To produce a current disconnector for automotive safety systems having a conductor (1) which has at least one weakened disconnection point (7a, 7b), the conductor (1) is overmoulded in a plastic injection-moulding tool (2, 3). According to the invention, the disconnection point or disconnection points (7a, 7b) of the conductor (1) is/are produced in the plastic injection-moulding tool (2, 3). This not only simplifies production, it also prevents damage to the conductor, which is fragile owing to the weakened disconnection point, before it is stabilised by the overmoulding. Preferably, the disconnection point or disconnection points (7a, 7b) is/are produced by the closing movement of the plastic injection-moulding tool (2, 3). The disconnection point or disconnection points (7a. 7b) can also be produced in the preheating region of the plastic injection-moulding tool.

In a method of forming a synthetic resin structure integral with two-dimensional steel fabric, a warp and woof are made from a steel metal, and these wires are woven in a planar configuration to provide a two-dimensional steel fabric which is then pressed into a flat structure. Two flat structures are set at a metallic mold die, into which a synthetic resin is injected so as to form a synthetic resin body integral with the flat structures. This makes it possible to secure a sufficient space between the flat structures, and spread the synthetic resin fully into the flat structures so as to reinforce a surface of the synthetic resin body with durability and high rigidity. Through the toughness, strength and price of the steel metal, it is possible to provide a marketability with products manufactured by using the present method.

A sheath member has a cylindrical and flexible main body to accommodate an electric wire and a deformation restricting portion molded on an outer peripheral side of the main body and extending over a predetermined shape maintaining range such that the main body is maintained in a desired routing shape.

A method for producing a surface heater for heating a sub-region of a vehicle includes a first step, a second step, a third step, and a fourth step. The first step includes arranging heating wires on a film and either: i) the film is subsequently formed to a predefined shape, or ii) providing a film which has been formed to a predefined shape. The second step includes inserting the formed film into an injection-molding tool. The heating wires point either toward the wall or into the hollow space of the injection-molding tool. The third step includes overmolding with a predefined material. The fourth step includes applying a transparent lacquer layer to the finished injection-molded part.

A bird spike is insertion molded, using a technique in which a wire that forms at least one of the spikes is bent while coupled to one of the mold parts, and a molten plastic is injected about at least a bent portion of the bent first wire. The wire can be bent before the mold closes but after attachment to the mold, while the mold is closing, and/or after the mold is closed. The wire can be bent in any suitable manner, preferably having first and second bends of at least 60, and a bump of at least 1 mm between the first and second bends. A robot arm can be used to concurrently secure multiple straight wires from a wire holder platform, and positioned them onto the mold part.

A bird spike is insertion molded, using a technique in which a wire that forms at least one of the spikes is bent while coupled to one of the mold parts, and a molten plastic is injected about at least a bent portion of the bent first wire. The wire can be bent before the mold closes but after attachment to the mold, while the mold is closing, and/or after the mold is closed. The wire can be bent in any suitable manner, preferably having first and second bends of at least 60?, and a bump of at least 1 mm between the first and second bends. A robot arm can be used to concurrently secure multiple straight wires from a wire holder platform, and positioned them onto the mold part.

In a method of forming a synthetic resin structure integral with two-dimensional steel fabric, a warp and woof are made from a steel metal, and these wires are woven in a planar configuration to provide a two-dimensional steel fabric which is then pressed into a flat structure. Two flat structures are set at a metallic mold die, into which a synthetic resin is injected so as to form a synthetic resin body integral with the flat structures. This makes it possible to secure a sufficient space between the flat structures, and spread the synthetic resin fully into the flat structures so as to reinforce a surface of the synthetic resin body with durability and high rigidity. Through the toughness, strength and price of the steel metal, it is possible to provide a marketability with products manufactured by using the present method.

A method for manufacturing a resin molded stator may include: preparing a straight winding core in which neighboring partial core backs are coupled by a joint; bending the core at joints and causing distal ends of teeth to face an outer peripheral surface of a core metal to obtain a core metal assembly including a stator mounted on the core metal, arranging the core metal assembly in a mold; injecting resin into the mold, covering windings with resin, curing the resin; and removing the stator from the mold and the core metal. The core metal may include a plurality of ribs projecting outward from the outer peripheral surface, the number of the ribs being between three and the number of the teeth. Each rib may extend parallel to a center axis, and each rib may be located in a gap between the distal ends of adjacent teeth.

A bird spike is insertion molded, using a technique in which a wire that forms at least one of the spikes is bent while coupled to one of the mold parts, and a molten plastic is injected about at least a bent portion of the bent first wire. The wire can be bent before the mold closes but after attachment to the mold, while the mold is closing, and/or after the mold is closed. The wire can be bent in any suitable manner, preferably having first and second bends of at least 60, and a bump of at least 1 mm between the first and second bends. A robot arm can be used to concurrently secure multiple straight wires from a wire holder platform, and positioned them onto the mold part.

A current breaker for automotive safety systems has a separating punch and a conductor formed with at least one localized decrease in thickness constituting a weakened separating point severable by the separating punch. This current breaker is made by overmolding the conductor in a plastic-injection mold with an encapsulation by a method having a first step of forming the separating point of the conductor in the plastic-injection mold before or during overmolding and a second step of forming with the mold above and below the conductor in the encapsulation a passage fully exposing the separating point and dimensioned to hold the separating punch.