Integrated assembly consisting of an electrical conductor, a fuse, and a connector.

Abstract

Assembly consisting of an electrical conductor (10), at least one fuse (40) and at least one connector (50), comprising: a conductor body (11) with at least one conductor terminal (12, 13) attached to it; a conductor housing (20) with a support section (21) which engages with the conductor body (11) and at least one connector interface (22, 23) which contains the at least one conductor terminal (12, 13), wherein the connector interface (22, 23) comprises an elongated slot (22a, 22b) which is provided through the at least one connector interface (22, 23) and is accessible from an outside of the conductor housing (20); at least one fuse (40) configured to be movable through the elongated slot (22a, 22b) from the outside of the conductor housing (20) and into the interior of the at least one connector interface (22, 23) and to which at least one conductor terminal (12, 13) is connected; and at least one connector (50) with a connector housing (51) supported on the at least one connector interface (22, 23) and at least one connector terminal (52) arranged in the connector housing (51) and connected to the respective fuse (40).

Description

Background of the invention

[0001] This invention relates generally to electrical distribution systems for supplying electrical energy from a single electrical energy source to a variety of electrically operated devices. In particular, this invention relates to an integrated assembly comprising an electrical conductor, a fuse, and a connector, which can be used, for example, in a power distribution system for motor vehicles.

[0002] In most electrical distribution systems, an electrical conductor is provided to deliver electrical energy from an electrical power source to an electrically operated device. In many cases, a single electrical conductor is provided to deliver electrical energy from a single electrical power source to a variety of electrically operated devices. In these cases, the single electrical conductor (commonly referred to as a busbar) is often formed from a relatively rigid metallic material pre-shaped into a desired form. Typically, the outer surface of the electrical conductor is covered with an electrical insulating material, except at a variety of predetermined exposed contact areas that are not covered by the insulating material.These exposed contact areas facilitate the connection of the respective conductor terminals to the electrical conductor, so that each of these conductor terminals can quickly and easily supply electrical energy to the respective electrically operated devices.

[0003] Many power distribution systems of this general type also contain one or more fuses that protect electrically operated devices from damage caused by the passage of excessive amounts of electric current. In systems with a single electrical conductor, such as those described above, appropriate fuses are typically connected between the single electrical conductor and each of the electrically operated devices connected to it. DE 10 2017 214 619 A1 discloses a busbar distribution assembly. US 4,738,639 A discloses an electrical connector.

[0004] Although known power distribution systems such as those described above function satisfactorily, it would be desirable to provide an integrated assembly consisting of an electrical conductor, a fuse and a connector that could be used, for example, in a power distribution system for motor vehicles.

[0005] The object of the invention is to provide an alternative or improved assembly.

[0006] The object of the invention is solved by an assembly according to the independent claim. Summary of the invention

[0007] This invention relates to an integrated assembly comprising an electrical conductor, a fuse, and a connector, which can be used, for example, in a power distribution system for motor vehicles. The integrated assembly includes a conductor body with a conductor terminal attached to it. A conductor housing includes a support section that engages with the conductor body and a connector interface containing the conductor terminal. A conductor cover is detachably attached to the conductor section and covers the conductor body. A fuse is located in the connector interface and is connected to the conductor terminal. A connector includes a connector housing supported on the connector interface and a connector terminal located in the connector housing. To complete the integrated assembly, the connector terminal is connected to the fuse.

[0008] Various aspects of this invention will become apparent to those skilled in the art based on the following detailed description of the preferred embodiments, when read with reference to the accompanying drawings. Brief description of the drawings Fig. Figure 1 is an expanded perspective view of an electrical conductor, a conductor housing and a conductor cover according to this invention. Fig. Figure 2 is an enlarged perspective view of a section of a first embodiment of the electrical conductor made of Fig. 1 and its connection to a conductor terminal. Fig. Figure 3 is an enlarged top view of a section through the first embodiment of the electrical conductor along line 3-3. Fig. 2. Fig. Figure 4 is an enlarged perspective view of a section of a second embodiment of the electrical conductor made of Fig. 1 and its connection to a conductor terminal. Fig. Figure 5 is an enlarged top view of a section through the second embodiment of the electrical conductor along line 5-5. Fig. 4. Fig. Figure 6 is a perspective view of the electrical conductor, the conductor housing, and the conductor cover. Fig. 1 in assembled state. Fig. Figure 7 is an enlarged perspective view of parts of the electrical conductor assembly, the conductor housing, and the components in Fig. 6 shown conductor cover, which has been partially broken off for clarity. Fig. Figure 8 is an expanded perspective view of the electrical conductor, the conductor housing, and the conductor cover made of Fig. 6 and Fig. 7, together with a safety device before assembly. Fig. 9 is a perspective representation similar to Fig. 8, which shows the fuse after installation in the assembly consisting of the electrical conductor, the conductor housing and the conductor cover. Fig. 10 is a perspective representation similar to Fig. 9, with the ladder housing and ladder removed for clarity. Fig. Figure 11 is an expanded perspective view of part of the assembly consisting of the electrical conductor, the conductor housing and the conductor cover, as well as the components shown in Figure 11. Fig. 9 and Fig. 10 shown fuse together with a connector before assembly. Fig. 12 is a perspective representation similar to Fig. 11, in which the connector is shown after installation in the assembly consisting of the electrical conductor, the conductor housing, the conductor cover and the fuse. Fig. 13 is a perspective representation similar to Fig. 12, wherein the conductor housing, conductor cover and connector housing of the connector have been removed for clarity. Fig. Figure 14 is a perspective view of the integrated assembly consisting of the electrical conductor, the fuse and the connector according to this invention. Detailed description of preferred embodiments

[0009] Referring to the drawings, it is now in Fig. Figures 1 to 7 illustrate an assembly comprising an electrical conductor (generally designated 10), a conductor housing (generally designated 20), and a conductor cover (generally designated 30) according to this invention. The illustrated electrical conductor 10 includes a conductor body 11, which is preferably designed as an elongated, flat, planar strip of material with a relatively small thickness compared to its length and / or width. Furthermore, the conductor body 11 is preferably made of a metallic material, such as copper or aluminum, which is electrically conductive. As a result, the conductor body 11 is flexible (i.e., it can be bent, flexed, or twisted without breaking), which advantageously allows it to be easily deformed into a desired shape to facilitate assembly and installation.However, the conductor body 11 can be formed with any desired thickness or shape and can furthermore be made from any desired electrically conductive material.

[0010] As in Fig. 2 and Fig. As shown in Figure 3, the conductor body 11 can be configured as several layers 11a (such as two layers in the illustrated embodiment) of the electrically conductive material. If desired, adjacent pairs of these multiple layers 11a can be separated from each other by one or more intermediate layers 11b of an electrically non-conductive material, although this is not necessary. Alternatively, as shown in Fig. 4 and Fig. As shown in Figure 5, the conductor body 11 can be made as a single layer 11a of the electrically conductive material. In both cases, each of the outer surfaces of the conductor body 11 can be wholly or partially covered with a layer of an electrically non-conductive material 11c (see Figure 5). Fig. 2 to 5), although this is not necessary either.

[0011] The first and second conductor terminals 12 and 13 are attached to the conductor body 11 to facilitate the connection of the electrical conductor 10 to appropriate electrically operated devices (not shown) in a power distribution system, as described above. In the illustrated embodiment, two such conductor terminals 12 and 13 are attached to opposite edges of the conductor body 11. However, any desired number of such conductor terminals 12 and 13 can be attached to the conductor body 11 at any desired position. The illustrated first and second conductor terminals 12 and 13 are each a socket terminal suitable for receiving a flat plug terminal (not shown). However, the first and second conductor terminals 12 and 13 can be implemented in any desired structure or combination of structures.

[0012] Fig. 2 and Fig. Figure 3 shows a first embodiment of a connection between a multilayer conductor body 11 and the first conductor terminal 12. As shown therein, a contact section of the first conductor terminal 12 extends between the adjacent layers 11a of the multilayer conductor body 11. The contact section of the first conductor terminal 12 can be attached to either one or both adjacent layers 11a of the conductor body 11 in any desired manner, such as by welding. Figure 3 shows a corresponding embodiment of a connection between a multilayer conductor body 11 and the first conductor terminal 12. Fig. 4 and Fig. Figure 5 shows a second embodiment of a connection between a single-layer conductor body 11 and the first conductor terminal 12. As shown therein, a contact section of the first conductor terminal 12 extends adjacent to the single layer 11a of the conductor body 11. The contact section of the first conductor terminal 12 can also be attached to the adjacent layer 11a of the conductor body 11 in any desired manner, such as by welding.

[0013] As in Fig. As can be seen most clearly in Figure 1, the illustrated conductor housing 20 includes a central support section 21, on opposite sides of which first and second connector interfaces 22 and 23 are provided, of which only the first connector interface 22 is shown in detail. The conductor housing 20 is preferably formed from a lightweight, electrically non-conductive material, such as plastic. However, the conductor housing 20 can be formed in any desired manner, with any desired shape, and from any desired material. As explained in detail below, each of the first and second connector interfaces 22 and 23 provided on the conductor housing 20 corresponds to one of the first and second conductor terminals 12 and 13 provided on the conductor body 11 of the electrical connector 10.Elongated slots 22a or similar openings are provided by the connector interfaces 22 and 23. Corresponding brackets 22b are also provided within each of the connector interfaces 22 and 23 next to the associated slots 22a. Additionally, the connector interfaces 22 and 23 are provided with corresponding lateral openings 22c and 23c. The purpose of the slots 22a, the brackets 22b, and the openings 22c and 23c is explained below. Finally, the support section 21 of the conductor housing 20 includes a pair of outwardly extending projections 24 (one of which is located in ). Fig. 1 is visible). The illustrated projections 24 extend from opposite sides of the support section 21 of the conductor housing 20 and are intended for a purpose which is also explained below.

[0014] As also in Fig. As can be best seen in Figure 1, the illustrated conductor cover 30 includes a central plate 31, which is generally flat and rectangular. The plate 31 is preferably formed from a lightweight, electrically non-conductive material, such as plastic. However, the plate 31 can be formed in any desired manner, with any desired shape, and from any desired material. Furthermore, the plate 31 additionally includes a pair of holders 32 (one of which is in Fig. (1 is visible). The illustrated brackets 32 extend from opposite sides of the plate 31 of the conductor cover 30 and each have openings 32a extending through them. As will be explained in more detail below, the openings 32a are adapted by the brackets 32 provided on the plate 31 so that they can accommodate the projections 24 which extend from the support section 21 to detachably hold the conductor cover 30 on the conductor housing 20.

[0015] Fig. 6 and Fig. Figure 7 shows the electrical conductor 10, the conductor housing 20, and the conductor cover 30 in an assembled state. As shown therein, the conductor body 11 of the electrical conductor 10 is arranged between the support section 21 of the conductor housing 20 and the plate 31 of the conductor cover 30. To achieve this, the conductor body 11 of the electrical conductor 10 is first positioned next to the support section 21 of the conductor housing 20. In this arrangement, the first and second conductor terminals 12 and 13 extend from the conductor body 11 to the corresponding parts of the connector interfaces 22 and 23 provided on the conductor housing 20, as shown in Figure 7. Fig. Figure 7 shows that the plate 31 of the conductor cover 30 is then positioned next to the conductor body 11 of the electrical conductor 10. The supports 32 provided on the plate 31 of the conductor cover 30 are aligned with the projections 24 provided on the support section 21 of the conductor housing 20. This results in the conductor cover 30 being moved next to the conductor body 11, as shown in Figure 7. Fig. 6 and Fig. Figure 7 shows that the projections 24 extend through the openings 32a of the supports 32, so that the conductor cover 30 is detachably held on the conductor housing 20.

[0016] Fig. 8, Fig. 9 and Fig. Figure 10 illustrates how a fuse, generally designated 40, can be installed in the combined assembly of the electrical conductor 10, the conductor housing 20, and the conductor cover 30. The fuse 40 shown includes a body 41 with first and second fuse terminals 42 and 43 extending from it. The fuse 40 is conventional in the prior art and is known to be designed to prevent more than a predetermined maximum amount of electric current from passing through it. If the amount of electric current flowing through the fuse 40 exceeds this predetermined maximum amount, the body 41 creates an open circuit between the first and second fuse terminals 42 and 43, thus preventing further electric current from flowing through the fuse 40.The illustrated first and second fuse terminals 42 and 43 are each designed as flat plug terminals, although this is not necessary.

[0017] As in Fig. As shown in Figure 8, the fuse 40 is initially aligned with the slot 22a, which extends through the first connector interface 22 of the conductor housing 20. Then, as shown in Fig. 9 and Fig. As shown in Figure 10, the fuse 40 is inserted through slot 22a into the interior of connector interface 22, so that the first terminal 42 of the fuse 40 is connected to the first conductor terminal 12 provided on the conductor body 11. As a result, an electrically conductive path is provided from the conductor body 11 through the first conductor terminal 12, the first terminal 42 of the fuse 40, and the body 41 of the fuse 40 to the second terminal 43 of the fuse 40. A similar fuse (not shown) can be installed in the same manner at the second conductor terminal 13, which is located inside the second connector interface 23 of the conductor housing 20.

[0018] Fig. 11, Fig. 12 and Fig. Figure 13 illustrates how a connector, generally marked 50, can be installed on the combined assembly of the electrical conductor 10, the conductor housing 20, and the conductor cover 30 to form an integrated assembly, generally marked 60. Fig. Figure 14, comprising the electrical conductor 20, the fuse 40, and the connector 50 according to this invention. The connector 50 is conventional in the prior art and is suitable for connecting the second terminal 43 of the fuse 40 to an electrically operated device (not shown), as described above. To achieve this, the connector 50 includes a hollow connector housing 51, which carries a connector terminal 52. The illustrated connector housing 51 is preferably formed from a lightweight, electrically non-conductive material, such as plastic. However, the connector housing 51 can be formed by any desired method, with any desired shape, and from any desired material. The illustrated connector terminal 52 is a socket terminal suitable for receiving a flat pin connector.The connector terminal 52 can, however, be configured in any desired structure. Additionally, the connector 50 can be optionally equipped with a connector position locking device 53, the design and function of which conform to the state of the art.

[0019] As in Fig. As shown in Figure 11, the connector housing 51 of the connector 50 is initially aligned with the lateral opening 22c that extends through the first connector interface 22 of the conductor housing 20. Consequently, the connector terminal 52 (held within the connector housing 51) is aligned with the second terminal 43 of the fuse 40 (held within the first connector interface 22). Then, as shown in Fig. 12 and Fig.As shown in Figure 13, the connector housing 51 is moved over the lateral opening 22c, which extends through the first connector interface 22 of the conductor housing 20. Consequently, the connector terminal 52, supported in the connector housing 51, is connected to the second terminal 43 of the fuse 40. This extends the electrically conductive path described above from the second terminal 42 of the fuse 40, via the connector terminal 52, to the electrically operated device. A similar connector (not shown) can be mounted on the second connector interface 23 in the same manner. This completes the assembly of the integrated unit 60 consisting of the electrical conductor 20, the fuse 40, and the connector 50 according to this invention.

[0020] The illustrated integrated assembly 60 is particularly suitable for use in a power distribution system for motor vehicles or other vehicles, wherein a single electrical conductor is provided for the delivery of electrical energy from an electrical power source to a plurality of electrically operated devices. However, as will be evident from the following description, the integrated assembly 60 of this invention can be used in any desired environment for any desired purpose.

Claims

[1] Assembly comprising an electrical conductor (10), at least one fuse (40) and at least one connector (50), comprising: a conductor body (11) with at least one conductor terminal (12, 13) attached to it; a conductor housing (20) with a support section (21) which engages with the conductor body (11) and at least one connector interface (22, 23) which contains the at least one conductor terminal (12, 13), wherein the connector interface (22, 23) comprises an elongated slot (22a, 22b) which is provided through the at least one connector interface (22, 23) and is accessible from an outside of the conductor housing (20); at least one fuse (40) configured to be movable through the elongated slot (22a, 22b) from the outside of the conductor housing (20) and into the interior of the at least one connector interface (22, 23) and to which at least one conductor terminal (12, 13) is connected; and at least one connector (50) with a connector housing (51) supported on the at least one connector interface (22, 23) and at least one connector terminal (52) arranged in the connector housing (51) and connected to the respective fuse (40). [2] Assembly according to claim 1, wherein the conductor body (11) is an elongated, flat, planar strip of material. [3] Assembly according to claim 1, wherein the conductor body (11) has several layers (11a, 11b, 11c), and wherein a section of the conductor clamp (12, 13) extends between adjacent layers (11a) and is attached to them. [4] Assembly according to claim 1, wherein the conductor body (11) has a single layer (11a) and wherein a section of the conductor clamp (12, 13) is attached to an outer surface of the single layer (11a). [5] Assembly according to claim 1, wherein the support section (21) of the conductor housing (20) engages with a first surface of the conductor body (11), and wherein a conductor cover (30) is further included, which is attached to the conductor housing (20) and engages with a second surface of the conductor body (11) opposite the first surface. [6] Assembly according to claim 5, wherein the conductor housing (20) has a projection (24) and the conductor cover (30) includes a retaining device (32) which interacts with the projection (24) on the conductor housing (20) to detachably attach the conductor cover (30) to the conductor housing (20). [7] Assembly according to claim 5, wherein the conductor housing (20) has first and second projections (24) and the conductor cover (30) includes first and second supports (32) which each interact with the first and second projections (24) on the conductor housing (20) to detachably attach the conductor cover (30) to the conductor housing (20). [8] Assembly according to claim 1, comprising a plurality of conductor terminals (12, 13) attached to the conductor body (11) and a plurality of connector interfaces (22, 23) provided on the conductor housing (20) and each comprising the plurality of conductor terminals (12, 13). [9] Assembly according to claim 1, comprising a plurality of fuses (40) which are each arranged in the plurality of connector interfaces (22, 23) and each connected to the plurality of conductor terminals (12, 13). [10] Assembly according to claim 9, comprising a plurality of connectors (50) with corresponding connector housings (51) each supported by the plurality of connectors (50), and a plurality of connector terminals (52) each arranged in the plurality of connector housings (51) and each connected to the plurality of fuses (40). [11] Assembly according to claim 1, wherein the connector interface (22, 23) includes a holder (22b) which holds the fuse (40) within the connector interface (22, 23). [12] Assembly according to claim 1, wherein the connector interface (22, 23) has an opening (22c, 23c) and the connector (50) is supported on the connector interface (22, 23) such that the connector terminal (52) extends through the opening (22c, 23c) into engagement with the locking device (40).

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