CA1112321A - Electrical contact and method of making - Google Patents
Electrical contact and method of makingInfo
- Publication number
- CA1112321A CA1112321A CA322,536A CA322536A CA1112321A CA 1112321 A CA1112321 A CA 1112321A CA 322536 A CA322536 A CA 322536A CA 1112321 A CA1112321 A CA 1112321A
- Authority
- CA
- Canada
- Prior art keywords
- wires
- contact
- sleeve
- electrical
- socket
- 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
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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
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
- H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
- H01R4/183—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section
- H01R4/184—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion
- H01R4/185—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion combined with a U-shaped insulation-receiving portion
Abstract
ELECTRICAL CONTACT AND METHOD OF MAKING
ABSTRACT
An electrical contact for an electrical connector, and method of making it, wherein the contact includes a plurality of axially aligned wires extending from a forward end of a holder which has a rear portion for receiving a electrical conductor. The holder is manufactured by stamping it as a flat metallic piece with enlarged forward and rear portions then forming the forward portion in a die to form a socket like portion for the plurality of fine, axially aligned wires and forming the rear portion to receive the conductor.
ABSTRACT
An electrical contact for an electrical connector, and method of making it, wherein the contact includes a plurality of axially aligned wires extending from a forward end of a holder which has a rear portion for receiving a electrical conductor. The holder is manufactured by stamping it as a flat metallic piece with enlarged forward and rear portions then forming the forward portion in a die to form a socket like portion for the plurality of fine, axially aligned wires and forming the rear portion to receive the conductor.
Description
ELECTRICAL CONTACT AND METHOD OF MAKING
CROSS REFERENCE TO RELATED PATENTS
U~ S. Patent 3,725,844 issued to McKeown et al. -for "Hermaphroditic Electrical Contact", subsequently referred to as the "Brush Contact Patent".
Canadian patent application S.N~ 307,214 filed July 12, 1978 by R. W. Normann et al. for "Electrical Connector Contact and Method of Making", subsequently referred to as the "Welded Brush Contact Patent".
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TECHNICAL FIELD
The present invention relates to a novel electrical contact and a novel method for making it. More particularly~
the present invention relates to an electrical contact holder which is mad~ by stamping a flat metallic stock in an appro-prirate shape with an enlarged forward portion, then forming ~ the enlarged portion to make a socke~ for receiving a plurality - ~ o contact wires which are secured within the holder.
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BACKGROUND ART
Prior art electrical contacts are well known which have a plurality of fine, axially aligned wires 5 ~sometimes called "brush wires") extending from one end of a holder which is adapted to receive a conductor in a socket in the other end. In such applications, one of which is disclosed in the Brush Contact Patent, the holder is made from a cylindrical stock with holes 10 drilled from either end to form two sockets, the forward one for the brush wires and the rear one for the conductor.
The insertion of a conductor into the rear socket 15 can not presently be accomplished with automated equipment and is generally accomplished by hand at a relatively higher expense than if the conductor could be inserted into and Eixed within the contact by automated equipment.
The drilling of holes in such a holder requires precise positioning of the drill for the holes to provide a wall which has uniform thickness to give good ; performance, yet is thin enough to be crimped to maintain 25 the wires therein.
Furthermore, the drilling operation is itself undesirable in that it adds expense to the manufacturing process and further requires that additional machining 30 capacity, machine operators and transer o~ parts.
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; The contact described in the Brush Contact Patent further contemplated that each holder be separately and indi~idually handled during manufacturing and assembly.
35 Such separate handling is time consuming and expensive.
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, The contact described in the Brush contact Patent also requies that the sockets be plated with a plating solution to improve the electrical characteristics. This plating is an extra step, and furthermore, it requires in 5 some applications that vents or exil: holes be drilled transversely into the socket to allow the plating solution to be removed from the socket.
The electrical contacts described in the Welded 10 Brush Contact Patent have similar sockets drilled into cylindrical stock and thus have similar limitations and undesirable features.
Accordingly, there are undesirable features and 15 limitations of the prior art contacts.
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SUMMA:RY OF THE INVENTION
The present invention overcomes the undesirablefeatures and limitations of the prior art by providing a 5 contact for an electrical connector wh.ich is less expensive and may, in some instances, be of a higher quality than the electrical contacts which are manufactured by other methods. Fur~her, the present method allows a more mechanized manufacture of a contact 10 which requires less labor, handling and transporting of parts during manufacturing~ The electrical contact of the present invention allows several contacts ~o be handled together to reduce costs.
Accordingly, the present invention is an e:Lectr.ical connector contact which may use automated equipment advanta~eously to produce contact with low manufacturing cost.
~', The present contact is also desirable in that stock pre-plated with an electrically conducting material can be used in place of the plating by a plating solution.
The use of preplated stock not only eliminates the step of plating but also the necessity of vent or exit holes 25 to be drilled.
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~ " ~ , According to -the presen-t invention there isprovided an electrical contact for use as a termina-tion of an elec-trical conductor ;n an elec-trical connector assembly. The contact has a plurality of axially-aligned wires, each having an acutely angled forward end surface and a stamped and Eormed electrically conducting holder body including a xear por-tion, a medial portion, and a forward sleeve portion, the forward sleeve portion receiving the rear ends of the plurality oE
axially-aligned wires. The rear portion is adapted to receive the electrical conductor in electrical circuit relationship and the medial portion electrically couPles the rear end forward portions. Means is provided Eor securing the axially-aligned wires, within the forward sleeve portion to prevent the accidental loss of thewires from the sleeve portion.
In the method of the present invention a flat metallic stock is stamped into a shape including an enlarged forward p~tion, a medial portion and an enlarged rear portion. The sides oE the Eorward and rear portions ~0 are formed by bending the sides into forward and rear sleeve portions, respectively. The plurality of axially-aligned wires may then be inserted into the forward sleeve and the wires secured within the sleeve. The electrical conduc-tor may be inserted within the rear sleeve and secured in place.
; More specifically, the sides of the forward portion are formed up to provide a socket for receiving a plurality of axially-aligned elec-trical contact wires. The rear portion i5 formed into a trough-like shape for receiving an electrical conductor. A conductor may be placed ln the trough b~ automated equipment and thereaEter the rear por-tion crimped around the conductor to secure -the conductor to the contact with optionally additional portionC rearward of the ~ ' ~, -~ tm/l~g -5-, `, ~c!
rear portion crimped around the insulation of the conductor to better secure the conductor.
~ ccordingly, the present invention is a me-thod of making a contac-t to which an electrical conductor may be simply, quickly~ cheaply and mechanically a-ttached. The contact may he made cheaply and in an automa-ted way with good qualitv and without requiring a drilling operation.
Other objects and advantages of the present invention will become apparent to one skilled in the art in view of the following description and drawings and the appended claims.
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BRIEF DESCRIPTION OE THE DRAWINGS
FIGURE 1 is a front view of an electrical contact holder of the present invention after the holder is 5 stamped into a flat shape.
FIGURE 2 shows the sequence of manufacturing and assembly steps for forming the holder from the flat piece of FIGURE 1 into a electrical contact.
FIGURE 3 is a cross-sectional view of the contact holder of FIGURE 2, taken along the line III-III looking in the direction of the arrows.
FIGURE 4 is a cross-sectional view of the contact holder of FIGURE 2, taken along the line IV-IV looking in the direction of the arrows.
FIGURE 5 is a cross-sectional view of the contact 20 holder of FIGURE 2, taken along the line V-V looking in the direction oE the arrows.
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FIGURE 6 is a cross-sectional view of the contact holder o FIGURE 2, taken along the line VI-VI looking in 25 the direction of the arrows.
FIGURE 7 is a cro~s-sectional view of the contact holder of FIGURE 2~ taken along the line VII-VII lookiny in the direckion of the arrows.
,~ 30 FIGURE 8 is a cross~sectional view of the contact ~ -holder of FIGURE 2, taken along the line VIII-VIII in FIGURE 2, lookin~ in ~he direction of the arrows.
FIGURE ~9 shows a view of a completed electrical contact beore a conductor has been connected thereto.
: FIGURE 10 shows an alternate structure for the stamped hoIder oF FI~URE lo 4~
FlGURE 11 is a partial Eront view of the finished holder of the alternate holder s~ructure of FIGURE 1().
, DETAILED I~ESC.F<IPTION OF THE ~)RAWINGS
FIGURE 1 is a view of a brush contact holder 100 which has been stamped from a flat stock, before the 5 holder has been formed into a three-dimensional holder.
The stamped holder 100 includes a forward portion 110, which will become a forward socket for axially aligned brush contact wires.
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10The forward portion 110 is connected by a necked down or relatively narrower portion 1~0 to a second portion 130 which will be a socket for receiving an electrical conductor. A portion 140 of the holder is formed for gripping the insulation of the conductor. A
15 carrier strip attachment 150 attaches the holder 100 to a carrier strip (not shown).
The forward portion 110 has sides 112, 114. The -rear portion 130 includes sides 132, 134. The insulation 20 gripping portion 140 includes triangular portions 142, 144.
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FIGURE 2 shows the steps in the manufacture of the brush contact from a thin, flat stock o - -25 electrically-conducting material. A single flat holder is stamped from a strip (i.e., 1at strip stock) and then each flat holder is ormed progressively in steps as the holder moves through the die stations into the desired three-dimensional shape.
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The flat strip stock which is used is preferably a copper-based alloy pre-plated with a material, such as tin, which either resists oxides and salts or which produces soft, friable oxides. Tin plating is relatively 5 cheap while producing performance results which are acceptable for most uses. Where superior results are desired, a gold plating could be used. Another acceptable material is stock which has an inlaid strip or is clad wi~h a similar conducting material in one or more 10 strategic locations (i.e., the forward and/or rear sockets or a portion thereof.) The plated oe clad or inlaid portion is placed on the side of the flat stock which will become the inside portion when the contact is rolled.
The hoIders 100 in various stages of completion are mounted to a carrier strip 160 which includes pilot holes 162 to allow the carrier strip 160 and holders 100 to be advanced from one station to the next in the die.
At the die position A, corresponding to the first die station, the holder 100 has been stamped as a flat piece which includes the holder portions 110, 120, 130, 140. The holder 100 is connected by a carrier strip attachment 150 to the carrier strip 160. The holder is flat (i.e., substantially one dimensional) at this stage.
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At die position B. corresponding to the second die station, the die has formed or molded the three portions 110, 130, 140 ~pward and out of the plane ~or single dimension) in which the holder 100 was at the die 5 position A. The sides 112, 114 of t,he forwar~ portion 110 of the holder extend at approximately a 90 angle - upward from the plane in which the holder had been stamped at this stage. The ~hree formed portions 110, 130~ 140 are generally trough shaped at this stageO
At the die position Cr the sides 112, 114 of the forward portion 110 of the hvlder have been bent or rolled further by the die, with the sides 112 and 114 being directed toward each other~ but not completely -15 together The portions 130, 140 are not significantly formed at this position from their form the die at position B.
At the die position D, the outside edges of the 20 sides 112, 114 of the forward portion have been guided into adjacent, almost abutting positions to form a sleeve or bottomless socket. The edges of the sides 112, 114 meet at an open seam 113 which extends the length of the forward portion on sleeYeD The open seam 113 allows a 25 small clearance for each in inserting the brush wires, although it may not be necessary in some applications.
At the die position E, a plurality of thin, straight, generally axially aligned wires 200r each wi~h 30 acutely angled forward end surfaces 210~ have been inserted into the forward socket or sleeve portion 110 and crimps 115 have been applied to the forward socket portion 110 to secure the wires 200 in place within the socket. The crimps 115 extend radially around the 35 forward portion 110 o~ the holder and across the seam 113 which is now closed (the sides 112, 114 now abut) due to the crimping.
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Within the die at the die station E, a removable pin (not shown) is inserted into the rear portion of the forward socket 110 to provide a rear stop for the wires being inserted from the forward end. Af~er the crimps 115 secure the wires 200 in place within the socket, the pin can be removed.
The wi~es 200 are preferably secured together at the rear ends thereof to form a one-piece bundle. One such 10 method of securing the wires into the bundle is described in the Welded Brush Contact Patent.
At the die position F, the forward portion 110 has been crimped with an additional crimp 116 to provide 15 additional holding of the wires 200 within forward portion of the socket 110.
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At the position G, the forward end of portion 110 has yet another crimp 117 which "si~es" the forward end of the holder to the approximate circumference of the bundle of axially-aligned wires 200 when the wires are 5 tightly packed. The holder is "sized" to provide a tighter fit of the wires 200 and bring each of the wires - 200 into better alignment with each other and the axis of the socket.
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Also at the die position G, an insulated wire may be positioned within the rear portion 130 of ~he holder 100.
Xn the forward portion of the wire 300, insulation has been removed to expose the bare conductor 310. The bare conductor 310 extends generally in the region of the rear 15 portion 130 which at this stage of manufacturing is trough shaped and will become subsequently the rear socket upon completion of the forming. The conductor or wire 300 has insulation 320 in the portion which is in the region of the insulation-retaining portion 140.
~0 The wire 300 is preferably inserted with the trough formed by sides 132, 134 by positioning the wire above the trough with îts axis aligned with the troughl then moving the wire down intc the trough. Such an insertion 25 of the wire is advantageous in that it can be accomplished with automated equipment. Further, the trough guides the wire down into a proper position.
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Typically, the insulated wire 300 is inser~ed into 30 the trough 130 and secured in place by the user after the forward portion of the contact has been completely manufactured and assembled by the manufacturer. Thus, the explanation of the use of the conductor 300 is for clarity and completeness only in understanding the 35 environment of the present invention.
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~12-Xf the wire 300 is ~o be inserted manually~ the rear socket 130 might be completely formed prior to insertion.
The axis of the wire 300 would then be aligned with the axis of the socket 130. l'he wire would be moved in 5 translation along the common axis Eor insertion.
At the die position H, the sides 132, 134 of thQ
portion 130 and the portions 142, 144 have been ~ormed up and over the wire 300. The sides 132, 134 oE the portion 10 130 (now crimped over the conductor) provide an electri-cal and mechanical connection to the bare conductor 310;
the portions 142, 144 retain the insulated conductor 300 as the portions 142, 144, which are crimped around the wire, grip the insulation 320 and provide mechanical 15 strain relief to protect the electrical coupliny of the sides 132, 134 to the bare conductor 310.
FIGURE 3 is a cross sectional view of the holder portion 110 at the die position B. It shows the holder 20 portion 110 at its stase of completion at this position - which is with the sides 11~ 114 bent ~pward r the outer edges of which extend approximately perpendicular to the carrier strip (not shown) and the originally flat, stamped piece. The cross-section of the holder is now in ~5 ~he shape of the letter "U".
' FIGU~E 4 is a cross-sectional view of the holder portion 110 at the die position C. It shows the holder portion 110 at its stage of completion at this position 30 which i5 with the outer edges of the sides 112, 114 bent ~ inward toward each other in a partial circular shape.
; The cross~section of the holder is now in the shape of thQ ~ r , . .. : ' FIGURE 5 is a cross-sectional view of the holder at the die position D. It shows the holder portion 110 at its stage of completion at this position which is with the outer edges of the sides 112, 114 positioned almost adjacent to each other at the open seam 113 to form a sleeve. The cross-section of the holder is now substantially in the shape of the letter "O" with a small hiatus at the open seam 113.
FIGURE 6 is a cross sectional view of the holder at the die position F. It shows the holder portion 110 at its stage of completion at this position which is with a plurality of wires 200 held relatively loosely with:in the holder by the sides 112, 114.
~'' . - ' FIGURE 7 is a cross-sectional view oE the holder at the die position G. It shows the holder portion 110 at its stage of completion at this position which is with the wires 200 held within the socket 110 more tightly S than FI~URE 6, by virtue of the ~Isizinq~ of the socket to the circumference of the wires.
FIGURE 8 is a cross-sectional view of the rear socket 130 holder at the die position H. It~ shows the 10 conductor 300 held within ~he rear socket 1~0 by a "B-typel' crimp of the sides 132, 134. This type of crimp, which is well known in the art, looks like the letter "B" in its cross-section, as shown in this view.
FIGURE 9 illustrates a perspective view of an electrical contact of the present invention before an electrical conductor is attached. The contact includes the holder forward portion or socket 110 with axially aligned wires 200, each having angled end surfaces 210, 20 extending from the forward end of the holder. A
plurality of crimps 115, 116, 117 secure the wires within the holder forward socket 110. The medial necked down portion 120 connects the forward socket 110 with the rear trough 130, which is empty and not formed into a socket.
25 The insulation gripping portions 142, 144 are shown.
The contact 100, as shown in FIGtJRE 9, has been severed from the carrier strip and the carrier strip attachment has been trimmed from the contact as well.
Typically, the contact would not be separated from the 5 carrier strip and the carrier strip at:tachment until the elec~rical conductor had been attachecl if it was desired to mechanically couple the conductor to the contact.
Also, the attachment of the contacts the carrier strip presents a simple way to handle a plurality of contacts 10 simultaneously. The uniEorm orientation of the contacts with respect to the carrier strip and ~niform spacin~
between successive contacts on the carrier strip facilitates mechanical or automated handling.
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15FIGURE 10 shows an alternative embodiment or configuration of the stamped holder of FIGURE 1. A
stamped holder 400, in a flat, essentially one-dimensional form, is shown. The portions 120, 130, 140 and 150 may be identical to the respective portions 20 shown in FIGURE 1. A orward enlarged portion 410, which will become the forward wire-retaining socket when it is ! formed into its three-dimensional shape, includes portions 411, 412, 413, 414, 415, 416. The medial portions 412, 415 are laterally cffset from the ~5 respective forward portions 411, 414 and rear portions 413, 416. When the forward socket is formed, the seam of the meeting sides is offset.
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FIGURE 11 shows a partial front view of the holder of FIGVRE 10 formed into a three-dimensional piece.
Brush wires 200 (partially shown~ extend from the forward socket 410. The portions 411, 412, 413 meet the 5 respective portions 414l 415, 416 at a seam 417 which includes a laterally-offset medial portion. The laterally-offset seam 417, in contrast to the straight seam 113 of the embodiment of FIGURES 2-9, provides added assurance that one of the wires 200 will not slip through 1~ the seam. In many applications, the crimping of the forward portion alone is su~ficient to retain the wires securely within the holder. As an alternative method of making the present contact in place of the welded bundle, a plurality of individual thin, axially aligned contact 15 wires might be used. In such a case, the seam 113 (shown at the die position D in E'IGURE 2) would probably have to be closed (or substantially closed) in order to retain the individual wires within the socket. The plurality of fine, axially aligned wires used in such an alternate 20 embodiment are preferably individual strands which are, - funneled into the orward socket 110, with -the rear portion of the forwa~d socket including suitable means for stopping the wires at a desired depth.
A sleeve may be applied over the contact brush wires to protect the wires. Such a sleeve would extend forwardly and outside of ~he axially aligned wires.
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Other objects and advantages of the present invention will be apparent to those sk:illed in the art in view of the foregoing description. For example, the sides oE the seam could overlap or the seam might be 5 welded (or both). The wires might be secured or retained within the holder in additional or alternative manners, such as being soldered in place within the socket in addition to or in place of the disclosed crimping. Also;
other rear portions of the holder; such as a 10 solderless-wrap or printed circuit board taill ~ight be advantageous for receiving a conductor in certain applications. In some instances, the rear portion of the contact may be a solder tab and may not require an enlarged rear portion or any forming. The die sequence 15 shown could also be altered to fit the manufacturing requirements, as what is shown as one step could be expanded into several steps and what is shown as several steps and might be combined as one. Blank or idle die stations might be advantageous in some instances. The 20 ~oregoiny description accordingly should be considered as illustrative only and should not interpreted to limit the scope of the present invention, which is defined by the following claims. ~
CROSS REFERENCE TO RELATED PATENTS
U~ S. Patent 3,725,844 issued to McKeown et al. -for "Hermaphroditic Electrical Contact", subsequently referred to as the "Brush Contact Patent".
Canadian patent application S.N~ 307,214 filed July 12, 1978 by R. W. Normann et al. for "Electrical Connector Contact and Method of Making", subsequently referred to as the "Welded Brush Contact Patent".
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TECHNICAL FIELD
The present invention relates to a novel electrical contact and a novel method for making it. More particularly~
the present invention relates to an electrical contact holder which is mad~ by stamping a flat metallic stock in an appro-prirate shape with an enlarged forward portion, then forming ~ the enlarged portion to make a socke~ for receiving a plurality - ~ o contact wires which are secured within the holder.
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BACKGROUND ART
Prior art electrical contacts are well known which have a plurality of fine, axially aligned wires 5 ~sometimes called "brush wires") extending from one end of a holder which is adapted to receive a conductor in a socket in the other end. In such applications, one of which is disclosed in the Brush Contact Patent, the holder is made from a cylindrical stock with holes 10 drilled from either end to form two sockets, the forward one for the brush wires and the rear one for the conductor.
The insertion of a conductor into the rear socket 15 can not presently be accomplished with automated equipment and is generally accomplished by hand at a relatively higher expense than if the conductor could be inserted into and Eixed within the contact by automated equipment.
The drilling of holes in such a holder requires precise positioning of the drill for the holes to provide a wall which has uniform thickness to give good ; performance, yet is thin enough to be crimped to maintain 25 the wires therein.
Furthermore, the drilling operation is itself undesirable in that it adds expense to the manufacturing process and further requires that additional machining 30 capacity, machine operators and transer o~ parts.
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; The contact described in the Brush Contact Patent further contemplated that each holder be separately and indi~idually handled during manufacturing and assembly.
35 Such separate handling is time consuming and expensive.
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, The contact described in the Brush contact Patent also requies that the sockets be plated with a plating solution to improve the electrical characteristics. This plating is an extra step, and furthermore, it requires in 5 some applications that vents or exil: holes be drilled transversely into the socket to allow the plating solution to be removed from the socket.
The electrical contacts described in the Welded 10 Brush Contact Patent have similar sockets drilled into cylindrical stock and thus have similar limitations and undesirable features.
Accordingly, there are undesirable features and 15 limitations of the prior art contacts.
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SUMMA:RY OF THE INVENTION
The present invention overcomes the undesirablefeatures and limitations of the prior art by providing a 5 contact for an electrical connector wh.ich is less expensive and may, in some instances, be of a higher quality than the electrical contacts which are manufactured by other methods. Fur~her, the present method allows a more mechanized manufacture of a contact 10 which requires less labor, handling and transporting of parts during manufacturing~ The electrical contact of the present invention allows several contacts ~o be handled together to reduce costs.
Accordingly, the present invention is an e:Lectr.ical connector contact which may use automated equipment advanta~eously to produce contact with low manufacturing cost.
~', The present contact is also desirable in that stock pre-plated with an electrically conducting material can be used in place of the plating by a plating solution.
The use of preplated stock not only eliminates the step of plating but also the necessity of vent or exit holes 25 to be drilled.
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~ " ~ , According to -the presen-t invention there isprovided an electrical contact for use as a termina-tion of an elec-trical conductor ;n an elec-trical connector assembly. The contact has a plurality of axially-aligned wires, each having an acutely angled forward end surface and a stamped and Eormed electrically conducting holder body including a xear por-tion, a medial portion, and a forward sleeve portion, the forward sleeve portion receiving the rear ends of the plurality oE
axially-aligned wires. The rear portion is adapted to receive the electrical conductor in electrical circuit relationship and the medial portion electrically couPles the rear end forward portions. Means is provided Eor securing the axially-aligned wires, within the forward sleeve portion to prevent the accidental loss of thewires from the sleeve portion.
In the method of the present invention a flat metallic stock is stamped into a shape including an enlarged forward p~tion, a medial portion and an enlarged rear portion. The sides oE the Eorward and rear portions ~0 are formed by bending the sides into forward and rear sleeve portions, respectively. The plurality of axially-aligned wires may then be inserted into the forward sleeve and the wires secured within the sleeve. The electrical conduc-tor may be inserted within the rear sleeve and secured in place.
; More specifically, the sides of the forward portion are formed up to provide a socket for receiving a plurality of axially-aligned elec-trical contact wires. The rear portion i5 formed into a trough-like shape for receiving an electrical conductor. A conductor may be placed ln the trough b~ automated equipment and thereaEter the rear por-tion crimped around the conductor to secure -the conductor to the contact with optionally additional portionC rearward of the ~ ' ~, -~ tm/l~g -5-, `, ~c!
rear portion crimped around the insulation of the conductor to better secure the conductor.
~ ccordingly, the present invention is a me-thod of making a contac-t to which an electrical conductor may be simply, quickly~ cheaply and mechanically a-ttached. The contact may he made cheaply and in an automa-ted way with good qualitv and without requiring a drilling operation.
Other objects and advantages of the present invention will become apparent to one skilled in the art in view of the following description and drawings and the appended claims.
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BRIEF DESCRIPTION OE THE DRAWINGS
FIGURE 1 is a front view of an electrical contact holder of the present invention after the holder is 5 stamped into a flat shape.
FIGURE 2 shows the sequence of manufacturing and assembly steps for forming the holder from the flat piece of FIGURE 1 into a electrical contact.
FIGURE 3 is a cross-sectional view of the contact holder of FIGURE 2, taken along the line III-III looking in the direction of the arrows.
FIGURE 4 is a cross-sectional view of the contact holder of FIGURE 2, taken along the line IV-IV looking in the direction of the arrows.
FIGURE 5 is a cross-sectional view of the contact 20 holder of FIGURE 2, taken along the line V-V looking in the direction oE the arrows.
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FIGURE 6 is a cross-sectional view of the contact holder o FIGURE 2, taken along the line VI-VI looking in 25 the direction of the arrows.
FIGURE 7 is a cro~s-sectional view of the contact holder of FIGURE 2~ taken along the line VII-VII lookiny in the direckion of the arrows.
,~ 30 FIGURE 8 is a cross~sectional view of the contact ~ -holder of FIGURE 2, taken along the line VIII-VIII in FIGURE 2, lookin~ in ~he direction of the arrows.
FIGURE ~9 shows a view of a completed electrical contact beore a conductor has been connected thereto.
: FIGURE 10 shows an alternate structure for the stamped hoIder oF FI~URE lo 4~
FlGURE 11 is a partial Eront view of the finished holder of the alternate holder s~ructure of FIGURE 1().
, DETAILED I~ESC.F<IPTION OF THE ~)RAWINGS
FIGURE 1 is a view of a brush contact holder 100 which has been stamped from a flat stock, before the 5 holder has been formed into a three-dimensional holder.
The stamped holder 100 includes a forward portion 110, which will become a forward socket for axially aligned brush contact wires.
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10The forward portion 110 is connected by a necked down or relatively narrower portion 1~0 to a second portion 130 which will be a socket for receiving an electrical conductor. A portion 140 of the holder is formed for gripping the insulation of the conductor. A
15 carrier strip attachment 150 attaches the holder 100 to a carrier strip (not shown).
The forward portion 110 has sides 112, 114. The -rear portion 130 includes sides 132, 134. The insulation 20 gripping portion 140 includes triangular portions 142, 144.
~ .
FIGURE 2 shows the steps in the manufacture of the brush contact from a thin, flat stock o - -25 electrically-conducting material. A single flat holder is stamped from a strip (i.e., 1at strip stock) and then each flat holder is ormed progressively in steps as the holder moves through the die stations into the desired three-dimensional shape.
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The flat strip stock which is used is preferably a copper-based alloy pre-plated with a material, such as tin, which either resists oxides and salts or which produces soft, friable oxides. Tin plating is relatively 5 cheap while producing performance results which are acceptable for most uses. Where superior results are desired, a gold plating could be used. Another acceptable material is stock which has an inlaid strip or is clad wi~h a similar conducting material in one or more 10 strategic locations (i.e., the forward and/or rear sockets or a portion thereof.) The plated oe clad or inlaid portion is placed on the side of the flat stock which will become the inside portion when the contact is rolled.
The hoIders 100 in various stages of completion are mounted to a carrier strip 160 which includes pilot holes 162 to allow the carrier strip 160 and holders 100 to be advanced from one station to the next in the die.
At the die position A, corresponding to the first die station, the holder 100 has been stamped as a flat piece which includes the holder portions 110, 120, 130, 140. The holder 100 is connected by a carrier strip attachment 150 to the carrier strip 160. The holder is flat (i.e., substantially one dimensional) at this stage.
~, . . .
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At die position B. corresponding to the second die station, the die has formed or molded the three portions 110, 130, 140 ~pward and out of the plane ~or single dimension) in which the holder 100 was at the die 5 position A. The sides 112, 114 of t,he forwar~ portion 110 of the holder extend at approximately a 90 angle - upward from the plane in which the holder had been stamped at this stage. The ~hree formed portions 110, 130~ 140 are generally trough shaped at this stageO
At the die position Cr the sides 112, 114 of the forward portion 110 of the hvlder have been bent or rolled further by the die, with the sides 112 and 114 being directed toward each other~ but not completely -15 together The portions 130, 140 are not significantly formed at this position from their form the die at position B.
At the die position D, the outside edges of the 20 sides 112, 114 of the forward portion have been guided into adjacent, almost abutting positions to form a sleeve or bottomless socket. The edges of the sides 112, 114 meet at an open seam 113 which extends the length of the forward portion on sleeYeD The open seam 113 allows a 25 small clearance for each in inserting the brush wires, although it may not be necessary in some applications.
At the die position E, a plurality of thin, straight, generally axially aligned wires 200r each wi~h 30 acutely angled forward end surfaces 210~ have been inserted into the forward socket or sleeve portion 110 and crimps 115 have been applied to the forward socket portion 110 to secure the wires 200 in place within the socket. The crimps 115 extend radially around the 35 forward portion 110 o~ the holder and across the seam 113 which is now closed (the sides 112, 114 now abut) due to the crimping.
' ~ , ~'' ;
Within the die at the die station E, a removable pin (not shown) is inserted into the rear portion of the forward socket 110 to provide a rear stop for the wires being inserted from the forward end. Af~er the crimps 115 secure the wires 200 in place within the socket, the pin can be removed.
The wi~es 200 are preferably secured together at the rear ends thereof to form a one-piece bundle. One such 10 method of securing the wires into the bundle is described in the Welded Brush Contact Patent.
At the die position F, the forward portion 110 has been crimped with an additional crimp 116 to provide 15 additional holding of the wires 200 within forward portion of the socket 110.
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At the position G, the forward end of portion 110 has yet another crimp 117 which "si~es" the forward end of the holder to the approximate circumference of the bundle of axially-aligned wires 200 when the wires are 5 tightly packed. The holder is "sized" to provide a tighter fit of the wires 200 and bring each of the wires - 200 into better alignment with each other and the axis of the socket.
.
Also at the die position G, an insulated wire may be positioned within the rear portion 130 of ~he holder 100.
Xn the forward portion of the wire 300, insulation has been removed to expose the bare conductor 310. The bare conductor 310 extends generally in the region of the rear 15 portion 130 which at this stage of manufacturing is trough shaped and will become subsequently the rear socket upon completion of the forming. The conductor or wire 300 has insulation 320 in the portion which is in the region of the insulation-retaining portion 140.
~0 The wire 300 is preferably inserted with the trough formed by sides 132, 134 by positioning the wire above the trough with îts axis aligned with the troughl then moving the wire down intc the trough. Such an insertion 25 of the wire is advantageous in that it can be accomplished with automated equipment. Further, the trough guides the wire down into a proper position.
, .
Typically, the insulated wire 300 is inser~ed into 30 the trough 130 and secured in place by the user after the forward portion of the contact has been completely manufactured and assembled by the manufacturer. Thus, the explanation of the use of the conductor 300 is for clarity and completeness only in understanding the 35 environment of the present invention.
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~12-Xf the wire 300 is ~o be inserted manually~ the rear socket 130 might be completely formed prior to insertion.
The axis of the wire 300 would then be aligned with the axis of the socket 130. l'he wire would be moved in 5 translation along the common axis Eor insertion.
At the die position H, the sides 132, 134 of thQ
portion 130 and the portions 142, 144 have been ~ormed up and over the wire 300. The sides 132, 134 oE the portion 10 130 (now crimped over the conductor) provide an electri-cal and mechanical connection to the bare conductor 310;
the portions 142, 144 retain the insulated conductor 300 as the portions 142, 144, which are crimped around the wire, grip the insulation 320 and provide mechanical 15 strain relief to protect the electrical coupliny of the sides 132, 134 to the bare conductor 310.
FIGURE 3 is a cross sectional view of the holder portion 110 at the die position B. It shows the holder 20 portion 110 at its stase of completion at this position - which is with the sides 11~ 114 bent ~pward r the outer edges of which extend approximately perpendicular to the carrier strip (not shown) and the originally flat, stamped piece. The cross-section of the holder is now in ~5 ~he shape of the letter "U".
' FIGU~E 4 is a cross-sectional view of the holder portion 110 at the die position C. It shows the holder portion 110 at its stage of completion at this position 30 which i5 with the outer edges of the sides 112, 114 bent ~ inward toward each other in a partial circular shape.
; The cross~section of the holder is now in the shape of thQ ~ r , . .. : ' FIGURE 5 is a cross-sectional view of the holder at the die position D. It shows the holder portion 110 at its stage of completion at this position which is with the outer edges of the sides 112, 114 positioned almost adjacent to each other at the open seam 113 to form a sleeve. The cross-section of the holder is now substantially in the shape of the letter "O" with a small hiatus at the open seam 113.
FIGURE 6 is a cross sectional view of the holder at the die position F. It shows the holder portion 110 at its stage of completion at this position which is with a plurality of wires 200 held relatively loosely with:in the holder by the sides 112, 114.
~'' . - ' FIGURE 7 is a cross-sectional view oE the holder at the die position G. It shows the holder portion 110 at its stage of completion at this position which is with the wires 200 held within the socket 110 more tightly S than FI~URE 6, by virtue of the ~Isizinq~ of the socket to the circumference of the wires.
FIGURE 8 is a cross-sectional view of the rear socket 130 holder at the die position H. It~ shows the 10 conductor 300 held within ~he rear socket 1~0 by a "B-typel' crimp of the sides 132, 134. This type of crimp, which is well known in the art, looks like the letter "B" in its cross-section, as shown in this view.
FIGURE 9 illustrates a perspective view of an electrical contact of the present invention before an electrical conductor is attached. The contact includes the holder forward portion or socket 110 with axially aligned wires 200, each having angled end surfaces 210, 20 extending from the forward end of the holder. A
plurality of crimps 115, 116, 117 secure the wires within the holder forward socket 110. The medial necked down portion 120 connects the forward socket 110 with the rear trough 130, which is empty and not formed into a socket.
25 The insulation gripping portions 142, 144 are shown.
The contact 100, as shown in FIGtJRE 9, has been severed from the carrier strip and the carrier strip attachment has been trimmed from the contact as well.
Typically, the contact would not be separated from the 5 carrier strip and the carrier strip at:tachment until the elec~rical conductor had been attachecl if it was desired to mechanically couple the conductor to the contact.
Also, the attachment of the contacts the carrier strip presents a simple way to handle a plurality of contacts 10 simultaneously. The uniEorm orientation of the contacts with respect to the carrier strip and ~niform spacin~
between successive contacts on the carrier strip facilitates mechanical or automated handling.
' ':
15FIGURE 10 shows an alternative embodiment or configuration of the stamped holder of FIGURE 1. A
stamped holder 400, in a flat, essentially one-dimensional form, is shown. The portions 120, 130, 140 and 150 may be identical to the respective portions 20 shown in FIGURE 1. A orward enlarged portion 410, which will become the forward wire-retaining socket when it is ! formed into its three-dimensional shape, includes portions 411, 412, 413, 414, 415, 416. The medial portions 412, 415 are laterally cffset from the ~5 respective forward portions 411, 414 and rear portions 413, 416. When the forward socket is formed, the seam of the meeting sides is offset.
:
~
.
FIGURE 11 shows a partial front view of the holder of FIGVRE 10 formed into a three-dimensional piece.
Brush wires 200 (partially shown~ extend from the forward socket 410. The portions 411, 412, 413 meet the 5 respective portions 414l 415, 416 at a seam 417 which includes a laterally-offset medial portion. The laterally-offset seam 417, in contrast to the straight seam 113 of the embodiment of FIGURES 2-9, provides added assurance that one of the wires 200 will not slip through 1~ the seam. In many applications, the crimping of the forward portion alone is su~ficient to retain the wires securely within the holder. As an alternative method of making the present contact in place of the welded bundle, a plurality of individual thin, axially aligned contact 15 wires might be used. In such a case, the seam 113 (shown at the die position D in E'IGURE 2) would probably have to be closed (or substantially closed) in order to retain the individual wires within the socket. The plurality of fine, axially aligned wires used in such an alternate 20 embodiment are preferably individual strands which are, - funneled into the orward socket 110, with -the rear portion of the forwa~d socket including suitable means for stopping the wires at a desired depth.
A sleeve may be applied over the contact brush wires to protect the wires. Such a sleeve would extend forwardly and outside of ~he axially aligned wires.
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Other objects and advantages of the present invention will be apparent to those sk:illed in the art in view of the foregoing description. For example, the sides oE the seam could overlap or the seam might be 5 welded (or both). The wires might be secured or retained within the holder in additional or alternative manners, such as being soldered in place within the socket in addition to or in place of the disclosed crimping. Also;
other rear portions of the holder; such as a 10 solderless-wrap or printed circuit board taill ~ight be advantageous for receiving a conductor in certain applications. In some instances, the rear portion of the contact may be a solder tab and may not require an enlarged rear portion or any forming. The die sequence 15 shown could also be altered to fit the manufacturing requirements, as what is shown as one step could be expanded into several steps and what is shown as several steps and might be combined as one. Blank or idle die stations might be advantageous in some instances. The 20 ~oregoiny description accordingly should be considered as illustrative only and should not interpreted to limit the scope of the present invention, which is defined by the following claims. ~
Claims (21)
OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. An electrical contact for use as a termination of an electrical conductor in an electrical connector assembly, said contact comprising:
a plurality of axially-aligned wires, each having an acutely angled forward end surface;
a stamped and formed electrically conducting holder body including a rear portion, a medial portion, and a forward sleeve portion, said rear portion adapted to receive the electrical conductor in electrical circuit relationship, said medial portion electrically coupling the rear and forward portions and said forward sleeve portion receiving the rear ends of the plurality of axially-aligned wires, said forward sleeve portion having a seam extending the length thereof; and means for securing the axially-aligned wires within the forward sleeve portion to prevent the accidental loss of the wires from the sleeve portion.
a plurality of axially-aligned wires, each having an acutely angled forward end surface;
a stamped and formed electrically conducting holder body including a rear portion, a medial portion, and a forward sleeve portion, said rear portion adapted to receive the electrical conductor in electrical circuit relationship, said medial portion electrically coupling the rear and forward portions and said forward sleeve portion receiving the rear ends of the plurality of axially-aligned wires, said forward sleeve portion having a seam extending the length thereof; and means for securing the axially-aligned wires within the forward sleeve portion to prevent the accidental loss of the wires from the sleeve portion.
2. An electrical contact of the type described in Claim 1 wherein the seam includes a laterally-offset portion along the length of the forward sleeve.
3. An electrical contact of the type described in Claim 1 wherein the seam is formed by the meeting of two sides which abut.
4. An electrical contact of the type described in Claim 1 wherein the seam is an unwelded seam.
5. An electrical contact of the type described in Claim 1 wherein the plurality of axially aligned wires are secured together toward the rear ends thereof.
6. An electrical contact of the type described in Claim 1 wherein the means securing the wires within the forward sleeve is a plurality of radial inwardly directed crimps of the forward sleeve, said plurality of crimps located at axially spaced locations along the forward sleeve.
7. An electrical contact of the typed described in Claim 1 wherein the holder body includes a base layer of electrically conducting material covered with an other material in at least a portion of the forward sleeve portion, said other material being an electrically conducing material which resists oxides and salts so as to provide a low electrical resistance between the holder and the wires when the wires are secured within the holder.
8. An electrical contact of the type described in Claim 7 wherein the base material is a copper-containing alloy and other material is tin.
9. In a method of making an electrical contact for an electrical connector, the method including the steps of: making a contact body having a forward portion in either a sleeve or socket shape for receiving a plurality of fine, axially-aligned wires extending therefrom and a rear portion for receiving an electrical conductor;
inserting the plurality of wires within the forward portion; and securing the wires in the forward portion to retain the wires therein; the improvement wherein the step of making a contact body includes the steps of:
stamping the contact body as a flat piece of substantially uniform thickness with enlarged forward and rear portions, which, when the respective edges of the forward and rear portions are formed upward, forms the forward sleeve and rear sleeve, respectively; and forming the respective sides of said enlarged forward portion upward and around into a position with the outside edges of the sides adjoining to form the forward portion into a socket or sleeve shape, whereby a three-dimensional contact for holding a plurality of axially-aligned wires is formed a stamped, flat piece of uniform thickness.
inserting the plurality of wires within the forward portion; and securing the wires in the forward portion to retain the wires therein; the improvement wherein the step of making a contact body includes the steps of:
stamping the contact body as a flat piece of substantially uniform thickness with enlarged forward and rear portions, which, when the respective edges of the forward and rear portions are formed upward, forms the forward sleeve and rear sleeve, respectively; and forming the respective sides of said enlarged forward portion upward and around into a position with the outside edges of the sides adjoining to form the forward portion into a socket or sleeve shape, whereby a three-dimensional contact for holding a plurality of axially-aligned wires is formed a stamped, flat piece of uniform thickness.
10. A method of the type described in Claim 9 wherein the method includes the additional step of forming the rear portion into a trough for receiving the conductor.
11. A method of the type described in claim 10 wherein the method further includes the steps of laying the conductor into the rear trough portion and forming the sides of the rear trough portion around and over the conductor to secure the conductor thereto in electrical circuit relationship.
12. A method of terminating an electrical conductor with an electrical contact of the type including a plurality of axially-aligned wires extending forwardly from the contact and a rear portion for receiving the electrical conductor, the steps of the method comprising:
stamping a flat metallic stock into a shape including an enlarged forward portion, a medial portion and an enlarged rear portion;
forming by bending the sides of the forward and rear portions into forward and rear sleeve portions respectively;
inserting the plurality of axially-aligned wires into the forward sleeve;
securing the wires within the sleeve; and inserting the electrical conductor within the rear sleeve and securing it in place, whereby an electrical contact holder is formed from a flat piece of stock.
stamping a flat metallic stock into a shape including an enlarged forward portion, a medial portion and an enlarged rear portion;
forming by bending the sides of the forward and rear portions into forward and rear sleeve portions respectively;
inserting the plurality of axially-aligned wires into the forward sleeve;
securing the wires within the sleeve; and inserting the electrical conductor within the rear sleeve and securing it in place, whereby an electrical contact holder is formed from a flat piece of stock.
13. An electrical contact for use as a termination of an electrical conductor in an electrical connector assembly, said contact comprising:
a plurality of axially-aligned wires, each having an acutely angled forward end surface;
a stamped and formed electrically conducting holder body including a rear portion, a medial portion, and a forward sleeve portion, said rear portion adapted to receive the electrical conductor in electrical circuit relationship, said medial portion electrically coupling the rear and forward portions and said forward sleeve portion receiving the rear ends of the plurality of axially-aligned wires, said forward sleeve portion having a seam extending the length thereof; and means for securing the axially-aligned wires within the forward sleeve portion to prevent the accidental loss of the wires from the sleeve portion, said securing means including means for restricting axial movement of the wires and additionally a crimp at the forward end of the forward sleeve portion for providing a fitting of the sleeve to the size of the plurality of wires and for bringing the wires into better alignment.
a plurality of axially-aligned wires, each having an acutely angled forward end surface;
a stamped and formed electrically conducting holder body including a rear portion, a medial portion, and a forward sleeve portion, said rear portion adapted to receive the electrical conductor in electrical circuit relationship, said medial portion electrically coupling the rear and forward portions and said forward sleeve portion receiving the rear ends of the plurality of axially-aligned wires, said forward sleeve portion having a seam extending the length thereof; and means for securing the axially-aligned wires within the forward sleeve portion to prevent the accidental loss of the wires from the sleeve portion, said securing means including means for restricting axial movement of the wires and additionally a crimp at the forward end of the forward sleeve portion for providing a fitting of the sleeve to the size of the plurality of wires and for bringing the wires into better alignment.
14. A method of making an electrical contact comprising the steps of:
stamping a contact body as a single flat piece of electrically conducting stock having uniform thickness and including forward and rear portions, said stamping of the forward portion including stamping the forward portion into a generally rectangular portion having a lateral offset along one side and a complementary lateral projection along the other side;
forming the forward portion of the contact body into a generally cylindrically-shaped socket by progressively bending the edges around to a position where the edges adjoin at a first seam with the lateral projection inter-fitting within the lateral offset at a seam portion which is circumferentially offset from the first seam;
inserting a plurality of fine contact wires into the forward portion of the contact body; and crimping the forward portion of the contact body at a first location near the rear end thereof to retain the wires therein at a second location longitudinally spaced from the first location, said crimping at two longitudinally spaced locations for axially aligning said contact wires with each other and the socket.
stamping a contact body as a single flat piece of electrically conducting stock having uniform thickness and including forward and rear portions, said stamping of the forward portion including stamping the forward portion into a generally rectangular portion having a lateral offset along one side and a complementary lateral projection along the other side;
forming the forward portion of the contact body into a generally cylindrically-shaped socket by progressively bending the edges around to a position where the edges adjoin at a first seam with the lateral projection inter-fitting within the lateral offset at a seam portion which is circumferentially offset from the first seam;
inserting a plurality of fine contact wires into the forward portion of the contact body; and crimping the forward portion of the contact body at a first location near the rear end thereof to retain the wires therein at a second location longitudinally spaced from the first location, said crimping at two longitudinally spaced locations for axially aligning said contact wires with each other and the socket.
15. A method of making an electrical contact as described in Claim 14 wherein the step of crimping additionally includes forming a crimp at the forward end of the socket to make the forward end of the socket approximately the diameter of the plurality of contact wires.
16. A method of making a contact as described in Claim 15 wherein the method includes the steps of forming the rear portion of the contact body into a trough-like shape having conductor-receiving members and insulation-receiving portions.
17. A method of making an electrical contact comprising the steps of:
stamping a contact body as a single flat piece of electrically conducting stock having uniform thickness and including forward and rear portions, said stamping of the forward portion including stamping the forward portion into a generally rectangular portion having a lateral offset along one side and a complementary lateral projection along the other side;
forming the forward portion of the contact body into a generally cylindrically-shaped socket by progressively bending the edges around to a position where the edges adjoin at a first seam with the lateral projection interfitting within the lateral offset at a seam portion which is circumferentially offset from the first seam;
inserting a plurality of fine contact wires into the forward portion of the contact body; and crimping the forward portion of the contact body at a first location near the rear end thereof to retain the wires therein.
stamping a contact body as a single flat piece of electrically conducting stock having uniform thickness and including forward and rear portions, said stamping of the forward portion including stamping the forward portion into a generally rectangular portion having a lateral offset along one side and a complementary lateral projection along the other side;
forming the forward portion of the contact body into a generally cylindrically-shaped socket by progressively bending the edges around to a position where the edges adjoin at a first seam with the lateral projection interfitting within the lateral offset at a seam portion which is circumferentially offset from the first seam;
inserting a plurality of fine contact wires into the forward portion of the contact body; and crimping the forward portion of the contact body at a first location near the rear end thereof to retain the wires therein.
18. A method of making an electrical contact comprising the steps of:
stamping a contact body as a single flat piece of electrically conducting stock having uniform thickness and including forward and rear portions, said stamping of the forward portion including stamping the forward portion into a generally rectangular portion;
forming the forward portion of the contact body into a generally cylindrically-shaped socket by progressively bending the edges around to a position where the edges adjoin at a seam;
inserting a plurality of fine contact wires into the forward portion of the contact body; and crimping the forward portion of the contact body at a first location near the rear end thereof to retain the wires therein at a second location longitudinally spaced from the first location, said crimping at a plurality of spaced locations for axially aligning said contact wires with each other and the socket.
stamping a contact body as a single flat piece of electrically conducting stock having uniform thickness and including forward and rear portions, said stamping of the forward portion including stamping the forward portion into a generally rectangular portion;
forming the forward portion of the contact body into a generally cylindrically-shaped socket by progressively bending the edges around to a position where the edges adjoin at a seam;
inserting a plurality of fine contact wires into the forward portion of the contact body; and crimping the forward portion of the contact body at a first location near the rear end thereof to retain the wires therein at a second location longitudinally spaced from the first location, said crimping at a plurality of spaced locations for axially aligning said contact wires with each other and the socket.
19. A method of making a mateable hermaphroditic electrical contact comprising the steps of:
stamping a contact body from a flat piece of electrically conducting stock, said stamping providing the flat piece with a generally rectangular forward portion having oppositely disposed first and second sides, each of said sides having therealong a laterally offset portion;
forming the rectangular forward portion of the flat piece into a contact body having a generally cylindrically-shaped socket by progressively bending the sides around to a position where the sides adjoin at a seam and the laterally offset portions interfit;
arranging several pieces of conductive wire in parallel relationship;
inserting one end of the wires into the socket exposing the other end for mating; and crimping at least a portion of the cylindrically-shaped socket to retain the wires therein, whereby the retained and aligned wires and the cylindrically-shaped socket provide the mateable hermaphroditic electrical contact.
stamping a contact body from a flat piece of electrically conducting stock, said stamping providing the flat piece with a generally rectangular forward portion having oppositely disposed first and second sides, each of said sides having therealong a laterally offset portion;
forming the rectangular forward portion of the flat piece into a contact body having a generally cylindrically-shaped socket by progressively bending the sides around to a position where the sides adjoin at a seam and the laterally offset portions interfit;
arranging several pieces of conductive wire in parallel relationship;
inserting one end of the wires into the socket exposing the other end for mating; and crimping at least a portion of the cylindrically-shaped socket to retain the wires therein, whereby the retained and aligned wires and the cylindrically-shaped socket provide the mateable hermaphroditic electrical contact.
20. A method of making an electrical contact as recited in Claim 19 wherein the step of crimping includes forming at least two longitudinally spaced apart crimps.
21. A method of making an electrical contact as recited in Claim 20 wherein the step of crimping additionally includes forming a crimp at the forward end of the socket to make the forward end of the socket approximately the diameter of the plurality of contact wires.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US91097578A | 1978-05-30 | 1978-05-30 | |
| US910,975 | 1986-09-24 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1112321A true CA1112321A (en) | 1981-11-10 |
Family
ID=25429597
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA322,536A Expired CA1112321A (en) | 1978-05-30 | 1979-03-01 | Electrical contact and method of making |
Country Status (9)
| Country | Link |
|---|---|
| JP (1) | JPS54156196A (en) |
| BR (1) | BR7903450A (en) |
| CA (1) | CA1112321A (en) |
| CH (1) | CH631293A5 (en) |
| DE (1) | DE2922067A1 (en) |
| FR (1) | FR2427702A1 (en) |
| GB (1) | GB2022332B (en) |
| IN (1) | IN151697B (en) |
| IT (1) | IT1166857B (en) |
Families Citing this family (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS60170179A (en) * | 1984-02-14 | 1985-09-03 | ヒロセ電機株式会社 | Contactor for connector and method of producing same |
| SE8901230D0 (en) * | 1988-08-01 | 1989-04-07 | Aweidmueller Gmbh & Co C | PROCEDURES FOR PREPARING THE CONTACT BODY PROVIDED WITH AN INSULATION ELEMENT, SUCH AS CONTACT SHELTS AND CABLES AND THEIR APPLICATION OF DISOLATED LEADERS, AND ACCORDING TO THE PROCEDURE |
| JP2528238Y2 (en) * | 1989-05-17 | 1997-03-05 | 日本航空電子工業 株式会社 | Crimp contact |
| JPH0487167U (en) * | 1990-12-01 | 1992-07-29 | ||
| FR2859047A1 (en) * | 2003-08-19 | 2005-02-25 | Framatome Connectors Int | Improved electrical wire contact crimping method having outer shaft two stages deformed using die stamps with second crimping stage forming smaller localised gap size. |
| JP4823935B2 (en) * | 2006-03-27 | 2011-11-24 | 株式会社オートネットワーク技術研究所 | Terminal original plate, continuous terminal, manufacturing method of terminal original plate, manufacturing method of continuous terminal, and manufacturing method of electric wire with terminal |
| WO2010024033A1 (en) * | 2008-08-27 | 2010-03-04 | 住友電装株式会社 | Terminal metal fitting and method of manufacturing terminal metal fitting |
| WO2010024032A1 (en) * | 2008-08-29 | 2010-03-04 | 住友電装株式会社 | Terminal metal fitting, method of manufacturing cable with terminal metal fitting, and terminal-crimping mold |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB467014A (en) * | 1936-10-03 | 1937-06-09 | Ernst Kleinmann | Improvements relating to electrical brush contacts |
| US3725844A (en) * | 1971-03-15 | 1973-04-03 | Bendix Corp | Hermaphroditic electrical contact |
| CA1104692A (en) * | 1977-12-22 | 1981-07-07 | Theodore L. Wilklow | Electrical connector contact comprising a plurality of wires and method of making it |
-
1979
- 1979-03-01 CA CA322,536A patent/CA1112321A/en not_active Expired
- 1979-04-30 GB GB7914887A patent/GB2022332B/en not_active Expired
- 1979-05-01 IN IN290/DEL/79A patent/IN151697B/en unknown
- 1979-05-28 IT IT23033/79A patent/IT1166857B/en active
- 1979-05-29 BR BR7903450A patent/BR7903450A/en unknown
- 1979-05-30 FR FR7913828A patent/FR2427702A1/en active Granted
- 1979-05-30 DE DE19792922067 patent/DE2922067A1/en not_active Withdrawn
- 1979-05-30 JP JP6628279A patent/JPS54156196A/en active Pending
- 1979-05-30 CH CH504579A patent/CH631293A5/en not_active IP Right Cessation
Also Published As
| Publication number | Publication date |
|---|---|
| IN151697B (en) | 1983-07-02 |
| GB2022332A (en) | 1979-12-12 |
| BR7903450A (en) | 1979-12-11 |
| CH631293A5 (en) | 1982-07-30 |
| JPS54156196A (en) | 1979-12-08 |
| GB2022332B (en) | 1983-02-09 |
| FR2427702B1 (en) | 1983-04-15 |
| DE2922067A1 (en) | 1979-12-06 |
| IT7923033A0 (en) | 1979-05-28 |
| IT1166857B (en) | 1987-05-06 |
| FR2427702A1 (en) | 1979-12-28 |
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