Automated wiring system and method

Claim 2

In a method of making an electrical interconnection module having a desired predetermined electrical interconnection pattern, the steps of: providing an elongated core having at least two axially extending rows of receiving means at spaced predetermined locations thereof, automatically coupling wires between selected ones of said receiving means in a predetermined order as determined by said predetermined electrical interconnection pattern and so as to traverse selected paths along said structure in a manner so that receiving means between which electrical connections are desired in the completed module in accordance with said desired predetermined electrical interconnection pattern are coupled via first predetermined paths while receiving means between which electrical connections are not desired are coupled via second predetermined paths, said first predetermined paths being contained on one side of said core between said rows and said second predetermined paths being contained on the other side of said core, and removing a continuous predetermined portion of said core between said rows aNd on the side containing said second predetermined paths so that the wire portions traversing said second predetermined portion are electrically disconnected to thereby provide said module with said desired predetermined electrical interconnection pattern.

Claim 3

The invention in accordance with claim 3, wherein said method includes providing module output terminals at predetermined ones of said receiving means and electrically connecting said terminals to the respective wires coupled thereto.

Claim 4

The invention in accordance with claim 4, wherein the step of automatically coupling is accomplished using a continuous wire.

Claim 5

The invention in accordance with claim 4, wherein said core is formed of two separable members, and wherein the step of removing includes separating said members.

Claim 6

The invention in accordance with claim 4, wherein said method includes the step of encapsulating the core following said removing so as to provide a unitary structure having terminals extending therefrom.

Claim 7

The invention in accordance with claim 4, wherein slots are provided in said core at said predetermined locations.

Claim 8

The invention in accordance with claim 4, wherein the step of electrically connecting is performed by dip-soldering.

Claim 9

The invention in accordance with claim 4, wherein the step of electrically connecting is performed by using conductive epoxy.

Claim 10

The invention in accordance with claim 4, wherein the step of electrically connecting is performed by using infrared heat-bonding.

Claim 11

The invention in accordance with claim 4, wherein said terminals are provided in the form of terminal blanks having terminal portions disposed in predetermined ones of said slots, and wherein the step of removing includes removing portions of said terminal blanks so that said terminal portions are electrically separated from one another.

Claim 12

The invention in accordance with claim 8, wherein certain ones of said slots are terminal slots for receiving respective ones of said terminals and other ones of said slots are nonterminal slots, and wherein the step of automatic coupling is such that each nonterminal slot receives at least a plurality of wires or no wires.

Claim 13

The invention in accordance with claim 13, wherein the step of electrically connecting causes each wire disposed in a terminal slot during the step of automatic coupling to be electrically connected to the respective terminal also disposed therein and causes the plurality of wires disposed in each nonterminal slot during the step of automatic coupling to be electrically connected to each other.

Claim 14

In a method of making an electrical interconnection module having a desired predetermined electrical interconnection pattern, the steps of: providing an elongated core having at least two axially extending rows of receiving means at spaced predetermined locations thereof, automatically coupling wires between selected ones of said receiving means in a predetermined order as determined by said predetermined electrical interconnection pattern and so as to traverse selected paths along said structure in a manner so that receiving means between which electrical connections are desired in the completed module in accordance with said desired predetermined electrical interconnection pattern are coupled via first predetermined paths while receiving means between which electrical connections are not desired are coupled via second predetermined paths, said first predetermined paths being contained on one side of said core between said rows and said second predetermined paths being contained on the other side of said core, and cutting the wires traversing said second predetermined paths by cutting the wires along a continuous uninterrupted path between said rows on the side of said core containing said second predetermined paths.

Claim 15

The invention in accordance with claim 15, wherein said method includes providing module output tErminals at predetermined ones of said receiving means and electrically connecting said terminals to the respective wires coupled thereto.

Claim 16

The invention in accordance with claim 16, wherein said cutting occurs for all wires traversing said portion between said rows.

Claim 17

The invention in accordance with claim 15, wherein the step of automatically coupling is accomplished using a continuous wire.

Claim 18

In a method of making an interconnection module, the steps of: providing an elongated core having at least one longitudinal recess and a plurality of traversely extending slots; forming wire loops traversing said slots and said recess by winding a continuous wire upon said core, said wire loops traversing said slots in a predetermined order determined in accordance with the interconnection pattern desired for said module; providing two parallel rows of upstanding terminals attached to a temporary central backing portion with said terminals spaced along said backing portion to coincide with the longitudinal spacing of said slots; assembling said plurality of terminals upon said core with the terminals overlaying the loops in the slots and the backing portion overlaying the said recess, bonding each loop to an overlaying terminal; and disconnecting unwanted electrical interconnections among the various terminal and loop assemblies by removing portions of the loops overlaying the recess and said backing portion.