and capable of pivoting relative to the cover; a gear cam arm, which is configured to engage with the housing and pivot to move the cover to the fully closed position; and a lock, which is configured to be movable into a fixed position to secure the cover in the fully closed position.

2. The power distribution assembly of claim 1, wherein the cover includes a readable medium and the body includes a reader window configured to align with the readable medium when the cover is in the fully closed position.

3. The power distribution assembly of claim 2, wherein the reader window is configured to be out of alignment with the readable medium when the cover is not in the fully closed position.

4. A power distribution assembly as described in claim 1, wherein the wall includes a first side wall, an opposite second side wall, a first end wall extending between the first side wall and the second side wall, and a second end wall extending between the first side wall and the second side wall adjacent to the ends of the first side wall and the second side wall opposite to the first end wall, wherein the first side wall, the second side wall, the first end wall and the second end wall define the opening, and the first side wall includes a first gear box structure, the first gear box structure has a gear box opening, the gear box opening is configured to align with the gear cam arm and allow the gear cam arm to be inserted into the first gear box structure.

5. A power distribution assembly as described in claim 4, wherein the CPA device includes a second gear cam arm spaced apart from the first gear cam arm, and the second side wall includes a second gear box structure, the second gear box structure having a second gear box opening, the second gear box opening being configured to align with the second gear cam arm and allow the second gear cam arm to be inserted into the second gear box structure.

6. The power distribution assembly of claim 5, wherein the cover includes a readable medium and the body includes a reader window configured to align with the readable medium when the cover is in the fully closed position.

7. The power distribution assembly of claim 1, wherein the lock is a twist lock configured to selectively secure the cover in the fixed position when the twist lock is rotated.

8. The power distribution assembly of claim 1, further comprising: A human machine interface is configured to communicate with the closure detection switch to indicate when the closure is not in the fully closed position.

9. The power distribution assembly of claim 8, wherein the human machine interface is a light located on a vehicle instrument cluster.

10. A power distribution assembly as described in claim 1, wherein the wall includes a first side wall, an opposite second side wall, a first end wall extending between the first side wall and the second side wall, and a second end wall extending between the first side wall and the second side wall adjacent to the ends of the first side wall and the second side wall opposite to the first end wall, wherein the first side wall, the second side wall, the first end wall and the second end wall define the opening, and the housing includes a groove track recessed within the first end wall and the cover includes a flange extending generally parallel to the main panel and spaced apart from the main panel, wherein the flange is configured to slide further within the groove track when the cover is pivoted from the fully closed position toward the open position.

11. A power distribution assembly, comprising: a housing including a wall defining an opening configured to allow selective access to components within the housing; a cover having: a main panel sized and shaped to cover the opening; a hinge assembly located at a first end of the main panel and configured to secure the cover to the housing for pivotal movement between an open position providing access to the opening and a fully closed position in which the cover overlies and seals the opening; a CPA device comprising: a body mounted to the cover adjacent the second end of the primary panel, spaced apart from the first end and pivotable relative to the cover; a gear cam arm configured to engage the housing and pivot to move the cover into the fully closed position; and a lock configured to be movable into a securing position to secure the cover in the fully closed position; a closure detection switch configured to detect when the cover is not in the secured position relative to the housing; and A current diverter is configured to cooperate with the closure detection switch when the cover is in the fixed position.

12. The power distribution assembly of claim 11, wherein the cover includes a readable medium and the body includes a reader window configured to align with the readable medium when the cover is in the fully closed position.

13. A power distribution assembly as described in claim 11, wherein the wall includes a first side wall, an opposite second side wall, a first end wall extending between the first side wall and the second side wall, and a second end wall extending between the first side wall and the second side wall adjacent to the ends of the first side wall and the second side wall opposite to the first end wall, wherein the first side wall, the second side wall, the first end wall and the second end wall define the opening, and the first side wall includes a first gear box structure, the first gear box structure has a gear box opening, the gear box opening is configured to align with the gear cam arm and allow the gear cam arm to be inserted into the first gear box structure.

14. The power distribution assembly of claim 11, further comprising: A human machine interface is configured to communicate with the closure detection switch to indicate when the closure is not in the fully closed position.

15. A power distribution assembly as described in claim 11, wherein the wall includes a first side wall, an opposite second side wall, a first end wall extending between the first side wall and the second side wall, and a second end wall extending between the first side wall and the second side wall adjacent to the ends of the first side wall and the second side wall opposite to the first end wall, wherein the first side wall, the second side wall, the first end wall and the second end wall define the opening, and the housing includes a groove track recessed within the first end wall and the cover includes a flange extending generally parallel to the main panel and spaced apart from the main panel, wherein the flange is configured to slide further within the groove track when the cover is pivoted from the fully closed position toward the open position.

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