Method of making a customizable electrical article

• US 4,783,906 A
• Filed: 11/25/1986
• Issued: 11/15/1988
• Est. Priority Date: 11/12/1985
• Status: Expired due to Fees

• Current Assignee: AMP Limited
• Original Assignee: AMP Limited
• Inventors: Rose, William H., Shaffer, David T., Granitz, Richard F., Gingerich, David J.
• Primary Examiner(s): Goldberg, Howard N.
• Assistant Examiner(s): Arbes, Carl J.
• Application Number:
  US06/934,883
• Time in Patent Office: 721 Days
• Field of Search: 29/827, 174/52 FP, 439/395, 439/401, 439/402, 439/403, 439/404, 439/405, 439/516, 439/736, 439/885, 361/421, 357/70
• US Class Current: 29/827
• CPC Class Codes: H02K 11/026 Suppressors associated with brushes, brush holders or their supports
• CPC Class Codes: H02K 11/40 Structural association with grounding devices
• CPC Class Codes: H02K 2211/03 Machines characterised by circuit boards, e.g. pcb
• CPC Class Codes: H02K 5/148 Slidably supported brushes
• CPC Class Codes: H02K 5/225 Terminal boxes or connection arrangements specially adapted for submersible motors H02K5/132
• CPC Class Codes: Y10T 29/49121 Beam lead frame or beam lead device

Abstract

A lead frame assembly comprises a stamped and formed lead frame having spaced pairs of electrical terminals and other contact sections. Severable sections initially interconnect potential electrical circuit sections of the lead frame separating the lead frame into separate metal members defining discrete electrical circuits if severed. A dielectric covering is molded over the lead frame exposing the pairs of terminals and other contact sections for termination or electrical engagement. Openings are formed in the housing exposing the severable sections of the lead frame for severing, to be selectively severed creating separate electrical circuit sections, or to be retained unsevered, as desired. After the molding of the covering over the lead frame, the article thus fabricated can be customized by selective severing and connecting of components as desired. Thus a method has been described for making a customizable lead frame assembly.

Claims

1. A method of forming a lead frame assembly comprising the steps of:

forming an integral lead frame from metal sufficiently thick withstand handling after forming, said lead frame having a general outer periphery having a plurality of openings located inwardly from said general outer periphery defining integrally joined metal sections, said integral lead frame including formed thereon a plurality of electrical engagement sections each of which is adapted to be electrically engaged by a respective electrical conductor means, and said integral lead frame further including a sufficient number of severable sections located at selected locations inwardly from said general outer periphery and remote from said electrical engagement sections so that severing thereof would separate said integral member into separate metal members at least two of which each include at least two said electrical engagement sections and define electrical circuit paths;

securing a dielectric covering over said integral lead frame and extending at least outwardly to said general outer periphery thereof and around substantial portions of said metal sections exposing at least said electrical engagement sections and including a general outer surface disposed outwardly from said severable sections, whereby a lead frame assembly is fully fabricated; and

locating and severing at least an appropriate one of said severable sections thereby forming at least two separate electrical circuits each having at least two said electrical engagement sections, whereby a fully fabricated lead frame assembly is capable of being customized after fabrication thereof by selective severing of said severable sections.

2. A method of forming an electrical article for electrically connecting an electrical power supply means and at least one electrical load means comprising the steps of:

forming an integral lead frame having a general outer periphery and having a plurality of metal sections each including at least two contact sections formed therein thereby defining potential circuit sections, said plurality of metal sections being initially interconnected only by severable sections located inwardly from said general outer periphery of said lead frame and remote from said contact sections; and

molding a dielectric covering onto said lead frame and extending at least outwardly to said general outer periphery thereof and around substantial portions of said interconnected metal sections with said contact sections being exposed to be electrically connected to said power input means and said load means, and said covering including a general outer surface disposed outwardly from said severable sections and having molded therein openings exposing said severable sections and having dimensions wider than said severable sections such that said severable sections are severable therewithin to form at least two electrically separate metal members from said metal sections defining at least two discrete electrical circuits each having at least two said contact sections for electrically interconnecting said power supply means and a said load means, whereby an electrical article is fully fabricated and is adapted to be customized remote from the fabrication site by selective severing of said severable sections.

3. A method as set forth in claim 2 further including after said molding step the steps of selecting at least one of said severable sections to remain unsevered and severing the remaining others of said severable sections.