Planar circuit sheet

Abstract: An electrical planar circuit sheet for receiving replaceable components with blade-type terminals comprises a plurality of discrete, spaced planar circuits, each circuit comprising a first element and a second element that are spaced by an insulative gap. First resilient blade terminals extend outwardly from said first element and second resilient blade terminals extend outwardly from said second element. Spring clips (70) engaged on said first and second blade terminals provide direct electrical and mechanical connection to the blade-type terminals of a discrete component. Each of these spring clips (70) comprises a frame (74) adapted to engage one of the blade terminal such that a spring (72), disposed within the frame (74), extends toward this blade terminal. The spring (72) terminates substantially adjacent the blade terminal, whereby a blade-type terminal of a discrete component is frictionally engageable between the spring (72) and the blade terminal. The circuit sheets may be stacked to form multilayer circuit sheets.

Description: The present invention relates generally to an electrical planar circuit sheet (such as e.g. a fuse panel), for receiving replaceable electrical circuit elements with blade-type terminals (such as fuses and the like). There are several prior art fuse holders that incorporate stamping and forming methods to mass produce contact terminals. This prior art is exemplified by U.S. Patent No. 4,616,416 to and U.S. Patent No. 4,712,299 to Loewen et al. However, both of these patents apply only to the metal terminal elements of fuse holders or other electrical connectors. Prior art U.S. Patent No. 4,872,262 to David R. March does address the need for a fuse holder for replaceable circuit elements having blade-type terminals. Such fuses are well known in the industry and comprise a pair of spaced blades partially enclosed in an insulative housing. The blades are interconnected within the housing by a conductive interconnect which self-destructs at a preselected amperage. The blades extend from the housing for frictional connection to a suitable, typically plastic housing. Examples of such fuses include "ATC" fuses manufactured by Cooper Industries, Inc. of Houston Texas and "ATO" fuses manufactured by Littelfuse. Blade-type fuses have found widespread use in electrical systems found in automobiles, motorboats and many other products. The disclosure of U.S. Patent No. 4,872,262 does show improvements and economies over prior art. However, U.S. Patent No. 4,872,262 still suffers from certain drawbacks such as requiring a multiplicity of parts as well as requiring separate fuse holder blocks for separate circuits. Other patents of interest in this area, which pose similar or other problems, include U.S. Patent Nos. 2,116,269; 3,140,364; 3,457,640; 3,618,207; 4,197,636; 4,337,574; 4,801,278; 4,938,715 and 5,113.168. According to U.S. Patent No 5,306,181 a planar fuse panel is produced by stamping a section of conductive metal - of the desired thickness, temper and shape - out from a sheet of conductive metal. Simultaneously, bent tabs and gaps are formed in the same stamping operation for frictionally engaging blade terminals from blade-type fuses. The edges of the fuse panel include a plurality of male blade connectors of a known configuration. A multiplicity of circuits are included in the planar fuse panel depending on the number of circuits desired. Each circuit has an overall rectangular shape with a first portion consisting of an "L" shaped element and a second portion comprising a rectangular shaped element located in the shoulder of the first element. Spaces are formed bridging the two portions of each circuit with the bent tabs extending into each space to frictionally engage the blade-type terminal from a fuse or the like. The conductive metal is appropriately finished and/or plated and then insulative layers, such as polyester or polyamide film, are applied (e.g., laminated) to both surfaces of the metal in sheet form. It is an object of the present invention to make the connection of blade-type terminals to an electrical planar circuit, of the type disclosed for example in U.S. Patent No 5,306,181, more reliable and more effective. This object is achieved by an electrical planar circuit sheet as claimed in claim 1. DE-A-43 19 079 discloses a connection box that is integrated in the dashboard of a car. The connection box includes an electrical planar circuit sheet having all the features of the preamble of claim 1. DE-A-43 19 079 does not disclose how components are connected to the blade terminals of the circuit sheet. Discrete spring clips for connecting blade terminals to blade terminals are known from EP-A-0 463 608 and GB-A-2 2265 769. The blade terminals are individually received and mechanically retained in electrically conductive connecting springs, which are electrically interconnected so as to provide electrical contact between the blade terminals. In accordance with the present invention, the bent tabs and gaps disclosed in U.S. Patent No 5,306,181 for frictionally engaging a blade-type terminal from a fuse or the like, are replaced by blade terminals extending from the fuseplane. Discret spring clips are used to provide direct electrical and mechanical contact between these blade terminals extending from the fuseplane and a blade extending from a blade-type component by frictionally engaging the two blade terminals. This is in contrast to prior art devices which utilize intermediate connectors for indirect electrical connection between a blade terminal of the fuse plane and a blade-type component. It will therefore be appreciated that, according to the present invention, blade-type fuses or the like, can be directly connected to other blade terminals of the the circuit sheet in a reliable and effective manner. It will further be appreciated that a simplified process of thermoplastic molding can be used to insulate the circuit sheet, whereas the stamped bent tabs and gaps disclosed in U.S. Patent No 5,306,181 would not have allowed such a simple process of thermoplastic molding. The present invention also provides a method of connecting a first electrical blade terminal to a second blade terminal with a spring clip. The spring clip comprises a frame means adapted to engage a first blade terminal such that a spring means, disposed within the frame means, extends toward the blade terminal, said spring means terminating substantially adjacent the blade terminal, whereby a second blade terminal is frictionally engageable between the spring means and the first blade terminal. It is also disclosed herein that multilayer circuit sheets, e.g. multilayer fuseplanes, can be constructed with the electrical planar circuit sheets of the invention. These new multilayer circuit sheets (e.g. fuseplanes) allow for higher current density and/or larger numbers of circuits in substantially equivalent space. Carefully selected configurations of elements and spaces therebetween cooperate to nest the multiple layers together. In these new multilayer circuit sheets the individual circuits are advantageously maintained in spaced relationship from one another by molding material which encapsulates said circuits except for a portion of the blade terminals. The circuit sheets of the present invention exhibit a low profile configuration which eliminates the need for terminal blocks and preclude crimping or soldering operations. Customer configurations can be made quickly and inexpensively and are designed on computerized numerically controlled equipment. An important feature is that a planar fuse panel according to the present invention is much more economical to design, to produce and to use than prior art holders for blade-type circuit elements. The circuit sheets and spring clips of the present invention can also readily accommodate other electrical or electronic components such as relays, and the like. The above-discussed and other features and advantages of the present invention will be appreciated and understood by those skilled in the art from the following detailed description and drawings, wherein like elements are numbered alike in the several FIGURES: FIGURE 1 is a plan view of the of the planar fuse panel disclosed in US-A-5,306,181; FIGURE 2 is an enlarged detailed plan view of the area encircled as 2 in FIGURE 1; FIGURE 3 is a cross-sectional elevation view of the planar fuse panel of FIGURE 2 along the line 3-3- of FIGURE 2; FIGURE 4 is a cross-sectional elevation view of the planar fuse panel of FIGURE 2 along the line 4-4 of FIGURE 2; FIGURE 5 is a partial elevated side view of the planar fuse panel of FIGURE 1; FIGURE 6 is a plan view of an alternate prior art embodiment of the planar fuse panel disclosed US-A-5,306,181; FIGURE 7 is an enlarged detailed plan view of the area encircled as 7 in FIGURE 1; FIGURE 8 is a cross-sectional elevation view of the planar fuse panel of FIGURE 7 along the line 8-8 of FIGURE 7; FIGURE 9 is a cross-sectional elevation view of the planar fuse panel of FIGURE 7 along the lines 9-9 of FIGURE 7; FIGURE 10 is a partial elevated side view of the planar fuse panel of FIGURE 6; FIGURE 11 is a plan view of still another prior art embodiment of the planar fuse panel disclosed in US-A-5,306,181; FIGURE 12 is an enlarged detailed plan view of the area encircled as 12 in FIGURE 11; FIGURE 13 is a cross-sectional elevation view of the planar fuse panel of FIGURE 12 along the line 13-13 of FIGURE 12; and FIGURE 14 is a partial elevated side view of the planar fuse panel of FIGURE 11; FIGURE 15 is a top view of a new embodiment of the fuseplane where the several circuits utilize a collective element and blade terminals; FIGURE 16 is a top view of FIGURE 15 after application of thermoplastic insulative material; FIGURE 16A is a cross-sectional elevation view of an alternative embodiment of the planar fuse plane of FIGURE 16; FIGURE 17 is a side view of FIGURE 15; FIGURE 18 is a side view of FIGURE 16; FIGURE 19 is a plan view of the top layer of a new multilayer fuseplane; FIGURE 19A is an end view of FIGURE 19; FIGURE 19B is a side view of FIGURE 19; FIGURE 20 is a plan view of the bottom layer of a new multilayer fuseplane; FIGURE 20A is an end view of FIGURE 20; FIGURE 20B is a side view of FIGURE 20; FIGURE 21 is a plan view of the new multilayer fuseplane in assembled form; FIGURE 21A is an exploded end view of FIGURE 21; FIGURE 21B is a side view of FIGURE 21; FIGURE 22 is a perspective view of a spring clip according to the invention; FIGURE 23 is a plan view of the spring clip in an engaged position; and FIGURE 24 is a side view of FIGURE 24. A prior art planar fuse panel in accordance with US-A-5,306,181 is shown in plan view in FIGURE 1. Referring jointly now to FIGURES 1-5, a prior art embodiment is shown generally at 10. Planar fuse panel 10 comprises an electrical bus member or terminal plate 12. Terminal plate 12 is composed of a resilient metal such as copper or brass in thicknesses suitable to carry the intended electrical load. Electrical bus member 12 is sandwiched between two layers of insulation 30 and 32, preferably applied by heat and pressure in a lamination process. Bus member 12 has stamped therein a multitude of discrete, spaced planar circuits with each circuit preferably having an overall rectangular configuration. In the FIGURE 1 embodiment, each discrete circuit comprises a first element 13 having an "L" shape and a second rectangularly shaped element 15 disposed adjacent to, but spaced from the shoulder or step 14 in "L" shaped element 13, with a corresponding "L" shaped gap 16 thus being defined between elements 13 and 15. Each discrete circuit (composed of elements 13 and 15) are spaced from each other by a border 19 defined by insulative film 30, 32. Electrical bus member 12 has a plurality of rectangular spaces 17 with a single space 17 being disposed between pairs of elements 13 and 15 and across gap 16. Each space 17 includes a plurality of fuse terminal members 18 extending into space 17. Each terminal member 18 terminates at an integral fuse terminal 22 and 24. Integral fuse terminal or bent tab 22 extending from element 15 consists of three pressure tabs 22a, 22b and 22c. Fuse terminal 22 is aligned and spaced apart from a corresponding fuse terminal 24 on element 13 which also consists of three pressure tabs 24a, 24b and 24c. In the particular embodiment illustrated in the drawings, the fuse terminals 22 and 24 are pressure clip terminals comprising bent tabs which are adapted to accept and frictionally engage and retain the generally flat blade portions of a plug-in fuse. Accordingly, tabs 22b and 22c are spaced from tab 22a to define a slit having a width slightly less than the width of a blade-type terminal. Similarly, tabs 24b and 24c are spaced from tab 24a in a similar manner. It will be appreciated that tabs 22b and 22c are coplanar and opposed from, but offset to, tab 22a. Similarly, tabs 24b and 24c are coplanar and opposed from, but offset to, tab 24a. The electrical bus member 12, in this particular embodiment, is adapted to be connected to any power source or load by means of a multiplicity of electrical terminals 20 which are standard spade quick-connect terminals extending from each element 13, 15 either in coplanar relationship or at an angle to terminal plate 12. Terminals 20 are mutually aligned and arranged on opposed, longitudinal edges of substantially rectangular planar sheet 12. Insulation layers 30 and 32 can be made from polyester or polyamide (or any other suitable material), both of which are flame retardant. Referring now to FIGURE 3 which is a cross-sectional elevation view of the planar fuse panel of FIGURE 2 along the line 3-3 of FIGURE 2. The low profile of the planar fuse panel is clearly shown. A blade-type fuse 26 (in phantom) is shown inserted between two (22a and 22c) of the three tabs frictionally engaging and retaining one blade 29 of the blade-type fuse. It will be appreciated that the resilient nature of tabs 22, 24 permit blade 29 to deflect the tabs outwardly and allow a strong frictional engagement. In this cross-section, it is seen how electrical bus member 12 is sandwiched between layers of insulation 30 and 32. FIGURE 4 is a similar cross-sectional elevation view along the line 4-4 of FIGURE 2. Retaining tabs 24a and 24b are shown for retaining the second blade of the blade-type fuse. Again, the unique sandwhiching of electrical bus member 12 between insulation layers 30 and 32 is clearly shown. FIGURE 5, which is a partial elevated side view of the planar fuse panel of FIGURE 1 shows two of the electrical terminals 20 and their relationship to the fuse terminals 18 via the electrical bus members 12. In this case, terminals 20 are bent at an angle of 90 degrees with respect to plate 12. At opposed ends of fuse panel 10, adjacent bus member 12, are extension tabs 34 and 36 with each extension tab containing an opening 38, 40, respectively. Extension tabs 34, 36 are coplanar with fuse plane 12 and are stamped out simultaneously with the initial stamping operation. Tabs 34 and 36 are similarly laminated between the two non-conductive films 30, 32. Extension tabs 34 and 36 together with openings 38, 40 are for the purpose of mounting fuse panel 10. It will be appreciated that in a preferred embodiment, insulative film 30, 32 fully encapsulates planar sheet 12 with the exception of terminals 20, space 17 and bent tabs 22, 24. Turning now to FIGURES 6-10, an other prior art embodiment is shown generally at 10'. It will be appreciated that in this alternative embodiment of FIGURES 6-10 (as well as a second alternative embodiment in FIGURES 11-14), all of the common elements would be marked with the same numbers as in the FIGURE 1 embodiment with the addition of a prime or double prime. The FIGURES 6-10 embodiment differs from the FIGURE 1 embodiment only in the configuration of the tabs 22', 24' for frictionally engaging a blade 29' from a fuse 26'. As best shown in FIGURE 7, rather than each connective element 13 and 15 of a particular circuit comprising three tabs for a total of six tabs, in the embodiment of FIGURE 6, each element 13', 15' includes only two tabs for a total of four engaging tabs. In the FIGURE 6 embodiment, element 13 includes a pair of spaced tabs 22a' and 22b' while element 15 includes a pair of spaced tabs 24a', 24b'. Tabs 22a', 22b', on the one hand, and tabs 24a', 24b' on the other hand are disposed and off-set from one another again to define a slot having a width which is slightly less than the width of a blade 29' so that the tabs are resiliently deformed upon insertion of the blade and then urged together to form a tight friction fit. Turning now to the alternative embodiment of FIGURES 11-14, a planar fuse plate is shown at 10". In the alternative embodiment of FIGURE 11, each element 13" and 15" of a particular circuit is comprised of two metal layers 40 and 42 as best shown in FIGURE 13. In this embodiment, the space 17" includes a total of four tabs 22, 24 with element 15" having a tab 22a" and 22b" and element 13" having two tabs 24a" and 24b". Preferably, metal layer 42 is slightly thicker than metal layer 40 and the tabs 22a" and 24a" extending from metal layers 40 are angled towards and normally in contact with bent tabs 22b" and 24b" as shown in FIGURE 13. In this two metal layer embodiment, metal layer 42 is intended to carry the current while metal layer 40 supplies the spring force to normally contact layer 40 prior to insertion of a blade 29" from fuse 26". Metal layers 40 and 42 are both sandwiched between nonconductive polymeric films 30" and 32" as in the previously discussed embodiments. It will be appreciated that fuse holder 10 may also be used as a power and signal plane to carry electrical signals and/or power, in addition to holding fuses. In FIGURES 15-18, is illustrated a new fuse plane 60 which uses blade-type terminals 50, as opposed to cooperating bent tabs of US-A-5,306,181, for engaging a fuse or the like to complete a circuit. This embodiment uses a molding material (a filled or unfilled thermoset or thermoplastic) 55 (shown only in FIGURES 16 and 18) to insulate the fuse plane 60. One of skill in the art will appreciate that to use molding material on the fuse plane with bent tabs (of FIGURES 1-14) would be a very expensive proposition due to the intricate molding processes and numerous molds which would be required. However, it will also be appreciated that such molding material does provide good insulation and is useful in making a fuseplane stiff for plug-in operation. The present inventors have discovered that a fuseplane of the type described can be produced having the benefit of encasement in a molding material yet without multiple molds. Blade-type connections 50 can be used instead of the spaces 17 and bent tabs 22 and 24 utilized in the embodiment discussed above, such that the blades 50 can extend through the plastic resin, thus being exposed for connection. This relieves the need to provide open spaces in the molded plastic which simplifies the molding process. The exposed blades can then be connected to a fuse or similar circuit connecting device. For each operable unit of tabs, i.e., 22a, 22b and 22c; or 24a, 24b and 24c, a single blade terminal 50 is utilized. Therefore, where, in the embodiment above, either a six tab arrangement or a four tab arrangement is used, two blade terminals will be used instead, one terminal for each element 51 and 52 of the circuit. The blade terminals 50 are long enough to extend through the plastic molded covering material so that they are exposed. The exposed blade terminals can be connected in a number of known ways, whether the connection be to a fuse for completing a discrete circuit or by plugging the fuse plane into another device to function simultaneously therewith. Although one of skill in the art will appreciate that any configuration of elements can be used, the embodiment described in FIGURE 15 utilizes a single element 52 as a collective ground or positive terminal with a plurality of connective elements 51-51"'. Space is economized in the arrangement. The fuseplane element of FIGURES 15-18 is made by placing the stamped, metal sheet elements in a mold followed by injecting a suitable polymeric molding material. The stamped, metal sheet may be placed in the mold and retained in spaced relationship therein by suitable retainers. However, in a preferred embodiment, the stamped, metal sheet is initially encapsulated between two sheets of protective polymeric film by a suitable lamination technique as described with reference to FIGURES 1-14. By employing an intermediate step of first laminating each fuseplane between nonconductive films prior to molding a molding material to surround the fuseplane, the sometimes difficult and costly steps of retaining the stamped, metal sheet in the mold is alleviated. FIGURE 16A depicts this preferred configuration wherein element 60 has been initially laminated between a pair of polymeric films 80, 82 (as in the FIGURES 1-14 embodiments) prior to insertion in a mold and embedded in molding material 55. Another new embodiment, which has been made effective by the use of blade terminals, is the multilayer fuseplane. This embodiment is illustrated in FIGURES 19 through 21B. The fuseplane utilizes the same basic concept as the single layer fuseplane above in that discrete circuits are formed from a metal blank and then laminated between two sheets of insulative material either individually or in a stack-up where one or more fuse planes are stacked having interleaved layers of insulation. In this embodiment, however, the configuration of the elements is such that terminals 50-50' from layers above and below the subject layer can extend therethrough. Moreover, in this embodiment there are no bent tabs; only blade terminals 50-50' are used. The blade terminals used are of different lengths for each level of the multilayer fuseplane, numeral 50 representing a standard length and 50' representing an extended length sufficient to pass through another fuseplane. This is necessary to ensure that all of the exposed blade terminals extending either from the top of the assembled multilayer fuseplane or from the bottom of the same will be exposed for substantially the same length. This promotes uniformity and ease of connection. Multiple layer fuseplanes are beneficial to the electronics and electrical packaging industry because they are capable of comparatively higher current densities and/or larger number of circuits than a single layer fuseplane. The reason for this is that the more current that is required to be carried by the circuit the more metal is necessary to carry that load. Therefore, if a single layer fuseplane is used, only a limited number of circuits could be employed due to space constraints. However, where the multiple layer fuseplane is employed, a larger number of circuits can be employed in only a minimally expanded area. Multilayer fuseplanes must be constructed to nest with one another so that blade terminals extending from one layer are not impacted by another layer. To accomplish this end it is necessary to provide holes or openings in fuseplanes above or below a subject fuseplane so that the terminals on the subject fuseplane can extend through the layers on top or below it. By referring to FIGURES 19-21B in view of the description above, one can easily surmise the construction. FIGURES 19, 19A and 19B show a top view, an end and a side view of the top layer 60 of a preferred embodiment. As will be appreciated, the top view of FIGURE 19 shows elements 62 having various shapes and spaces 65 which are left for the extending blade terminals. The bottom layer 60' is illustrated in FIGURE 20, 20A and 20B has elements 62' and spaces 65' complementary to each of the other layers. Each of these figures also illustrate the blade terminals 50, 50' on each of the elements. The two opposing edges 66, 66' of layer 60 each includes a transverse connecting tab 67, 67' with a male member 68, 68' extending transversely from each respective tab 67, 67'. FIGURES 21, 21A and 21B illustrate the two layers of FIGURES 19 and 20, in their assembled form. During assembly, layers of nonconductive insulative materials 69, 69' and 69" are interleaved over and between metal layers 60, 60' so as to sandwich and encapsulate each conductive layer 60, 60' between a pair of nonconductive insulative films 69, 69' or 69', 69". As one of skill in the art will appreciate, the multilayer fuseplane can be constructed using two (or any other desired number of layers) individual layers which have been punched from a suitable metal and individually laminated, and then stacked. This is the method as illustrated in FIGURES 1-14. Alternatively, the punched metal elements can be maintained in spaced relationship to one another by a suitable device (or more preferably laminated between two layers of polymeric film) and then plastic resin pumped in to surround, insulate and encapsulate the layers of metal elements. This method is shown in FIGURES 15-18. The multiple layer fuseplane can then be connected in the same manner as discussed relative to the embodiment immediately preceding. A variety of terminals such as female-to-female connectors, fasten tabs, etc may be accomodated. Of course, any one of the individual fuseplanes of FIGURES 19 or 20 may be made as a single fuseplane (as opposed to being combined in a multiple fuseplane) device. The important common feature is the use of blade-type terminals extending outwardly from each circuit element along the edges of the fuseplane and/or from openings made internally of the fuseplane with the blades preferably extending angularly from the fuseplane (most preferably at an angle of about 90 degrees) and with the blades accepting a variety of I/O configurations. The blade-type terminals extending from the fuseplane embodiments of FIGURES 15-21 may be connected to an intermediate connector which, in turn, is connected to a blade-type components such as item 26 in FIGURES 3. In this way, the blade extending from the fuseplane is indirectly electrically connected to the blade from component 26 via the intermediate connector. According to an important aspect of the present invention, connecting means are provided which directly electrically and mechanically connect the blade from a fuseplane to the blade from a component (such as fuse 26). A preferred example of such a direct attachment means is a discrete clip connector such as the spring clip 70 in FIGURES 22-24. Spring clip 70 operates to provide a frictional engagement device for holding electrically conductive elements when opposing bent tabs are not provided. Spring clip 70 thus provides direct electrical and mechanical engagement between the blade terminals 50 of the fuseplane (one of these blade terminals is identified with reference number 76 in FIGURES 22-24) and the blade-type terminals 77 of a component. As illustrated in FIGURES 22, 23 and 24 collectively, the spring clip 70 comprises a unitary construction having a resilient spring means 72 and a frame portion 74 which is in a channel shape including flanges 75 and 75' extending from each side of the channel toward each other. It should be noted that the flanges are the preferred embodiment but that a continuous wall could replace the flanges if desired. Generally, from the channel end of the frame 74, a resilient spring means 72 extends toward the flanges 75 and 75'. The spring means can be any type of resilient configuration and simply must be capable of urging one conductive blade terminal 77 (extending outwardly from any of the fuseplanes shown in FIGURES 15-21) into electrical and mechanical communication with another terminal 76 (shown in phantom) which is secured by the flanges 75 and 75' of the frame portion 74 of the spring clip 70. In the preferred embodiment, the spring means 72 is a bent member which extends from a back portion 80 of frame 74. The spring means 72 is formed from a vertically extending length of the metal which forms the channel. The spring in the preferred embodiment is bent in three distinct places along its length at 72', 73 and 73'. Bend 72' is an increasing radius bend which bend begins at about the level of the top end 82, and above cutouts 82', of frame 74. The length of metal then extends straight at approximately 35° to the back wall 80 of the frame for a suitable distance where at 73, the length of metal bends again back toward the back of the frame 74 and away from the flanges 75 and 75'. The length of metal which will be the spring means 72 then continues toward the back wall 80 of the frame 74 at an angle of approximately 35° thereto and terminates in close proximity to the back wall 80 of the frame 74 with a bend 73' which turns the spring means to an attitude parallel to the back wall 80. In the most preferred embodiment, flanges 75 and 75' extend only partially along frame 74. A gap 71 is defined which communicates with barbs 71'. This ensures that the spring clip remains secured in the desired position when subjected to the pressure of an entering blade terminal 77 so that a reliable electrical connection is achieved. The spring clip 70 can be made from any resilient material including but not limited to metal and plastic. It is not necessary for the clip to be conductive; it merely urges two parts, which are conductive, together.

Claims: An electrical planar circuit sheet comprising: a planar resilient metal sheet means having a plurality of discrete, spaced planar circuits formed therein, each circuit comprising a first element (51) and a second element (52), said first element being spaced from said second element by an insulative gap; first connecting terminals (50, 76) extending from said first element (51) and second connecting terminals (50, 76) extending from said second element (52), wherein said first and second connecting terminals (50, 76) are blade terminals extending outwardly from said sheet means; and at least one component connected to said connecting terminals (50, 76); characterized by a discrete spring clip (70) with a spring means (72), wherein said at least one component includes a blade-type component terminal (77) which is connected by said discrete spring clip (70) to one (76) of said connecting terminals (50, 76) in such a way that said spring means (72) is providing direct electrical and mechanical contact between said component terminal (77) and said connecting terminal (76). The circuit sheet of claim 1 wherein said spring clip (70) comprises: a frame means (74) engaged on one of said connecting terminals (76), said spring means (72) being disposed within the frame means (74) in such a way said component terminal (77) is frictionally engaged between the spring means (72) and the blade terminal (76). The circuit sheet of claim 2 wherein: the frame means (74) comprises a channel with flanges (75, 75') extending from each side of the channel toward a center of the channel. The circuit sheet of claim 2 or 3 wherein: the spring means (72) is an integral part of the frame means (74). The circuit sheet of claim 4 wherein: the spring means (72) is resilient metal and is bent from a blank to form the spring clip (70). The circuit sheet of any one of claims 2 to 5 wherein: the flanges (75, 75') extend only partially along the length of the frame to define openings (71) which are engageable with at least one barb (71') on the blade terminal (76) to positively engage said spring clip (70) with the blade terminal (76). The circuit sheet of any one of claims 1 to 6 comprising: a dielectric protective layer (69, 69', 69") surrounding said planar sheet means with the exception of at least a portion of said first and second blade terminals. The circuit sheet of claim 7 wherein: said dielectric protective layer comprises insulative film laminated to opposed planar surfaces of said sheet means. The circuit sheet of any one of claims 1 to 8 comprising: at least one internal space formed at a predetermined location through said sheet means, at least one of said first or second blade terminals extending outwardly from said space. The circuit sheet of any one of claims 1 to 9 wherein: said first or second blade terminals (76) extend outwardly from an edge of said sheet means. The circuit sheet of any one of claims 1 to 9 wherein: at least one of said first or second blade terminals extends outwardly and angularly from said sheet means. The circuit sheet of any one of claims 1 to 9 comprising: a molding material encapsulating said first assembly with the exception of at least a portion of said first and second blade terminals. A multilayer circuit sheet including: a plurality of circuit sheets as claimed in any one of claims 1 to 12 arranged in a stack-up. The multilayer circuit sheet as claimed in claim 13 wherein: said circuit sheets include spaces (65) formed therein so that the blade terminals of one of the layers extend through the spaces of the other; whereby a multilayer stacked fuseplane having multiple blade terminals extending outwardly therefrom is produced. The multilayer circuit sheet of claim 14 wherein: the blade terminals vary in length among each layer so that when the layers are stacked, all of the blade terminals extend a substantially similar distance perpendicularly to the fuseplane. The multilayer circuit sheet claim 13, 14 or 15 wherein: said circuits are maintained in spaced relationship from one another by molding material (55) which encapsulates said circuits except for a portion of the blade terminals. The multilayer circuit sheet as claimed in claim 16 wherein: a dielectric film (69, 69', 69") is laminated to opposed surfaces of said planar sheet means, said dielectric film being encapsulated by said molding material (55). A method of connecting a first electrical blade terminal (76) to a second blade terminal (77) with a spring clip (70), said spring clip (70) including a frame means (74) for receiving said first and second blade terminal (76, 77) and a spring means (72) disposed within said frame means (74); characterized in that said frame means (74) is engaged on said first blade terminal (76), such that said spring means (72) extends toward said first blade terminal (76) and terminates substantially adjacent said first blade terminal (76), and said second blade terminal (77) is frictionally engaged between said spring means (72) and said first blade terminal (76), whereby said spring means (72) provides direct electrical and mechanical contact between said first and said second blade terminal (76, 77). The method as claimed in claim 18 wherein: said frame means (76) is a channel with flanges (75, 75') extending from each side of the channel toward a center of the channel. The method as claimed in claim 19 wherein: said flanges (75, 75') extend only partially the length of the frame to define openings (71) which are engageable with at least one barb (71') on said first blade terminal (76) to positively engage said spring clip (70) with said first blade terminal (76). The method as claimed in any one of claims 18 to 20 wherein: said spring means (72) is an integral part of said frame means (74). The method as claimed in any one of claims 18 to 21 wherein: said frame means (74) is resilient. The method as claimed in any one of claims 18 to 22 wherein: said spring means (72) is resilient metal and is bent from a blank to form said spring clip (70). The method as claimed in any one of claims 18 to 23 wherein: one terminal (76) is a connecting terminal of a fuse panel and the other terminal (77) is a blade-type terminal of a fuse.

Inventors: HAINES ROBERT B, MONIE WAYNE G, POTTER VAN H, RAFFLES SCOTT J, RICHIE BENJAMIN L JR, WOODLEY JOSEPH V, HAINES, ROBERT B., MONIE, WAYNE G., POTTER, VAN H., RAFFLES, SCOTT J., RICHIE, BENJAMIN L., JR., WOODLEY, JOSEPH V.
Applicants: ROGERS CORP, ROGERS CORPORATION
Application year: 1995
Main classification: H01H85
IPC codes: H01H85, H01R13, B60R16