Title of Invention	METHOD AND MACHINE FOR MANUFACTURING ELECTRICAL CIRCUITS
Abstract	Method and machine for manufacturing electrical circuits. The machine (1) for manufacturing electrical circuits(2) from a web (3) of electrically conductive material comprises means (4) for feeding the web (3) along a defined path (P), a stamping station (11) for applying a certain quantity of insulating varnish on certain portions of the web (3) and a punching station (22) for cutting the electrical circuits (2) out of the web (3).

Title of Invention

METHOD AND MACHINE FOR MANUFACTURING ELECTRICAL CIRCUITS

Abstract

Method and machine for manufacturing electrical circuits. The machine (1) for manufacturing electrical circuits(2) from a web (3) of electrically conductive material comprises means (4) for feeding the web (3) along a defined path (P), a stamping station (11) for applying a certain quantity of insulating varnish on certain portions of the web (3) and a punching station (22) for cutting the electrical circuits (2) out of the web (3).

Full Text	WO2006/079894 PCT/IB2006/000108 1 Description Method ar.d machine for manufacturing electrical circuits Technical Field This invention relates to a method for manufacturing electrical circuits. In particular, but without thereby limiting its scope, the invention relates to a method for manufacturing electrical circuits for powering the brushes of electric motors. Background art In an electric motor, brush wear caused by the turning commutator leads to the formation of dust consisting of particles of electrically conductive material scattered around the commutator. When used for motorcycle and automotive vehicle applications, the motors must be protected against infiltration, for example of rain water. To obtain this type of protection, the motor guards are made watertight. The watertight guards, however, trap the particles of electrically conductive material inside the casing, causing them to accumulate on the circuits and eventually creating short circuits or interrupting the power supply as a result of the creation of electrical bridges. In the latter case, power is not distributed equally between the brushes and the balance required for correct operation is altered. Methods of embedding electrical circuits, which are often formed or punched from a sheet or web of electrically conductive aterial, in the structure of the brush holder were therefore devised to overcome this problem. This solution, however, although certainly effective, proved WO 2006/079894 PCT7IB20O6/O001O8 2 complex and expensive to implement. Moreover, the circuits can be enibedded only in brush holders made of plastic because the high melting point of metal would damage the electrical conductors during the forming process. To overcome this problem, brush holders with recesses to precisely accommodate the circuits were made so that the circuits were exposed to dust only at the top. This solution, however, while offering undoubted advantages in terms of simplicity has the drawback of not fully solving the problem of short circuiting and electrical bridging. To overcome this drawback, a method of coating electrical circuits by dipping them in a suitable insulating material was devised. This method of manufacturing electrical circuits, however, although it effectively insulates the circuits from electrically conductive dust, has evident disadvantages in terms of cost and complexity. Indeed, after the circuit has been dipped in the insulating material and dried, the insulating material has to be removed from the parts of the circuit to be connected to the electrical conductors. Owing to the very small size of the circuits, the operation of cleaning the contacts is difficult to perform and may result in poor electrical conduction. In other terms, it may give rise to the very problem that coating the circuit was designed to eliminate. This invention therefore has for an aim to provide a method for manufacturing electrical circuits that is free of the above mentioned disadvantages and that is at once practical and inexpensive to implement. Disclosure of the Invention The technical characteristics of the invention, with reference to the above aim may be clearly inferred from the contents of the appended claims, especially claim 1, and any of the claims that depend, either directly or indirectly, on claim I. This invention also relates to a machine for manufacturing WO 2006/079894 PCT/TB2006/000108 3 electrical circuits. The machine according to the invention is described in claim 11, and any of the claims that depend, either directly or indirectly, on claim 11. Brief Description of the Drawings The technical characteristics of the invention, with reference to the above aims, are clearly described in the claims below and its advantages are apparent from the detailed description which follows, with reference to the accompanying drawings which illustrate a preferred embodiment of the invention provided merely by way of example without restricting the scope of the inventive concept, and in which: Figure 1 is a schematic perspective view of a preferred embodiment of a machine for manufacturing electrical circuits according to the present invention; Figures 2 to 7 illustrate a part of the machine of Figure 1 in a sequence of operating steps. Detailed Description'of the Preferred Embodiments of the Invention With reference to Figure 1, the numeral 1 denotes in its entirety a machine for manufacturing electrical circuits 2 from a web 3 of electrically conductive material. The machine 1, which is represented schematically in the accompanying drawings, comprises means for feeding the web 3 along a defined feed path P. The web feed means are represented schematically as a block 4. The machine 1 also comprises a web cleaning station 5 eguipped with one or more rotary brushes 6 and a pickling unit, not illustrated, the term "pickling" denoting a cleaning process performed by chemical or electrolytic means. The brush 6 is rotationally driven by an electric motor 7 through a reduction unit 8. At the outfeed end of the cleaning station 5, the machine 1 comprises a first unit 9, for drying the web 3, the unit 9 comprising an element 10 for blowing warm air on the web 3 . WO 2006/079894 PCT/1B2006/000108 4 Downstream of the cleaning station 5, relative to the feed direction indicated by the arrow FI, the machine 1 comprises a stamping station 11 where a certain quantity of insulating varnish is applied to the web 3 in such a way as to form a plurality cf impressions 12 on it. Each impression 12 covers a certain portion of the web 3 and reproduces the final form that the electrical circuit 2 will eventually have, though slightly larger in size. The web 3 stamping station 11 comprises a pattern 13, a first pad 14 and second pad 15. The pattern 13 is siiaped substantially like a parallelepiped and has on its upper face 13a a plurality of cavities 16, each reproducing the above mentioned impression 12. The cavities 16 are distributed in succession in a first direction Dl parallel to the straight section of the feed path P at the stamping, station 11. The first pad 14 is prismatic in shape, with a convex bottom face 14a, and is made of a resilient material, advantageously based on silicone. The first pad 14 is mounted on a block 17 which is in turn stably connected to an operating arm 18. The operating arm 18 is moved by actuating means, not illustrated in a second direction D2 perpendicular to a plane PI in which the web 3 lies when it is at the stamping station. The operating arm 18 is also moved by the same actuating means, not illustrated, in a third direction D3 perpendicular to the second direction D2 and parallel to the plane PI. The second pad 15 is moved in reciprocating fashion by actuating means, which are not illustrated, in the above mentioned first direction Dl and, during its movement, engages the top face 13a of the pattern 13 and transfers a certain amount of insulating varnish to it. The insulating varnish, stored in a tank that is schematically represented as a block 19, is fed by the tank to the second pad 15 through a conduit 20. Similarly to what is described above, the machine 1 also comprises, at the. outfeed end cf the stamping station 11, a second drying unit 21 for quickly drying the ir.sulating varnish applied WO 2006/079894 PCT/TB2006/000108 5 to the web 3. The second drying rait 21 comprises an element 10 for blowing warm air on the web 3. Downstream of the stamping station 11, the machine 1 further comprises a punching station 22 for cutting the circuits 2 out of the web 3 by punching. As illustrated schematically in Figure 1, the punching station 22 comprises a die 23 and a matrix 24. The die 23, shown under the web 3 in the accompanying drawings, has the design 25 of a circuit 2 made in it in relief, whilst the matrix 24, non illustrated in detail in the drawings, has on it the same design of the circuit 2 but in this case the design is recessed. According to methods described in more detail below, the relief design 25 and the recessed design that is not illustrated engage, each other and the web. 3 in such a way as to punch out a circuit 2. Downstream of the punching station 22, again relative to the direction indicated by the arrow Fl, the machine 1 comprises the aforementioned web 3 feed means 4. A block 2 6 in Figure 1 schematically represents a control unit. The control unit 2 6 controls and coordinates the operation and movement of all the parts of the machine 1. In use, the web 3 of electrically conductive material is unwound from a roll, which is not illustrated in the drawings, and fed towards the cleaning station 5. In the station 5, the web 3, which has a top face 3 a and a bottom face 3b, is cleaned both by mechanical means and by pickling. More specifically, mechanical cleaning is accomplished by brushing at least the top face 3a to which the varnish is applied, using the aforementioned rotary brushes 6, one of which is shown in Figure 1, drawn in dashed line style. Pickling, as mentioned above, may be carried out either using suitable chemicals, selected according to the type cf metal 35 the web is made of, or by an electrolytic process. Both methods are well known in the trade and are not therefore described in this specification. WO 2006/079894 PCT/IB2006/000108 6 Still with reference to Figure 1, after leaving the cleaning station 5, the web 3, which is advanced in steps by the feed means 4, is struck at least on its top face 3a by a jet of warm air emitted by the blowing element 10 of the first drying unit 9. The jet of warm air is designed to dry the top face 3a to remove any traces of liquid substances used during the previous, cleaning step. Again with reference to Figure 1, the web 3 advances along the feed path P, in the direction indicated by the arrow Fl, and reaches the stamping station 11. The following detailed description of the operations carried out at the stamping station 11 is made with reference to Figures 2 to 7, which are scaled-up views of the .station 11 itself. As shown in Figure 2, the operating arm 18, driven by respective actuating means that are not illustrated, positions the first pad 14 above the pattern 13 in such a way that the convex, bottom face 14a of the first pad 14 itself faces the top face 13a of the pattern 13. The cavities 16 reproducing the impression 12 are full, that is to say, each cavity 16 contains a sufficient quantity of insulating varnish. The operations by which they are filled are described in more detail below. With reference to Figure 3, the operating arm 18 moves down in the direction D2, as indicated by the arrow F2, to place the first pad 14 in a first end position in which it is in contact with, the top face 13a of the pattern 13. The first pad 14 is deformed by compression. In Figure 3, the face 13a is hidden by the first pad 14. At its aforementioned first end position, thanks to the high deformability of the material it is made of and to the compressive action exerted by the arm 18, the first pad 14 penetrates inside the cavities 16 of the pattern 13 and its bottom face 14a receives a certain quantity of varnish from the cavities IS. In other words, as clearly illustrated in Figure 4, some of the varnish that was previously inside the cavities 16 is transferred to the bottom face 14a according to the aforementioned WO 2006/079894 PCT/ TB2006/000108 7 impression 12. Figure 4 shows the pad 14 after the arm. 18 has lifted it in the direction of the arrow F3, causing the faces 13a, 14a of the pattern 13 and of the first pad 14, respectively, to move apart. As shown in Figure 5, the arm 18, controlled by the unit 26, advances in the direction D3, as indicated by the arrow F4, and moves the first pad 14 to the position where its bottom face 14a faces the web 3 of electrically conductive material. With reference to Figure 6, the arm 18 extends downwardly in the direction indicated by the arrow F5 and moves the first pad 14 down to a second end position in which it is in contact with the web 3 of electrically conductive material. The first pad 14 is deformed by compression. At this second end position, the first pad 14 transfers to the top face 3a of the web 3 at least a part of the varnish that it had received in the form of impressions 12 on its bottom convex face 14a. In Figure 6, the second pad 15 has started moving in the direction Dl indicated by the arrow F6 to meter the insulating varnish transferred to the top face 13a of the pattern 13. More specifically, the second pad 15 moves over the pattern 13 twice and, as it does so, releases a quantity of insulating varnish that is transferred not only to the inside of the cavitities 16 but also to the smooth surface of the face 13a. While releasing the varnish, the second pad 15 also exerts a scraping action on the top face 13a of the pattern 13. As a result of this scraping action, when the second pad 15 has moved over the pattern 13 for the second time, that is to say, when the second pad 15 has returned to the position shown in Figure 5, the insulating varnish is located only inside the cavities 16. As illustrated in Figure 7, in which the arm 1.8 has already lifted the first pad 14 in the direction indicated by the arrow F7, another impression,, labelled 12' for clarity, appears on the top face 3a of the web 3 as a result of the first pad 14 transferring insulating varnish when it is in its second end position, illustrated in Figure 6. The working cycle of the first pad 14 is completed when the WO 2006/079894 PCT/IB2006/000108 8 operating arm 18 moves back in the direction D3 as indicated by the arrow F8 to the position shown in Figure 2, ready to start another cycle. While the first pad 14 performs this movement, the second pad 15 moves over the pattern 13 a second time in the direction indicated by the arrow Fl to return to the position illustrated in Figure 2, and the feed means 4 advance the" web 3 along its path P in the direction indicated by the arrow Fl, shown in Figures 1 and 7, by a step L egual to the spacing between one impression 12 and the next. The spacing L between the impressions 12 made on the web 3 is egual to the spacing between the cavities 16 in the pattern 13. Advantageously, a device, not illustrated, is positioned on the path P between the second drying unit 21 and the punching station 22 for applying a lubricating substance to the V7eb 3, for example by spraying, in order to facilitate the cutting action of the punching die 23. Advantageously, to enable the insulating varnish to be progressively layered on the web 3, the impressions 12 are obtained by repeated stamping actions of the first pad 14. For example, in the embodiment illustrated in the accompanying drawings, each finished impression 12 is made by the first pad 14 applying varnish to the web 3 in five successive stamping actions. As illustrated in Figure 1, after leaving the stamping station 11, the web 3, which is advanced in steps by the feed means 4, is struck by a jet of warm air emitted by the blowing element 10 of the second drying unit 21. This jet of warm air is. designed to guickly dry the insulating varnish that has been applied to the web 3. As it proceeds along the path P, each portion of the web 3 reaches the punching station 22 where it is engaged by the die 23 and the matrix 24. The die 23 and matrix 24 move towards each other in substantially known manner and by means of actuators that are well known and therefore not described in detail in this specification, so as to engage each other and the web 3 to form the electrical circuits 2 by punching. WO 2006/079894 PCT/IB2006/000108 9 The die 23 which, through the relief design 25, physically cuts the electrical circuit 2 out of the web 3, engages the lower face 3b of the web 3, whilst the matrix 24 opposes the action of the die 23 by acting on the top face 3a. Advantageously, in an alternative embodiment of the machine 1 that is not illustrated, the web 3 engages a feed roller which positions the web with its top face 3a - that is, the one on which the impressions 12 are made - down so that the electrical circuits 2 drop when they are punched out. In this specification, the term "varnish" means any fluid insulating material that can be applied to a web of electrically conductive material and that will adhere permanently to the web. In this specification the phrase "punch at least partly" denotes the fact that at least a part of the web portions coated with insulating varnish are cut out. Indeed, for safety reasons, a part around the edges of the coated portions remain on the punched web. This is done for safety reasons because it would be extremely risky 'to cut out from the web a circuit that is not perfectly and completely coated with insulating varnish. It would indeed be extremely difficult and unduly expensive to provide means for exactly cutting out only the web portions that have been coated with varnish, Advantageously, the web 3 that leaves the punching station 22, that is to say the part of the web from which the circuits 2 25 have been punched out, can easily be surface cleaned, melted down and re-used. The invention described has evident industrial applications and may be subject to modifications and variations without thereby departing from the scope of the inventive concept. Moreover, all the details of the invention may be substituted by technically equivalent elements. WO 2006/079894 PCT/ IB2006/000108 10 Claims 1. A method for manufacturing electrical circuits (2) characterised in that it comprises: - the step of step-feeding a web (3) of electrically conductive material along a path (P); - the step of coating certain portions of the web (3) with an insulating varnish; - the step of punching the given portions of the web (3) at least partly to define the electrical circuits (2). 2. The method according to claim 1, characterised in that "the step of coating certain portions comprises the step of applying to the web (3) a given quantity of varnish to make a given impression (12). 3. The method according to claim 2, characterised in that the step of applying the varnish comprises the step of receiving the varnish from a pattern (13) and transferring the varnish to the web (3) . 4. The method according to claim. 3, characterised in that the step of applying the varnish to the web (3) is performed by a first pad (14) made of a resilient material. 5. The method according to claim 3 or 4, characterised inthatit comprises a step of metering the varnish transferred to the pattern (13). 6. The method according to any of the claims from 2 to 5, characterised in that it comprises a step of drying the varnish applied to the web (3) . 7. The method according to any of the claims from 1 to 6, characterised in that it comprises a step of cleaning at least one face (3a, 3b) of the web (3) to improve the adhesion of the varnish to the web (3) itself. 8. The method according to any of the claims from 1 to 7, characterised in that the cleaning step comprises the step of brushing the web (3) . 9. The method according to any of the claims from 1 to 8, characterised in that the cleaning step comprises the step of pickling at least one face of the web (3). WO 2006/079894 PCMB2006/000108 11 10. The method according to, any of the claims from 1 to 9, characterised in that it comprises a step of spraying a lubricating substance on the web (3) in order to facilitate the punching step. 11. A machine for manufacturing electrical circuits (2) characterised in that it comprises: - means for feeding a web (3) of electrically conductive material along a path (P); - a stamping station for applying a given quantity of insulating varnish to given portions of the web (3); - a punching station for punching the given portions at least partly to define the electrical circuits (2) . 12. The machine according to claim 11, characterised in that the stamping station (11) comprises a first pad (14) designed to apply a given quantity of varnish to the web (3) to make a given impression (12). 13. The machine according to claim 12, characterised in that it comprises a pattern (13) from which the first pad (14) receives the varnish to be applied to the web (3) . 14. The machine according to claim 13, characterised in that the pattern (13) comprises a cavity (16) that reproduces the impression (12), the cavity (16) being designed to hold a certain quantity of the varnish. 15. The machine according to claim 14, characterised in that the pattern (13) comprises a plurality of cavities (16), the cavities (16) being distributed in succession in a first direction (Dl) parallel to the web (3) feed path (P) at the stamping station (11) . 16. The machine according to any of the claims from 13 to 15, characterised in that it comprises a second pad (15) for transferring the varnish to the pattern (13). 17. The machine according to any of the claims from 13 to 16, characterised in that, the first pad (14) is mobile between a first end position in which it is in contact with the pattern (13) and where its face (14a) receives a given quantity of varnish in the shape of the impression (12) , and a second end position in which it is in contact with the web (3) of electrically conductive WO 2006/079894 PCT/IB2006/00O108 12 material and where it at least partly transfers the given quantity of varnish to the web (3). 18. The machine according to any of the claims from 11 to 17, characterised in that it comprises step-feeding means (4) for advancing the web (3) in defined steps (L) . 19. The machine according to claim 18 when it depends directly or indirectly on claim 15, characterised in that the spacing between each of the plurality of cavities (16) on the pattern (13) and the cavity (16) adjacent to it is equal to the feed step (L) of the web (3) . 20. The machine according to any of the claims from 11 to 19, characterised in that it comprises a station (5) for cleaning the web (3) . 21. An electrical circuit characterised in that it is manufactured according to a method, as defined in any of the foregoing claims from 1 to 10. 22. An electrical circuit characterised in that it is manufactured using a machine (1) as defined in any of the foregoing claims from 11 to 20. Method and machine for manufacturing electrical circuits. The machine (1) for manufacturing electrical circuits(2) from a web (3) of electrically conductive material comprises means (4) for feeding the web (3) along a defined path (P), a stamping station (11) for applying a certain quantity of insulating varnish on certain portions of the web (3) and a punching station (22) for cutting the electrical circuits (2) out of the web (3).

Full Text

WO2006/079894 PCT/IB2006/000108
1
Description
Method ar.d machine for manufacturing electrical circuits
Technical Field
This invention relates to a method for manufacturing
electrical circuits.
In particular, but without thereby limiting its scope, the
invention relates to a method for manufacturing electrical
circuits for powering the brushes of electric motors.
Background art
In an electric motor, brush wear caused by the turning
commutator leads to the formation of dust consisting of particles
of electrically conductive material scattered around the
commutator.
When used for motorcycle and automotive vehicle
applications, the motors must be protected against infiltration,
for example of rain water.
To obtain this type of protection, the motor guards are made
watertight.
The watertight guards, however, trap the particles of
electrically conductive material inside the casing, causing them
to accumulate on the circuits and eventually creating short
circuits or interrupting the power supply as a result of the
creation of electrical bridges.
In the latter case, power is not distributed equally between
the brushes and the balance required for correct operation is
altered.
Methods of embedding electrical circuits, which are often
formed or punched from a sheet or web of electrically conductive
aterial, in the structure of the brush holder were therefore
devised to overcome this problem.
This solution, however, although certainly effective, proved

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complex and expensive to implement.
Moreover, the circuits can be enibedded only in brush holders
made of plastic because the high melting point of metal would
damage the electrical conductors during the forming process.
To overcome this problem, brush holders with recesses to
precisely accommodate the circuits were made so that the circuits
were exposed to dust only at the top.
This solution, however, while offering undoubted advantages
in terms of simplicity has the drawback of not fully solving the
problem of short circuiting and electrical bridging.
To overcome this drawback, a method of coating electrical
circuits by dipping them in a suitable insulating material was
devised.
This method of manufacturing electrical circuits, however,
although it effectively insulates the circuits from electrically
conductive dust, has evident disadvantages in terms of cost and
complexity.
Indeed, after the circuit has been dipped in the insulating
material and dried, the insulating material has to be removed from
the parts of the circuit to be connected to the electrical
conductors.
Owing to the very small size of the circuits, the operation
of cleaning the contacts is difficult to perform and may result in
poor electrical conduction. In other terms, it may give rise to
the very problem that coating the circuit was designed to
eliminate.
This invention therefore has for an aim to provide a method
for manufacturing electrical circuits that is free of the above
mentioned disadvantages and that is at once practical and
inexpensive to implement.
Disclosure of the Invention
The technical characteristics of the invention, with
reference to the above aim may be clearly inferred from the
contents of the appended claims, especially claim 1, and any of
the claims that depend, either directly or indirectly, on claim I.
This invention also relates to a machine for manufacturing

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electrical circuits.
The machine according to the invention is described in claim
11, and any of the claims that depend, either directly or
indirectly, on claim 11.
Brief Description of the Drawings
The technical characteristics of the invention, with
reference to the above aims, are clearly described in the claims
below and its advantages are apparent from the detailed
description which follows, with reference to the accompanying
drawings which illustrate a preferred embodiment of the invention
provided merely by way of example without restricting the scope of
the inventive concept, and in which:
Figure 1 is a schematic perspective view of a preferred
embodiment of a machine for manufacturing electrical circuits
according to the present invention;
Figures 2 to 7 illustrate a part of the machine of Figure 1
in a sequence of operating steps.
Detailed Description'of the Preferred Embodiments of the Invention
With reference to Figure 1, the numeral 1 denotes in its
entirety a machine for manufacturing electrical circuits 2 from a
web 3 of electrically conductive material.
The machine 1, which is represented schematically in the
accompanying drawings, comprises means for feeding the web 3 along
a defined feed path P.
The web feed means are represented schematically as a block
4.
The machine 1 also comprises a web cleaning station 5
eguipped with one or more rotary brushes 6 and a pickling unit,
not illustrated, the term "pickling" denoting a cleaning process
performed by chemical or electrolytic means.
The brush 6 is rotationally driven by an electric motor 7
through a reduction unit 8.
At the outfeed end of the cleaning station 5, the machine 1
comprises a first unit 9, for drying the web 3, the unit 9
comprising an element 10 for blowing warm air on the web 3 .

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Downstream of the cleaning station 5, relative to the feed
direction indicated by the arrow FI, the machine 1 comprises a
stamping station 11 where a certain quantity of insulating varnish
is applied to the web 3 in such a way as to form a plurality cf
impressions 12 on it. Each impression 12 covers a certain portion
of the web 3 and reproduces the final form that the electrical
circuit 2 will eventually have, though slightly larger in size.
The web 3 stamping station 11 comprises a pattern 13, a
first pad 14 and second pad 15.
The pattern 13 is siiaped substantially like a parallelepiped
and has on its upper face 13a a plurality of cavities 16, each
reproducing the above mentioned impression 12.
The cavities 16 are distributed in succession in a first
direction Dl parallel to the straight section of the feed path P
at the stamping, station 11.
The first pad 14 is prismatic in shape, with a convex bottom
face 14a, and is made of a resilient material, advantageously
based on silicone.
The first pad 14 is mounted on a block 17 which is in turn
stably connected to an operating arm 18.
The operating arm 18 is moved by actuating means, not
illustrated in a second direction D2 perpendicular to a plane PI
in which the web 3 lies when it is at the stamping station.
The operating arm 18 is also moved by the same actuating
means, not illustrated, in a third direction D3 perpendicular to
the second direction D2 and parallel to the plane PI.
The second pad 15 is moved in reciprocating fashion by
actuating means, which are not illustrated, in the above mentioned
first direction Dl and, during its movement, engages the top face
13a of the pattern 13 and transfers a certain amount of insulating
varnish to it.
The insulating varnish, stored in a tank that is
schematically represented as a block 19, is fed by the tank to the
second pad 15 through a conduit 20.
Similarly to what is described above, the machine 1 also
comprises, at the. outfeed end cf the stamping station 11, a second
drying unit 21 for quickly drying the ir.sulating varnish applied

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to the web 3. The second drying rait 21 comprises an element 10
for blowing warm air on the web 3.
Downstream of the stamping station 11, the machine 1 further
comprises a punching station 22 for cutting the circuits 2 out of
the web 3 by punching.
As illustrated schematically in Figure 1, the punching
station 22 comprises a die 23 and a matrix 24.
The die 23, shown under the web 3 in the accompanying
drawings, has the design 25 of a circuit 2 made in it in relief,
whilst the matrix 24, non illustrated in detail in the drawings,
has on it the same design of the circuit 2 but in this case the
design is recessed.
According to methods described in more detail below, the
relief design 25 and the recessed design that is not illustrated
engage, each other and the web. 3 in such a way as to punch out a
circuit 2.
Downstream of the punching station 22, again relative to the
direction indicated by the arrow Fl, the machine 1 comprises the
aforementioned web 3 feed means 4.
A block 2 6 in Figure 1 schematically represents a control
unit. The control unit 2 6 controls and coordinates the operation
and movement of all the parts of the machine 1.
In use, the web 3 of electrically conductive material is
unwound from a roll, which is not illustrated in the drawings, and
fed towards the cleaning station 5.
In the station 5, the web 3, which has a top face 3 a and a
bottom face 3b, is cleaned both by mechanical means and by
pickling.
More specifically, mechanical cleaning is accomplished by
brushing at least the top face 3a to which the varnish is applied,
using the aforementioned rotary brushes 6, one of which is shown
in Figure 1, drawn in dashed line style.
Pickling, as mentioned above, may be carried out either
using suitable chemicals, selected according to the type cf metal
35 the web is made of, or by an electrolytic process. Both methods
are well known in the trade and are not therefore described in
this specification.

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Still with reference to Figure 1, after leaving the cleaning
station 5, the web 3, which is advanced in steps by the feed means
4, is struck at least on its top face 3a by a jet of warm air
emitted by the blowing element 10 of the first drying unit 9.
The jet of warm air is designed to dry the top face 3a to
remove any traces of liquid substances used during the previous,
cleaning step.
Again with reference to Figure 1, the web 3 advances along
the feed path P, in the direction indicated by the arrow Fl, and
reaches the stamping station 11.
The following detailed description of the operations carried
out at the stamping station 11 is made with reference to Figures 2
to 7, which are scaled-up views of the .station 11 itself.
As shown in Figure 2, the operating arm 18, driven by
respective actuating means that are not illustrated, positions the
first pad 14 above the pattern 13 in such a way that the convex,
bottom face 14a of the first pad 14 itself faces the top face 13a
of the pattern 13.
The cavities 16 reproducing the impression 12 are full, that
is to say, each cavity 16 contains a sufficient quantity of
insulating varnish.
The operations by which they are filled are described in
more detail below.
With reference to Figure 3, the operating arm 18 moves down
in the direction D2, as indicated by the arrow F2, to place the
first pad 14 in a first end position in which it is in contact
with, the top face 13a of the pattern 13. The first pad 14 is
deformed by compression.
In Figure 3, the face 13a is hidden by the first pad 14.
At its aforementioned first end position, thanks to the high
deformability of the material it is made of and to the compressive
action exerted by the arm 18, the first pad 14 penetrates inside
the cavities 16 of the pattern 13 and its bottom face 14a receives
a certain quantity of varnish from the cavities IS.
In other words, as clearly illustrated in Figure 4, some of
the varnish that was previously inside the cavities 16 is
transferred to the bottom face 14a according to the aforementioned

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impression 12.
Figure 4 shows the pad 14 after the arm. 18 has lifted it in
the direction of the arrow F3, causing the faces 13a, 14a of the
pattern 13 and of the first pad 14, respectively, to move apart.
As shown in Figure 5, the arm 18, controlled by the unit 26,
advances in the direction D3, as indicated by the arrow F4, and
moves the first pad 14 to the position where its bottom face 14a
faces the web 3 of electrically conductive material.
With reference to Figure 6, the arm 18 extends downwardly in
the direction indicated by the arrow F5 and moves the first pad 14
down to a second end position in which it is in contact with the
web 3 of electrically conductive material. The first pad 14 is
deformed by compression.
At this second end position, the first pad 14 transfers to
the top face 3a of the web 3 at least a part of the varnish that
it had received in the form of impressions 12 on its bottom convex
face 14a.
In Figure 6, the second pad 15 has started moving in the
direction Dl indicated by the arrow F6 to meter the insulating
varnish transferred to the top face 13a of the pattern 13.
More specifically, the second pad 15 moves over the pattern
13 twice and, as it does so, releases a quantity of insulating
varnish that is transferred not only to the inside of the
cavitities 16 but also to the smooth surface of the face 13a.
While releasing the varnish, the second pad 15 also exerts a
scraping action on the top face 13a of the pattern 13. As a result
of this scraping action, when the second pad 15 has moved over the
pattern 13 for the second time, that is to say, when the second
pad 15 has returned to the position shown in Figure 5, the
insulating varnish is located only inside the cavities 16.
As illustrated in Figure 7, in which the arm 1.8 has already
lifted the first pad 14 in the direction indicated by the arrow
F7, another impression,, labelled 12' for clarity, appears on the
top face 3a of the web 3 as a result of the first pad 14
transferring insulating varnish when it is in its second end
position, illustrated in Figure 6.
The working cycle of the first pad 14 is completed when the

WO 2006/079894 PCT/IB2006/000108
8
operating arm 18 moves back in the direction D3 as indicated by
the arrow F8 to the position shown in Figure 2, ready to start
another cycle.
While the first pad 14 performs this movement, the second
pad 15 moves over the pattern 13 a second time in the direction
indicated by the arrow Fl to return to the position illustrated in
Figure 2, and the feed means 4 advance the" web 3 along its path P
in the direction indicated by the arrow Fl, shown in Figures 1 and
7, by a step L egual to the spacing between one impression 12 and
the next.
The spacing L between the impressions 12 made on the web 3
is egual to the spacing between the cavities 16 in the pattern 13.
Advantageously, a device, not illustrated, is positioned on
the path P between the second drying unit 21 and the punching
station 22 for applying a lubricating substance to the V7eb 3, for
example by spraying, in order to facilitate the cutting action of
the punching die 23.
Advantageously, to enable the insulating varnish to be
progressively layered on the web 3, the impressions 12 are
obtained by repeated stamping actions of the first pad 14. For
example, in the embodiment illustrated in the accompanying
drawings, each finished impression 12 is made by the first pad 14
applying varnish to the web 3 in five successive stamping actions.
As illustrated in Figure 1, after leaving the stamping
station 11, the web 3, which is advanced in steps by the feed
means 4, is struck by a jet of warm air emitted by the blowing
element 10 of the second drying unit 21.
This jet of warm air is. designed to guickly dry the
insulating varnish that has been applied to the web 3.
As it proceeds along the path P, each portion of the web 3
reaches the punching station 22 where it is engaged by the die 23
and the matrix 24.
The die 23 and matrix 24 move towards each other in
substantially known manner and by means of actuators that are well
known and therefore not described in detail in this specification,
so as to engage each other and the web 3 to form the electrical
circuits 2 by punching.

WO 2006/079894 PCT/IB2006/000108
9
The die 23 which, through the relief design 25, physically
cuts the electrical circuit 2 out of the web 3, engages the lower
face 3b of the web 3, whilst the matrix 24 opposes the action of
the die 23 by acting on the top face 3a.
Advantageously, in an alternative embodiment of the machine
1 that is not illustrated, the web 3 engages a feed roller which
positions the web with its top face 3a - that is, the one on which
the impressions 12 are made - down so that the electrical circuits
2 drop when they are punched out.
In this specification, the term "varnish" means any fluid
insulating material that can be applied to a web of electrically
conductive material and that will adhere permanently to the web.
In this specification the phrase "punch at least partly"
denotes the fact that at least a part of the web portions coated
with insulating varnish are cut out.
Indeed, for safety reasons, a part around the edges of the
coated portions remain on the punched web. This is done for safety
reasons because it would be extremely risky 'to cut out from the
web a circuit that is not perfectly and completely coated with
insulating varnish. It would indeed be extremely difficult and
unduly expensive to provide means for exactly cutting out only the
web portions that have been coated with varnish,
Advantageously, the web 3 that leaves the punching station
22, that is to say the part of the web from which the circuits 2
25 have been punched out, can easily be surface cleaned, melted down
and re-used.
The invention described has evident industrial applications
and may be subject to modifications and variations without thereby
departing from the scope of the inventive concept. Moreover, all
the details of the invention may be substituted by technically
equivalent elements.

WO 2006/079894 PCT/ IB2006/000108
10
Claims
1. A method for manufacturing electrical circuits (2)
characterised in that it comprises:
- the step of step-feeding a web (3) of electrically conductive
material along a path (P);
- the step of coating certain portions of the web (3) with an
insulating varnish;
- the step of punching the given portions of the web (3) at least
partly to define the electrical circuits (2).
2. The method according to claim 1, characterised in that "the
step of coating certain portions comprises the step of applying to
the web (3) a given quantity of varnish to make a given impression
(12).
3. The method according to claim 2, characterised in that the
step of applying the varnish comprises the step of receiving the
varnish from a pattern (13) and transferring the varnish to the
web (3) .
4. The method according to claim. 3, characterised in that the
step of applying the varnish to the web (3) is performed by a
first pad (14) made of a resilient material.
5. The method according to claim 3 or 4, characterised inthatit
comprises a step of metering the varnish transferred to the
pattern (13).
6. The method according to any of the claims from 2 to 5,
characterised in that it comprises a step of drying the varnish
applied to the web (3) .
7. The method according to any of the claims from 1 to 6,
characterised in that it comprises a step of cleaning at least one
face (3a, 3b) of the web (3) to improve the adhesion of the varnish
to the web (3) itself.
8. The method according to any of the claims from 1 to 7,
characterised in that the cleaning step comprises the step of
brushing the web (3) .
9. The method according to any of the claims from 1 to 8,
characterised in that the cleaning step comprises the step of
pickling at least one face of the web (3).

WO 2006/079894 PCMB2006/000108
11
10. The method according to, any of the claims from 1 to 9,
characterised in that it comprises a step of spraying a lubricating
substance on the web (3) in order to facilitate the punching step.
11. A machine for manufacturing electrical circuits (2)
characterised in that it comprises:
- means for feeding a web (3) of electrically conductive material
along a path (P);
- a stamping station for applying a given quantity of insulating
varnish to given portions of the web (3);
- a punching station for punching the given portions at least
partly to define the electrical circuits (2) .
12. The machine according to claim 11, characterised in that the
stamping station (11) comprises a first pad (14) designed to apply
a given quantity of varnish to the web (3) to make a given
impression (12).
13. The machine according to claim 12, characterised in that it
comprises a pattern (13) from which the first pad (14) receives
the varnish to be applied to the web (3) .
14. The machine according to claim 13, characterised in that the
pattern (13) comprises a cavity (16) that reproduces the
impression (12), the cavity (16) being designed to hold a certain
quantity of the varnish.
15. The machine according to claim 14, characterised in that the
pattern (13) comprises a plurality of cavities (16), the cavities
(16) being distributed in succession in a first direction (Dl)
parallel to the web (3) feed path (P) at the stamping station
(11) .
16. The machine according to any of the claims from 13 to 15,
characterised in that it comprises a second pad (15) for
transferring the varnish to the pattern (13).
17. The machine according to any of the claims from 13 to 16,
characterised in that, the first pad (14) is mobile between a first
end position in which it is in contact with the pattern (13) and
where its face (14a) receives a given quantity of varnish in the
shape of the impression (12) , and a second end position in which
it is in contact with the web (3) of electrically conductive

WO 2006/079894 PCT/IB2006/00O108
12
material and where it at least partly transfers the given quantity
of varnish to the web (3).
18. The machine according to any of the claims from 11 to 17,
characterised in that it comprises step-feeding means (4) for
advancing the web (3) in defined steps (L) .
19. The machine according to claim 18 when it depends directly or
indirectly on claim 15, characterised in that the spacing between
each of the plurality of cavities (16) on the pattern (13) and the
cavity (16) adjacent to it is equal to the feed step (L) of the
web (3) .
20. The machine according to any of the claims from 11 to 19,
characterised in that it comprises a station (5) for cleaning the
web (3) .
21. An electrical circuit characterised in that it is manufactured
according to a method, as defined in any of the foregoing claims
from 1 to 10.
22. An electrical circuit characterised in that it is manufactured
using a machine (1) as defined in any of the foregoing claims from
11 to 20.

Method and machine for manufacturing electrical circuits. The machine (1) for manufacturing electrical circuits(2)
from a web (3) of electrically conductive material comprises means (4) for feeding the web (3) along a defined path (P), a stamping
station (11) for applying a certain quantity of insulating varnish on certain portions of the web (3) and a punching station (22) for
cutting the electrical circuits (2) out of the web (3).

Documents:

http://ipindiaonline.gov.in/patentsearch/GrantedSearch/viewdoc.aspx?id=hMqzE7+Zqp/7NqOpRE56Nw==&loc=wDBSZCsAt7zoiVrqcFJsRw==

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Patent Number

271073

Indian Patent Application Number

2675/KOLNP/2007

PG Journal Number

06/2016

Publication Date

05-Feb-2016

Grant Date

31-Jan-2016

Date of Filing

18-Jul-2007

Name of Patentee

SPAL AUTOMOTIVE S.R.L.

Applicant Address

VIA PER CARPI, 26/B I-42015 CORREGGIO (REGGIO EMILIA)

Inventors:

#	Inventor's Name	Inventor's Address
1	SPAGGIARI ALESSANDRO	VIA LEONARDO DA VINCI, 8, I-42015 CORREGGIO (REGGIO EMILIA)

PCT International Classification Number

H05K 3/28, H05K 3/04

PCT International Application Number

PCT/IB06/000108

PCT International Filing date

2006-01-24

PCT Conventions:

#	PCT Application Number	Date of Convention	Priority Country
1	BO2005A000048	2005-01-31	Italy