# Patent

## Title
Method for the manufacture of a roller shutter slat

## Abstract

This is a divisional of copending application Ser. No. 07/633,533 filed on Dec. 27, 1990, now U.S. Pat. No. 5,092,030.

## Background
1. Field of the Invention

The invention relates to a method for attaching tabs to electric wire ends and also to an apparatus used in the method, the tabs being small markers which distinguish one electric wire from another.

2. Description of Prior Art

It is a widespread practice to connect a plurality of individual electric wires with conductive terminals at their ends to a common integrated electric connector and to detachably join the connector to another integrated electric connector of the same or similar type or to any other electric apparatuses. It is also a common practice to apply markings to the individual wires in order to avoid erroneous or confused connection thereof. Wire-identifying tabs carrying or printed with the markings have usually been attached to the electric wires not automatically but manually because the tabs in general are of cylindrical shape. Such a manual operation in attaching the tabs to the wires has consequently made lower the efficiency in mass-production of the integrated connectors in a case wherein ten thousands or more connectors of the same type are manufactured.

An object of the invention, which was made in view of the current circumstances described above, is therefore to provide on one hand a method for mechanically or automatically attaching cylindrical wire-identifying tabs to electric wires and also to provide on the other hand an apparatus used in the method with an improved efficiency, wherein the wire-identifying tabs have, as already proposed in the industry, outer peripheral surfaces on which wire-identifying symbolic marks are printed or written and each have a slit extending over the full length in axial direction of each tab.

This object is accomplished in the following manner as described below by using the reference numerals on the accompanying drawings which illustrate embodiments of the present invention. From an aspect of the invention, a method for attaching wire-identifying tabs comprises the steps of mounting the wire-identifying tab 1 having a slit 2 onto a pair of thin rigid sheets 11 and 11 disposed in parallel and almost in contact with each other at their upper portions, the slit 2 allowing the rigid sheets 11 to be inserted in the tab so that their opposite surfaces are gripped together by the slit after the tab is completely inserted to the sheets 11 from their one ends and in parallel with them, subsequently inserting an end of an electric wire (K) into the wire-identifying tab 1 while the pair of the thin rigid sheets 11 and 11 are being relatively displaced apart from each other in a direction perpendicular to the tab 1 so as to increase the width of its slit 2, and finally pulling the rigid sheets 11 and 11 away from the wire-identifying tab 1 so as to release engagement of the sheets 11 with the tab 1, thereby securedly fitting outer peripheral surface of the end of the electric wire (K) in the wire-identifying tab 1.

From a further aspect of the invention, a method for attaching wire-identifying tabs comprises the steps of preparing a pair of thin rigid sheets 11 and 11 respectively having contact portions 11a lying parallel and substantially in contact with each other so as to receive a wire-identifying tab 1, the rigid sheets further having wire-receiving portions 11b tapered outwardly to form a space with an increasing distance between them, mounting the tab 1 having a slit 2 onto a pair of the contact portions 11a of the sheets 11, the slit 2 allowing said contact portions 11a to be inserted in the tab so that their opposite surfaces are gripped together by the slit after the tab is completely inserted to the said portions of the sheets 11 from their one ends, subsequently causing an end of an electric wire (K) to take a position parallel with the rigid sheets and to move into the space between the wire- receiving portions 11b of the rigid sheets 11 towards the contact portions 11a, then inserting the end of the electric wire (K) into the wire-identifying tab 1 while said wire is causing the contact portions 11a of the thin rigid sheets 11 and 11 to be relatively displaced apart from each other thereby increasing the width of the slit 2 of the tab 1 wherein the sheets serve as a guide means for the electric wire, and finally releasing engagement of the wire-identifying tab 1 with the contact portions 11a of said sheets 11 to thereby fixedly secure the tab 1 to an outer peripheral surface of the end of the electric wire (K).

From a still further aspect, the present invention provides an apparatus for attaching wire-identifying tabs in accordance with the above-summarized method. The apparatus comprises a wire receiving section (A) to hold in place an end of an electric wire (K), a tab receiving section (B) to hold in place a wire-identifying tab 1, at least one of the sections (A) and (B) being controlled to move relative to the other so as come into or out of contact therewith, the wire receiving section (A) including at least one of a wire end supporter 24 and a terminal supporter 25 adapted to support a terminal fixed to the end of the wire (K), the wire end supporter 24 being disposed apart from the terminal supporter 25 by a distance equal to or longer than the wire-identifying tab 1, the tab receiving section (B) including a pair of thin rigid sheets 11 and 11 substantially in contact with each other and disposed at an end portion of the tab receiving section (B) opposite to the wire receiving section (A), the rigid sheets extending parallel with the electric wire when it is received on the section (A), a tab holding space 12 formed behind the rigid sheets 11 and remote from the wire receiving section (A) so as to hold the wire-identifying tab 1, an urging means 14 also disposed remote from said section (A) so as to elastically press a marking portion 3 of the tab 1, and a retracting means for retracting the thin rigid sheets 11 out of the tab holding space 12.

The wire-identifying tabs used in the method and the apparatus in the invention each have the marking portion to which a proper identification mark is applied. The tabs are of a cylindrical shape and each having a slit formed to extend in an axial direction throughout the full length of the tab.

The identification mark may be applied to the marking portion of the wire-identifying tab by means of any suitable apparatus such as a printing machine employing an ink, a thermal printer employing an ink ribbon, or a marking press adapted to form a carved seal.

In order to facilitate the marking operation, it is preferable to form the marking portion of the tab with an appropriate plastics. It is more desirable to make the whole tab as an integral piece by using such plastics.

In exercising the method and in operation of the apparatus in the invention, the end of each electric wire (K) will be manually or mechanically caused to rest on predetermined places (i.e., on the supporters 24 and 25). The the wire-identifying tab 1 is also manually or mechanically caused to take a predetermined position (i.e., to be set in the tab holding space 12) so that the wire (K) and the tab 1 can subsequently be forced in a simple manner to move towards each other until they contact mutually.

According to the method and apparatus in the invention, the wire-identifying tabs can be attached easily and readily to the electric wire ends even if any crimp contacts or solderless contacts or any insulating sleeves have been fixed to said ends. Thus, high operation efficiency is ensured in attaching such wire-identifying tabs to the wires which are to be connected to one integrated connector.

In the accompanying drawings which illustrate a method and apparatus in the invention:

FIG. 1 is a side elevation showing an apparatus as a whole in an embodiment of the invention;

FIG. 2 is a front elevation of the apparatus in the embodiment;

FIG. 3 is a side elevation of a principal part of the apparatus;

FIG. 4 is a front elevation the principal part;

FIGS. 5A to 5E are schemes showing sequential steps of a method exercised in an embodiment of the invention;

FIGS. 6 and 7 are perspective views illustrating some of the steps;

FIG. 8 is a vertical cross-sectional view also showing one of the steps;

FIGS. 9 and 10 are further perspective views illustrating some steps of another method in another embodiment;

FIGS. 11A to 11D are schemes showing sequential steps of still another method exercised in a further embodiment of the invention.

Preferred embodiments of the invention will now be described in detail referring to the accompanying drawings.

A first embodiment is illustrated in FIGS. 1 to 8 wherein FIGS. 1 to 5E show an apparatus in the embodiment, with FIGS. 5A to 5E showing a method therein. FIGS. 6 to 8 illustrate a relationship between an electric wire (K) and a wire-identifying tab 1 in the method.

For reasons of convenience, the apparatus in the first embodiment will be described at first.

As shown in FIGS. 1 and 2 illustrating the apparatus on the whole, the apparatus which is manually operated and vertically arranged comprises an actuating lever 31 for actuating a main shaft 32. With the actuating lever 31 pushed downwards, the main shaft 32 is lowered which will automatically return to its home position as shown in FIGS. 1 and 2 by releasing the lever 31. Secured to a lower end of the main shaft 32 is a retaining shaft 19 to which a tab receiving section (B) is tightly connected as shown in FIGS. 3 and 4. A wire receiving section (A) is fixed on a base frame 33 which is located below the tab receiving section (B).

As will be apparent already, the apparatus is composed of two main parts, that is, the wire receiving section (A) for holding in place an end of the electric wire (K) and the tab receiving section (B) for holding in place the wire-identifying tab 1. In this embodiment, the tab receiving section (B) is raised and lowered by operating the lever 31 so as to move towards and away from the wire receiving section (A). The wire receiving section (A) comprises a pair of upright plates 21 and 22 spaced apart from each other by a distance equal to or more than the length of the wire-identifying tab 1. Supporters 24 and 25 are formed near tops of the upright plates 21 and 22, respectively, so as to receive and hold the end of wire (K) and a flat portion of conductive terminal (T) attached to said wire end. The wire receiving section further comprises a perpendicular plate 23 which are perpendicular to and extending between the upright plates 24 and 25.

On the other hand, the tab receiving section (B) comprises a pair of thin rigid sheets 11 and 11 disposed at its lower portion opposite to the wire receiving section (A). As is shown in FIG. 3, the rigid sheets 11 have their lower portions 11b and 11b which taper downwards to increase a distance between them thereby forming a conical or horn-like shape in the side elevation. The rigid sheets 11 further comprise upper portions 11a and 11a substantially in contact with each other and parallel with the wire which is to be laid on the wire receiving section. Rocking members 15 and 15 are pivoted by pins 16 to the lower portion of the tab receiving section so that said rigid sheets are secured to the rocking members 15 so as to be opened and closed together with them.

A tab holding space 12 holding the wire-identifying tab 1 is formed above the rigid sheets 11 and remote from the wire receiving section (A). A coiled spring 14 as an urging means is also disposed above the rigid sheets and remote from said section (A) so as to elastically push a reciprocating head 13 which in turn presses a marking portion 3 of the tab 1. A retracting means is also provided to retract the thin rigid sheets 11 downwards out of the tab holding space 12 when said sheets are lowered from their position in FIG. 5C to their lower position in FIG. 5D.

FIGS. 5A to 5E illustrate in course of time such a function or operation of the various members. In particular, the rocking members 15 are opened sideways due to a spring means (not shown) as schematized in FIG. 5D when they are released from the wire-identifying tab 1. Guide rollers 17 respectively cause the rocking members 15 to return to their home position in FIG. 5A when the tab receiving section is retracted upwards as shown in FIG. 5E.

The wire-identifying tab 1 shown in FIG. 6 comprises a marking portion 3 which is made flat on the outer peripheral surface of the tab so that any suitable identifying mark 4 can be applied to the portion 3. A slit 2 extends axially of the wire-identifying tab from one end thereof to the other end. The tab 1 is D-shaped in its cross section and comprises a small lug 5 protruding from its inner surface, the lug being of a size such as to engage with a crimped pit (p) on the surface of a sleeve (s) of the terminal (T) when the tab is attached to the wire (K) as shown in FIG. 8.

The wire-identifying tab 1 in FIGS. 9 and 10 is attached to the wire (K) at its end portion in close proximity of a terminal cover (C).

FIGS. 11A to 11D illustrate in course of time an operation in another embodiment wherein the rocking members 15 in the first embodiment are dispensed with. The thin rigid sheets 11 and 11 are directly secured to an elevating frame 18. In this case, the rigid sheet 11 are more elongate in vertical direction than in those in the first embodiment so as to form a vertically elongate conical or horn-like shape in the side elevation. The wire (K) is directly guided into the tab along the elongate rigid sheets. Other features are the same as the first embodiment.

Though the receiving sections (A) and (B) are arranged vertically relative to each other in the embodiments described above, it will however be understood that they may be arranged in a horizontal direction.

It is a matter of course that any other appropriate modifications can be made within a scope of the present invention.

## Claims

1. A method for attaching a wire-identifying tab to an end portion of an electric wire, the tab having a marking portion (3) to which an identification mark (4) is applied and being of a cylindrical shape having a slit (2) extending axially along a fully length of the tab, the method comprising the steps of: mounting the wire-identifying tab (1) onto upper portions of a pair of thin rigid sheets (11) disposed in parallel and substantially in contact with each other at said upper portions by sliding the tab along the slit from one end onto the upper portions so that opposite surfaces of the upper portions are gripped together by the slit after the tab is completely inserted to the sheets (11) from their one ends and in parallel with the upper portions; subsequently forcing the end of the electric wire (K) into the wire-identifying tab between the upper portions of the sheets in a direction perpendicular to the tab (1) while the upper portions of the pair of the rigid sheets (11) are relatively separated from each other so as to increase the width of the slit (2) of the tab; and finally pulling the rigid sheets (11) away from the wire-identifying tab (1) so as to disengage the sheets (11) from the tab (1), thereby securing an outer peripheral surface of the end of the electric wire in the wire-identifying tab (1).

2. A method for attaching a wire-identifying tab to an electric wire end portion, the tab comprising a marking portion (3) having an identification mark (4) and being a cylinder having a slit (2) extending axially over the full length of the tab, the method comprising the steps of: preparing a pair of rigid sheets (11) each having an upper contact portion (11a) lying parallel and substantially in contact with each other with wire-receiving portions (11b) tapered outwardly from the upper contact portions forming a space with an increasing distance between said wire-receiving portions mounting the tab (1) onto the pair of the upper contact portions (11a) by sliding the tab along the upper contact portions from one end with the upper contact portions within the slit (2) so that opposite surfaces of the upper contact portions are gripped together by the slit after the tab has been inserted onto the upper contact portions; subsequently positioning the end of the electric wire in parallel with the rigid sheets in the space between the wire-receiving portions (11b) towards and parallel with the contact portions (11a); then forcing the end of the electric wire into the tab (1) while said wire forces the contact portions (11a) to be relatively displaced apart from each other thereby increasing the width of the slit (2) of the tab (1) wherein the sheets serve as a guide means for the electric wire; and finally disengaging the tab (1) from the contact portions (11a) of said sheets (11) to thereby secure the tab (1) to an outer peripheral surface of the end of the electric wire.

3. A method for attaching a wire-identifying tab to an end portion of an electric wire, the tab having a marking portion (3) to which an identification mark (4) is applied and being of a cylindrical shape and having a slit (2) extending axially over a full length of the tab, the method comprising the steps of: mounting the wire-identifying tab (1) above a pair of thin rigid sheets (11) disposed in parallel and substantially in contact with each other at upper portions thereof, inserting the upper portions of the rigid sheets (11) into the slit (2) of the tab so that the upper portions of the rigid sheets are gripped together by the slit, subsequently sliding the end of the electric wire (K) into the wire-identifying tab (1) through the slit (2) in a direction perpendicular to the tab while the pair of the rigid sheets (11) are displaced apart from each other so as to increase the width of the slit (2); and finally pulling the rigid sheets (11) away from the wire-identifying tab (1) so as to disengage the sheets (11) from the tab (1), thereby securing an outer peripheral surface of the end of the electric wire in the wire-identifying tab (1).

4. A method for attaching a wire-identifying tab to an electric wire end portion, the tab comprising a marking portion (3) having an identification mark (4) and being a cylinder having a slit (2) extending axially over a full length of the tab, the method comprising the steps of: preparing a pair of rigid sheets (11) each having end contact portions (11a) lying parallel and substantially in contact with each other, the sheets further having wire-receiving portions (11b) extending from said contact portions and tapered outwardly thereby forming a space with an increasing distance between said wire-receiving portions in a direction away from said contact portions; inserting the contact portions (11a) into the slit (2) allowing said contact portions (11a) to be inserted in the tab so that opposite surface of the contact portions are gripped together by the slit after the contact portions (11a) are inserted into the slit (2); subsequently positioning the end of the electric wire in parallel with the spaced rigid sheets and the slit (2) and moving the end of the wire into the space between the wire-receiving portions (11b) towards the contact portions (11a); forcing the end of the electric wire into the tab (1) while said wire forces the contact portions (11a) to be relatively displaced apart from each other thereby increasing the width of the slit (2) of the tab (1) wherein the rigid sheets serve as a guide means for the electric wire; and finally disengaging the tab (1) from the contact portions (11a) of said rigid sheets (11) which secures the tab (1) to an outer peripheral surface of the end of the electric wire.