FORM 2
The Patent Act 1970
(39 of 1970)
&
The Patent Rules  2005

COMPLETE SPECIFICATION
(SEE MEMBER 10 AND RULE 13)

TITLE OF THE INVENTION

“MODULAR POWER DISTRIBUTION MODULE”

APPLICANT:

Name : Mahindra & Mahindra Ltd.

Nationality : Indian

Address : Mahindra Research Valley  Mahindra World
City Plot No. 41/1  Anjur P.O. Chengalpattu
Kancheepuram Dist  Tamilnadu.- 603204

The following specification particularly describes and ascertains the nature of this invention and the manner in which it is to be performed:-

FIELD OF INVENTION
[001] The embodiments herein relate to a vehicle power distribution module  and more particularly but not exclusively to a modular and serviceable power distribution module for distributing power within a vehicle.

BACKGROUND OF INVENTION
[002] Power distribution blocks are used to distribute power from a single power source to multiple electronic components. The distribution block ensures a clean  efficient method for supplying the required power to multiple components without the need to couple each component individually to the power source. The distribution block thus may be mounted in an area of the vehicle which is usually in a confined engine compartment or to an easily accessable area from where the output wires may be run to the various component areas without the difficulties associated with individually wiring each component directly to the power source.
[003] Generally electric components in a vehicle includes Fuse boxes  power relays  mini relays and diagnostic connectors for distributing power to various components of the vehicle. Conventionally the fuse box  relays and diagnostic connectors are placed nearer to the engine of the vehicle to minimize the space utilization and to provide a compact design. The mounting arrangement of the fuse box with the combination of relay and diagnostic connector are to be such that no cutting and twisting of wires should be involved in the design. Any cutting or twisting of wires may cease the power distribution within the vehicle.
[004] Also many patents disclose power distribution blocks  where the entire electrical components are disposed in housing with a cover secured on top of the electrical components and terminals. The entire housing is mounted in an accessible region of the vehicle. Unfortunately environmentally sealed housing do not provide user friendly atmosphere for serviceability of the electrical components. Further  the sealed housing usually retains heat which leads to pressure and temperature differentials between the interior and exterior of the housing. Also  the sealed housing complicates the distribution of the power since many connections must pass through the sealed housing.
[005] Currently  modular standard distribution blocks which are available in market for mounting fuse box  relays and diagnostic connector are large in size  hence cannot be directly used to mount the electrical components. Further  manufacturing and utilizing individual block for fuse box  relay  and diagnostic connector results in huge investment in terms of time and cost.
[006] Therefore  there exists a need to develop a compact power distribution module which may be readily mounted to the vehicle. Furthermore  there is a need for a power distribution module which utilizes less space and minimizes the cost and time involved in its production.

OBJECT OF INVENTION
[007] The principal object of the invention is to provide a modular compact power distribution module to mount fuse box  power relays  mini relays and diagnostic connector in a given limited space.
[008] A further object of the invention is to provide serviceable sub modules  wherein said sub modules are easily detachable from a main module.
[009] Yet another object of the invention is to provide a compact power distribution module that minimizes the time involved and cost involved in manufacturing the mounting bracket.
[0010] Yet another object of the invention is to provide a compact power distribution module that could overcome the aforementioned drawbacks of the conventional mounting blocks.
[0011] These and other objects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood  however  that the following descriptions  while indicating preferred embodiments and numerous specific details thereof  are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof  and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF FIGURES

[0012] This invention is illustrated in the accompanying drawings  throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the drawings  in which:
[0013] Fig. 1a illustrates a perspective view of a clamping member according to an embodiment of the present invention.
[0014] Fig. 1b illustrates another perspective view of a clamping member according to an embodiment of the present invention;
[0015] Fig. 2 illustrates a perspective view of whole assembly including the clamping member and other sub-assembly components according to an embodiment of the present invention;
[0016] Fig. 3 illustrates an exploded view of whole assembly including the clamping member and other sub-assembly components according to an embodiment of the present invention;
[0017] Fig. 4a illustrates an exploded view of the clamping member along with a fuse box and a connecting member according to an embodiment of the present invention;
[0018] Fig. 4b illustrates an exploded view of a first sub module along with the first main module according to an embodiment of the present invention;
[0019] Fig. 5 illustrates a perspective view of whole assembly including the clamping member and other sub-assembly components according to another embodiment of the present invention; and
[0020] Fig. 6 illustrates an exploded view of whole assembly including the clamping member and other sub-assembly components according to another embodiment of the present invention.

DETAILED DESCRIPTION OF INVENTION
[0021] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. For example  it should be noted that while some embodiments are explained with respect to power distribution module for the ease of describing  other modules apart from power distribution module may also incorporate the subject matter of the invention with little or no modifications. Accordingly  the examples should not be construed as limiting the scope of the embodiments herein.
[0022] The embodiments herein provide a modular power distributing module that could be easily connected to wall of the vehicles. Further  the embodiments herein provide a power distributing module that could be mounted within a limited space available in the vehicle. Furthermore  the embodiments herein provide a power distributing module wherein each component of the module is detachable from one another for ease of assembling and servicing. Referring now to the drawings  and more particularly to FIGS. 1 through 6  where similar reference characters denote corresponding features consistently throughout the figures  there are shown embodiments.
[0023] Fig. 1a-4b depicts the architecture of the power distribution module (100) according to an embodiment of the present invention. However  it is also within the scope of invention that different combinations of the power distribution module (100) could be obtained  as can be deduced from this description. The power distribution module (100) according to an embodiment of the present invention includes a clamping member (101)  a connecting member (102)  a latching member (103). The power distribution module (100) further includes a first sub-assembly component (104)  a first frame (105a)  a second frame (105b) and a second sub-assembly component (106). The whole power distribution module (100) is mounted to wall of the vehicle by plurality of mounting bolts.
[0024] With reference to the above mentioned Figs. 1a-4b  the power distribution module (100) includes a clamping member (101)  a first frame (105a)  a second frame (105b)  a connecting member (102) and a latching member (103). The clamping member (101) further includes a first clamping bar (107) and a second clamping bar (108) wherein the first clamping bar (107) is transversely connected to the second clamping bar (108) by plurality of weld nuts (not shown in fig). The first clamping bar (107) and the second clamping bar (108) are made up of cold rolled carbon steel  which provides strength for holding the sub-components. Further the first clamping bar (107) consists of at least one holding member (109) to hold the first frame (105a). The holding member (109) further defines an embossed surface (110) which engages with a first lock member (111a) provided in the first frame (105a) to support the first frame (105a). Further the first frame (105a) consists of plurality of first lock member (111a) defined on its body to engage with the holding member (109)  the connecting member (102) and the latching member (103).
[0025] A first sub-assembly component (104) i.e. a fuse box (112) is mounted on top of the first frame (105a) which is further connected with the second clamping bar (108) by at least one connecting member (102) in such a way that there is no tension or force acting on the frame (105a). Also  the connecting member (102) is provided with an opening which acts as a slot to compensate manufacturing tolerances. The connecting member (102) is a L-shaped member having an opening (113) in one of the sides to accommodate a fastener. The other side of the connecting member (102) comprises an embossed surface (119) to engage with the first lock member (111a) provided in the frame (105a).
[0026] A second sub-assembly component (106) mounted on a second frame (105b) is connected to the first frame (105a) by at least one latching member (103). The second sub-assembly components include a heater relay (116)  a starter & ECU relay (117)  a mini relay (118) and a diagnostic connector (115). Further the second frame (105b) consists of plurality of second lock member (111b) defined on its body to engage with an embossed surface (120) of the latching member (103) to secure the second sub-assembly component (106) with the first sub-assembly component (104). The latching member (103) defines plurality of openings (121) at predetermined locations to facilitate connection between the first frame (105a) and the second frame (105b).
[0027] In one embodiment of the present invention  the power distribution module (100) includes the clamping member (101) having the first clamping bar (107) and the second clamping bar (108) as shown in Figs. 1a-1b. The first clamping bar (107) is transversely integrated to the second clamping bar (108) by plurality of weld nuts (not shown in fig). Further the first clamping bar (107) includes the holding member (109) to support the first frame (105a) such that the embossed surface (110) defined in the holding member (109) engages with the first lock member (111a) provided in the first frame (105a).
[0028] In one embodiment the present invention includes the first frame (105a) which consists of plurality of first lock member (111a) defined on its body to engage with the holding member (109)  the connecting member (102) and the latching member (103). The first frame (105a) is configured in such a way that it can accommodate the first sub-assembly component (104)(fuse box (112) ) on its top surface.
[0029] In one embodiment of the present invention the power distribution module (100) includes the connecting member (102) as shown in figs. 4a-4b. The first frame (105a) is connected to the second clamping bar (108) by the connecting member (102) in such a way that there is no tension or force acting on the frame (105a). Also  the connecting member (102) is provided with an opening which acts as a slot to compensate manufacturing tolerances. The connecting member (102) is a L-shaped member having the opening (113) in one of the sides to accommodate a fastener. The other side of the connecting member (102) comprises an embossed surface (119) to engage with the first lock member (111a) provided in the first frame (105a).
[0030] In one embodiment the present invention includes the latching member (103) as shown in figs. 2 and 3. The latching member (103) joins the second sub-assembly component (106) mounted on the second frame (105b) with the first sub-assembly component (104) mounted on the first frame (105a). Further the second frame (105b) consists of plurality of second lock member (111b) defined on its body to engage with an embossed surface (120) of the latching member (103). The latching member (103) defines plurality of openings (121) at predetermined locations to facilitate connection between the first frame (105a) and the second frame (105b).
[0031] In one embodiment the whole power distribution module (100) is mounted to the wall of the vehicle by plurality of mounting bolts. The clamping member (101) is provided with a hole in the first clamping bar (107) and the second clamping bar (108) to receive a weld nut to integrate the first clamping bar (107) with the second clamping bar (108).

[0032] In further additional embodiment of the present invention as described in fig. 5 the power distribution module (100) includes a clamping member (101)  a first frame (105a)  a second frame (105b)  and a latching member (103). The clamping member (101) further includes a first clamping bar (107) and a second clamping bar (108) wherein the first clamping bar (107) is transversely connected to the second clamping bar (108) by plurality of weld nuts (not shown in fig). Further the first clamping bar (107) consists of at least one holding member (109) to hold the first frame (105a). The holding member (109) further defines an embossed surface (110) which engages with a first lock member (111a) provided in the first frame (105a) to support the first frame (105a). Further the first frame (105a) consists of plurality of first lock member (111a) defined on its body to engage with the holding member (109)  and the latching member (103). A first sub-assembly component (104) i.e. a fuse box (112) is mounted on top surface of the first frame (105a).
[0033] A second sub-assembly component (106) mounted on a second frame (105b) is connected to the first frame (105a) by at least one latching member (103). The second sub-assembly components include a heater relay (116)  a starter & ECU relay (117)  a mini relay (118) and a diagnostic connector (115). Further the second frame (105b) consists of plurality of second lock member (111b) defined on its body to engage with an embossed surface (120) of the latching member (103) to secure the second sub-assembly component (106) with the first sub-assembly component (104). The latching member (103) defines plurality of openings (121) at predetermined locations to facilitate connection between the first frame (105a) and the second frame (105b).
[0034] In one embodiment the present invention includes the power distribution module (100) in which each component of the module (100) is detachable from one another. Thus the power distribution module (100) facilitates easy assembling and servicing of the sub-assembly components.
Referal numerals:
100 Power distribution module
101 Clamping member
102 Connecting member
103 Latching member
104 First sub-assembly component (not shown in figure)
105a First frame
105b Second frame
106 Second sub-assembly component (not shown in figure)
107 First clamping bar
108 Second clamping bar
109 Holding member
110 Embossed surface on holding member
111a First lock member
111b Second lock member
112 Fuse box
113 Opening in connecting member
115 Diagnostic connector
116 Heater relay
117 Starter & ECU relay
118 Mini relay
119 Embossed surface on connecting member
120 Embossed surface on latching member
121 Opening in latching member

CLAIMS
We claim 

1. A modular power distribution module (100) for vehicles  said module comprising:

a clamping member (101) having a first clamping bar (107) adapted to be engaged with a second clamping bar (108)  wherein the first clamping bar (107) includes at least one holding member (109) to hold a first sub-assembly component (104)  and

at least one latching member (103) to join the first sub-assembly component (104) to at least one second sub-assembly component (106)  wherein the first sub-assembly component (104) and second sub-assembly component (106) includes a first frame (105a) and a second frame (105b) repectively.

2. The power distribution module (100) as claimed in claim 1  wherein at least one connecting member (102) is provided to connect the first sub-assembly component (104) with the second clamping bar (108).

3. The power distribution module (100) as claimed in claim 1  wherein the first clamping bar (107) and the second clamping bar (108) are integrated by passing at least one weld nut through at least one hole provided in at least one of the first clamping bar (107) and the second clamping bar (108).

4. The power distribution module (100) as claimed in claim 1  wherein the first clamping bar (107) is placed tranverse to the second clamping bar (108).

5. The power distribution module (100) as claimed in claim 1  wherein the first frame (105a) of the first sub-assembly component (104) is adapted to accommodate the holding member (109)  the connecting member (102) and the latching member (103) by plurality of first lock member (111a).

6. The power distribution module (100) as claimed in claim 1  wherein the second sub-assembly component (106) includes a diagnostic connector (115)  a heater relay (116)  a starter & ECU relay (117)  and a mini relay (118).
7. The power distribution module (100) as claimed in claim 1  wherein the second frame (105b) of the second sub-assembly component (106) is adapted to accommodate the latching member (103) by a second lock member (111b).

8. The power distribution module (100) as claimed in claim 2  wherein the connecting member (102) is a l-shaped member having at least one opening (113) in one of the sides to receive a fastener for connecting the first frame (105a) of the first sub-assembly component (104) with the second clamping bar (108).

9. The power distribution module (100) as claimed in claim 1  wherein the holding member (109) provided in the first clamping bar (107) includes an embossed surface (110) to hold the fuse box (112).

10. The power distribution module (100) as claimed in claim 1  wherein the connecting member (102) includes an embossed surface (119) to interface the fuse box (112) with the second clamping bar (108).

11. The power distribution module (100) as claimed in claim 1  wherein the latching member (103) includes an embossed surface (120) to interface the fuse box (112) with the heater relay (116)  the starter & ECU relay (117) and the mini relay (118).

12. The power distribution module (100) as claimed in claim 1  wherein the latching member (103) defines a plurality of openings (121) at predetermined locations to facilitate a connection between the first sub-assembly component (104) and the second sub-assembly component (106).

13. The power distribution module (100) as claimed in claim 1  wherein the first clamping bar (107) and the second clamping bar (108) is made up of cold rolled carbon steel.
14. A method of assembling a power distribution module (100) for vehicles  said method comprising:

mounting a clamping member (101) to wall of the vehicle using plurality of mounting bolts  wherein the clamping member (101) includes a first clamping bar (107) adapted to engage with a second clamping bar (108);
connecting a first sub-assembly component (104) to the first clamping bar (107) by at least one holding member (109); and
joining the first sub-assembly component (104) to at least one second sub-assembly component (106) by at least one latching member (103)  wherein the first sub-assembly component (104) and second sub-assembly component (106) (108) includes a first frame (105a) and a second frame (105b) repectively.

Date: 28th Sept  2012 Dr. Kalyan Chakravarthy
Patent Agent

ABSTRACT

A modular power distribution module (100) is disclosed having a clamping member (101) which includes a first clamping bar (107) adapted to be engaged with a second clamping bar (108). The first clamping bar (107) includes a holding member (109) to hold a first sub-assembly component (104). A latching member (103) is provided to join the first sub-assembly component (104) to a second sub-assembly component (106). The first sub-assembly component (104) and second sub-assembly component (106) include a first frame (105a) and a second frame (105b) repectively. A connecting member (102) is provided to connect the first sub-assembly component (104) with the second clamping bar (108). Reference Fig. 1