Sumitomo Wiring Systems, Limited

Noriko Kobayashi

Tatsuya Sumida

Yuuji Saka

Hisaki Mayumi

Yukitaka Saito

Shinji Kawakita

A method is provided of connecting wires of a wiring harness to a junction box to form branch circuits. An electrical conductor material is formed in parallel strips in a Y-axis direction on one surface of an insulator board, and wires are arranged in an X-axis direction on the other side of the insulator board. A circuit assembly is formed by connecting the exposed cores of one end of the wires to the conductor material through openings provided in the insulator board. Connector terminals are installed at the other end of the wires that extend outward and away from the insulator board. Groups of wires are gathered and placed in same connectors in which joint terminals are provided. The wires are joined to the connectors to form multiple wire harnesses. The aforesaid circuit assembly is then installed within an upper and lower case assembly provided with lateral openings through which the wire harness can pass.

Junction box and wire harness connection method

An electrical junction box for a vehicle has a casing, and an electrical circuit comprising a fuse connection circuit, a relay connection circuit and a connector connection circuit. The casing has, at opposite sides, connector sockets for electrical connectors. In the casing is a connector module comprising a plurality of insulation substrates stacked one on another and parallel elongated bus bars on a first surface of each substrate and parallel flexible conductors on a second surface of the substrate, which extend orthogonally to said bus bars. Each said insulation substrate has apertures through it at which the bus bars and flexible conductors are connected to each other to provide desired circuit connections. The bus bars extend from the insulation substrates and provide tabs projecting into the connector sockets. A thin junction box is obtained.

Electrical junction box for a vehicle

An electrical junction box for a vehicle has a casing, and an electrical circuit. The electrical circuit has a fuse connection circuit, a relay connection circuit and a connector connection circuit. The casing has, at opposite sides, connector sockets for electrical connectors. A connector module in the casing has a plurality of insulation substrates stacked one on another and parallel elongated bus bars on a first surface of each substrate and parallel flexible conductors on a second surface of the substrate, which extend orthogonally to the bus bars. Each insulation substrate has apertures through it at which the bus bars and flexible conductors are connected to each other to provide desired circuit connections. The bus bars extend from the insulation substrates and provide tabs projecting into the connector sockets. A thin junction box is obtained.

An electrical junction box for a vehicle has a connector circuit having bus bars fixed on an insulation substrate to connect to electrical connectors, a fuse circuit having bus bars fixed on an insulation substrate to connect to fuses, and a relay circuit having third bus bars fixed on an insulation substrate to connect to relays in use. In assembling the box, in order to avoid generation of stress and allow for dislocation of the circuits, the method includes the steps of: (i) joining upstanding welding portions of bus bars of the connector circuit and the fuse or relay circuit by arranging them adjacent each other and welding them together; and (ii) after step (i), joining laterally projecting welding portions of bus bars of the connector circuit and the fuse or relay circuits by welding them together when superimposed one on the other.

Junction box

An electrical junction box for a vehicle has a casing and in the casing a connector circuit having first bus bars fixed on a connector circuit substrate to connect to electrical connectors, a fuse circuit with second bus bars on a fuse circuit substrate, discrete from the connector circuit, to connect to fuses, and a relay circuit having third bus bars on a relay circuit substrate, discrete from the connector circuit, to connect to relays. The first bus bars have welding portions welded to and the bus bars of one of the fuse and relay circuits have welding portions opposed thereto. At the adjacent pairs of these welded connections an insulating partitioning member is interposed between the welded connections so as to prevent contact between them.

Growing community of inventors

Yokkaichi, Japan

Noriko Kobayashi