Power distribution module, housing thereof, and assembly accommodating one or more electrical components

Abstract

Power distribution modules, housings thereof, and assemblies that house one or more electrical components are provided herein. In some embodiments, the power distribution module may include a base including a lower cavity wall and a cover including an upper cavity wall, where the lower cavity wall and the upper cavity wall define a cavity operable to receive one or more protective components. The power distribution module may further include a sealing member engaged with the upper cavity wall and the lower cavity wall, where the sealing member includes a wall and a plurality of engagement features along the wall, where the plurality of engagement features are operable to couple the sealing member to the upper cavity wall or the lower cavity wall. The sealing member may further include a plurality of ridges extending from the wall, where the plurality of ridges are operable to engage the upper cavity wall or the lower cavity wall.

Description

Technical Field

[0001] Embodiments of the present disclosure generally relate to the field of electrical devices, and more particularly, to a distribution housing having an improved seal. Background Art

[0002] Distribution housings are traditionally used to house electrical components such as fuse blocks, fuses, relays, etc. Exposing the distribution housing to adverse environmental and weather conditions can damage or destroy the electrical components within the housing. Although various distribution housings have been developed to protect the internal electrical components from such adverse external conditions, finding an effective sealing member remains a challenge.

[0003] Improvements in the present invention may be useful in relation to these and other considerations. Summary of the Invention

[0004] This summary is provided to introduce some concepts that will be further described in the detailed description below. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as a basis for determining the scope of the claimed subject matter.

[0005] In one or more embodiments, a distribution module may include a base including a lower cavity wall and a lid including an upper cavity wall, wherein the lower cavity wall and the upper cavity wall define a cavity operable to receive one or more protection components. The distribution module may further include a sealing member engaged with the upper cavity wall and the lower cavity wall, wherein the sealing member includes a wall and a plurality of engagement features along the wall, wherein the plurality of engagement features are operable to couple the sealing member to the upper cavity wall or the lower cavity wall. The sealing member may further include a plurality of ridges extending from the wall, wherein the plurality of ridges are operable to engage the upper cavity wall or the lower cavity wall.

[0006] In one or more embodiments, a housing of a distribution module may include a base including a lower cavity wall and a lid including an upper cavity wall, wherein the lower cavity wall and the upper cavity wall define a cavity operable to receive one or more protection components. The housing may further include a sealing member engaged with the upper cavity wall and the lower cavity wall, wherein the sealing member includes a wall, a plurality of engagement features along the wall, wherein the plurality of engagement features are operable to couple the sealing member to the upper cavity wall or the lower cavity wall, and a plurality of ridges extending from the wall, wherein the plurality of ridges are operable to engage the upper cavity wall or the lower cavity wall.

[0007] In one or more embodiments, a component for housing one or more electrical components can include a base including a lower cavity wall and a lid coupled to the base, where the lid includes an upper cavity wall, and where the lower cavity wall and the upper cavity wall define a cavity operable to house one or more protective components. The component can further include a flexible seal member engaged with the upper cavity wall and the lower cavity wall, where the seal member includes a wall and a plurality of engagement features protruding from the wall, where the plurality of engagement features are operable to couple the seal member to at least one of: the upper cavity wall and the lower cavity wall. The seal member can further include a plurality of ridges extending laterally from a surface of the wall, where the plurality of ridges are operable to engage the upper cavity wall or the lower cavity wall. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The drawings illustrate examples of ways in which the disclosed embodiments have thus far been designed for practical application of their principles, where:

[0009] Figure 1A is a perspective view of a power distribution module including a lid in an example manner according to the present disclosure;

[0010] Figure 1B is a perspective view of the power distribution module without the lid in an example manner according to the present disclosure;

[0011] Figure 2 is a perspective view of the underside of the lid including the seal member in an example manner according to the present disclosure;

[0012] Figure 3 is a perspective view of the underside of the lid showing a channel in an example manner according to the present disclosure;

[0013] Figures 4A - 4B is a perspective view of the seal member in an example manner according to the present disclosure;

[0014] Figure 5 is a cross-sectional view of the power distribution module in an example manner according to the present disclosure;

[0015] Figures 6A - 6B is a cross-sectional view of a portion of the power distribution module in an example manner according to the present disclosure;

[0016] Figure 7 is a perspective view of the power distribution module without the lid in an example manner according to the present disclosure;

[0017] Figure 8 is a cross-sectional view of a portion of the power distribution module in an example manner according to the present disclosure;

[0018] Figures 9A - 9C is a perspective view of the seal member in an example manner according to the present disclosure;

[0019] Figure 10An exploded view of a sealing member and a base of a power distribution module according to an exemplary aspect of the present disclosure; and

[0020] Figure 11 A close-up view of the connection between the sealing member and the base of the power distribution module according to an exemplary aspect of the present disclosure.

[0021] The drawings are not necessarily to scale. The drawings are merely illustrative and are not intended to depict specific parameters of the present disclosure. The drawings are intended to depict exemplary embodiments of the present disclosure and should not be construed as limiting the scope. In the drawings, like numerals represent like elements.

[0022] In addition, for clarity, some elements in some of the drawings may be omitted or not drawn to scale. Also, for clarity, some reference numerals may be omitted in some of the drawings. Detailed Description

[0023] Embodiments according to the present disclosure will now be described more fully hereinafter with reference to the drawings. The components, devices, and methods may be implemented in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the system and method to those skilled in the art.

[0024] Figures 1A - 1B A power distribution module (PDM) 100 according to one or more embodiments of the present disclosure is depicted. As shown, the PDM 100 may include a housing 102 having a base 104 and a lid 106 secured to the base 104. Although not limited to any particular type or arrangement, the lid 106 may be secured to the base 104 by one or more fasteners 105. Figure 1A The PDM 100 with the lid 106 is shown, while Figure 1B the PDM 100 with the lid 106 removed is shown. The lid 106 may be removed, for example, to replace a blown fuse within the cavity 108 defined by the base 104 and the lid 106. As Figure 1BAs best shown, the housing 102 can encapsulate one or more electrical components 107 (e.g., fuses, relays, etc.) within the cavity 108 of the base 104. In some embodiments, the lid 106 can snap-fit onto the base 104 and / or include fasteners 105 to releasably secure the lid 106 to the base 104. Although not specifically shown, the lid 106 can also include devices that further facilitate grasping and removal, such as protrusions, projections, recesses, etc. Although non-limiting, the various components of the housing 102 can be made of an insulating material, such as an insulating plastic, e.g., nylon, glass-filled nylon, polyester, and polycarbonate. In various embodiments, the base 104 and the lid 106 can be made of the same or different materials.

[0025] As will be described in more detail herein, the cavity 108 can be surrounded by a flexible seal member 110 that is fixed or coupled to the lower cavity wall 111. The seal member 110 is provided to prevent moisture and other contaminants from reaching the electrical components 107. Although non-limiting, the seal member 110 can be a polymer or an elastomer, such as silicone rubber, NBR, TPE, EPDM, FKM, and the like.

[0026] Figure 2 The underside of the lid 106 according to one or more embodiments of the present disclosure is shown. As shown, the lid 106 can include an upper cavity wall 113 that defines a second cavity 112. The second cavity 112 can be aligned with the cavity 108 of the base 104. As will be described in more detail below, the lid 106 can receive the seal member 110 within a channel 114 formed in the upper cavity wall 113. During use, the seal member 110 acts as a mechanical gasket located within the channel 114 such that the compression generated by the engagement between the lid 106 and the base 104 creates a seal at their interface.

[0027] Figure 3 The channel 114 of the lid 106 is shown in more detail. As shown, the channel 114 can be defined by an inner wall 115 and an outer wall 116 of the upper cavity wall 113. Between the inner wall 115 and the outer wall 116 is a bottom wall 117 that can be a flat surface extending perpendicular to the inner wall 115 and the outer wall 116. Although non-limiting, the inner wall 115 and the outer wall 116 can extend parallel to each other and can be separated by a constant distance.

[0028] In the illustrated embodiment, the inner wall 115 may include a plurality of retention grooves 118 and a plurality of retention protrusions 119, all of which are operable to engage the seal member 110 so as to retain the seal member 110 within the passage 114. Each retention groove 118 may include a rear wall 120 connected to a pair of angled side walls 121. As shown, the angled side walls 121 extend away from each other toward the rear wall 120 to retain the seal member 110 within the retention groove 118. The retention protrusions 119 extend from the top surface 122 of the inner wall 115 and may include a lip or overhang 123 that extends outwardly from the inner wall 115 above the passage 114. Once the seal member 110 is positioned within the passage 114, the overhang 123 prevents the seal member 110 from being easily removed from the passage. Although six (6) retention grooves 118 and six (6) retention protrusions 119 are depicted, it should be understood that more or fewer of each may be possible in alternative embodiments.

[0029] The outer wall 116 may similarly include a plurality of retention grooves 124 and a plurality of retention protrusions 125, all of which are operable to engage the seal member 110 so as to retain the seal member 110 within the passage 114. Each retention groove 124 may include a rear wall 126 connected to a pair of angled side walls 127. As shown, the angled side walls 127 extend away from each other toward the rear wall 126 to retain the seal member 110 within the retention groove 124. The retention protrusions 125 extend from the top surface 128 of the outer wall 116 and may include a lip or overhang 129 that extends toward the inner wall 115 above the passage 114. Although eight (8) retention grooves 124 and six (6) retention protrusions 125 are depicted, it should be understood that more or fewer of each may be possible in alternative embodiments.

[0030] Turning now to Figures 4A - 4B , the seal member 110 will be described in more detail. As shown, the seal member 110 may include a first end 136 opposite a second end 137, and a first side 138 opposite a second side 139. The seal member 110 may include a wall 140 having an inner wall / surface 141, an outer wall / surface 142, an upper surface 143, and a lower side 144. As Figure 4B best shown in

[0031] As further shown, the sealing member 110 may include a first plurality of engaging members 146 along the inner side portion 141, and a second plurality of engaging members 147 along the outer side portion 142. Each of the first plurality of engaging members 146 may include a main wall 148 extending between a set of side walls 149. In other words, each of the first plurality of engaging members 146 may have a convex dovetail shape complementary to the shape of each corresponding retaining groove 118 of the inner wall 115 of the lid 106. Each of the second plurality of engaging members 147 may include a base 150 and a flange 151 extending from the base 150. In other words, each of the second plurality of engaging members 146 may have a T-shape complementary to the shape of each corresponding retaining groove 124 of the outer wall 116 of the lid 106. These dovetail and "T" shape features on the lid 106 and the sealing member 110 ensure that the components are assembled together with an encapsulating force on the seal, which helps to prevent the sealing member 110 from falling out of the lid 106 when the lid 106 is opened from the base 104.

[0032] Now turning to Figures 5 - 6B , the engagement between the sealing member 110, the lid 106, and the base 104 will be described in more detail. As shown, the sealing member 110 may be located on top of the lower cavity wall 111 of the base 104 such that the inner side portion 141 and the outer side portion 142 straddle the lower cavity wall 111. In some embodiments, the sealing member 110 may have a plurality of ridges or teeth 152 extending from the inner side portion 141 and / or the outer side portion 142 for engaging with the surface of the lower cavity wall 111.

[0033] The sealing member 110 may also be inserted into the channel 114 of the upper cavity wall 113 of the lid 106. That is, when the lid 106 and the base 104 are in the closed position, the sealing member 110 may be located between the inner wall 115 and the outer wall 116 of the lid 106. As Figure 6A best shown, the retaining protrusion 119 of the inner wall 115 of the lid 106 may extend under and engage with the inner side portion 141 of the sealing member 110, while the retaining protrusion 125 of the outer wall 116 of the lid 106 may extend under and engage with the outer side portion 142 of the sealing member 110.

[0034] Figure 6B Shown is the sealing member 110 including one of the first plurality of engaging members 146 along the inner side portion 141 of the wall 140. As shown, the main wall 148 of the engaging member 146 abuts against the rear wall 120 of the retaining groove 118 of the inner wall 115 of the lid 106. Similarly, the retaining protrusion 125 of the outer wall 116 of the lid 106 is shown extending under and engaging with the sealing member 110 at the outer side portion 142.

[0035] Figure 7Depicts another power distribution module (PDM) 200 in accordance with one or more embodiments of the present disclosure. In some aspects, PDM 200 may be the same as or similar to the aforementioned PDM 100. Thus, for the sake of brevity, only some features of PDM 200 will be described hereinafter. PDM 200 may include a housing 202 that includes a base 204 and a lid (not shown) fixed to the base 204. The housing 202 may encapsulate one or more electrical components (not shown) within a cavity 208 of the base 204. The cavity 208 may be surrounded by a sealing member 210 that is fixed or coupled to the lower cavity wall 211.

[0036] As Figure 8 shown, the sealing member 210 may be located on top of the lower cavity wall 211 of the base 204 such that the inner portion 241 and the outer portion 242 of the sealing member 210 straddle the lower cavity wall 211. The sealing member 210 may also be located within a channel 214 of the upper cavity wall 213 of the lid 206. That is, the sealing member 210 may be located between the inner wall 215 and the outer wall 216 of the upper cavity wall 213. In some embodiments, the sealing member 210 may have a plurality of ridges or teeth 252 extending outwardly from the lower cavity wall 211 for engaging an inner surface of the channel 214 formed in the upper cavity wall 213 of the lid 206. In other embodiments, the sealing member 210 may additionally or alternatively have teeth 252 along its inner portion.

[0037] Now turning to Figures 9A - 9C , the sealing member 210 will be described in more detail. As shown, the sealing member 210 may include a first end 236 opposite a second end 237, and a first side 238 opposite a second side 239. The sealing member 210 may include a wall 240 defined by an inner portion 241, an outer portion 242, an upper surface 243, and a lower side 244. As Figure 9B best shown in

[0038] As Figures 9B - 9C further shown, the sealing member 210 may include a plurality of engagement members 246 within the sealing member channel 245. Although non-limiting, the engagement members 246 may include knobs or heads 258 extending from a tubular portion 260. As shown, the head 258 may be generally cylindrical and may extend between surfaces defining the sealing member channel 245.

[0039] The connection between the engagement member 246 and the base 204 is in Figures 10 - 11Shown in. As shown, the lower cavity wall 211 of the base 204 may include a plurality of openings 265, which are operable to receive the engagement member 246 therein. For example, the opening 265 may include a passage 267 connected to the cavity 268, where the passage 267 is narrower than the cavity 268. When the sealing member 210 is positioned on top of the lower cavity wall 211, the head 258 of the engagement member 246 is squeezed through the passage 267 and into the cavity 268. Once each head 258 relaxes to fill the corresponding cavity 268, the engagement member 246 is fixed within the opening 265.

[0040] As used herein, an element or step recited in the singular and preceded by the word "a" or "an" should be understood as not excluding a plurality of elements or steps, unless such exclusion is explicitly recited. Additionally, a reference to "one embodiment" of the present disclosure is not intended to be construed as excluding the existence of additional embodiments that also incorporate the recited features.

[0041] The use of the terms "comprises," "comprising," "includes," or "including" and variations thereof herein is intended to cover the items listed thereafter and their equivalents as well as additional items. Thus, the terms "comprises," "comprising," "includes," or "including" and variations thereof are open-ended expressions and may be used interchangeably herein.

[0042] The phrases "at least one," "one or more," and "and / or" as used herein are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the statements "at least one of A, B, and C," "at least one of A, B, or C," "one or more of A, B, and C," "one or more of A, B, or C," and "A, B, and / or C" means either A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B, and C together.

[0043] All directional references (e.g., proximal, distal, up, down, upward, downward, left, right, lateral, longitudinal, front, back, top, bottom, above, below, vertical, horizontal, radial, axial, clockwise, and counterclockwise) are for identification purposes only to assist the reader in understanding the present disclosure and do not create a limitation, particularly with respect to the position, orientation, or use of the present disclosure. Unless otherwise stated, connection references (e.g., attached, coupled, connected, and joined) should be construed broadly and may include intermediate members between element assemblies and relative movement between elements. Similarly, a connection reference does not necessarily infer that the two elements are directly connected and in a fixed relationship with each other.

[0044] Furthermore, identifying references (e.g., primary, secondary, first, second, third, fourth, etc.) do not imply importance or priority, but are used to distinguish one feature from another. The drawings are for illustrative purposes only, and the dimensions, positions, sequences, and relative sizes reflected in the drawings may vary.

[0045] In addition, the terms "substantially" or "essentially", and the terms "approximately" or "approximately" may be used interchangeably in some embodiments, and any relevant measure acceptable to a person of ordinary skill in the art may be used to describe. For example, these terms may be used as a comparison with a reference parameter to indicate a deviation that can provide the desired function. Although non-limiting, the deviation from the reference parameter may be, for example, an amount less than 1%, less than 3%, less than 5%, less than 10%, less than 15%, less than 20%, etc.

[0046] The scope of the present disclosure is not limited by the specific embodiments described herein. In fact, various other embodiments and modifications of the present disclosure will be apparent to a person of ordinary skill in the art in addition to those described herein, based on the foregoing description and the drawings. Accordingly, such other embodiments and modifications are intended to fall within the scope of the present disclosure. In addition, the present disclosure has been described herein in the context of a particular implementation in a particular environment for a particular purpose. A person of ordinary skill in the art will recognize that its usefulness is not limited thereto, and the present disclosure can be beneficially implemented for any number of purposes in any number of environments. Accordingly, the appended claims will be construed in accordance with the full scope and spirit of the present disclosure as described herein.

Claims

1. A power distribution module, which comprises: a base including a lower cavity wall; a lid including an upper cavity wall, wherein the lower cavity wall and the upper cavity wall define a cavity, and the cavity is operable to accommodate one or more protection components; and a sealing member engaged with the upper cavity wall and the lower cavity wall, wherein the sealing member comprises: a wall; a plurality of engagement features along the wall, wherein the plurality of engagement features are operable to couple the sealing member to the upper cavity wall or the lower cavity wall; and a plurality of ridges extending from the wall, wherein the plurality of ridges are operable to engage the upper cavity wall or the lower cavity wall.

2. The power distribution module according to claim 1, wherein the upper cavity wall comprises: an inner wall; and an outer wall spaced from the inner wall by a channel, wherein the sealing member is located within the channel.

3. The power distribution module according to claim 2, wherein the inner wall of the upper cavity wall includes a plurality of retaining grooves operable to receive the plurality of engagement features.

4. The power distribution module according to claim 2, wherein the inner wall of the upper cavity wall includes a plurality of retaining protrusions operable to engage the upper surface of the sealing member.

5. The power distribution module according to claim 2, wherein the outer wall of the upper cavity wall includes a second plurality of retaining grooves and a second plurality of retaining protrusions.

6. The power distribution module according to claim 1, wherein the lower cavity wall extends into the channel of the upper cavity wall.

7. The power distribution module according to claim 1, wherein the wall of the sealing member comprises: an inner portion; and an outer portion opposite to the inner portion, wherein the inner portion and the outer portion define a sealing member channel, and wherein the lower cavity wall extends into the sealing member channel.

8. The power distribution module according to claim 1, wherein one or more of the plurality of engagement features along the wall include heads extending from a tubular portion.

9. The power distribution module according to claim 8, wherein the lower cavity wall includes a plurality of openings, and wherein the head is located within one of the plurality of openings.

10. A housing of a power distribution module, the housing comprises: a base including a lower cavity wall; a lid including an upper cavity wall, wherein the lower cavity wall and the upper cavity wall define a cavity, and the cavity is operable to accommodate one or more protection components; and a sealing member engaged with the upper cavity wall and the lower cavity wall, wherein the sealing member comprises: a wall; a plurality of engagement features along the wall, wherein the plurality of engagement features are operable to couple the sealing member to the upper cavity wall or the lower cavity wall; and a plurality of ridges extending from the wall, wherein the plurality of ridges are operable to engage the upper cavity wall or the lower cavity wall.

11. The power distribution module according to claim 10, wherein the upper cavity wall comprises: an inner wall; and an outer wall spaced from the inner wall by a channel, wherein the sealing member is located within the channel.

12. The power distribution module according to claim 11, wherein The inner wall of the upper cavity wall includes a plurality of retaining grooves that are operable to receive the plurality of engagement features, and a plurality of retaining protrusions that are operable to engage the upper surface of the sealing member.

13. The power distribution module according to claim 11, wherein, the outer wall of the upper cavity wall includes a second plurality of retaining grooves and a second plurality of retaining protrusions.

14. The power distribution module according to claim 10, wherein, the lower cavity wall extends into the channel of the upper cavity wall.

15. The power distribution module according to claim 10, wherein, the wall of the sealing member includes: an inner portion; and an outer portion that is opposite to the inner portion, wherein the inner portion and the outer portion define a sealing member channel, and wherein the lower cavity wall extends into the sealing member channel.

16. The power distribution module according to claim 10, wherein, one or more of the plurality of engagement features along the wall include knobs extending from a tubular portion, wherein the lower cavity wall includes a plurality of openings, and wherein the knobs are located within one of the plurality of openings.

17. An assembly for housing one or more electrical components, the assembly comprising: a base including a lower cavity wall; a lid coupled to the base, wherein the lid includes an upper cavity wall, and wherein the lower cavity wall and the upper cavity wall define a cavity that is operable to house one or more protective components; and a flexible sealing member that engages the upper cavity wall and the lower cavity wall, wherein the sealing member includes: a wall; a plurality of engagement features protruding from the wall, wherein the plurality of engagement features are operable to couple the sealing member to at least one of: the upper cavity wall and the lower cavity wall; and a plurality of ridges extending laterally from the surface of the wall, wherein the plurality of ridges are operable to engage the upper cavity wall or the lower cavity wall.

18. The assembly according to claim 17, wherein, the upper cavity wall includes: an inner wall; and an outer wall that is separated from the inner wall by a channel, wherein the flexible sealing member is located within the channel, and wherein a portion of the lower cavity wall extends into the cavity.

19. The assembly according to claim 18, wherein, the inner wall of the upper cavity wall includes a plurality of retaining grooves that are operable to receive the plurality of engagement features of the flexible sealing member, and a plurality of retaining protrusions that are operable to engage the upper surface of the flexible sealing member.

20. The power distribution module according to claim 19, wherein, the outer wall of the upper cavity wall includes a second plurality of retaining grooves and a second plurality of retaining protrusions, the second plurality of retaining protrusions being operable to engage the sealing member, and wherein the plurality of retaining grooves and the second plurality of retaining grooves face each other across the channel.

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