Method of making wire-circuit sheet

• US 5,832,602 A
• Filed: 12/23/1996
• Issued: 11/10/1998
• Est. Priority Date: 01/25/1994
• Status: Expired due to Fees

• Current Assignee: Yazaki Corporation
• Original Assignee: Yazaki Corporation
• Inventors: Sugiyama, Akira, Kato, Sanae, Uezono, Kouichi, Ozaki, Keiichi
• Primary Examiner(s): Arbes, Carl J.
• Application Number:
  US08/779,940
• Time in Patent Office: 687 Days
• Field of Search: 29/755, 29/739, 29/850, 29/825, 29/564.2, 29/566.2
• US Class Current: 29/850
• CPC Class Codes: B60R 16/0238 Electrical distribution centers
• CPC Class Codes: H01R 4/029 Welded connections H01R4/021 - H01R4/028 take precedence
• CPC Class Codes: H01R 9/2458 Electrical interconnections between terminal blocks
• CPC Class Codes: H02B 1/202 Cable lay-outs
• CPC Class Codes: H05K 1/0393 Flexible materials H05K1/038 takes precedence; specific organic compositions are classified in H05K1/0313 and subgroups
• CPC Class Codes: H05K 13/06 Wiring by machine
• CPC Class Codes: H05K 2201/10287 Metal wires as connectors or conductors
• CPC Class Codes: H05K 3/103 by bonding or embedding conductive wires or strips
• CPC Class Codes: H05K 3/281 by means of a preformed insulating foil H05K3/284 takes precedence
• CPC Class Codes: H05K 7/026 Multiple connections subassemblies
• CPC Class Codes: Y10T 29/49117 Conductor or circuit manufacturing
• CPC Class Codes: Y10T 29/49149 by metal fusion bonding
• CPC Class Codes: Y10T 29/49162 by using wire as conductive path
• CPC Class Codes: Y10T 29/5138 and means to machine work part to fit cooperating work part
• CPC Class Codes: Y10T 29/5149 to sever electric terminal from supply strip
• CPC Class Codes: Y10T 29/53174 Means to fasten electrical component to wiring board, base, or substrate
• CPC Class Codes: Y10T 29/53243 Multiple, independent conductors

Abstract

A wire-circuit sheet comprising; a resin sheet with circuit connecting holes, wires lying across the circuit connecting holes, and a cutting holes to punch the resin sheet so as to cut simultaneously the wires. Further, a wire-circuit sheet and its manufacturing method comprising; a resin sheet on which a plurality of wires lie as crossing or coming close to each other, cutting holes being provided at the crossing or close points of the plurality of wires to cut off the wires and the sheet together, and the wires being fixed and sandwiched in between laminated resin sheets with a sticky surface. Moreover, in an electric junction box utilizing the wire-circuit sheet, a busbar-wire connecting method comprising the steps of: forming insertion holes through a cover in order to insert and fix busbar-tabs as terminals; inserting the busbar-tabs as terminals into the insertion holes in the cover; mounting a wire-circuit sheet at a predetermined position on the cover; and using the busbar-tabs as welding electrodes to weld the wires and the busbar-tabs together to connect them in a conductive state.

Claims

1. A method of manufacturing a wire-circuit sheet comprising the steps of:

slidably inserting a plurality of wiring pins into holes formed on a wire-laying base plate, said plurality of pins being resiliently by springs which bias said pins to a position where said pins extend from a surface of said base plate;

laying wires between said pins by a wire positioning feeder;

pressing a first resin sheet having adhesive on a surface of said first resin sheet to said wires laid on said base plate to bond said first resin sheet to said wires; and

pressing a second resin sheet having adhesive on a surface of said second resin sheet to said first resin sheet with said bonded wires, so that said wires are bonded between said first and second resin sheets.

2. A manufacturing method for a wire-circuit sheet as claimed in claim 1, wherein said first and second resin sheets are continuously supplied from rolled sheets.

3. A manufacturing method for a wire-circuit sheet as claimed in claim 1, wherein said first and second resin sheets are supplied as each piece of resin sheets by handling arms with a vacuum suction cap.

4. A manufacturing method for a wire-circuit sheet as claimed in claim 1, further comprising forming positioning holes in said first and second resin sheets with said wires being fixed therebetween.

5. A manufacturing method for a wire-circuit sheet as claimed in claim 1, further comprising forming cutting holes in at least one position where a plurality of wires lie sufficiently close to each other that said wires and said sheets are cut off together.