Bus bar structure

• US 20030096541A1
• Filed: 11/18/2002
• Published: 05/22/2003
• Est. Priority Date: 05/28/1997
• Status: Active Grant

• Current Assignee: Autonetworks Technologies, Ltd. (Sumitomo Corporation)
• Original Assignee: Autonetworks Technologies, Ltd. (Sumitomo Corporation)
• Inventors: Saka, Yoshifumi, Togawa, Atsuhiro, Fujii, Atsuhiko, Onizuka, Takahiro
• Granted Patent: US 6,761,598 B2
• Time in Patent Office: Days
• US Class Current: 439/876
• CPC Class Codes: H01R 43/0221 Laser welding H01R43/0228 takes precedence
• CPC Class Codes: H01R 9/2458 Electrical interconnections between terminal blocks
• CPC Class Codes: H01R 9/2491 Terminal blocks structurally associated with plugs or sockets
• CPC Class Codes: H05K 3/202 using self-supporting metal foil pattern
• CPC Class Codes: H05K 3/222 Completing of printed circuits by adding non-printed jumper connections printed jumper connections H05K3/4685
• CPC Class Codes: H05K 3/328 by welding
• CPC Class Codes: H05K 3/361 Assembling flexible printed circuits with other printed circuits
• CPC Class Codes: H05K 3/4015 using auxiliary conductive elements, e.g. pieces of metal foil, metallic spheres
• CPC Class Codes: Y10S 439/907 Contact having three contact surfaces, including diverse surface
• CPC Class Codes: Y10S 439/949 Junction box with busbar for plug-socket type interconnection with receptacle

Abstract

A bus bar structure includes: a bus bar stored in an electric junction box; and a tab terminal electrically connected to a pattern portion of the bus bar. The tab terminal is separately formed with the bus bar. The pattern portion is welded with the tab terminal by using a laser beam.

Claims

1. A method of manufacturing a bus bar structure, comprising:

providing a continuous bus bar comprising a first pattern portion and a second pattern portion, the second pattern portion being spaced from the first pattern portion by a predetermined distance;

providing a tab terminal, the tab terminal comprising;

a bent leg portion in a first plane, and

a standing portion in a second plane intersecting the first plane, the standing portion connected to the bent leg portion at a line of intersection of the first plane and the second plane, the standing portion having a length longer than the predetermined distance;

positioning the tab terminal such that the bent leg portion is in contact with the first pattern portion and the standing portion is oriented facing the second pattern portion such that, if the standing portion were bent about the line of intersection toward the second pattern portion, the standing portion would contact the second pattern portion; and

attaching the bent leg portion to the first pattern portion.

2. The method of claim 1, further comprising:

providing a laser beam source,

wherein the attaching the bent leg portion to the first pattern portion comprises welding the bent leg portion to the first pattern portion using a laser beam from the laser beam source.

9. The method of claim 1, wherein the tab terminal is secured to the continuous bus bar by laser welding.

3. A method of manufacturing a bus bar structure, comprising:

providing a bus bar having a pattern portion;

providing a first tab terminal separate from the bus bar;

providing a laser beam source; and

welding the first tab terminal to the pattern portion using a laser beam from the laser beam source.

4. The method of claim 3, wherein the first tab terminal has a bent leg portion which contacts the pattern portion, and the welding the first tab terminal comprises irradiating the bent leg portion with the laser beam.

5. The method of claim 3, wherein the first tab terminal is integrally formed with a junction terminal.

6. The method of claim 3, further comprising:

integrally forming a second tab terminal with the pattern portion, the second tab terminal being shorter than a predetermined length, wherein

the first tab terminal is longer than the predetermined length.

7. A method of manufacturing a bus bar structure, comprising:

providing a bus bar that defines a first pattern portion and a second pattern portion;

positioning a jumper between the first pattern portion and the second pattern portion;

providing a laser beam source; and

welding the jumper to the first pattern portion and the second pattern portion using a laser beam from the laser beam source.

8. A method of manufacturing a bus bar structure, comprising:

providing a bus bar having a pattern portion;

providing a laser beam source;

directly welding a conductor of at least one of an FPC and a PCB to the pattern portion using a laser beam from the laser beam source.