US20010009201A1 - Circuit board, electrical connection box having the circuit board and method of making the circuit board - Google Patents
Circuit board, electrical connection box having the circuit board and method of making the circuit board Download PDFInfo
- Publication number
- US20010009201A1 US20010009201A1 US09/758,389 US75838901A US2001009201A1 US 20010009201 A1 US20010009201 A1 US 20010009201A1 US 75838901 A US75838901 A US 75838901A US 2001009201 A1 US2001009201 A1 US 2001009201A1
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- bus bars
- circuit board
- holes
- insulation board
- crossing
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- 238000004519 manufacturing process Methods 0.000 title claims description 7
- 238000009413 insulation Methods 0.000 claims abstract description 38
- 238000003466 welding Methods 0.000 claims description 21
- 238000005304 joining Methods 0.000 claims description 10
- 238000000034 method Methods 0.000 claims description 9
- 239000000969 carrier Substances 0.000 description 14
- 239000011295 pitch Substances 0.000 description 11
- 230000015572 biosynthetic process Effects 0.000 description 7
- 239000002184 metal Substances 0.000 description 7
- 230000035515 penetration Effects 0.000 description 6
- 239000000463 material Substances 0.000 description 4
- 238000003475 lamination Methods 0.000 description 3
- 238000005520 cutting process Methods 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 230000004075 alteration Effects 0.000 description 1
- 238000003491 array Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 230000020169 heat generation Effects 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 239000012774 insulation material Substances 0.000 description 1
- 239000010410 layer Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000002991 molded plastic Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
Images
Classifications
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/40—Forming printed elements for providing electric connections to or between printed circuits
- H05K3/4038—Through-connections; Vertical interconnect access [VIA] connections
- H05K3/4084—Through-connections; Vertical interconnect access [VIA] connections by deforming at least one of the conductive layers
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R12/00—Structural associations of a plurality of mutually-insulated electrical connecting elements, specially adapted for printed circuits, e.g. printed circuit boards [PCB], flat or ribbon cables, or like generally planar structures, e.g. terminal strips, terminal blocks; Coupling devices specially adapted for printed circuits, flat or ribbon cables, or like generally planar structures; Terminals specially adapted for contact with, or insertion into, printed circuits, flat or ribbon cables, or like generally planar structures
- H01R12/50—Fixed connections
- H01R12/51—Fixed connections for rigid printed circuits or like structures
- H01R12/52—Fixed connections for rigid printed circuits or like structures connecting to other rigid printed circuits or like structures
- H01R12/526—Fixed connections for rigid printed circuits or like structures connecting to other rigid printed circuits or like structures the printed circuits being on the same board
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K1/00—Printed circuits
- H05K1/02—Details
- H05K1/0286—Programmable, customizable or modifiable circuits
- H05K1/0287—Programmable, customizable or modifiable circuits having an universal lay-out, e.g. pad or land grid patterns or mesh patterns
- H05K1/0289—Programmable, customizable or modifiable circuits having an universal lay-out, e.g. pad or land grid patterns or mesh patterns having a matrix lay-out, i.e. having selectively interconnectable sets of X-conductors and Y-conductors in different planes
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R29/00—Coupling parts for selective co-operation with a counterpart in different ways to establish different circuits, e.g. for voltage selection, for series-parallel selection, programmable connectors
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
- H01R43/0214—Resistance welding
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2201/00—Indexing scheme relating to printed circuits covered by H05K1/00
- H05K2201/10—Details of components or other objects attached to or integrated in a printed circuit board
- H05K2201/10227—Other objects, e.g. metallic pieces
- H05K2201/10272—Busbars, i.e. thick metal bars mounted on the PCB as high-current conductors
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2203/00—Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
- H05K2203/06—Lamination
- H05K2203/063—Lamination of preperforated insulating layer
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K2203/00—Indexing scheme relating to apparatus or processes for manufacturing printed circuits covered by H05K3/00
- H05K2203/15—Position of the PCB during processing
- H05K2203/1572—Processing both sides of a PCB by the same process; Providing a similar arrangement of components on both sides; Making interlayer connections from two sides
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K3/00—Apparatus or processes for manufacturing printed circuits
- H05K3/10—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern
- H05K3/20—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern by affixing prefabricated conductor pattern
- H05K3/202—Apparatus or processes for manufacturing printed circuits in which conductive material is applied to the insulating support in such a manner as to form the desired conductive pattern by affixing prefabricated conductor pattern using self-supporting metal foil pattern
Definitions
- This invention relates to a circuit board and to an electrical connection box containing such a circuit board, e.g. an electrical connection box for use in an automobile or other vehicle.
- the invention also relates to a method of making such a circuit board.
- a pressure welding system of wiring a wire such as a single core wire or the like, along a circuit on an insulation board and connecting a pressure welding terminal on said wire by pressure welding. It is also known to use bus bars formed by stamping an electro-conductive metal plate into a circuit board shape.
- bus bars are used as an interior circuit
- a mold for stamping must be made in accordance with the circuit.
- the alteration of a circuit cannot be easily carried out and the costs of preparation of a mold are high.
- the yield of the electro-conductive metal plate is poor, which also raises costs. For example, if seven or eight sheets of bus bars were arranged in multi-layer lamination with insulation boards between them, the cost is high, because of a sharp increase of the number of circuits accommodated in the inside of an electrical connection box.
- Insulation sheets 1 a , 1 b are laminated on both sides of an electro-conductive member 3 , which is made in a lattice shape by stamping out the removed parts 3 a of an electro-conductive metal plate.
- the circuit is formed by cutting the unwanted connection points 3 b .
- Wiring is connected to the electro-conductive member 3 to make connection with exterior circuits. Since the circuit is formed by cutting the points 3 b , variation of the circuit is easily achieved.
- the lattice-shape is formed by stamping and there are a lot of the removed parts 3 a , there remains the problem that the yield of the electro-conductive metal plate is not improved.
- the present invention has as a first object to reduce the cost related to forming the interior circuit. Another object is to permit easy variation of a circuit. A third object is to design a cost reduction by easily forming insulation materials which lie between the third bus bars.
- a circuit board having an insulation board with first and second opposite main faces.
- a plurality of first strip bus bars are arranged on the first main face.
- the first strip bus bars extend in parallel in a first direction.
- a plurality of second strip bus bars are arranged on the second main face.
- the second strip bus bars extend in parallel in a second direction crossing the first strip bus bar extending in the first direction, whereby, as seen in plan view, on one of the main faces there is an array of crossing points of the first and second bus bars.
- the insulation board has a plurality of holes through it at a plurality of the crossing points.
- the mutually crossing bus bars are bent each towards each other at the holes and mutually joined through the board to establish electrical connection between them, whereby a predetermined wiring pattern is obtained.
- bus bars are joined by welding, but other joining methods are possible. Resistance welding is most preferred.
- first bus bars are located in grooves in the first main face of the insulation board, and the second bus bars are located in grooves in the second main face.
- the thickness of each of the mutually crossing bus bars in the direction of the insulation board is reduced, compared with the thickness of adjacent portions, by 15 to 25%.
- this thickness reduction is accompanied by elongating the bus bar via stretching, to provide the bent portion. This can avoid disturbance of the ends of the bus bars.
- a second aspect of the invention provides a method of making a circuit board, comprising the steps of:
- step (iv) is preferably performed to provide the bent portions at the appropriate positions, before locating the bus bars on the insulation board.
- step (iv) at least one of said first bus bars and said second bus bars are joined at opposite ends thereof to a pair of carrier members which maintain their relative positions.
- one of the bent portions may have a protrusion directed towards the other of said mutually crossing pair of bus bars.
- the use of material of the bus bars can be efficient, so that the yield of the material can be improved. Further, stamping by a mold which has been specifically designed for the individual circuit required is unnecessary. Therefore the cost for formation of the circuit board can be greatly reduced.
- the bus bars respectively arranged in parallel in the two directions, which are typically orthogonal, may have a nominal thickness, in the direction of the insulation board, in the range of 0.5 mm to 1.0 mm. Both ends thereof may be linked with carriers, and the carriers are cut to be removed after the bent parts are joined, e.g. resistance-welded.
- bus bars of the two directions are assembled on the insulation board, portions of them which are unnecessary in the circuit may be cut, after joining of the upper and lower bent parts, to form the requisite circuit. It is possible to use standard sets of the bus bars for both of the two directions, to simplify and reduce cost.
- the pitches (spacing) of the strip bus bars can be selected to correspond with the spacings of terminals of exterior components, such as a connector, a fuse and a relay.
- some of the bus bars arranged in parallel in one direction may correspond with the terminal pitch of a fuse, while others may correspond with the terminal pitch of a relay.
- Some of the bus bars arranged in the second direction may correspond with the small pitch of a connector terminal hole, while others may correspond with a middle-size pitch, and the remainder may correspond with a large pitch.
- tabs connected with these bus bars can be directly connected with the connector, the fuse and the relay, etc.
- the present invention provides an electric connection box including the above circuit board.
- the circuit board of the above-described construction may be arranged as a single layer in the electric connection box, or a plural number of circuit boards may be further arranged by lamination through insulation boards.
- FIG. 1(A) is a plan view of a circuit board which is a first embodiment of the present invention
- FIG. 1(B) is a sectional view on line I-I of FIG. 1(A);
- FIG. 1(C) is an enlarged sectional view of a portion of FIG. 1(B);
- FIG. 2(A) is a plan view of the bus bars of the X direction in the circuit board of FIG. 1(A);
- FIG. 2(B) is a plan view of the bus bars of the Y direction
- FIG. 3(A) is a plan view of the insulation board of the circuit board of FIG. 1(A);
- FIG. 3(B) is a sectional view on line II-II of FIG. 3(A);
- FIG. 3(C) is an enlarged sectional view of a portion of FIG. 3(B);
- FIG. 4 is a plan view showing the assembled state of the bus bars of the X direction and the Y direction, in the circuit board of FIG. 1(A);
- FIG. 5 is a sectional view showing the resistance welding of the bus bars of the X and Y directions, in the circuit board of FIG. 1(A);
- FIGS. 6 (A) and (B) are sectional views showing modified examples of the circuit board of FIG. 1(A);
- FIGS. 7 (A) and (B) show a prior art example discussed above.
- FIGS. 1 to 5 illustrate the circuit board 10 .
- Strip bus bars 14 are provided as parallel discrete spaced metal strips extending in an X direction on the upper face of an insulation board 11 .
- Strip bus bars 15 are similarly provided as parallel discrete spaced metal strips extending in a Y direction, orthogonal to the X direction, on the lower face of the insulation board 11 at regular spacings.
- the strip bus bars 14 , 15 of the X and Y directions are thus arranged crosswise through the insulation board 11 so as to form a lattice with mutual crossing points of the bus bars.
- the bus bars 14 , 15 are located in recesses or grooves 11 a , 11 b in the upper and lower faces of the insulation board 11 .
- the ends of the bus bars 14 of the X direction are initially linked with the carriers 16 A, 16 B, and may be arranged on the upper face of the insulation board 11 in this condition.
- the carrier 16 B is cut off after the formation of the bent parts 14 a described below and before the bus bars 14 are placed on the board 11 .
- the width of the bus bars 14 is, for example, 2 mm, and their nominal thickness is, for example, 0.64 mm.
- the spacings (pitches) of the parallel bus bars 14 of the X direction may, as desired, be varied. For example, some may have a pitch of 4 mm, others a pitch of 10 mm and yet others a pitch of 6.8 mm, corresponding with the spacing of terminals of a connector, a fuse and a relay.
- the bus bars 15 of the Y direction are similar. Both ends in their longitudinal direction when formed are linked with the carriers 17 A, 17 B.
- the bus bars 15 are arranged on the lower face of the insulation board 10 in this condition.
- the bus bars 15 have a width of, for example, 2 mm, a nominal thickness of, for example, 0.64 mm and a uniform pitch of, for example, 4 mm.
- the board thickness of the parts 11 c between the respective bottom faces of the grooves 11 a and 11 b are as thin as, for example, 0.8 mm at the cross positions. At the crossing points where the upper and lower bus bars are to be connected penetration holes 11 d are provided.
- the penetration holes 11 d provide a clearance since their upper parts 11 d - 1 are larger than the width of bus bars, and their lower parts 11 d - 2 are enlarged in a taper manner.
- the amount of protrusion of the bent parts 14 a , 15 a of the upper and lower bus bars 14 , 15 , which are resistance-welded through the penetration holes 11 d , is thus fixed, for example, at half (0.4 mm) of the board thickness of 0.8 mm.
- the protruding faces are mutually brought in contact.
- the parts 14 a , 15 a are bent in an approximately arc shape so as to protrude by 0.4 mm by press working.
- the bus bars 14 , 15 are extended in length by this press working so as to be reduced in thickness by, for example, 15 to 25% (20% in the present embodiment) of their nominal thickness.
- the bent parts 14 a , 15 a are made so that the dimension between the two ends of each bus bar before formation and after formation of the bent part may be the same.
- the bent parts 14 b are formed by press working when both ends of the bus bars 14 of the X direction are linked to the carriers 16 A, 16 B. Even if the number of the bent parts 14 b are different in each bus bar 14 , the deviation in the end positions of the respective bus bars 14 does not occur, and distortion and cracking do not occur in the carriers 16 A, 16 B. The same applies for the bus bars 15 of the Y direction and the carriers 17 A, 17 B.
- the bus bars 14 can be arranged on the upper face of the insulation board 11 when linked with the carriers 16 A, 16 B, and the bus bars 15 can be arranged on the lower face of the insulation board 11 when linked with the carriers 17 A, 17 B. Then the bent parts 14 a of the bus bars 14 protrude downwards in the penetration holes 11 d , and the bent parts 15 a of the bus bars 15 protrude upwards to bring the faces of the upper and lower bent parts 14 a and 15 a , respectively, in contact.
- the resistance welding is carried out by pressing the electrodes 50 , 51 of a resistance welder on the bent parts 14 a , 15 a from above and below, respectively, so that resistance welds 30 (see FIG. 1) are formed between the bus bars 14 , 15 .
- the carriers 16 A and 16 B of the bus bars 14 and the carriers 17 A, 17 B of the bus bars 15 are separated collectively.
- fine protrusions 20 of, for example, 0.3 mm height are provided on the upper faces of the bent parts 15 a of the bus bars 15 in the press working. Further, when the fine protrusions 20 are provided, the bent part 15 a including the fine protrusion 20 is also formed by length extension so that that the thickness of the bus bar is reduced by, for example, 15 to 25%, and the dimension between the two ends of each bus bar 15 is the same as that before the formation of the bent part.
- the welding zone can be concentrated at a small area in resistance welding, so that heat generation occurs easily, and the welding quality can be raised.
- the circuit board 10 formed as described above is for example accommodated in the lower casing part of an electrical connection box and assembled by placing an upper casing part thereon.
- the casing is typically of molded plastics material and has lateral openings to receive components which have terminals to engage the ends of the bus bars 14 , 15 e.g. connectors, fuses and relays.
- a plurality of the circuit boards 10 may be arranged in a stack in a box by lamination through a further insulation board or boards.
- the arrays of strip bus bars are arranged to give a lattice shape on the upper and lower faces of an insulation board.
- Penetration holes are provided on the insulation board at intersection points where conduction is required, and bent parts provided on the upper and lower bus bars are mutually joined through the penetration holes.
- the bus bars 14 , 15 are in the form of parallel spaced discrete metal strips. They are preferably joined without use of bonding material, e.g. by resistance-welding. Thereby, the connection of the upper and lower bus bars can be securely and easily obtained, and variation of the circuits is simple to achieve.
- the bent parts are formed by reducing the bus bar thickness by, for example, 15 to 25%, such that the dimension between the ends of the bus bars is the same before and after the formation of bent parts. Therefore, the parallel bus bars can be processed when they are joined with the carriers. Accordingly, their installation on the insulation board is easy and the resistance welding can be carried out in a condition in which the positioning of the bus bars was accurately carried out. As a result, the quality of the resistance welding can be high.
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- Engineering & Computer Science (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Manufacturing & Machinery (AREA)
- Connection Or Junction Boxes (AREA)
- Multi-Conductor Connections (AREA)
- Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
- Coupling Device And Connection With Printed Circuit (AREA)
Abstract
Description
- 1. Field of Invention
- This invention relates to a circuit board and to an electrical connection box containing such a circuit board, e.g. an electrical connection box for use in an automobile or other vehicle. The invention also relates to a method of making such a circuit board.
- 2. Description of Related Art
- To form a circuit board constituting the interior circuit of an electrical connection box, e.g. a junction box for an automobile and the like, there has conventionally been used a pressure welding system of wiring a wire, such as a single core wire or the like, along a circuit on an insulation board and connecting a pressure welding terminal on said wire by pressure welding. It is also known to use bus bars formed by stamping an electro-conductive metal plate into a circuit board shape.
- When a pressure welding system is used for the formation of an interior circuit, circuits accommodated in an electrical connection box have recently increased in accordance with a large increase of electric parts to be connected. Since the shape of an insulation board where an electric wire is wired in the pressure welding system becomes complicated, problems occur such that the wiring work and the processing of an insulation board require a long time, resulting in increased production costs.
- Further, when bus bars are used as an interior circuit, a mold for stamping must be made in accordance with the circuit. As a result, the alteration of a circuit cannot be easily carried out and the costs of preparation of a mold are high. Further, because a lot of residual parts are not used after stamping, the yield of the electro-conductive metal plate is poor, which also raises costs. For example, if seven or eight sheets of bus bars were arranged in multi-layer lamination with insulation boards between them, the cost is high, because of a sharp increase of the number of circuits accommodated in the inside of an electrical connection box.
- A
circuit board 2 for the interior of an electric connection box, shown in present FIGS. 7(A) and 7(B), is proposed in JP-A-56-130989, in view of the above problems.Insulation sheets conductive member 3, which is made in a lattice shape by stamping out the removedparts 3 a of an electro-conductive metal plate. The circuit is formed by cutting theunwanted connection points 3 b. Wiring is connected to the electro-conductive member 3 to make connection with exterior circuits. Since the circuit is formed by cutting thepoints 3 b, variation of the circuit is easily achieved. However, since the lattice-shape is formed by stamping and there are a lot of the removedparts 3 a, there remains the problem that the yield of the electro-conductive metal plate is not improved. - The present invention has as a first object to reduce the cost related to forming the interior circuit. Another object is to permit easy variation of a circuit. A third object is to design a cost reduction by easily forming insulation materials which lie between the third bus bars.
- In a first aspect of the invention, a circuit board is provided having an insulation board with first and second opposite main faces. A plurality of first strip bus bars are arranged on the first main face. The first strip bus bars extend in parallel in a first direction. A plurality of second strip bus bars are arranged on the second main face. The second strip bus bars extend in parallel in a second direction crossing the first strip bus bar extending in the first direction, whereby, as seen in plan view, on one of the main faces there is an array of crossing points of the first and second bus bars. The insulation board has a plurality of holes through it at a plurality of the crossing points. The mutually crossing bus bars are bent each towards each other at the holes and mutually joined through the board to establish electrical connection between them, whereby a predetermined wiring pattern is obtained.
- Preferably, at the holes the bus bars are joined by welding, but other joining methods are possible. Resistance welding is most preferred.
- Preferably the first bus bars are located in grooves in the first main face of the insulation board, and the second bus bars are located in grooves in the second main face.
- Suitably at the holes, the thickness of each of the mutually crossing bus bars in the direction of the insulation board is reduced, compared with the thickness of adjacent portions, by 15 to 25%. In the manufacture of the circuit board, this thickness reduction is accompanied by elongating the bus bar via stretching, to provide the bent portion. This can avoid disturbance of the ends of the bus bars.
- A second aspect of the invention provides a method of making a circuit board, comprising the steps of:
- (i) providing an insulation board having first and second opposite main faces and a plurality of holes at locations through which electrical connection is made through the board;
- (ii) locating a plurality of first bus bars on the first main face extending in parallel in a first direction;
- (iii) locating a plurality of second bus bars on the second main face extending in parallel in a second direction crossing the first direction, whereby as seen in plan view on one of the main faces there is an array of crossing points of the bus bars, a plurality of said crossing points coinciding with said holes;
- (iv) providing each of the mutually crossing pair of the bus bars at the position of each of the holes with a portion bent towards the other bus bar of the pair;
- (v) joining the mutually crossing pair of bus bars at said holes to establish electrical connection between them.
- In this method, step (iv) is preferably performed to provide the bent portions at the appropriate positions, before locating the bus bars on the insulation board. Preferably, during step (iv), at least one of said first bus bars and said second bus bars are joined at opposite ends thereof to a pair of carrier members which maintain their relative positions.
- Prior to the joining step (v), one of the bent portions may have a protrusion directed towards the other of said mutually crossing pair of bus bars.
- Within the invention the use of material of the bus bars can be efficient, so that the yield of the material can be improved. Further, stamping by a mold which has been specifically designed for the individual circuit required is unnecessary. Therefore the cost for formation of the circuit board can be greatly reduced.
- The bus bars respectively arranged in parallel in the two directions, which are typically orthogonal, may have a nominal thickness, in the direction of the insulation board, in the range of 0.5 mm to 1.0 mm. Both ends thereof may be linked with carriers, and the carriers are cut to be removed after the bent parts are joined, e.g. resistance-welded.
- After the bus bars of the two directions are assembled on the insulation board, portions of them which are unnecessary in the circuit may be cut, after joining of the upper and lower bent parts, to form the requisite circuit. It is possible to use standard sets of the bus bars for both of the two directions, to simplify and reduce cost.
- Further, the pitches (spacing) of the strip bus bars can be selected to correspond with the spacings of terminals of exterior components, such as a connector, a fuse and a relay. For example, some of the bus bars arranged in parallel in one direction may correspond with the terminal pitch of a fuse, while others may correspond with the terminal pitch of a relay. Some of the bus bars arranged in the second direction may correspond with the small pitch of a connector terminal hole, while others may correspond with a middle-size pitch, and the remainder may correspond with a large pitch.
- Thus, tabs connected with these bus bars can be directly connected with the connector, the fuse and the relay, etc.
- Further, the present invention provides an electric connection box including the above circuit board. The circuit board of the above-described construction may be arranged as a single layer in the electric connection box, or a plural number of circuit boards may be further arranged by lamination through insulation boards.
- Embodiments of the invention will now be described by way of non-limiting examples with reference to the accompanying drawings, in which:
- FIG. 1(A) is a plan view of a circuit board which is a first embodiment of the present invention;
- FIG. 1(B) is a sectional view on line I-I of FIG. 1(A);
- FIG. 1(C) is an enlarged sectional view of a portion of FIG. 1(B);
- FIG. 2(A) is a plan view of the bus bars of the X direction in the circuit board of FIG. 1(A);
- FIG. 2(B) is a plan view of the bus bars of the Y direction;
- FIG. 3(A) is a plan view of the insulation board of the circuit board of FIG. 1(A);
- FIG. 3(B) is a sectional view on line II-II of FIG. 3(A);
- FIG. 3(C) is an enlarged sectional view of a portion of FIG. 3(B);
- FIG. 4 is a plan view showing the assembled state of the bus bars of the X direction and the Y direction, in the circuit board of FIG. 1(A);
- FIG. 5 is a sectional view showing the resistance welding of the bus bars of the X and Y directions, in the circuit board of FIG. 1(A);
- FIGS.6(A) and (B) are sectional views showing modified examples of the circuit board of FIG. 1(A); and
- FIGS.7(A) and (B) show a prior art example discussed above.
- One embodiment of the present invention is shown in FIGS.1 to 5 which illustrate the
circuit board 10. Strip bus bars 14 are provided as parallel discrete spaced metal strips extending in an X direction on the upper face of aninsulation board 11. Strip bus bars 15 are similarly provided as parallel discrete spaced metal strips extending in a Y direction, orthogonal to the X direction, on the lower face of theinsulation board 11 at regular spacings. The strip bus bars 14, 15 of the X and Y directions are thus arranged crosswise through theinsulation board 11 so as to form a lattice with mutual crossing points of the bus bars. As FIG. 1(B) shows, the bus bars 14, 15 are located in recesses orgrooves insulation board 11. - As shown in FIG. 2(A), the ends of the bus bars14 of the X direction are initially linked with the
carriers 16A, 16B, and may be arranged on the upper face of theinsulation board 11 in this condition. However, as indicated by FIG. 1(A) in this embodiment, the carrier 16B is cut off after the formation of thebent parts 14 a described below and before the bus bars 14 are placed on theboard 11. The width of the bus bars 14 is, for example, 2 mm, and their nominal thickness is, for example, 0.64 mm. The spacings (pitches) of the parallel bus bars 14 of the X direction may, as desired, be varied. For example, some may have a pitch of 4 mm, others a pitch of 10 mm and yet others a pitch of 6.8 mm, corresponding with the spacing of terminals of a connector, a fuse and a relay. - As shown in FIG. 2(B), the bus bars15 of the Y direction are similar. Both ends in their longitudinal direction when formed are linked with the
carriers insulation board 10 in this condition. The bus bars 15 have a width of, for example, 2 mm, a nominal thickness of, for example, 0.64 mm and a uniform pitch of, for example, 4 mm. - Downwardly
bent parts 14 a formed by press molding are provided at requisite points on the bus bars 14. Similarly, upwardlybent parts 15 a formed by press molding are provided on the bus bars 15. Thesebent parts - Since there are
grooves insulation board 11, the board thickness of theparts 11 c between the respective bottom faces of thegrooves - As shown in FIGS.3(A)-(C), the penetration holes 11 d provide a clearance since their
upper parts 11 d-1 are larger than the width of bus bars, and theirlower parts 11 d-2 are enlarged in a taper manner. - The amount of protrusion of the
bent parts parts bent parts - The bent parts14 b are formed by press working when both ends of the bus bars 14 of the X direction are linked to the
carriers 16A, 16B. Even if the number of the bent parts 14 b are different in eachbus bar 14, the deviation in the end positions of the respective bus bars 14 does not occur, and distortion and cracking do not occur in thecarriers 16A, 16B. The same applies for the bus bars 15 of the Y direction and thecarriers - As shown in FIG. 4, the bus bars14 can be arranged on the upper face of the
insulation board 11 when linked with thecarriers 16A, 16B, and the bus bars 15 can be arranged on the lower face of theinsulation board 11 when linked with thecarriers bent parts 14 a of the bus bars 14 protrude downwards in the penetration holes 11 d, and thebent parts 15 a of the bus bars 15 protrude upwards to bring the faces of the upper and lowerbent parts - As shown in FIG. 5, the resistance welding is carried out by pressing the
electrodes bent parts bent parts carriers 16A and 16B of the bus bars 14 and thecarriers - Thus, in the present invention, as the parallel sets of bus bars14, 15 are linked with the
carriers 16A and 16B and thecarriers - In a variation of this embodiment shown in FIG. 6,
fine protrusions 20 of, for example, 0.3 mm height are provided on the upper faces of thebent parts 15 a of the bus bars 15 in the press working. Further, when thefine protrusions 20 are provided, thebent part 15 a including thefine protrusion 20 is also formed by length extension so that that the thickness of the bus bar is reduced by, for example, 15 to 25%, and the dimension between the two ends of eachbus bar 15 is the same as that before the formation of the bent part. - When the
fine protrusions 20 are provided on the contact face as described above, the welding zone can be concentrated at a small area in resistance welding, so that heat generation occurs easily, and the welding quality can be raised. - The
circuit board 10 formed as described above is for example accommodated in the lower casing part of an electrical connection box and assembled by placing an upper casing part thereon. The casing is typically of molded plastics material and has lateral openings to receive components which have terminals to engage the ends of the bus bars 14, 15 e.g. connectors, fuses and relays. Further, a plurality of thecircuit boards 10 may be arranged in a stack in a box by lamination through a further insulation board or boards. - As the above embodiment illustrates, according to the present invention, for an interior circuit of an electrical connection box, the arrays of strip bus bars are arranged to give a lattice shape on the upper and lower faces of an insulation board. Penetration holes are provided on the insulation board at intersection points where conduction is required, and bent parts provided on the upper and lower bus bars are mutually joined through the penetration holes. The bus bars14, 15 are in the form of parallel spaced discrete metal strips. They are preferably joined without use of bonding material, e.g. by resistance-welding. Thereby, the connection of the upper and lower bus bars can be securely and easily obtained, and variation of the circuits is simple to achieve. Further, the bent parts are formed by reducing the bus bar thickness by, for example, 15 to 25%, such that the dimension between the ends of the bus bars is the same before and after the formation of bent parts. Therefore, the parallel bus bars can be processed when they are joined with the carriers. Accordingly, their installation on the insulation board is easy and the resistance welding can be carried out in a condition in which the positioning of the bus bars was accurately carried out. As a result, the quality of the resistance welding can be high.
- While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the spirit and scope of the invention.
Claims (16)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2000-010732 | 2000-01-19 | ||
JP2000010732A JP3799468B2 (en) | 2000-01-19 | 2000-01-19 | Circuit board manufacturing method, circuit board manufactured by the method, and electrical junction box including the circuit board |
Publications (2)
Publication Number | Publication Date |
---|---|
US20010009201A1 true US20010009201A1 (en) | 2001-07-26 |
US6443737B2 US6443737B2 (en) | 2002-09-03 |
Family
ID=18538719
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/758,389 Expired - Fee Related US6443737B2 (en) | 2000-01-19 | 2001-01-12 | Circuit board, electrical connection box having the circuit board and method of making the circuit board |
Country Status (4)
Country | Link |
---|---|
US (1) | US6443737B2 (en) |
EP (1) | EP1119225B1 (en) |
JP (1) | JP3799468B2 (en) |
DE (1) | DE60104573T2 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6607115B2 (en) * | 2000-07-21 | 2003-08-19 | Sumitomo Wiring Systems, Ltd. | Junction box |
Families Citing this family (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP3446672B2 (en) * | 1999-07-30 | 2003-09-16 | 住友電装株式会社 | Electrical junction box |
DE10117798A1 (en) * | 2001-04-10 | 2002-12-05 | Bosch Gmbh Robert | plug |
JP4161877B2 (en) * | 2003-11-05 | 2008-10-08 | 住友電装株式会社 | Circuit structure, manufacturing method thereof and power distribution unit |
JP4939899B2 (en) * | 2006-10-30 | 2012-05-30 | オムロンオートモーティブエレクトロニクス株式会社 | Conductive terminal welding method and conductive terminal structure |
JP2016025229A (en) * | 2014-07-22 | 2016-02-08 | 株式会社オートネットワーク技術研究所 | Circuit structure |
JP6287815B2 (en) * | 2014-12-24 | 2018-03-07 | 株式会社オートネットワーク技術研究所 | Method for manufacturing circuit structure |
JP6440778B2 (en) * | 2017-07-04 | 2018-12-19 | 古河電気工業株式会社 | Electric wire structure, electric connection structure, and electric wire structure manufacturing method |
Family Cites Families (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2019625A (en) * | 1934-03-30 | 1935-11-05 | Rca Corp | Electrical apparatus |
US3290557A (en) * | 1962-02-23 | 1966-12-06 | Sippican Corp | Wiring device with selectively severable conductor for forming predetermined circuit pattern |
GB1108903A (en) * | 1965-07-31 | 1968-04-10 | Amp Inc | Electrical plugboard assembly |
JPS5832795B2 (en) | 1980-03-18 | 1983-07-15 | 品川自動車電線株式会社 | Continuous substrate for matrix wiring |
US4801765A (en) * | 1986-01-06 | 1989-01-31 | American Telephone And Telegraph Company, At&T Bell Laboratories | Electronic component package using multi-level lead frames |
US4859806A (en) * | 1988-05-17 | 1989-08-22 | Microelectronics And Computer Technology Corporation | Discretionary interconnect |
EP0600052B1 (en) * | 1992-06-15 | 1996-04-17 | Dyconex Patente Ag | Process for producing subsequently conditionable contact points on circuit substrates and circuit substrates with such contact points |
JP3361738B2 (en) * | 1998-01-29 | 2003-01-07 | 矢崎総業株式会社 | Connection box for indoor wiring |
-
2000
- 2000-01-19 JP JP2000010732A patent/JP3799468B2/en not_active Expired - Fee Related
-
2001
- 2001-01-12 US US09/758,389 patent/US6443737B2/en not_active Expired - Fee Related
- 2001-01-15 DE DE60104573T patent/DE60104573T2/en not_active Expired - Lifetime
- 2001-01-15 EP EP01300312A patent/EP1119225B1/en not_active Expired - Lifetime
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6607115B2 (en) * | 2000-07-21 | 2003-08-19 | Sumitomo Wiring Systems, Ltd. | Junction box |
Also Published As
Publication number | Publication date |
---|---|
DE60104573T2 (en) | 2005-08-04 |
EP1119225A3 (en) | 2003-05-07 |
DE60104573D1 (en) | 2004-09-09 |
JP3799468B2 (en) | 2006-07-19 |
JP2001203012A (en) | 2001-07-27 |
EP1119225A2 (en) | 2001-07-25 |
US6443737B2 (en) | 2002-09-03 |
EP1119225B1 (en) | 2004-08-04 |
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