Method of making electric component

• US 4,821,413 A
• Filed: 04/07/1987
• Issued: 04/18/1989
• Est. Priority Date: 04/15/1986
• Status: Expired due to Fees

• Current Assignee: PREH Elektrofeinmechanische Werke Jakob PREH Nachf GmbH & Company
• Original Assignee: PREH Elektrofeinmechanische Werke Jakob PREH Nachf GmbH & Company
• Inventors: Winkler, Helmut, Schmitt, Herbert, Krause, Dietrich
• Primary Examiner(s): Arbes, Carl J.
• Application Number:
  US07/035,520
• Time in Patent Office: 742 Days
• Field of Search: 29/882, 29/883, 29/884, 264/272.11, 264/272.15
• US Class Current: 29/883
• CPC Class Codes: H01R 13/025 formed by the conductors of a cable end
• CPC Class Codes: H01R 13/405 Securing in non-demountable manner, e.g. moulding, riveting
• CPC Class Codes: H05K 2201/09118 Moulded substrate
• CPC Class Codes: H05K 2203/1327 Moulding over PCB locally or completely applying non-metallic protective coatings for encapsulating mounted components H05K3/284
• CPC Class Codes: H05K 3/202 using self-supporting metal foil pattern
• CPC Class Codes: H05K 3/4092 Integral conductive tabs, i.e. conductive parts partly detached from the substrate
• CPC Class Codes: H05K 7/026 Multiple connections subassemblies
• CPC Class Codes: Y10T 29/4922 with molding of insulation
• CPC Class Codes: Y10T 29/49222 forming array of contacts or terminals

Abstract

In an electric component a plastic sheath encloses conductive connections d leaves their terminal ends exposed. In order to keep the conductive connections at specific distances to the plastic sheath and to guarantee that the conductive connections are not exposed at the plastic sheath in intermediate areas, the conductive connections are secured together in spaced relation by a plastic carrier surrounding the conductive connections at spaced regions along their length. The plastic carrier has pins projecting therefrom which have end surfaces which serve to space the conductive connections a true distance from the surface of a mould in which a plastic sheath is moulded around the conductive connections and the plastic carrier. The plastic carrier and the conductive connections are encapsulated with the plastic sheath with the pins properly positioning the conductive carriers within the plastic sheath without forming any undesired openings in the plastic sheath.

Claims

1. A method of making a component characterized by forming a terminal frame having conductive connections with terminal ends and connecting bars connecting the conductive connections in a predetermined spaced relation,

moulding a plastic carrier around at least a first portion of the conductive connections out of the range of the connecting bars to fix the predetermined spacing,

then cutting the connecting bars to electrically separate the conductive connections, and

then moulding a plastic sheath around at least a second portion of the conductive connections and the plastic carrier while maintaining said predetermined spaced relation.

2. A method according to claim 1 characterized in that the plastic carrier is moulded around the conductive connections at spaced points along the length of the conductive connections.

3. A method according to claim 2 characterized in that the plastic carrier is moulded with pins projecting therefrom which have surfaces which engage the surface of the mould when the plastic sheath is moulded around the conductive connections and plastic carrier to position the conductive connections with the plastic sheath.

4. A method of making a component provided by a terminal frame having a plurality of conductive connections, each said conductive connection including a pair of terminal ends, said terminal frame further having means for connecting said conductive connections between their terminal ends in fixed spaced relation, comprising the steps of:

providing a first plastic material of a known electrical resistance;

moulding a carrier of said first plastic material around at least a first portion of said terminal frame proximate to said connecting means to further fix the spacing between said conductive connections, said carrier including a pair of opposed surfaces with one or more spacers projecting outwardly from one said surface;

disconnecting said connecting means from said conductive connections to electrically separate said conductive connections one from the other;

providing a second plastic material which has an electrical resistance that is higher than said known electrical resistance; and

moulding a sheath of said second plastic material around at least a second portion of said conductive connections and said carrier while maintaining said fixed spaced relation, said sheath also including a pair of opposed surfaces one of which is coplanar with an outer end of each said spacer, and the other of which includes an opening to expose each said conductive connection along a third portion thereof between said terminal ends, said terminal ends projecting from said sheath.