Circuit having bus bars and junction box containing the circuit

• US 20020030036A1
• Filed: 09/06/2001
• Published: 03/14/2002
• Est. Priority Date: 09/08/2000
• Status: Active Grant

• Current Assignee: Sumitomo Wiring Systems Limited (Sumitomo Corporation)
• Original Assignee: Sumitomo Wiring Systems Limited (Sumitomo Corporation)
• Inventors: Kasai, Koji
• Granted Patent: US 6,655,968 B2
• Time in Patent Office: Days
• US Class Current: 219/56.22
• CPC Class Codes: H05K 2201/0397 Tab
• CPC Class Codes: H05K 2201/10272 Busbars, i.e. thick metal bars mounted on the printed circuit board [PCB] as high-current conductors
• CPC Class Codes: H05K 3/244 Finish plating of conductors, especially of copper conductors, e.g. for pads or lands selective plating methods H05K3/243; finish plating of conductors made by printing techniques H05K3/246; solder as finish H05K3/3457, e.g. by plating H05K3/3473
• CPC Class Codes: H05K 3/328 by welding
• CPC Class Codes: H05K 7/026 Multiple connections subassemblies
• CPC Class Codes: Y10S 439/949 Junction box with busbar for plug-socket type interconnection with receptacle

Abstract

An electrical circuit for use in an electrical junction box of a vehicle, has two bus bars welded to each other at a weld. A first one of the bus bars is formed of a material having an electrical conductivity selected from (a) in the range of from about 10 to about 60% and (b) not less than about 60%, and the second of the two bus bars is formed of a material having an electrical conductivity of not less than about 60%. At least one of the bus bars is tin-plated and at the weld the bus bars are joined through a tin-plating layer. Appropriate selection of the bus bar material in view of current loads is achieved, and good welding results.

Claims

1. An electrical circuit having two bus bars welded to each other at a weld, wherein a first one of said two bus bars is formed of a material having an electrical conductivity selected from (a) in the range of from about 10 to about 60% and (b) not less than about 60% and the second of said two bus bars is formed of a material having an electrical conductivity of not less than about 60%, and wherein at least one of said bus bars is tin-plated and at said weld said bus bars are joined through a tin-plating layer.

2. An electrical circuit according to claim 1, wherein said material of said first bus bar is tin-plated brass and said material of said second bus bar is selected from tin-plated copper alloy, copper alloy without tin-plating, tin-plated oxygen-free copper and oxygen-free copper without tin-plating.

3. An electrical circuit according to claim 1, wherein said material of said first bus bar is brass without tin-plating and said material of said second bus bar is selected from tin-plated copper alloy and tin-plated oxygen-free copper.

4. An electrical circuit according to claim 1, wherein said material of said first bus bar is selected from tin-plated copper alloy and tin-plated oxygen-free copper and said material of said second bus bar is selected from tin-plated copper alloy, copper alloy without tin-plating, tin-plated oxygen-free copper and oxygen-free copper without tin-plating.

5. An electrical circuit according to claim 1, wherein said material of each said bus bar is in one-piece sheet form and said electrical circuit comprises first and second insulating bodies respectively carrying said first and second bus bars, said first and second bus bars having respective tab portions projecting from said respective insulating bodies and welded together at said weld.

6. An electrical circuit according to claim 1, wherein said bus bars are welded to each other by resistance welding.

7. An electrical circuit according to claim 6, wherein one of said bus bars has, prior to resistance welding, a projection on a surface thereof which is directed towards the other of said bus bars in said weld.

8. An electrical junction box containing an electrical circuit having two bus bars welded to each other at a weld, wherein a first one of said two bus bars is formed of a material having an electrical conductivity selected from (a) in the range of from about 10 to about 60% and (b) not less than about 60% and the second of said two bus bars is formed of a material having an electrical conductivity of not less than about 60%, and wherein at least one of said bus bars is tin-plated and at said weld said bus bars are joined through a tin-plating layer.

9. An electrical junction box according to claim 8, wherein said material of each said bus bar is in one-piece sheet form and said electrical circuit comprises first and second insulating bodies respectively carrying said first and second substrates, said first and second bus bars having respective tab portions projecting from said respective insulating bodies and welded together at said weld.

10. A vehicle in which is mounted an electrical junction box according to claim 8.

11. An electrical circuit having two bus bars welded to each other at a weld, wherein a first one of said two bus bars is formed of brass without tin-plating and the second one of said two bus bars is formed of a material selected from tinplated brass and brass without tin-plating.

12. An electrical circuit according to claim 11, wherein said material of each said bus bar is in one-piece sheet form and said electrical circuit comprises first and second insulating bodies respectively carrying said first and second substrates, said first and second bus bars having respective tab portions projecting from said respective insulating bodies and welded together at said weld.

13. An electrical circuit according to claim 11, wherein said bus bars are welded to each other by resistance welding.

14. An electrical circuit according to claim 13, wherein one of said bus bars has, prior to resistance welding, a projection on a surface thereof which is directed towards the other of said bus bars in said weld.

16. An electrical junction box according to claim 15, wherein said material of each said bus bar is in one-piece sheet form and said electrical circuit comprises first and second insulating bodies respectively carrying said first and second substrates, said first and second bus bars having respective tab portions projecting from said respective insulating bodies and welded together at said weld.

17. A vehicle in which is mounted an electrical junction box according to claim 15.

15. An electrical junction box containing an electrical circuit having two bus bars welded to each other at a weld, wherein a first one of said two bus bars is formed of brass without tin-plating and the second one of said two bus bars is formed of a material selected from tin-plated brass and brass without tin-plating.

18. A method of making an electrical circuit comprising the step of welding together two bus bars by resistance welding so as to join the two bus bars at a weld, wherein a first one of said two bus bars is formed of a material having an electrical conductivity selected from (a) in the range of from about 10 to about 60% and (b) not less than about 60% and the second of said two bus bars is formed of a material having an electrical conductivity of not less than about 60%, and wherein at least one of said bus bars is tin-plated and at said weld said bus bars are joined through a tin-plating layer.

19. A method of making an electrical circuit comprising the step of welding together two bus bars by resistance welding so as to join the two bus bars at a weld, wherein a first one of said two bus bars is formed of brass without tin-plating and the second one of said two bus bars is formed of a material selected from tinplated brass and brass without tin-plating.

20. An electrical junction box for a vehicle having a casing and mounted within said casing a first circuit module adapted to be connected to at least one electrical connector in use of said electrical junction box and a second circuit module selected from

(i) a fuse module adapted to be connected to electrical fuses in use of said electrical junction box,

(ii) a relay module adapted to be connected to electrical relays in use of said electrical junction box, and

(iii) a combined fuse and relay module adapted to be connected to electrical fuses and electrical relays in use of said electrical junction box,

each of said first and second circuit modules having at least one bus bar and an insulating body carrying said at least one bus bar,

two of said bus bars, respectively on first and second circuit modules, being welded to each other at a weld to form electrical connection between said first and second circuit modules,

wherein a first one of said two bus bars is formed of a material having an electrical conductivity selected from (a) in the range of from about 10 to about 60% and (b) not less than about 60% and the second of said two bus bars is formed of a material having an electrical conductivity of not less than about 60%, and wherein at least one of said bus bars is tin-plated and at said weld said bus bars are joined through a tin-plating layer.

21. An electrical junction box for a vehicle having a casing and mounted within said casing a first circuit module adapted to be connected to at least one electrical connector in use of said electrical junction box and a second circuit module selected from

(i) a fuse module adapted to be connected to electrical fuses in use of said electrical junction box,

(ii) a relay module adapted to be connected to electrical relays in use of said electrical junction box, and

(iii) a combined fuse and relay module adapted to be connected to electrical fuses and electrical relays in use of said electrical junction box,

each of said first and second circuit modules having at least one bus bar and an insulating body carrying said at least one bus bar,

two of said bus bars, respectively on first and second circuit modules, being welded to each other at a weld to form electrical connection between said first and second circuit modules,

wherein a first one of said two bus bars is formed of brass without tinplating and the second one of said two bus bars is formed of a material selected from tin-plated brass and brass without tin-plating.