CA1069282A - Channel type terminal connectors and method of making - Google Patents

Abstract

Abstract of the Disclosure Forming of wire contacting jaws for a channel type electrical terminal of conductive sheet metal is disclosed, without diminishing the length of the terminal, by first obtaining a stretching of the conductive metal into a preliminary displaced configuration in a first die. Then reverse e forming and coining the metal into a jaw formation deeper and narrower than the first configuration. Then in a third die substantially removing the reverse curvature, with added coining and stretching of the metal, into a final jaw formation which is deeper and narrower than that obtained in the second die, without rupture of the metal. Slight reverse curvature is retained adjacent the juncture of the sides of the jaw with the body of the terminal.

Description

This invention relates to wire termination systems in which a wire to be held in a terminal may be held ~etween a pair of jaws or within sets of jaws. More especially i-t relates to a method of forming generally U-shaped jaws in a terminal without shortening the original terminal blank and without rupturing the metal used therefor.
Terminal connectors of the type presently involved are Eormed of highly conductive metal which typically is shaped to provide an elongated channel. Insulation piercing jaws are provided within and along the edges of the channel, as disclosed more specifically in McKee and Witte application Serial No. 214,478 filed November 22, 1974, and McKee U.S.
Patent No. 3,902,154, issued August 26, 1975. In use, an insulted wire is forced into the channel so that the jaws penetrate the insulation and forcibly contact the conductor of the wire.
Terminals of the type here involved typically are used where space is at a premium and miniturization is im- -portant, as in molded, insulating receptacles designed to contain a large number of terminals. A primary example is in connectors for 50-wire telephone cables. In such recept-ables the tolerances are close, frequently on the order of just a few thousandths of an inch. In order to accommodate . such tolerances it has been recognized that the terminals must be of precise uniform dimensions.
The dimensional accuracy is important to insure proper configurations and spacings for very high reliability of forming good electrical contac~ of the jaws with the . .
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36g~zs~ , conductor of the inserted wire. High compressive strength of the jaws also is important to maintaining the spacing tolerances under the compressive stresses imposea by forcibly inserting a wire when forming a termination, l.e., to avoid compressive yielding or failure of the jaws. The compressive stresses may be of a high order, as in relying upon a camming or wedging action between the wire and the jaws to effect an intimate gas-tight contact therebetween, and which may involve forcible displacement or distortion of the material of the wire conductor by that action. It is also desirable to maintain the side and bottom walls integral with one another, and to avoid deformation of the bottom wall which would increase the required overall depth of the terminal.
All of the foregoing problems and requirements are exacerbated by the small size of the terminals involved. Thus there is very little material available for forming the necessary configurations or to lend mechanical strength.
These factors require close adherence to designs providing high stress capabilities relative to the inherent strength of the material available, including the geometry of the designs. Finally, highly conductive materials must be used in such terminals to maximize conduc~ivity. However, practical and economical materials meeting these parameters usually are of low ductility and more particularly have a low to medium ~ elongation capability, e._., 5% to 10~. This means that the -' materials will not accommodate significant tensile stretching without tensile cracking and failure.
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' It is an object of this invention to provide methods ~ for forming terminals of the aforementioned type, and which - ~;

`~ 30 methods overcome the noted problems and meet the related ~;

desirable parameters.
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It is a further object of this invention to form a plurality of such jaws in an improved electrical terminal, which jaws are oppositely disposed to each other.
It is a further object of this invention to form such contacting jaws as continuous portions of the sides of the terminal bodies, and particularly without corresponding deformations of joined portions of the terminal and without stress cracking or failure of the conductive material of which the jaws are formed.
Still a further object of this invention is to form the contacting jaws by means of a stamping die or a series of stamping die faces while maintaining close dimensional tolerances of the completed terminals.
A related object of this invention is to provide a progressive die including a plurality of ribs and valleys on the faces thereof in which the jaws of the terminals may be formed.
Another related object of this invention is to pro=
vide an improvèd die blank of current conducting metal for forming a plurality of electrical terminals in a progressive ~ -die, each terminal including a plurality of shoulders in the sides thereof arranged along side depressions therein for forming wire contacting jaws within the bodies of the terminals.
These and yet additional objects and features of the invention will become apparent from the following detailed discussion of an exemplary embodiment, and from the drawings ~
and appended claims. ~ -In a preferred form of the present invention a method of forming wire contacting jaws in an electrical wire ~, ::' .
, ,' '' 6~28~2 t~rmill~l is provi~ccl whcr~in the tcrmin.lls are form~d of a sheet of electrically conductivc metal. ~ first jaw-forming portion of tlle shcet is separated from the remainder of the sheet alol~g a substantial part of opposed edges of that por-tion, and remains joined to the sheet ~t its opposite ends.
The sheet is çontinuous bet~een those ends externally o~
that portion, as well as within that portion~ The first por-; tion, thus associated with the shect, is cleformecl laterally of the sheet to form a contact jaw without any corresponding deformation of the joined, continuous part of the sheet.The described first portion of the sheet is drawn through-out its width into a broad shallow wave form extending on one side of the sheet so that the wave form has a first base width. Then the opposite end portions of the first portion within the base width are reformed to be curved in a direction opposite to that of the center of the wave form, thus positioning the opposite end portion curves on the opposite side of the sheet from the center of the wave form, while the center segment of the wave form remains disposed in its original direction and obtains a reduced radius. Subsequently, further orming of the first portion takes place by returning the end portions toward the plane of the sheet while extending the center segment further outwardly from, and on its original side of, the sheet, and fuxther reducing the radius of curvature of the center segment. By particular controlling of the forming of the material to the final jaw configuration, including coining certain portions in the second and third steps and spreading the stretching of the metal over a maximum length while avoiding concentrated stretching, a dispersed `~ elon~ation of the metal in the first portion is obtained ..
_ ~ _ while ~ormin~ a jaw of a narrow, sharp, desirable configura~ion. The described forma~ion of the jaws may be obtained by manipulating the sheet on a set of die faces.

' Brief Description of the Drawin~
For a compl~te understanding of this invention ; reference should be made to the accompanying drawings in which:
Fig. 1 is a top plan view of a section of a blank of a flat metal sheet for use on a progressive die and showing a series of terminals in various stages of formation, Fi~. 2 is a cross-sectional view o~ a portion of the blank shown in Fig~ 1, taken along the line 2-2 in Fig. 1, disposed between a first ribbed die and a first mating die, Fig. 3 is a perspective view of a broken away portion of the blank shown in Fig. 1, at approximately the cross-sectional portion shown in Fig. 2, but showing the full width of a terminal blank as indicated at bracket 3 in Fig. 1, Fig. 4 is a cross-sectional view of a portion of the blank shown in Fig. 1, taken along the line 4-4 in Fig. 1, - 20 disposed between a second ribbed die and a second mating die, Fig. 5 is a perspective view of a broken away por~ion ~f the blank shown in~Fig. 1, at approximately the cross, sectional portion shown-in Fig. 4, but showing the full width of a terminal blank as indicated at bracket 5 in Fig. 1, Fi~. 6 is a cross-sectional view of a portion of the blank shown in Fig. 1, taken along the line 6-6 in Fig. 1, disposed between a third ribbed die and a third mating die, ` ~ig. 7 i~ a perspective view o~ a broken away portion of the blank shown in Fig. 1, at approximately the ..

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cross-scctioJIal portlon shown in li~. 6, ~ut sho~incJ the full width of a terminal blank as indicated at brac~et 7 in Fiy. 1, ~ig. 8 is a perspective view of a completely formed terminal scparated from the blank shown in Fig. 1, Fi~. 9 is a persp~ctive cross sectional view of a plurality of terminals identical to that shown in Fig 8, mounted in a receptacle body frequently referred to as an insulating high density connector body, Fi~. 10 is a cross-sectional an~ elevational vie~7 of a pair of terminals identical to the terminal shown in ~ig. 8 taken along the line 10-10 in ~;g. 9 and including a pair of insulated conductor ~1ires, not shown in Fiy. 9, disposed for insertion into the terminals, and Fig. 11 is a cross-sectional and elevational view of the pair of terminals sho~n in Fig. 10 illustratin~ insertion of the wires into the terminals.
Detailed Description of the Preferred Embod _ent Considering first Figs. 1-7, the improved method o~
making a terminal for use in a wire termination system is illustrated by showing successive steps in the formation of the terminal. Such terminals are especially useful as solder-less terminations in high density connectors, particularly those used in miniturized electrical and electronic components. It will be recognized that the metal used in the formation of such .
terminals, particularly those of the present invention, is quite thin but only slightly ductile. One especially suitable metal is a cadmium bronze alloy 961 in 0.006 inch sheets. Ordinarily - the tensile strength of this material is on the order of 73,000 psi., and it has an elongation capability of about 6-8~, preferably with a minimum of 7%.

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Fig. 1 shows a series of terminal blan~s of con-ductive m~tal on which successive steps of formation have b~en carr;.ed out iJI accordallce with the present invention. A pro-gressive die blank 2 is stamped to form foldable configurations such as the confi~uration 4 which are ultimately folded into terminals such as tcrminal 6. Sheet 2 may be as long as necessary to ~it both the stamping operation and the terminal forMing dies to be described later. Stems such as those shown at 8 and 10 maintain the foldable ~nd folded configurations evenly disposed thr~u~hout the length of the metal blank. The stems 8 may be finally severed, as at stem end 12, from a strip 14 at the - outer edge of blank 2, and the stems 10 may similarly be sevexed from a strip 16 in the center of blank 2. A completely finished and separated terminal 6 is shown as 6~ in Fig. 8.
- 15 As shown ln Fig. 1, the center strip 16 of the metal blank 2 includes a plurality of regularly spaced apertures 18 which function as an indexing me~nS for moving blank 2, including the foldable configurations 4, between terminal forming progressive die faces. It should be understood that although the foldable ~ 20 configurations 4 are illustrated in Fig. 1 in individual and successively more finished form from left to right, it is possible to shape those configurations in groups having the same form so that groups of the configurations 4 would bé
shaped identically. In that event the blank would be , advanced more rapidly in accordance with the spacin~s of the groups.
Also, it will be noted that Fig. 1 illustrates forming the foldable conEigurations 4 on both sidcs of the center strip 16 in blank ~. As viewed in Fig. 1, the configurations 4 below .

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thQ stri~ 16 arc exactly id~ntical to those loca~ed immediately above the~ Since the resulting terminals are used in large numbers (a 2-1/g inch long connector may contain as many as fifty terminals, for e~ple), it is desirahle to ob~ain high production rates. By dup]icating the configura-tions, and the steps involved in making them, on each side of the metal blank 2, a number of terminals can be made very rapidly with a minimum number o~ movements of the metal bl~nk and a correspondingly lesser unit cost.
Whether the apertures 18 or other indexing means are located along the center portion of blank 2 or along one edge thereof, it is important that the metal blank 2 remain the same width throuyhout as the blank progresses through the equipment for forming the terminals. Uniform width and lack of distortion of the blank in this respect insures that the shearing of the edge strips 14 and center $trip 16 from the stems 12 and 10 will result in finished terminals of uniform dimensions. Such uniformity can be achieved notwithstanding the formation of several impressed undulations in the sides of the terminals, shortly to be ~ 20 described. Formation of such undulations would be expected to rupture the material or to cause deformation of parallel connected 1at portions of the blank. The former of course is unacceptable and the latter would pull the outer edge portions 14 of the blank closer together, or distort the uniform linear configuration of the center strip 16, and not only create a substantial number of variations in the width of the blank but also distrub 1:he uniform orientation of the components of the tex~inals themselves.
` The impression of the undulations just referred to, and to which 1:he present invention is directed, is particularly illustrated a1: Figs. 2-7, but is best perceived with reference a -.-; , ~ .
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~ 8 ~ ' to the fol(klble configul-atioll of tlle ~lank ~~li in FicJ. 1 arld the completcly fillisilecl terminal 6~ .in Fig. ~. Configura-tion 4a includ~s notches 20 and is fla~ exccpt for impres-sions and pro~uberallces 22 and 24 wh.ich are not directly in-volved in the prescnt invention. Configuration 4a is ormed as the result of preceding stamping steps performed UpOI) the flat metal blan~ 2. Also included in configuration 4a are slots 26 ~which alternatively may be sheared slits, ~7ithout removing material) and which are preferably formed in pairs opposite the notches 20, so that each notch is disposecl along the ed~é of the foldable coniguration pointing at approxi-mately the midpoi,nt of a companion seve~ance 26. The por-tions of each blar.k 4 comprising the sections bet~een the ; slots 26 and the respective blank edges together wlth ad-15, joining sections at each end o those sections are formed into jaws in accordance with this invention.
' The end result of the desired shaping of configura-: tion 4a is shown in Fig. 8, a completed terminal 6~ ready for installation in a receptacle body such as an insulating high ' 20 density connector body. The stem ends 10 and 12 have been ; appropriately severed, as by shearing, from the metal , blank 2. Side or panel portions 28 and 30 of the terminal have bee~ folded into upright parallel positions, at approximately right angles to a terminal body base panel 32, .
,thus forming a narrow channel body 34 extending longitudinally ~;; of the terminal. The notches 20, ~hich have been beveled, are . j~
' disposed along the top edges of the sides 28 and 30, and slots 26 are disposed at the bottom edges at the junctions~of the sides with the terminal body base 32. The jaws 36 extend ,~ 30 into the channel for contacting the electrical conductor

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of a wirc to be disposed wi~hin the channel. Shoulders 38a are providcd at the junctures of the outer edges of the jaws 36 with nominally planar portions ~Oa of the sides, and shouldcrs 38b are formed at the junctures of the inner edges of the jaws with yoke portions 40b of the sides inter-mediate the jaws.
By way of a more specific illustration, in a terminal 6A for use in telephone wire connectors and in the production of which this invention is particularly advanta~ous, the channel body is about 0.050" wide ~outside dimension), about 0.058" high and about 0.40"
long from the outside of tab 174d to the near end as seen in Fig. 8. Such terminals are formed of the afore~
mentioned O.006" cadmium bronze alloy sheets and are used in a solderless ribbon-type miniature connector made and sold by TRl~ Inc., Elk Grove ~lllage, Illinois. Two pairs of opposed ja~s 36 are provided on 0.080" centers in each terminal, with each jaw being about 0.022" deep from the out-side surface of the respective channel side. Each jaw is _ 20 about 0.007" outside radius at the inner nose, and about 0.030" wide between the centers of curvature of the junctions between its legs and the respective side panel, which curves are of about 0.006" radius. Each jaw is beveled at the top and tapers inward slightly therebelow, as seen in Figs. 8, 10 and 11. Each slot 26 is 0.040" long and separates the respective jaw ! .
from the base paneI 32.
The forming of the jaws 36 is accomplished in steps which result in successive forms of the jaw-forming portions of the blanks as shown by the blanks 4b-4d in - 10 ~

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Fig. 1 and illustrated cross-sectionally and in perspective in Figs. 2-7. In Fig. 2 a portion of the side 28 of fold-able configuration 4b from which a pair of jaws 36 is to be formed is shown between a first ribbed die face 42 of a die 48 and a first mating die face 44 of a die 46. Both die faces are of configurations to include a plurality of ribs and valleys.
When the dies are moved together (as in Fig. 2 as by raising or lowering the first die 46, depending upon orientation of the die faces) the intervening two jaw-forming portions of the blank are formed into two broad shallow depression or wave configurations 50a and 50_ by first ribs 52 on the die face 44 and first valleys 54 in the die face 42. In this initial step the mating dies are not closed on the blank completely or "bottomed". The first depressions 50 are shaped such that the metal configuration 4b is not ruptured despite the fact that the material may have very limited elongation capabilities. one of the prime objectives of the first step is to form each depression 50 as the beginning of a jaw by causing the metal to flow and stretch over the longest available length of material by a minimum degree of ` stretch in any one section without rupture of the material. `
The initial shaping of the jaw portions of the blanks, in the manner just described, results in a blank with the shallow wave formation 56 of two depressions 50a and 50b as shown in Fig. 3 (see also the left side of con-figuration 4_ in Pig. 1). These depressions extend the full width of the jaw-forming portions, and are raised or otherwise displaced from the plane of configuration 4b, distorting one edge 58 of each of slots 26 while leaving the ~. ' I
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other edges 60 generally co-planar with the terminal body base 32 which remains flat. The zenith or peak of each depression 50 is indicated by a dashed line 62 and is perpendicular to a vertical plane containing the principal longitudinal axis of the terminal body base 32. These peaks also coincide with the edges of the notches 20 at their deepest and closest penetration toward the distorted edges 58 of slots 26.
For the specific example given above, the shallow wave forms created in the preliminary shaping of the jaws may be obtained by using a die 46 having rigs 52 spaced on 0.080"
centers, with outer ends of 0.015" radius and which protrude 0.20" from the otherwise generally flat face of the die.
Corresponding valleys 54 may be 0.042" wide and 1/32" deep, with 0.019" radius shoulders at each side. It has been found by using dies having such dimensions and the cadmium bronze alloy metal to form a terminal, that there is some spring-back of the metal depressions 50 when the ribbed die and the mating die faces are separated. The depressions 50 are pressed to a depth such that, after being released -from the dies, their inner depth is on the order of 0.010"
i.e., 0.016" to 0.018 outer height measured vertically from the outer surface of their peaks to the opposite flat surface of the side panel.
By approaching the formation of jaws 36 (see Figs. 7 and 8) gradually and over a maximum length, that is, by separately performing the first step of making shallow wave forms in the otherwise flat sides of the terminal blank in the manner just described, the side portions 28 of terminal 6A (Fig. 8) permit the creation of the wave forms therein as demonstrated in Figs. 2-3 without distortion or shortening of either base 32 or of ~''~ '' ' ~, .

.: , th~ rem~iJI~er o t:he sicles 28 ancl 30 despi~e the ~act that ~he sides and base are intcyrally conn~cted. Primarily, the wave forms (such as depressions S0) are obtained by dispcrsed stretching and inflow of metal from portions of the configura~
tion 4b adjacent but beyond the ends of the sections between the notches 20 and slots 26, as well as by dispersed stretch-ing within those sections. Some displacement of the por-tions of the blank intermediate the wave forms and the notches 61 (Fiy. 1, and which portions are about 0.020"
wide), apparently occurs as there is a change in the an~le o~ the adjacent edge of this notch as the deprcssions 50 are formed, compare blanks 4_-4d with blank 4a. However, the same displacement is not available between the waves or at the opposite end, where all o the blank remains integral and the elonyation must occur by stretchins. The stretching is not concentrated and is rela~ively uniform throughout the metal being worked.
In examining the second step of creating jaws 36, attention should be given to Figs. 4 and 5 as well as to configuration 4c in Fig. 1. The jaw-forming portions of the blank, after having undergone the initial ~orming step shown and described with respect to configuration 4b in Figs. 2 and 3, are placed between a second ribbed die ~ace 64 of a die 68 and a second mating die face 66 of a die 70. The blanks are located with the previously-formed depressions 50 centered on ribs and valleys of these die faces to be described. Preferably these dies are then ~ully closed ("bottomed") against the blank to reform and modify the pre-liminary shaping of the terminal side panel in the areas in-cluding the depressions 50, as shown fox example in Fi~. 4.Thereby, a number o significant modifications are made to xefoxm the depressions toward their ultimate jaw form.

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Referrinc3 to the die surfaces adjacent the de~
pression 50a, as sho~n in Fi~. 4, the die ~ace 64 include~
a second valley 72. The sides 74 and 76 of the second valley 72 converge toward each other as they extend into the body of die 68. At their outermost extremities, ad-jacent the face 64 of the second ribbed die, these sides are closer together than the sldes 78 and 80 of each valley ~4 as viewed in Fig. 2. At each of those extremities first shoulder rihs 82 and 84 are formed upon the second ribbed die face 64, extending outwardly beyond the generally flat plane of that die face. ~hese ribs provide surfaces which cooperate with first shoulder receiving grooves 86 and 88 in the second mating die face 66 for forming shoulder impressions 90 and 92 in the blank 4c. Similarly, a rib 94 between the grooves 86.and 88 mates with the ~alley 72 for reforming the center segment of the depression .. 50a. The second valley 72 and rib 94 are so dimensioned that the depression 50a may be further deepened within valley 72 from.the preliminary depth of that depression achieved between the first ribbed die face 42 and the first mating die face 44.
In order to insure the reverse curvature (from the curvature formed at the depth of depression 50a) for : the formation of shoulder impressions 90 and 92, the ~5 face 64 of the second ribbed die 68 may be provided with a shoulder return face portion 96 adjacent the ~ outer extremity of rib 84. A similar shouider return `~ face portion 98 may be provided adjacent the outer extremity of shoulder 82. The shoulder return face 3C portions ~6 and 98 in die face 64, and cooperative shoulders 100 and 102 of the face 66, serve to return : 14 : ' ';~

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the adj~cent portions of tho resuec~iva side p~n~l to its normal plane relative to the jaw deformations.
The described ribs, shoulders and valleys of die faces 64 and 66 are duplicated for reforming of the depression 50b in the same manner ~s described for depression 50a, as indicated by the parts identified by the same numerals with a subscript a. I-lowever, when it is desired to provide a plurality of jaws 36 in a side panel, as shown, the formation of the shoulder face portions 98 and 102 will be slightly varied from those of the face portions 96 and 100. As shown in Fig. 4, adjacent shoulder return face portions 98 and 98a in the face 64 of die 68 merge with an intervening arcuate section 104 intermèdiate shoulders 82 and 82a.
The center of this section is substantially co-planar with the major face surface of die face 64. Such a section 104 in cooperation with a corresponding portion 105 of the die face 66 which merges with surfaces 102 and 102a provides for a wave formation 106 in the side panel bet~een depressions 50a and 50b (which are to be finally formed into jaws 36). The center of this wave is maintained co-planar with the main body of the respective side panel.
The second mating die faces 64 and 66, as above de-scribed, preferably are adapted to be bottomed against the por-tions of blank 4c between those two die faces. Such bottoming insures proper formation of the various depressians and shoulders of the blank, which occurs by reformin~ the blank to the new configuration while coining and further stretching the metal in the work area, as described further below. At ~ 30 the same time, the remainder of the blank 4c is retained in ; a flat undistorted form between other flat portions of the dies.

: - 15 -? ' ~369~2 The resul~ of u~ iny sueh colnplelllentary die faccs as described wi-th respect to Fig. 4 is shown in Pig~ 5, albeit Fig. 5, likc ~ig. 3, illustrates the use of ~our sets of die ~aces rather tha1l two sets. Since Fig. 5 shows merely a fu~ther step in the formation of termi~al 6~ (sce Fi~. 8), which step is a further ~evelopment of the depressions sho~Jn in the frag-mentary portion o~ the terminAl illustrated in Fig. 3, it is only necessa~y to identify the particular changes which have occùrred. Portions of each o~ the original depressions 50 have been rcformed as shoulders 90 and 92, extending on the opposite side of the blank 2 from the central segments of depressions. The two sides of each depression 50 have been formed much closer together and the depressions themselves have been narxowed and deepened, with considerable reduction in the included angle defined between these sides.
Of primary importance is the fact that the terminal body base 32 has not been distorted or shortened in any manner. The length of slots 26 has remained unchanged but despite the increased length of the metal necessary for forming the depressions and adjacent shoulders, _ the metal has remained unruptured.
The manipuIation of the metal in the jaw-forming portions to form the depressions and the shoulders in the step of Fig. 4 includes reforming or reshaping of the stretched wave form o~ Fig. 3. In addition, and simulta-neously, controlled coining, that is, gradual, measured, compressive foxming of the metal i5 effected in the areas comprising the shoulders 90, 90a, 92 and 92a as those shoulders are formed, alon~ with some additional stretching of the metal throughout the portion being formed. The ~ ~ .

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, -: . . 1, ~69~82 coining is effected in and adjacent the center portions or bends of the arcuate end configurations of the impressions 90, 90a, 92 and 92a, between the outer end of each rib 82, 82a, 84 and 84a and the respective opposed groove 36, 86a, 88 or 88a. The metal is caused to flow into the convolu-tions on the die faces under the influence of pressure exerted through the die ~aces thus providing reshaping of the metal and avoiding rupture of the metal during the necessary lengthening and bending of the respective portion of the blank to form the described configuration. Any substantial concentrated or uneven tensile stretching of the metal is avoided in order to obviate the possibility of tensile fracture or failure, particularly at the tips of the several bends created in the shoulder and depression curved portions.
The above-described second step achieves quite minute dimensions, especially in obtaining the reverse curvatures provided by the shoulders in each side of each initial depression 50. Whereas, in forming the depressions 50 initially (see Fig. 2), the first rib 52 on the first mating die face 46 may impress each depression 50 into a valley 54 which measures 0.042" wide even at its deepest point, in the second, coining step (see Fig. 4), each de-pression 50 may be impressed into a valley 72 which may measure only about 0.025" where left and right sides 74 and 76 join shoulders 82 and 84, respectively.
Depressions 50a and 50b, as viewed in Fig. 5, include convex curvatures having their peaks along zenith line 62. Looking at the same face of sides 28 and : :. '' ' ~6~2~32 30, r~vcrs~, or concav~, curvatures a~e forlnecl at th~
shoulders 90, 92, 90a and 92a which extend from the outside edc3cs of the jaw-forming portions 50a and 50b to the slots 26. The nadirs o~ these shoulders are approximately ali.~ned with the ends of the slots 26, as illustrated by dashed lines 112 and 114. A dashed line 116 d~signates the zenith of the arcuate wave formation 106 intermediate the shoulders 92 and 92a, which zenith extends perpendicularly toward an imaginary line 118 aligned with the inside edges of slots 26.
The section 106 extends between an imaginary line 120 approximately at the outside edges of slots 26 to the outer edge of the panels and is shaped to present a convex surface on the same face o side 28 as the convex surfaces of depressions 50, with the outer edges leading do~nward to the shoulder ribs 92-92_. Creases at 122 accommodate the offset of the outer portions of shoulders 90, 90a, 92 and 92a.
The die faces 64 and 66 are of confiyurations and dimensions to extend ~he overall height of the jaw-forming portions to slightly greater than 0.018" when in the dies as in Fig. 4, as measured from the peaks of portions 50 to the opposite peaks of shoulders 90 and 92., Due to springback of the material, this height is about 0.018" in the blank 4c of Fig. 5.
In add:ition to dimensions already noted, a set of specific dimensions for die faces 64 and 66 for the spe-cific example re~Eerred to above includes locating the valleys 72-72a and ribs 94-94a on 0.080" centers.

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~ Il z The valleys 72 and 72a may be of a 0.0135" radii with their uppermost surfaces 0.007`' above the major flat surface (die line) of die face 6~, and each shoulder or rib 82, 82a, 84 and 84a may be of 0.0076"
5 radius with its peak 0.007" below the die line. The shoulders 96, 96a, 98, 98a and intervening surface 104 all may be of 0.025" radii, and are tangent at their upper edges with thc major flat surface tdie line) of die face 64. The centers O:e curvature of shoulders 82~84 and 82a and 8~a are spaced 0.020" on the respective sides of the centerlines o valleys 72 and 72a. Surface 104 is a continuation of the curvature of shoulders 98 and 98a and has its centerline midway between the centerlines of the valleys. These various arcuate 15 surfaces merge directly with one another at common tangent lines on the side of each rib, shoulder and valley. Referring to die face 66, each rib 94-94a may be of 0.0076" radius with its outermost peak 0.007"
above the major plane of the respective die face. The valleys 86, 86a, 88 and ~8a may be of 0;û135" radii, each having its center of curvature spaced 0.020" on the respective side of the centerline of the related rib and each extending 0.005" below the plane of the die face 66. Shoulders lO0 and lOOa are of 0.019" radii and surface 105 is of 0.024" radius including shoulder surfaces 102 ancl 102a, with each of these surfaces ex~ending tangent to the major plane of die face 66.
These various arcuate surfaces also merge directly with one another at common tangent lines.

-, - ~s outlined above, Figs. 2 and 3 il:Lustrate a prefeIrcd initial step in the process of forming ~erminals 6~, while Figs. 4 and 5 illustrate a pr~ferred intermediate ~e~ in formi~ such terminals. Figs 6 and 7 illustrate a preferr.~d third step of terminal formation prior to folding the sides of a processed configuration 4 into A completed terminal 6~.
In Fig. 6 a third ribbed die face 12~ of ~hird ribbed die 12~ is opposed ~y a third mating die face 128 of third matin~ die 130. The processed portion of configuration 4c shown in Fig. ~ is positioned between the faces of the third dies and is further formed thereby as in Fig. 6 to produce the configuration 4d as shown in ~ig~ 7~ Similarly to the first processing step illustrated in Fig. 2, but contrar~ to the intermediate processing step illustrated in Fig. ~, the dies 126 and 130 are not fully bottomed in the third processing step illustrated in Fig. Ç.
The ribbed die face 124 includes a third valley 132 having ~pposite sides 134 and 136 which ~20 are generally parallel to each other. Curved second shoulder ribs 138 and 140 connect the major planar ~- portions of the die face 124 with the sides 134 and 136, respectivelY~ ~f the third valley. Otherwise the face 124 of the third ribbed die adjacent valley 132 lies a}most entirely in the same horizontal plane. The ~alley 132, and more partlcularly the shoulders 138 ~nd 140, is adapted to receive and further shape depres-; ~ion 50a ~oll~wing the processing ~f such depression ~,. ' ::

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bet~7e~n di~ faces G8 and 70 as in Fig. 4. When it is desired to sirnultaneously proce~s a plurality o~ adjacent deprcssions, such as depressions 50a and 50b, a further third valley 132a identical to valley 132 may be disposed in the thixd ribbed die face 124. Li~e third valley 132, third valley 132a includes opposite sides 13~a and 136a which are parallel to each other. Curved second shoulder ribs 138a and l~Oa connect portions o~ the die face 124 with the sides 134a and 136a, respectively, of third valley 132a.
The third mating die ace 128 includes a third rib projection 1~2 which has a rounded but much more sharply pointed tip portion 144 than the end o~ rib 94 on the second mating die face 66, shown in Fig. 4. Rib projection 142 is adapted to press depression 50 (see Fig. 6) between the narrowly spaced apart second shoulder ribs 138 and 140 of the third ribbed die face 124, whereby those shoulders press and coin the sides of the depression against the sides of the rib 142.
The third rib projection 142 also extends much further outward-ly from third mating die face 128 than does rib 94 of the _ 20 second mating die ~ace. Accordingly, a depression 50 is further deepened, or elongated, between the third die faces 124 and 128. A similar rib projection 142a may be formed ; on mating die face 128, spaced apart from rib projection 142, when it is desired to process a plurality of depres-sions, such as 50a and 50b in configuration 4d ~see Fig. 1).
Face 128 of the third mating die 130 further com-plements ~ace 124 of the third ribbed die 126 in that the sides of~the third rib projectlon 142, namelyr right side 146 and , ~, .

~921~2 left side 1~, as viewed in Fig. 6, are, for most of their lenyth, closer to~ethcr than the sides 134 and 136 of valley 132. This relationship is maintained even though sides 14G
and 148 are angled toward each other as they approach tip portion 1~4 o~ tlle third rib projection 1~2, ~hile sides 134 and 136 of valley 132 are substantially parallel. Second shoulder -receivincJ curvatuxes 150 and 15:2 are situated at the extremi.ties of the sides 146 and 14~, respectiv~ly, of the third rib project.ion 1~2, and these second shoulder receivlng curvatures merge wïth sides 14G and 148 at co~mon tangent lines whére rib 142 is narrower than the valley 132 by an amount exceeding twice the thickness of the sheet material being formed, i.e., the total width of the rib 142 at this level plus a thickness of the material on each side would be less than the width of valley 132. The surfaces 150 and 152 curve outward from these merge areas and are tan~ent with the major planar surface of face 128 as illustrated.
When it is desired to process a plurality of depressions, such as 50a and 50b tsee Fig. 6), the third rib projection 142a is formed with sides 146a and 148a, and second shoulder receiving curvatures 150a and 152a, disposed . identically with respect to valley sides 134a and 136a and second shoulder ribs 138a and 140a, as the rib pro-- 25 jection sides and shoulder receiving curvatures of rib 142 are disposed relative to valley 132.
As suygested above in describing the third ribbed die face 124 as being almost entirely in ~he same horizontal - 2~ ~ -, 6;9~

plane, the fac~ 128 of the third ~ating die 130 also lies almost entirely in a hori20ntal p:Lane, thus furthcr complementing the third ribbed dic face 124 and the valleys and shoulders formed therein. The disposition of the thixd ribbed die fac~ 124 and third T~at:ing die face 128 in horizontal planes may correlate two yoke forming portions on these die faces, l.e., when a plurality of depressions are to be formed, a planar yoke-formillg face portion 154 on die face 124 joins the sccond shoulder rib 140 adjacent valley 132 with the further second shoulder rib 138a adjacent valley 132a, and an oppositely disposed planar yoke-receiving face portion 156 on the third mating die face 128 joins the second shoulder receiving curvature 152 adjacent rib projection 142 with the further second shoulder xeceiving curvature 15Oa adjacent rib projec-tion 142a Relative to the dimensions of the die faces set forth above with respect to the first ribbed and first mating dies 48 and 46 and with respect to the second mating dies 68 and 70, the faces of the third rib-bed die and the third mating die may be dimensioned as follows. The valleys 132 and 132a and the ribs 142 and 142a are spaced 0.080" on centers. Both of the valleys 132 and 132a extend inwardly into the third ribbed die face 1/32", and their sides 134 and 136 as well as 134a and 136a are parallel to one another and disposed 0.017" apart.
Each of the second shoulders 138, 140, 138a and 140a has I

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692~2 a raclius o~ 0.006". In a complementary manner, the tllixd mating die face 128 is dimensioned so that each of the rib projections 142 and 142a extends outwardly from dic face 128 a di~tance of 0.016". The radius of each of the tip portions 144 and l~a is 0.002" and the sides 146 and 14~ for projection 142 and 1~6a and 148a for projection 1~2a diverge inward from the lines of tangency with the rounded tip portion of each projection toward the horizontal plane of the face 128 of the die, defilling an included angle of 40 bisected by a line normal to face 128. Each of the shoulder-receiving curvatures 150, 152, 150a and 152a is of 0.010" radius, and the centers for each pair of these curvatures are symmetrically disposed about the centerli~e of the respective rib and are spaced apart 0.029". Using such dimensions for the face of die 130, the yoke-receiving face portion is 0.051" between the centers of the shoulder-receiving curvatures 152 and 150a.
In the third step for further forming the jaws 36, die faces 124 and 128 are engaged with a configuration 4c i.e., a portion of side 28 previously processed as il-lustrated in Figs. 4 and 5 and subsequently positioned between die faces 124 and 128. These two die faces then ; are closed on the blank as in Fig. 6, but the dies preferably are not bottomed.
Since substantially the same forming action occurs in and around the second depression 50b, it is only necessary to specifically describe the third step in forming of depression 50a. The primary stress .
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points are in the areas o~ enga~ement of the ~erminal blank between the second should~rs 138 and 140 of ribbed die face 124 and the second shoulder-receivin~ curvatures 150 and 152 of the mating die facc 128, as illustratcd with some exaggcration ln Fi~. 6, and in the en~agement of tip 144 in the apex o~ the depression 50a. Coining of the metal takes place in the side shoulder stress areas, between the should~rs 13~-140 and the curvatures 150-152, apparently along with some ~urther stretching of adjacent portions of the blank, to provide additional lenc3th in the jaw-~orrning portion for further deepening and for narrowing of the depression 50a.
Moreovex, these areas of coining are shifted slightly inward and up~ard of the shoulders 90 and 92 from the coining of the preceding step, and the stretching is distributed, to avoid tensile rupture of the metal. Simultaneously there is further stretching and further forming of the metal over the nose 144 to further distribute the stretch-ing and further forming stresses, l.e., in extending the aepression around tip portion 144 of the third rib projection 142. In the latter regard, it will be noted that the rib 142 is slightly higher (0.016") than the vertical dimension of the depression 50a of the blank 4c resulting rom the preceding step. Allowing for some springback of the metal used, the depression 50a is lengthened to approximately 0.022" (outside height dimension) in the blank 4d.
Because die faces 124 and 128 are not completely bottomed, shoulclers 90 and 92 of blank 4c are not completely eliminated in the further forming of blank 4d, but remain in part as slight residual shoulder ridges 158 , ~69~8Z
and 160 (Fi9s. G and 7) of the confi~uratlon of fi.nal shoulder ~orms 3~a and 38b (Fig. 8). Corre~pondingly, neither are the shouldcr return portions completely eliminated, since the~ are pressed into the modified, final forms 162 and 164 of side 28. When more than one depxessi.on in side 28 is desired, the wave formation 106 of blank 4c (Fi~. S) is substantially flattened to ~orm yo}ce 166 (Figs. 6 and 7) between the terminuses of shoulder return portlon 164 and an adjacent shoulder return porti.on 164a associated ~ith depression 50b. In the preferred orm of the terminal forming process or m~thod of the present invention, described above in terms of the dimensions of dies used in the ~ specific illustrative process, the distance bet~een the :~ 15 outermost surfaces of the shoulders 158 and 160 and the corresponaing outer face plane of yoke 1~6 and the remainder of side panel 28 will generally be only a few thousandths of an inch in the blank 4d ~Figs. 6 and 7) `. and in the ultimate folded form of terminal 6A (38a and ; 20 38b in Fig. 8).
-. It should be particularly noted that in the further orming of blank 4d from blank 4c, as described : with reference to Fig. 6, not only is each depression 50 deepened, but also its sides are brought closer together and straightened somewhat, more nearly approaching posi-tions normal to the plane of the respective side panel 28 or 30. Correspondingly, the shoulders at the base .of ~ach depression 50 are formed closer together and their radii of curvature reduced, thereby minimizing the distance between their nadirs or support peaks, i.e., the .
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shouldcr ridge surfaces opposite the dashed l.ines 170 and 172 in FicJ. 7. The net result is to provide jaws 36 which are of a ~eometry to withstand large compressive forces applied outwardly on their noses 176 and resisted by support forccs occurring primarily at the rid~e lines 170 and 172.
The ribs 142 also may be of appropriate configuration to provide a slight converging taper of the resulting jaw noses from the upper ends to the lower ends in the terminal 6A, as best seen in Figs. 10 and 11.
After the final formation of the depressions to form the jaws 36, as in blank ~d, the foldable configurations 4 ma~ be shaped in other respects to axrive at the final terminal form of Fig. 8. ~nong such steps are coining of the angular top surfaces of the jatls ~which have resulted from the notches 20~
to provide a smooth beveled surface on each jaw for the wire-engaging functions, folding the sides 28 and 30 approximately perpendicularly to the terminal body base . 32, folding tabs 174a, 174b, 174c and 174d (Fig. 8) into their proper positions, and severing stems 8 and 10 ~- from the metal blank 2. Stem 8 is bent to its bow form, and its distal end 8a is bent into a U-shaped configuration, to orm the completed terminal 6A.
Jaws 36, the completed result of the formative steps perfoxmed upon depressions 50, are accordingly disposed . along at least one side, and preferably both sides 28 and 30, of the terminal 6A to extend inwardly over the tcrminal body base panel 32. In~the form of the terminal , .

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6A shown in Fig. 8, two pairs of jaws 36 are disposed in the sides 2B and 30 so that the jaws extend toward each other and the tip portions 176 are positioned in opposition to each other.
When the completely formed terminals 6A have been severed from the metal blank 2 ancl finally formed into their ultimate configurations they may be mounted in a molded, insulating receptacle 178, such as shown in Fig. 9. Without describing the receptable 178 in great detail, it may be noted that it includes a plurality of generally channel-shaped passages 180 into which the terminals 6A may be insertedO
The U-shaped distal end 8a of each terminal may be hooked about a rib 182 or 182a on one side of receptacle 178 as each of the terminals is inserted into a passage 180, and tabs 174_ are bent up to the locking portion of Fig. 9.
Vertical passages 184 permit access to be had to each channel 34 running through the body of each terminal 64 in a passage 180. The sides 186 of each passage 180 are disposed so that the shoulders 38a and 38 of each terminal are closely fitted against them, and the shoulders may ; therefore provide the primary support force transfer from the jaws 36 to the sides 186 for supporting the jaws 36 against outward deformation of the jaws which might other-wise result from forcible insertion of wires against the jaw noses 176. In order to obtain the close fitting engage-ment of the shoulders against the sides of the passages 180, it is important that the widths of the terminals and the widths of the passages be precisely dimensioned.
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Referring now particularly to Figs. 10 and 11, the insertion into the receptacle of wir~s to carry electrical curr~nt, and fixing them there, normally is accomplish~d by forcing the wircs 188, includiny a center conductor 189 and an insulation covering 190, laterally of their axes through the vertical passages 184 into the inclined surfaces defined by notches 20 of jaws 36 and hetwe~n the noses 176. A tool blade 1~2 is shown.above each wire and havin~ an end surface to force each insulation-covered wire between a set of jaws 36. If a plurality of wires 188 are to be inserted substantially simultaneously, the tool may comprise a plurality of blade faces 19~. As each ram face 194 is forced downwardl~, it forces one wire 188 between jaws 36 of one terminal, and in the course of so position-ing wire 188, the insulation 190 is stripped from the ; wire and the conductor core 189 engages the noses 176 in order to obtain reliable electrical contact between the conductor and the terminal. Shoulders 38a and 38b by providing compressive support between the side walls of each terminal and the sides 186 of the passages 180 substantially in alignment with the side walls of each respective jaw 36, assist in assuring accurate and rigid positioning of the conductor engaging edges 176 to assure the desired engagement of the jaws with the conductor when a conductor is forced against the jaws.

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Fxom thc fore~oing dctailed description it may be ascertaincd that the prcsent invention includes obtaining addi-tional lengths of metal in and adjacent to, or between, a jaw or set of ja~ts disposed in at lcast one of the sid~s of an elec-trical terminal. Such additional len~ths are produced by coining the metal used in making the terminal and by limiting the stretching of the metal to a graclual and dispersed stretching throughout a substantial portion of the side of the terminal. It may also be ascertained that the base width of the jaws is pro~ressively narrowed to provide rigidi~y against out~ard collapse of each jaw under outward pressure exerted by disposing electrical wires in the terminal. The - shoulders at each side of each jaw insure contact with the side walls of the receptacle passages very near positions of alignment with the jaw sides, thus enhancing the compression strength of the ja~s upon the current-carrying wire.
Thus it will be seen that improvements have been provided in the formation of electrical terminals and which meet the aforestated objects.
While a particular embodiment of the present invention has been shown, it will be understood, of course, that the invention is not limlted thereto slnce modifica-tions may be made by those skilled in the art, particularly in light of the foregoing teachings. It is, therefore, contemplated by the appended claims to cover any such modifications as incorporate those features which come within th~ true spirit and scope of the invention.

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Claims (11)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. A method of forming a contact jaw in a first portion of a sheet of electrically conductive sheet metal, said first portion being joined to said sheet at opposite ends of said first portion and said sheet being continuous between said ends externally of said first portion, com-prising deforming said first portion laterally of the plane of said sheet to form such a jaw without correspond-ing deformation of the joined continuous portion of said sheet, drawing said first portion into a broad shallow wave form extending on one side of said sheet, said wave form having a first base width; reforming op-posite end portions of said first portion within said base width to have curvature opposite that of the center of said wave form and to extend on the opposite side of said sheet therefrom while maintaining the direction of extension and reducing the radius of curvature of the portion defining the center segment of said wave form; and subsequently further forming said first portion by returning said end portions toward the plane of said sheet and correspondingly further extending said center segment therebetween on said one side of said sheet and further reducing the radius of curvature of said center segment, thereby providing dispersed elongation of the material of said first portion in forming said jaw.

2. A method as in claim 1 including coining each of said end portions in the central curved segments thereof during said removing of said first portion.

3. A method as in claim 2 including coining and stretching each of said end portions in conjunction with said further forming of said first portion.

4. A method as in claim 1 including reducing the dimension between the centers of curvature of said end portions during said further forming of said first portion.

5. A method as in claim 4 including coining of each of said end portions between said center segment and the distal portion of each of said end portions during said further forming of said first portion.

6. A method as in claim 1 wherein the height of deformation, as measured normal to the plane of said sheet between the outward extremities of said end portions and the outward extremity of said center segment, is increased during said further forming of said first por-tion.

7. A method as in claim 1 wherein said further forming only partially displaces the central curved segments of said end portions to the plane of said sheet, whereby said central segments form ridges extending on said opposite side of said sheet at each side of said jaw.

8. A method as in claim 1 including maintaining said joined continuous portion of said sheet substantially planar throughout said deforming, reforming and further forming steps.

9. A method as in claim 1 including separating said first portion of said sheet from the remainder of said sheet along a substantial part of the length of said first portion prior to said deforming step, and wherein said de-forming step includes deforming and stretching such separated portion and adjacent parts of said sheet joined to the ends of such separated portion, said separated portion and said adjacent parts constituting said first portion.

10. A set of progressive dies for forming resiliently biased wire contacting jaws in an electrical terminal comprising:
a first ribbed die face including a plurality of first valleys intermediate the ribs, a first mating die face for engagement upon the first ribbed die face, said first mating die face including a plurality of ribs disposed for engagement into the first valleys on the first ribbed die face, a second ribbed die face including a plurality of second valleys thereon narrower and deeper than said first valleys on the first ribbed die face and first shoulder ribs along the outer edges of the outermost second valleys, a second mating die face for engagement upon the second ribbed die face, said second mating die face including a plurality of second ribs narrower and higher then the ribs on said first mating die face and disposed for engagement into the second valleys on the second ribbed die face, said second mating die face also including a plurality of first shoulder receiving grooves for engagement onto the first shoulder ribs of the second ribbed die face, a third ribbed die face including a plurality of third valleys thereon narrower and deeper than said second valleys and second shoulder ribs of less height than and of lesser radius than the first shoulder ribs in said second die face, and a third mating die face for engagement upon the third ribbed die face, said third mating die face including a plurality of third ribs narrower and higher than the second ribs on said second mating die face and disposed for engagement into the third valleys on the third ribbed die face, said third mating die face also including a plurality of second shoulder receiving grooves for engagement onto the second shoulder ribs of the third ribbed die face.

11. The set of progressive dies of claim 10 which further comprises a first yoke portion in the face of the second ribbed die arranged to interfit with a first mating yoke portion in the second mating die face, said first yoke portion being disposed intermediate the second valleys on the second ribbed die face and said first mating yoke portion being disposed intermediate the ribs on the second mating die face.