CA1104692A - Electrical connector contact comprising a plurality of wires and method of making it - Google Patents
Electrical connector contact comprising a plurality of wires and method of making itInfo
- Publication number
- CA1104692A CA1104692A CA307,214A CA307214A CA1104692A CA 1104692 A CA1104692 A CA 1104692A CA 307214 A CA307214 A CA 307214A CA 1104692 A CA1104692 A CA 1104692A
- Authority
- CA
- Canada
- Prior art keywords
- wires
- bundle
- sleeve
- contact
- electrical
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/16—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for manufacturing contact members, e.g. by punching and by bending
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/02—Contact members
- H01R13/15—Pins, blades or sockets having separate spring member for producing or increasing contact pressure
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
- H01R13/02—Contact members
- H01R13/33—Contact members made of resilient wire
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
- Manufacturing Of Electrical Connectors (AREA)
- Connector Housings Or Holding Contact Members (AREA)
Abstract
ABSTRACT
An electrical contact for an electrical connector including a sleeve and a plurality of axially-aligned fine wires, with each wire having an acutely angled end portion at one end thereof and with the plurality of wires secured together at the other end to form a bundle.
Preferably, the wires are secured together by a weld formed by a capacitor discharging across a gap to the wires, although other securing methods could be used.
The bundle of wires then may be inserted into the sleeve of the contact with the angled ends forward in the sleeve and the weld rearward in the sleeve. The sleeve then is crimped inwardly forward of, or including, the welded portion, to hold the bundle in place within the sleeve.
An electrical contact for an electrical connector including a sleeve and a plurality of axially-aligned fine wires, with each wire having an acutely angled end portion at one end thereof and with the plurality of wires secured together at the other end to form a bundle.
Preferably, the wires are secured together by a weld formed by a capacitor discharging across a gap to the wires, although other securing methods could be used.
The bundle of wires then may be inserted into the sleeve of the contact with the angled ends forward in the sleeve and the weld rearward in the sleeve. The sleeve then is crimped inwardly forward of, or including, the welded portion, to hold the bundle in place within the sleeve.
Description
~10469Z
BACKGROUND OF THE INVENTION
This invention relates to electrical contacts for an electrical connector and a method of making the contacts.
More specifically, this invention relates to electrical contacts of the type wherein a plurality of fine wires are held together and axially-aligned in a bundle within a sleeve and the wires provide surfaces for mating and electrical conductivity with a second contact in another connector. The second contact may be either a similar contact or one of a plurality of conventional but dis-similar contacts.
Electrical contacts of the type including a plurality of axially-aligned fine wires held in a sleeve are old and known in the prior art, as evidenced by U. S. Patent 3,725,844 issued April 3, 1973, to McKeown et al for "Hermaphroditic Electrical ~ontact". Such a contact typically includes a plurality of wires, each with acutely angled forward end portions and held within a holder simply by a crimp of the holder radially inwardly providing a frictional retention among the wires and between the holder and the plurality of wires.
The manufacture of electrical connectors of the type described in the Brush Contact Patent is not the ultimate in cost effectiveness. The manufacturing requires that the individual wires be separately made, handled, and channeled into a sleeve which is only fractionally larger internally.
Channeling the wires into such a sleeve may damage the wires in some instances.
The crimping operation in the manufacture of the prior art electrical connector is necessary to securely hold all of the wires together and within the sleeve. This presents an undesirable feature of requiring an undesirably high force to secure all the wires within the sleeve.
~ The electrical resistance of the prior art contact depends partially on the quality of the crimp, so a poor crimp can significantly increase the electrical resistance of the contact. Since a low resistance in a contact is necessary, particular care (with resulting expense) was directed to obtaining a good crimp.
In some instances it is desirable to verify that the correct number of wires (perhaps within a small tolerance) is included in the plurality of wires. In the prior art methods of making such a contact, a mechanical way of determining assembly with the wires in the comparatively heavy sleevé against a nominal weight. The heavy sleeve makes it difficult to determine the exact number of wires included.
The number of wires is important to the retention of wires within the sleeve and to the electrical resistance of the bundle in prior art applications.
Electrical contacts including a welded end are not themselves new. One such contact including a welded end is shown in a prior art U.S. patent Re 25,798, issued June 15, 1965 to Platz et al for-"Plug-In Connector". Such a contact was formed to have a relatively high mating force which is undesirable and a relatively high manufacturing cost.
The foregoing and other limitations of the prior art present problems in the manufacturing of the contact and the subsequent reliability of such a contact.
l~Q~92 SUMMARY OF THE INVENTION
The present invention overcomes the limitations of the prior art by providing an electrical contact which includes a one-piece sub-assembly of a plurality of axially-aligned electrically conduct;ng wires secured together at one end. Such an assembly is easier to handle, and, in some instances, less expensive to make and assemble and one which has a higher reliability and lower electrical resistance in use.
Thus, the invention relates to an electrical contact comprising: a sleeve having an axial passage;
and several electrically conducting wires axially aligned and axially mounted within the passage of the conduit, the wires bonded one to another at a rear end, each of the wires extending forwardly in the sleeve with the forward end portion of each wire terminating in an acutely angled end surface.
In another aspect, the invention relates to a one-piece assembly for use in making an electrical contact for an electrical connector, the assembly comprising:
a plurality of electrically conducting wires, each having an acutely angled forward end portion, the plurality of wires axially aligned parallel one to another and arranged together in a bundle; and means located near the rear end portion of the plurality of conducting wires ~or securing the wires together in a radial enlargement for retention when assembled within a sleeve of electrically conducting wires are joined together to form a one-piece assembly.
The electrical contact of the present invention obtains a higher reliability while reqlliring a smaller force to secure the wires within the sleeve and has a l~V~S~?2 signif;cantly lower mating force than the prior art electrical contact described in the above-identified U.S. patent Re 25,798.
In a particular embodiment a plurality of straight fine wires each with an acutely angled forward end portion are axially aligned to form a bundle. The wires, at the rear end portion of the bundle, are secured one to another by a weld to provide a contact with a lower electrical impedance and a greater mechanical resistance to disassembling forces. The welded bundle is then inserted into an electrical connector sleeve with the rear end of the bundle located rearwardly within the sleeve, and a crimp in the sleeve secures the bundle with the weld within the sleeve. The location of the crimp is advantageously located in the portion of the sleeve forward of the welded (or enlarged) portion or in the portion of the sleeve including the welded portion.
Such a crimping arrangement coacts with the weld to secure the wlres better within the sleeve and to provide a lower electrical resistance and a higher mechanical resistance to disassembly.
A welded brush bundle of the present invention could be treated as a sub-assembly, and inventoried in the bundle form, ready for insertion.
Such a sub-assembly could be easily weighed (or balanced against an appropriate standard) to determine whether the correct number of wires are included ~perhaps within a given tolerance in the accepted number or wires), Accordingly, it is an object of the present invention to provide a novel electrical contact for an electrical connector and a novel method of manufacturing the contact which is economical and which has a low mating force and low electrical resistance.
Further, it is an object of the present invention to provide a one-piece sub-assembly including a plurality of w;res with a rear welded portion which may be separately manufactured, inspected and inventoried.
The foregoing and other objects and advantages of the present invention will be apparent to one skilled in the art in view of the foregoing description and the accompanying drawings.
- 6a -BRIEF DESCRIPTION OF THE DRAWINGS
FIGURE 1 is a partial cross-sectional view of an electrical contact of the prior art with each of the wires forming the contact separately inserted and held together and within a sleeve by a crimping of the sleeve inward.
FIGURE 2 is a magnified view of one of the contact wires of the electrical contact of FIGURE 1.
FIGURE 3 is a partial crti~,~, sectional view of a bundle of fine wires used in the electrical contacts held 111 a sleeve for welding but prior to being welded.
FIGURE 4 shows the bundle of FIGURE 3 looking in the direction ofthe line 4-4 in FIGURE 3.
FIGURE 5 is a view of the bundle of fine wires following the step of welding the wires together to form 8 welded bundle, prior to insertion into a sleeve.
FIGURE 6 shows a view of another, larger welded bundle of fine wires.
FIGUR~ 7 shows a bundle of wires welded together arld he]d within a sleeve.
FIGURE 8 is a view of the wires i71 the sleeve~ in PIGUR~; 7 looking in the direction of line 8-8.
11~46~2 DETAILED DESCRIPTION OF THE DRAWINGS
FI~. 1 depicts in a partially cutaway view a form of a brush contact 10 for an electrical connector which is known in the art, similar to that describedin the Brush Contact Patent. The brush contact lû includes a sleeve or holder 20 and a plurality of fine wires 30 arranged in a bundle 40.
The sleeve or holder 20 has a forward axial passage or socket 21 (for receiving the fine wires 30) and a rear portion 22 for an electrical connection (or termination).
The rear portion 22 as shown in FIGURE 1 is a socket for the insertion and attachment of an electrical wire. Other configurations of the rear portion of the holder 20 are known ~nd may be substituted during the manufacturing of the holder, such other configurations include a printed circuit board tail and a solderless wire wrap tail, according to the type of electrical element which is being terminated in (or connected to) the contacts. The contact provides an electrical connectionbetween the wire tor other termination) in the rear and the forward contact.
The fîne wires 30 have acutely angled end portions 32 on at least the forward end of each wire. The rear portions 34 of the wires 3û are inserted in the holder 20 and held in place, typically by a crimped portion 25 of the holder to reduce the cross-section dimension of the holder to thereby hold the wires fixed with respect to the holder 20.
11~4~92 FIGURE 2 shows a single fine wire 30 of such a brush contact. The wire is typically cylindrical and made of an electrically conducting material such as berylium copper. For ease in manufacturing and assembling, the forward end 32 and rear end 34 are typically formed with acutely angled end portions to eliminate a requirement that the wires be directionally oriented. As is shown, the end portions have an angle of 30 in this view, but a greater or lesser angle could be used.
FIGURE 3 shows a bundle 40 of wires 30 which are in an electrically conducting welding holder (or socket) 100 for welding but not yet welded. The bundle 40 shown consists of seven wires, although more or less could be used. The bundle 40 at this state is common to both the ~rior art and to the present invention, at this stage of manufacture and assembly.
The holder 100 is generally cylindrical with an opening 102 at the top and is used only in preparation for and during the welding operation. The wires 30 which make up a single bundle 40 are channeled (or funneled) into the holder 100 through the opening 102 in preparation for welding.
The holder 100 is formed with Q slot 104 which extends partially around the periphery of the holder intermediate the height of the holder. The slot 104 accommodates a spring clip 110 which is inserted around the holder 100 and which secures the wires 30 together with each other in a tight bundle and in contact with a portion o~ the inside wall of the holder 100.
A welding system suitable for making the welded bundle of this invention is shown generally in diagramatic form in FIGURE 3. The welding system is a stored energy welding system which includes an electrode 200, a capacitor 210, a capacitor cha~ing system 220 and a switch 230. The capacitor 210 is coupled with its cathode to the electrode through the switch 230 and with its anode to the holder 100 and through the holder 100 to the wires 30 in the bundle40. The capacitor charging system 220 charges the capacitor to a predetermined, possibly variable voltage.
The electrode 200 is spatially located with respect to the proximate end portion of the bundle 40 to provide a suitable gap 300.
In operation of the welding system of FIGURE 3, the capacitor charging system 220 charges capacitor 210 to a predetermined voltflge. The switch 230 is closed (either manually or automatically), creating a potential (voltage) difference between the electrode 200 and the wires 30 in the bundle 40 approximately e~ual to the predetermined voltage, which causes an arc to cross the gap and bond the wires together.
One example of the apparatus used to accomplish the welding is as follows.
For a seven wire bundle of the berylium copper wire of .008 inch diameter, a Superior Model 527A arc/percussive butt welder power supply was used. A
capacitor of approximately 6400 microfarads, charged to approximately 90 volts, and a gap of .û20 inches were used with good results. Other ariations and modifications of such a we]ding schedule may be easily determiined and are well within the skill of those working in the f ield.
-~0-FIGURE 4 shows a cross sectional view of the bundle of wires 30 held by the spring clip in contact with each other and with the wall of the holder 100.
FIGURE 5 shows a bundle 40 of wires 30 after the welding process. One end of the bundle is no longer the individual separate wire strands but rather an enlarged porffon or nugget 50. As a result of the stored energy welding process described above, the bundle 40 after welding is slightly shorter in length than the wires 30 were originally. The enlarged welded portion or nugget 50 comprises a relatively small portion of the length (3-10%) of the welded assembly, a percentage which depends in part upon the length of the wire.
If the nugget 50 is formed by the stored energy welding system described previously, the nugget 50 is of the same material as the individual wires. This system has the advantage of not consuming additional material (which could change the weight of the bundle and make it difficult to determine the number of wires included in a parffcular bundle) and of not requiring clean-up of the welded bundle (i.e. excess solder and fluxes).
FIGUE~E 6 illustrates a larger bundle 40 of wires similarly prepared with a forward acutely angled end portion 32 and a rear enlarged portion or nugget ~0. Such a bundle would be suitable for greater current carrying capacity.
FIGURE 7 shows a portion of an electrical contact lû of the present invention with a welded bundle 40 of fine slraight brush wires 30 inserted into a holder 20.
The holder 20 has an ~xial passage 21 e~tending rearwardly from a forward opening 22 to a rear stoL, 23 which may be formed in any one of several methods.
~11-46~i2 The welded bundle 40 of wires 30 (e.g. as shown in FIGURE 5) is inserted through the forward opening 22 with the enlarged portion leading until the rear stop 23 is reached.
Therafter, a portion of the sleeve or holder 2G is crimped radially inwardly to form a crimped portion 25. The crimped portion is advantageously formed either at or forward of the enlarged portion 50 to thereby captivate the bundle 40 within the holder by restricting the forward movement of the nugget 50 and therefore the bundle 40. Such an arrangement of the nugget and the crimp allows the use of a lower crimping force than would otherwise to required.
Other resulting benefits are that the wires are better secured to one another and to the holder to provide both better mechanical attachment and a lower electrical resistance connection.
Other objects and advantages of the present invention will be apparent to those skilled in the art in view of the foregoing description. For example, other forms of welding such as tungsten-inert gas (tig) welding or percussive welding might be used, or a known substitute for welding (such as soldering) might be employed to advantage. Further, a different method of securing the bundle within the sleeve might be used without departing from the spirit of the present invention. The foregoing description accordingly should be considered as illustrative only and should not be interpreted to limit the scope of the present invention, which is defined by the following claims.
BACKGROUND OF THE INVENTION
This invention relates to electrical contacts for an electrical connector and a method of making the contacts.
More specifically, this invention relates to electrical contacts of the type wherein a plurality of fine wires are held together and axially-aligned in a bundle within a sleeve and the wires provide surfaces for mating and electrical conductivity with a second contact in another connector. The second contact may be either a similar contact or one of a plurality of conventional but dis-similar contacts.
Electrical contacts of the type including a plurality of axially-aligned fine wires held in a sleeve are old and known in the prior art, as evidenced by U. S. Patent 3,725,844 issued April 3, 1973, to McKeown et al for "Hermaphroditic Electrical ~ontact". Such a contact typically includes a plurality of wires, each with acutely angled forward end portions and held within a holder simply by a crimp of the holder radially inwardly providing a frictional retention among the wires and between the holder and the plurality of wires.
The manufacture of electrical connectors of the type described in the Brush Contact Patent is not the ultimate in cost effectiveness. The manufacturing requires that the individual wires be separately made, handled, and channeled into a sleeve which is only fractionally larger internally.
Channeling the wires into such a sleeve may damage the wires in some instances.
The crimping operation in the manufacture of the prior art electrical connector is necessary to securely hold all of the wires together and within the sleeve. This presents an undesirable feature of requiring an undesirably high force to secure all the wires within the sleeve.
~ The electrical resistance of the prior art contact depends partially on the quality of the crimp, so a poor crimp can significantly increase the electrical resistance of the contact. Since a low resistance in a contact is necessary, particular care (with resulting expense) was directed to obtaining a good crimp.
In some instances it is desirable to verify that the correct number of wires (perhaps within a small tolerance) is included in the plurality of wires. In the prior art methods of making such a contact, a mechanical way of determining assembly with the wires in the comparatively heavy sleevé against a nominal weight. The heavy sleeve makes it difficult to determine the exact number of wires included.
The number of wires is important to the retention of wires within the sleeve and to the electrical resistance of the bundle in prior art applications.
Electrical contacts including a welded end are not themselves new. One such contact including a welded end is shown in a prior art U.S. patent Re 25,798, issued June 15, 1965 to Platz et al for-"Plug-In Connector". Such a contact was formed to have a relatively high mating force which is undesirable and a relatively high manufacturing cost.
The foregoing and other limitations of the prior art present problems in the manufacturing of the contact and the subsequent reliability of such a contact.
l~Q~92 SUMMARY OF THE INVENTION
The present invention overcomes the limitations of the prior art by providing an electrical contact which includes a one-piece sub-assembly of a plurality of axially-aligned electrically conduct;ng wires secured together at one end. Such an assembly is easier to handle, and, in some instances, less expensive to make and assemble and one which has a higher reliability and lower electrical resistance in use.
Thus, the invention relates to an electrical contact comprising: a sleeve having an axial passage;
and several electrically conducting wires axially aligned and axially mounted within the passage of the conduit, the wires bonded one to another at a rear end, each of the wires extending forwardly in the sleeve with the forward end portion of each wire terminating in an acutely angled end surface.
In another aspect, the invention relates to a one-piece assembly for use in making an electrical contact for an electrical connector, the assembly comprising:
a plurality of electrically conducting wires, each having an acutely angled forward end portion, the plurality of wires axially aligned parallel one to another and arranged together in a bundle; and means located near the rear end portion of the plurality of conducting wires ~or securing the wires together in a radial enlargement for retention when assembled within a sleeve of electrically conducting wires are joined together to form a one-piece assembly.
The electrical contact of the present invention obtains a higher reliability while reqlliring a smaller force to secure the wires within the sleeve and has a l~V~S~?2 signif;cantly lower mating force than the prior art electrical contact described in the above-identified U.S. patent Re 25,798.
In a particular embodiment a plurality of straight fine wires each with an acutely angled forward end portion are axially aligned to form a bundle. The wires, at the rear end portion of the bundle, are secured one to another by a weld to provide a contact with a lower electrical impedance and a greater mechanical resistance to disassembling forces. The welded bundle is then inserted into an electrical connector sleeve with the rear end of the bundle located rearwardly within the sleeve, and a crimp in the sleeve secures the bundle with the weld within the sleeve. The location of the crimp is advantageously located in the portion of the sleeve forward of the welded (or enlarged) portion or in the portion of the sleeve including the welded portion.
Such a crimping arrangement coacts with the weld to secure the wlres better within the sleeve and to provide a lower electrical resistance and a higher mechanical resistance to disassembly.
A welded brush bundle of the present invention could be treated as a sub-assembly, and inventoried in the bundle form, ready for insertion.
Such a sub-assembly could be easily weighed (or balanced against an appropriate standard) to determine whether the correct number of wires are included ~perhaps within a given tolerance in the accepted number or wires), Accordingly, it is an object of the present invention to provide a novel electrical contact for an electrical connector and a novel method of manufacturing the contact which is economical and which has a low mating force and low electrical resistance.
Further, it is an object of the present invention to provide a one-piece sub-assembly including a plurality of w;res with a rear welded portion which may be separately manufactured, inspected and inventoried.
The foregoing and other objects and advantages of the present invention will be apparent to one skilled in the art in view of the foregoing description and the accompanying drawings.
- 6a -BRIEF DESCRIPTION OF THE DRAWINGS
FIGURE 1 is a partial cross-sectional view of an electrical contact of the prior art with each of the wires forming the contact separately inserted and held together and within a sleeve by a crimping of the sleeve inward.
FIGURE 2 is a magnified view of one of the contact wires of the electrical contact of FIGURE 1.
FIGURE 3 is a partial crti~,~, sectional view of a bundle of fine wires used in the electrical contacts held 111 a sleeve for welding but prior to being welded.
FIGURE 4 shows the bundle of FIGURE 3 looking in the direction ofthe line 4-4 in FIGURE 3.
FIGURE 5 is a view of the bundle of fine wires following the step of welding the wires together to form 8 welded bundle, prior to insertion into a sleeve.
FIGURE 6 shows a view of another, larger welded bundle of fine wires.
FIGUR~ 7 shows a bundle of wires welded together arld he]d within a sleeve.
FIGURE 8 is a view of the wires i71 the sleeve~ in PIGUR~; 7 looking in the direction of line 8-8.
11~46~2 DETAILED DESCRIPTION OF THE DRAWINGS
FI~. 1 depicts in a partially cutaway view a form of a brush contact 10 for an electrical connector which is known in the art, similar to that describedin the Brush Contact Patent. The brush contact lû includes a sleeve or holder 20 and a plurality of fine wires 30 arranged in a bundle 40.
The sleeve or holder 20 has a forward axial passage or socket 21 (for receiving the fine wires 30) and a rear portion 22 for an electrical connection (or termination).
The rear portion 22 as shown in FIGURE 1 is a socket for the insertion and attachment of an electrical wire. Other configurations of the rear portion of the holder 20 are known ~nd may be substituted during the manufacturing of the holder, such other configurations include a printed circuit board tail and a solderless wire wrap tail, according to the type of electrical element which is being terminated in (or connected to) the contacts. The contact provides an electrical connectionbetween the wire tor other termination) in the rear and the forward contact.
The fîne wires 30 have acutely angled end portions 32 on at least the forward end of each wire. The rear portions 34 of the wires 3û are inserted in the holder 20 and held in place, typically by a crimped portion 25 of the holder to reduce the cross-section dimension of the holder to thereby hold the wires fixed with respect to the holder 20.
11~4~92 FIGURE 2 shows a single fine wire 30 of such a brush contact. The wire is typically cylindrical and made of an electrically conducting material such as berylium copper. For ease in manufacturing and assembling, the forward end 32 and rear end 34 are typically formed with acutely angled end portions to eliminate a requirement that the wires be directionally oriented. As is shown, the end portions have an angle of 30 in this view, but a greater or lesser angle could be used.
FIGURE 3 shows a bundle 40 of wires 30 which are in an electrically conducting welding holder (or socket) 100 for welding but not yet welded. The bundle 40 shown consists of seven wires, although more or less could be used. The bundle 40 at this state is common to both the ~rior art and to the present invention, at this stage of manufacture and assembly.
The holder 100 is generally cylindrical with an opening 102 at the top and is used only in preparation for and during the welding operation. The wires 30 which make up a single bundle 40 are channeled (or funneled) into the holder 100 through the opening 102 in preparation for welding.
The holder 100 is formed with Q slot 104 which extends partially around the periphery of the holder intermediate the height of the holder. The slot 104 accommodates a spring clip 110 which is inserted around the holder 100 and which secures the wires 30 together with each other in a tight bundle and in contact with a portion o~ the inside wall of the holder 100.
A welding system suitable for making the welded bundle of this invention is shown generally in diagramatic form in FIGURE 3. The welding system is a stored energy welding system which includes an electrode 200, a capacitor 210, a capacitor cha~ing system 220 and a switch 230. The capacitor 210 is coupled with its cathode to the electrode through the switch 230 and with its anode to the holder 100 and through the holder 100 to the wires 30 in the bundle40. The capacitor charging system 220 charges the capacitor to a predetermined, possibly variable voltage.
The electrode 200 is spatially located with respect to the proximate end portion of the bundle 40 to provide a suitable gap 300.
In operation of the welding system of FIGURE 3, the capacitor charging system 220 charges capacitor 210 to a predetermined voltflge. The switch 230 is closed (either manually or automatically), creating a potential (voltage) difference between the electrode 200 and the wires 30 in the bundle 40 approximately e~ual to the predetermined voltage, which causes an arc to cross the gap and bond the wires together.
One example of the apparatus used to accomplish the welding is as follows.
For a seven wire bundle of the berylium copper wire of .008 inch diameter, a Superior Model 527A arc/percussive butt welder power supply was used. A
capacitor of approximately 6400 microfarads, charged to approximately 90 volts, and a gap of .û20 inches were used with good results. Other ariations and modifications of such a we]ding schedule may be easily determiined and are well within the skill of those working in the f ield.
-~0-FIGURE 4 shows a cross sectional view of the bundle of wires 30 held by the spring clip in contact with each other and with the wall of the holder 100.
FIGURE 5 shows a bundle 40 of wires 30 after the welding process. One end of the bundle is no longer the individual separate wire strands but rather an enlarged porffon or nugget 50. As a result of the stored energy welding process described above, the bundle 40 after welding is slightly shorter in length than the wires 30 were originally. The enlarged welded portion or nugget 50 comprises a relatively small portion of the length (3-10%) of the welded assembly, a percentage which depends in part upon the length of the wire.
If the nugget 50 is formed by the stored energy welding system described previously, the nugget 50 is of the same material as the individual wires. This system has the advantage of not consuming additional material (which could change the weight of the bundle and make it difficult to determine the number of wires included in a parffcular bundle) and of not requiring clean-up of the welded bundle (i.e. excess solder and fluxes).
FIGUE~E 6 illustrates a larger bundle 40 of wires similarly prepared with a forward acutely angled end portion 32 and a rear enlarged portion or nugget ~0. Such a bundle would be suitable for greater current carrying capacity.
FIGURE 7 shows a portion of an electrical contact lû of the present invention with a welded bundle 40 of fine slraight brush wires 30 inserted into a holder 20.
The holder 20 has an ~xial passage 21 e~tending rearwardly from a forward opening 22 to a rear stoL, 23 which may be formed in any one of several methods.
~11-46~i2 The welded bundle 40 of wires 30 (e.g. as shown in FIGURE 5) is inserted through the forward opening 22 with the enlarged portion leading until the rear stop 23 is reached.
Therafter, a portion of the sleeve or holder 2G is crimped radially inwardly to form a crimped portion 25. The crimped portion is advantageously formed either at or forward of the enlarged portion 50 to thereby captivate the bundle 40 within the holder by restricting the forward movement of the nugget 50 and therefore the bundle 40. Such an arrangement of the nugget and the crimp allows the use of a lower crimping force than would otherwise to required.
Other resulting benefits are that the wires are better secured to one another and to the holder to provide both better mechanical attachment and a lower electrical resistance connection.
Other objects and advantages of the present invention will be apparent to those skilled in the art in view of the foregoing description. For example, other forms of welding such as tungsten-inert gas (tig) welding or percussive welding might be used, or a known substitute for welding (such as soldering) might be employed to advantage. Further, a different method of securing the bundle within the sleeve might be used without departing from the spirit of the present invention. The foregoing description accordingly should be considered as illustrative only and should not be interpreted to limit the scope of the present invention, which is defined by the following claims.
Claims (15)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A method of assembling an electrical contact for an electrical connector, said contact including a plurality of wires held within a sleeve, the steps of the method comprising:
cutting a fine wire into a plurality of straight wire lengths of approximately equal length;
forming a tapered portion onto one end of each wire length;
axially aligning the wire lengths and assembling the lengths into a bundle, with the tapered end portion of each wire length located at the same end of the bundle;
welding the wires together at the other end of the bundle;
inserting the welded bundle into the sleeve; and securing the bundle of wires to the sleeve.
cutting a fine wire into a plurality of straight wire lengths of approximately equal length;
forming a tapered portion onto one end of each wire length;
axially aligning the wire lengths and assembling the lengths into a bundle, with the tapered end portion of each wire length located at the same end of the bundle;
welding the wires together at the other end of the bundle;
inserting the welded bundle into the sleeve; and securing the bundle of wires to the sleeve.
2. A method of the type described in Claim 1 wherein the step of welding the wires together further includes the making of a portion which extends outwardly from a cross section of the bundle of wires to form an enlarged portion.
3. A method of the type described in Claim 2 wherein the step of securing the bundle of wires to the sleeve includes a step of crimping performed after the enlarged portion has been inserted into the sleeve and the step of crimping includes forming a portion of the sleeve forward of the enlarged portion to an interior dimension smaller than the cross section of the enlarged portion, whereby the bundle of wires is held within the sleeve.
4. A method of the type described in Claim 1 wherein the step of welding includes the discharging of a capacitor charged to a voltage through an arc to the bundle whereby the voltage of the discharging capacitor arcs to the bundle and performs the welding.
5. A method of the type described in Claim 4 wherein prior to the step of welding the method additonally includes a step of securing the plurality of fine wires together in close axial alignment with a clip medially along the length of the wires and wherein after the step of welding, the step of removing the clip is performed.
6. A method including the steps described in Claim 1 wherein the step of securing the bundle within the sleeve comprises the step of crimping the sleeve radially inward to engage the wires whereby the wires are secured within the sleeve.
7. An electrical contact comprising:
an elongated electrically conducting sleeve having an axial passage that includes a forward end portion that terminates in an opening at one end of said sleeve and an interior passage portion, the forward end portion of said passage having a cross-sectional area larger than the cross-sectional area of the interior portion of said passage; and a sub-assembly including several electrical wires having a forward end portion that terminates in a tapered end and said wires secured one to another by a weld at the rear end of said wires, axially aligned and axially mounted in said axial passage so that a forward portion of the wires is spaced from the wall of the forward end portion of said passage to permit the spreading of said wires within the forward end portion of said passage.
an elongated electrically conducting sleeve having an axial passage that includes a forward end portion that terminates in an opening at one end of said sleeve and an interior passage portion, the forward end portion of said passage having a cross-sectional area larger than the cross-sectional area of the interior portion of said passage; and a sub-assembly including several electrical wires having a forward end portion that terminates in a tapered end and said wires secured one to another by a weld at the rear end of said wires, axially aligned and axially mounted in said axial passage so that a forward portion of the wires is spaced from the wall of the forward end portion of said passage to permit the spreading of said wires within the forward end portion of said passage.
8. A method of manufacturing an electrical contact for an electrical connector, said contact including a plurality of wires held within a cylindrical sleeve defining an axis, and having a forward aperture extending axially rearward to a stop located medially within the sleeve, the steps of the method comprising:
cutting a fine straight wire into a plurality of straight wire lengths of approximately equal length;
forming a tapered portion onto both ends of each wire length;
inserting the wire lengths into a metallic holder in axial alignment;
securing each of the wire lengths into intimate contact with the other wire lengths to form a bundle by a spring element which surrounds the bundle and urges the wires inward;
welding the wires together at a rear end of the bundle to form an enlarged welded portion;
removing the spring element from around the bundle;
removing the welded bundle from the holder and inserting the welded bundle into the sleeve through the aperture with the enlarged welded portion first, until the rear portion engages the sleeve stop;
securing the welded bundle of wires to the holder by applying a force to the sleeve to the wires and the welded portion whereby wires are secured together by the welded portion and to the sleeve.
cutting a fine straight wire into a plurality of straight wire lengths of approximately equal length;
forming a tapered portion onto both ends of each wire length;
inserting the wire lengths into a metallic holder in axial alignment;
securing each of the wire lengths into intimate contact with the other wire lengths to form a bundle by a spring element which surrounds the bundle and urges the wires inward;
welding the wires together at a rear end of the bundle to form an enlarged welded portion;
removing the spring element from around the bundle;
removing the welded bundle from the holder and inserting the welded bundle into the sleeve through the aperture with the enlarged welded portion first, until the rear portion engages the sleeve stop;
securing the welded bundle of wires to the holder by applying a force to the sleeve to the wires and the welded portion whereby wires are secured together by the welded portion and to the sleeve.
9. A method of manufacturing an electrical contact for an electrical connector, said contact including a plurality of straight metallic members secured within a holder, the steps of the method comprising:
obtaining a plurality of straight lengths of metallic members, each with a tapered portion on one end of each member;
axially aligning the members;
assembling the members into a bundle, with a tapered end portion of each member extending forwardly in the bundle;
securing the members together at one end of the bundle with an electrically conductive material forming the individual members together to form a unitary, one-piece bundle with portions of the members extending forwardly from the bundle while integral therewith;
inserting the unitary bundle into the holder; and securing the bundle of members in place within the holder and in electrical circuit relationship therewith, whereby an electrical contact for an electrical connector is formed with the members being in electrically conductive relationship with the other members find with the holder.
obtaining a plurality of straight lengths of metallic members, each with a tapered portion on one end of each member;
axially aligning the members;
assembling the members into a bundle, with a tapered end portion of each member extending forwardly in the bundle;
securing the members together at one end of the bundle with an electrically conductive material forming the individual members together to form a unitary, one-piece bundle with portions of the members extending forwardly from the bundle while integral therewith;
inserting the unitary bundle into the holder; and securing the bundle of members in place within the holder and in electrical circuit relationship therewith, whereby an electrical contact for an electrical connector is formed with the members being in electrically conductive relationship with the other members find with the holder.
10. A method of making an electrical contact for an electrical connector, said contact including a predetermined number of aligned wires held within sleeve, the steps of the method comprising:
providing a predetermined number of straight wire lengths of approximately equal length; and forming a tapered portion onto at least one end of the wire lengths;
axially aligning the wire lengths and gathering the lengths into a bundle, with a tapered end portion of each wire length extending forwardly of the bundle;
welding the wires together at the rear end of the bundle;
surrounding the welded bundle with a sleeve; and securing the bundle of wires to the sleeve by deforming the sleeve radially inwardly into the wires whereby wires are secured to the sleeve.
providing a predetermined number of straight wire lengths of approximately equal length; and forming a tapered portion onto at least one end of the wire lengths;
axially aligning the wire lengths and gathering the lengths into a bundle, with a tapered end portion of each wire length extending forwardly of the bundle;
welding the wires together at the rear end of the bundle;
surrounding the welded bundle with a sleeve; and securing the bundle of wires to the sleeve by deforming the sleeve radially inwardly into the wires whereby wires are secured to the sleeve.
11. An electrical contact for an electrical connector comprising:
a rear body portion adapted for connection in electric circuit relationship with an electrical conductor; and a forward contact portion adapted for mating with a second electrical contact, and making electrical circuit relationship between said second contact and said conduct, said contact portion including:
a sleeve having an axial passage;
a plurality of axially aligned fine metallic wires each having an acutely angled forward end portion adapted to receive the second electrical contact in electrical circuit relationship by yielding radially outwardly and each having a rear portion which is secured in fixed spatial relationship to the other wires by a metallic electrically conductive bonding material, the plurality of wires formed into a single structure by the bonding material; and means for securing the axially aligned wires within the sleeve in electrical circuit relationship between the wires and the sleeve whereby the contact forms an electrical circuit relationship between the conductor and the sleeve, the securing means forms an electrical circuit relationship between the sleeve and the wires, the bonding material interconnects the wires and the wires are adapted to make electrical circuit relationship with a second contact, whereby electrical circuit relationship between a conductor and a second contact is made.
a rear body portion adapted for connection in electric circuit relationship with an electrical conductor; and a forward contact portion adapted for mating with a second electrical contact, and making electrical circuit relationship between said second contact and said conduct, said contact portion including:
a sleeve having an axial passage;
a plurality of axially aligned fine metallic wires each having an acutely angled forward end portion adapted to receive the second electrical contact in electrical circuit relationship by yielding radially outwardly and each having a rear portion which is secured in fixed spatial relationship to the other wires by a metallic electrically conductive bonding material, the plurality of wires formed into a single structure by the bonding material; and means for securing the axially aligned wires within the sleeve in electrical circuit relationship between the wires and the sleeve whereby the contact forms an electrical circuit relationship between the conductor and the sleeve, the securing means forms an electrical circuit relationship between the sleeve and the wires, the bonding material interconnects the wires and the wires are adapted to make electrical circuit relationship with a second contact, whereby electrical circuit relationship between a conductor and a second contact is made.
12. A one-piece assembly for use in making an electrical contact for an electrical connector, said assembly comprising:
a plurality of electrically conducting wires, each having an acutely angled forward end portion, said plurality of wires axially aligned parallel one to another and arranged together in a bundle; and means located near the rear end portion of the plurality of conducting wires for securing the wires together in a radial enlargement for retention when assembled within a sleeve whereby the plurality of electrically conducting wires are joined together to form a one-piece assembly.
a plurality of electrically conducting wires, each having an acutely angled forward end portion, said plurality of wires axially aligned parallel one to another and arranged together in a bundle; and means located near the rear end portion of the plurality of conducting wires for securing the wires together in a radial enlargement for retention when assembled within a sleeve whereby the plurality of electrically conducting wires are joined together to form a one-piece assembly.
13. As assembly of the type described in Claim 12 wherein the securing means is a metallic nugget extending radially outwardly from the aligned wires and formed by welding the plurality of wires together.
14. An assembly of the type described in Claim 12 wherein a sleeve extends radially around at least a portion of the bundle of wires for maintaining the bundle in a predetermined location.
15. An electrical contact comprising:
a sleeve having an axial passage; and several electrically conducting wires axially aligned and axially mounted within the passage of said conduit, said wires bonded one to another at a rear end, each of said wires extending forwardly in said sleeve with the forward end portion of each wire terminating in an acutely angled end surface.
a sleeve having an axial passage; and several electrically conducting wires axially aligned and axially mounted within the passage of said conduit, said wires bonded one to another at a rear end, each of said wires extending forwardly in said sleeve with the forward end portion of each wire terminating in an acutely angled end surface.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US86336677A | 1977-12-22 | 1977-12-22 | |
| US863,366 | 1977-12-22 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1104692A true CA1104692A (en) | 1981-07-07 |
Family
ID=25340987
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA307,214A Expired CA1104692A (en) | 1977-12-22 | 1978-07-12 | Electrical connector contact comprising a plurality of wires and method of making it |
Country Status (8)
| Country | Link |
|---|---|
| JP (1) | JPS5491794A (en) |
| BR (1) | BR7808307A (en) |
| CA (1) | CA1104692A (en) |
| DE (1) | DE2851332A1 (en) |
| FR (1) | FR2412966A1 (en) |
| GB (1) | GB2010134B (en) |
| IN (1) | IN151701B (en) |
| IT (1) | IT1101568B (en) |
Families Citing this family (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CA1112321A (en) * | 1978-05-30 | 1981-11-10 | Richard W. Normann | Electrical contact and method of making |
| US4296985A (en) * | 1979-10-09 | 1981-10-27 | The Bendix Corporation | Integral electrical contact and method of making same |
| US4357742A (en) * | 1980-05-27 | 1982-11-09 | The Bendix Corporation | Electric brush contact forming apparatus |
| US5269056A (en) * | 1992-09-16 | 1993-12-14 | Oea, Inc. | Laser welding of wire strands to an electrode pin |
| EP3109944B1 (en) | 2015-06-23 | 2021-12-08 | Nexans | Method for producing an electrically active contact point at the end of an electrical conductor |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR1347257A (en) * | 1962-11-26 | 1963-12-27 | New Twist Connector Corp | Connection pin device |
| US3725844A (en) * | 1971-03-15 | 1973-04-03 | Bendix Corp | Hermaphroditic electrical contact |
| US4038743A (en) * | 1972-05-18 | 1977-08-02 | Essex International, Inc. | Terminating and splicing electrical conductors |
-
1978
- 1978-07-12 CA CA307,214A patent/CA1104692A/en not_active Expired
- 1978-11-24 GB GB7846032A patent/GB2010134B/en not_active Expired
- 1978-11-28 DE DE19782851332 patent/DE2851332A1/en not_active Withdrawn
- 1978-12-14 IT IT30811/78A patent/IT1101568B/en active
- 1978-12-19 BR BR7808307A patent/BR7808307A/en unknown
- 1978-12-20 JP JP15657178A patent/JPS5491794A/en active Pending
- 1978-12-22 FR FR7836236A patent/FR2412966A1/en active Granted
-
1979
- 1979-09-24 IN IN674/DEL/79A patent/IN151701B/en unknown
Also Published As
| Publication number | Publication date |
|---|---|
| FR2412966B1 (en) | 1983-02-18 |
| IN151701B (en) | 1983-07-02 |
| DE2851332A1 (en) | 1979-07-05 |
| IT7830811A0 (en) | 1978-12-14 |
| FR2412966A1 (en) | 1979-07-20 |
| BR7808307A (en) | 1979-08-07 |
| IT1101568B (en) | 1985-10-07 |
| GB2010134A (en) | 1979-06-27 |
| JPS5491794A (en) | 1979-07-20 |
| GB2010134B (en) | 1982-02-10 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |