EP3823099A1 - Female contact with folded socket and method of manufacture - Google Patents

Abstract

In some examples, it is described a method of manufacturing a female electrical contact, the method comprising:
attaching two extremities of each conductive wire of a plurality of conductive wires to a sheet of conductive material having a longitudinal axis, wherein attaching the two extremities of each wire is performed such that the plurality of wires are slanted with respect to the longitudinal axis of the sheet; and
folding the sheet of conductive material to form a conductive tubular socket having a longitudinal axis, the longitudinal axis of the tubular socket being substantially parallel to the longitudinal axis of the sheet, wherein folding the sheet is performed such that, after the sheet of conductive material is folded, the plurality of wires define a hyperboloid receiving space for a male electrical contact.

Description

FIELD OF INVENTION
• The invention relates, but is not limited to, a female electrical contact e.g. for an electrical connector. The invention also relates to a method of manufacture of such a contact.
BACKGROUND
• An electrical connector usually comprises at least one contact fitted in an insulator. The at least one contact may comprise a female contact (e.g. comprising a socket) configured to be mated with a male contact (e.g. a pin) and/or may comprise a male contact (e.g. a pin) configured to be mated with a female contact (e.g. comprising a socket).
• An electrical plug usually comprises a mobile connector. The electrical plug may comprise male contacts (e.g. comprising pins) and/or female contacts (e.g. comprising sockets). An electrical receptacle usually comprises a fixed connector (e.g. fixed in a wall). The electrical receptacle may comprise male contacts (e.g. comprising pins) and/or female contacts (e.g. comprising sockets). The electrical plug may be mated with the electrical receptacle.
• Some sockets may define a hyperboloid receiving space for a male electrical contact. Methods of manufacture of such sockets may have relatively low production rates and relatively high costs.
SUMMARY
• Aspects and embodiments of the invention are set out in the appended claims. These and other aspects and embodiments of the invention are also described herein.
BRIEF PRESENTATION OF DRAWINGS
• Aspects of the disclosure will now be described, by way of example, with reference to the accompanying drawings in which:
• Figure 1 schematically illustrates example steps of a method of manufacture of a contact of any one of the aspects of the disclosure;
• Figure 2A is an elevation view, in perspective, which schematically illustrates a first example female contact before it is folded around a longitudinal axis;
• Figure 2B is an elevation view, in perspective, which schematically illustrates the example female contact corresponding to Figure 2A after it is folded around a longitudinal axis;
• Figure 3A is an elevation view, in perspective, which schematically illustrates a second example female contact before it is folded around a longitudinal axis;
• Figure 3B is an elevation view, in perspective, which schematically illustrates the example female contact corresponding to Figure 3A after it is folded around a longitudinal axis;
• Figure 4A is an elevation view, in perspective, which schematically illustrates a third example female contact before it is folded around a longitudinal axis;
• Figure 4B is an elevation view, in perspective, which schematically illustrates the example female contact corresponding to Figure 4A after it is folded around a longitudinal axis;
• Figure 5 is a view of a longitudinal section of the contact of Figures 3B or 4B;
• Figure 6 is a view of a cross section of the contact of Figures 3B or 4B;
• Figure 7 is an elevation exploded view, in perspective, which schematically illustrates an example female contact and an outer shank;
• Figure 8 is an elevation view, in perspective, which schematically illustrates an example female contact in an outer shank; and
• Figure 9 is an elevation front view which schematically illustrates a plurality of example female contacts in a connector.
• In the drawings, similar elements bear identical numerical references.
SPECIFIC DESCRIPTION Overview
• The disclosure relates but is not limited to a female electrical contact comprising a tubular conductive socket having a longitudinal axis, and a plurality of conductive wires, each conductive wire comprising two extremities and being attached to the socket at the two extremities. The plurality of wires are slanted with respect to the longitudinal axis of the socket to define a hyperboloid receiving space for a male electrical contact. The socket is configured to form a structure which is folded around the longitudinal axis. In some examples, the socket may have a C-shaped or an O-shaped cross-section.
• The disclosure also relates to a method of manufacture of the contact. The method of manufacturing the female electrical contact comprises attaching two extremities of each conductive wire of a plurality of conductive wires to a sheet of conductive material having a longitudinal axis, and folding the sheet of conductive material to form a conductive tubular socket having a longitudinal axis, the longitudinal axis of the tubular socket being substantially parallel to the longitudinal axis of the sheet. In some examples the step of attaching the two extremities of each wire is performed such that the plurality of wires are slanted with respect to the longitudinal axis of the sheet. In some examples folding the sheet is performed such that, after the sheet of conductive material is folded, the plurality of wires define a hyperboloid receiving space for a male electrical contact.
• In some examples, folding the sheet of conductive material may comprise rolling the sheet of conductive material.
• The socket is folded around its longitudinal axis (e.g. by folding a sheet of conductive material) and has a relatively small overall size. A relatively high density of contacts and a relatively low pitch of contacts may be obtained in a connector comprising a plurality of contacts according to any aspects of the disclosure.
• The hyperboloid receiving space may have a relatively high cycle life for mating with a male contact (up to 100,000 mating cycles). The hyperboloid receiving space may enable relatively low contact resistance. The hyperboloid receiving space may provide a relatively high current carrying capacity. The hyperboloid receiving space may provide a relatively high immunity to mechanical shock, vibration, and/or fretting corrosion. The hyperboloid receiving space may enable a relatively low insertion force. The hyperboloid receiving space may be self-cleaning and may provide a wiping action upon mating with a male electrical contact.
• The contact of any aspects of the disclosure may be used in many technical fields, in particular but not only in fields where connectors with relatively low contact pitch and relatively high contact density may be required, e.g. for medical applications.
• The socket is folded around its longitudinal axis (e.g. by folding a sheet of conductive material) and is relatively easy and cheap to manufacture.
Detailed description of example embodiments
• Figure 1 schematically illustrates example steps of a method of manufacture 100 of a contact of any one of the aspects of the disclosure. The method 100 may be for manufacturing a first example female contact 1 as illustrated e.g. in Figures 2A and 2B.
• The method 100 of manufacturing the female electrical contact 1 may comprise:
• attaching, at S101, two extremities 4 of each conductive wire of a plurality of conductive wires 3 to a sheet 2 of conductive material having a longitudinal axis (X-X); and
• folding, at S102, the sheet 2 of conductive material to form a conductive tubular socket 20 having a longitudinal axis (X'-X'), the longitudinal axis (X'-X') of the tubular socket 20 being substantially parallel to the longitudinal axis (X-X) of the sheet 2.
• The socket 20 is configured to form a structure which is folded around the longitudinal axis X'-X'.
• In some examples, the attaching at S101 of the two extremities 4 of each wire 3 (see e.g. Figure 2A) is performed such that the plurality of wires 3 are slanted with respect to the longitudinal axis (X-X) of the sheet 2. An axis of each of the wire 3 forms an angle with respect to the axis (X-X). As illustrated in Figure 2A, the plurality of wires 3 may be slanted with respect to the longitudinal axis X-X by an angle α. Values of the angle α depend on dimensions of the sheet 2 (such as a length L and/or a width W, as illustrated in Figure 2A), as well as on dimensions of the socket 20 (such as a final diameter D of the socket 20 and/or a length L, as illustrated in Figure 2B). In some examples, typical values are such that: $$3°\le \mathrm{\alpha }\le 15°$$

  
• For examples the angle α may be typically comprised between 6° and 8°. The above values of the angle α are non-limiting examples only, and other values of the angle α are also envisaged.
• In some examples, the folding at S102 of the sheet 2 (see e.g. Figure 2B) is performed such that, after the sheet 2 of conductive material is folded, the plurality of wires 3 define a hyperboloid receiving space 5 for a male electrical contact (not shown in the Figures).
• Only the extremities 4 of the wires 3 are attached to the sheet 2 (a part of each of the wire 3 extending between the two extremities 4 is not attached to the sheet 2), and the hyperboloid receiving space 5 is the result of a combination of:
• the angle α between the wires 3 and the longitudinal axis X-X on the sheet 2, and
• the folding (e.g. rolling) of the sheet 2.
• In some examples, folding at S102 the sheet 2 of conductive material comprises rolling the sheet 2 of conductive material. In some examples, the rolling may be performed such that the socket 20 has a C-shaped cross-section (e.g. the socket is not totally closed on itself after the rolling) or an O-shape cross-section (see e.g. Figure 2B) after the sheet 2 of conductive material is rolled.
• As illustrated in Figures 2A and 2B, attaching at S101 the plurality of conductive wires 3 comprises attaching the extremities 4 of the plurality of conductive wires 3 to a surface 6 of the sheet 2 corresponding to an inner surface 6 of the socket 20 after the sheet 2 of conductive material is folded.
• Referring now to Figures 3A, 3B, 4A, 4B, 5 and 6, attaching at S101 the two extremities 4 of each conductive wire 3 of the plurality of conductive wires 3 may further comprise providing at least one fastener 7 for each extremity 4 of the conductive wires 3 on the surface 6 of the sheet 2 corresponding to the inner surface 6 of the socket 20 after the sheet of conductive material is folded.
• In some examples, providing the at least one fastener 7 may comprise providing a block 8 forming a pillar and extending towards the hyperboloid receiving space 5 after the sheet 2 of conductive material is folded. In some examples, the block 8 may further comprise a groove 9 configured to receive the extremity 4 of the conductive wire 3.
• In some examples, the plurality of conductive wires 3 is attached by soldering and/or gluing. Alternatively or additionally, in some examples, the plurality of conductive wires 3 is attached by plastic deformation such as tightening (e.g. of the groove 9) induced by the folding of the sheet 2.
• As illustrated in Figure 7, in some examples, the method 100 may further comprise placing the socket 20 in an outer shank 10.
• In some examples, the method 100 may further comprise placing the socket 20 in a protective sleeve (not shown on the Figures) configured to be placed between the socket 20 and the outer shank 10. The protective sleeve may enable to mechanically protect the socket 20 and may enable the socket to keep its C-shaped cross-section or its O-shape cross-section.
• Additionally or alternatively, as illustrated in Figures 4A and 4B, the method 100 may further comprise closing the socket 20 using complementary means 11 provided on the sheet 2 of conductive material. The complementary means 11 may be provided on a side of the sheet 2 corresponding to the longitudinal axis (X-X). In Figures 4A and 4B, the complementary means 11 comprise a tongue 12 provided on a side of the sheet 2, configured to cooperate with a recess 13 provided on a corresponding other side of the sheet 2. In Figures 4A and 4B, the shape of the tongue 12 is a trapeze and is configured to block the tongue 12 in the recess 13 along a direction tangent to a radius of the socket 20 (i.e. in a plane of a cross-section perpendicular to the axis (X'-X')) after the tongue 12 is placed in the recess 13. The complementary means 11 may enable the socket 20 to keep its O-shape cross-section. It should be understood that any other shape of the complementary means 11 which can block the tongue 12 in the recess 13 along a direction tangent to a radius of the socket 20 may be envisaged.
• As illustrated in Figure 8, the method may further comprise attaching the socket 20 to the outer shank 10 with a ring 14. In some examples, the ring 14 may be attached to the outer shank 10 (e.g. by gluing and/or soldering as non-limiting examples). Alternatively or additionally, the ring 14 may be formed by curving (e.g. by folding, such as e.g. rolling) a free extremity of the outer shank 10 after the socket 20 is placed in the outer shank 10.
• In some examples, attaching at S101 the plurality of wires 3 may comprise attaching at least 3 wires. In some examples, the plurality of wires may comprise at least 5 wires. Additionally or alternatively, in some examples attaching at S101 the plurality of wires 3 may comprise attaching wires 3 comprising gold plated beryllium copper.
• The method 100 may be performed to manufacture the socket 2 according to any aspects of the disclosure. The socket 20 of any aspects of the disclosure is formed by attaching the extremities 4 of the wires 3 to the sheet 2 of material and by folding (e.g. rolling) the sheet 2 around its longitudinal axis. The socket 20 is relatively easy and cheap to manufacture, and enable relatively high volumes on industrialization.
• In some examples, the hyperboloid receiving space 5 may have a restriction diameter d (i.e. a smallest diameter of the hyperboloid receiving space 5) such that: $$0.3\mathrm{mm}\le \mathrm{d}\le 50\mathrm{mm}\mathrm{.}$$

  
• The socket 20 may have a length L such that: $$2\mathrm{mm}\le \mathrm{L}\le 50\mathrm{mm}\mathrm{.}$$

  
• The socket 20 may have a diameter D such that: $$0.5\mathrm{mm}\le \mathrm{D}\le 50\mathrm{mm}\mathrm{.}$$

  
• It should be understood that values of the restriction diameter d, the length L of the socket and the diameter D of the socket may depend on technical applications for the socket. The above values of the restriction diameter d, the length L of the socket and the diameter D of the socket are thus non-limiting examples only, and other values are also envisaged.
• In some examples, the sheet of conductive material may have chosen dimensions before the attaching of the extremities of the conductive wires. Alternatively or additionally, the sheet of conductive material may be cut to chosen dimensions after the attaching of the extremities of the conductive wires. The method of manufacturing according to any aspects of the disclosure enables flexibility in the fabrication and different contact sizes may be easily obtained e.g. by changing the length of the cutting.
• As illustrated in Figure 9, the method 100 may further comprise placing the socket 20 in an insulator 15 to form a connector.
• In some examples, a pitch p between successive sockets 20 in the connector comprising a plurality of sockets 20 is such that: $$0.5\mathrm{mm}\le \mathrm{p}\le 5\mathrm{mm}\mathrm{.}$$

  
• It should be understood that values of the pitch p depend on the dimensions (such as the length L and/or the final diameter D) of the socket 20 and/or on technical applications for the socket. The above values of the pitch p are thus non-limiting examples only, and other values of the pitch are also envisaged.

Claims (15)

1. A method of manufacturing a female electrical contact, the method comprising:

   attaching two extremities of each conductive wire of a plurality of conductive wires to a sheet of conductive material having a longitudinal axis, wherein attaching the two extremities of each wire is performed such that the plurality of wires are slanted with respect to the longitudinal axis of the sheet; and

   folding the sheet of conductive material to form a conductive tubular socket having a longitudinal axis, the longitudinal axis of the tubular socket being substantially parallel to the longitudinal axis of the sheet, wherein folding the sheet is performed such that, after the sheet of conductive material is folded, the plurality of wires define a hyperboloid receiving space for a male electrical contact.
2. The method of the preceding claim, wherein folding the sheet of conductive material comprises rolling the sheet of conductive material.
3. The method of the preceding claim, wherein the rolling is performed such that the socket has a C-shaped cross-section or an O-shape cross-section after the sheet of conductive material is rolled.
4. The method of any of the preceding claims, wherein the plurality of conductive wires is attached by at least one of: soldering, gluing and/or plastic deformation such as tightening induced by the folding of the sheet.
5. The method of any of the preceding claims, comprising attaching the plurality of conductive wires to a surface of the sheet corresponding to an inner surface of the socket after the sheet of conductive material is folded.
6. The method of the preceding claim, wherein attaching the two extremities of each conductive wire of the plurality of conductive wires further comprises providing at least one fastener for each extremity of the conductive wires on the surface of the sheet corresponding to the inner surface of the socket after the sheet of conductive material is folded.
7. The method of the preceding claim, wherein providing the at least one fastener comprises providing a block forming a pillar and extending towards the hyperboloid receiving space after the sheet of conductive material is folded, the block further comprising a groove configured to receive the extremity of the conductive wire.
8. The method of any of the preceding claims, further comprising placing the socket in an outer shank.
9. The method of the preceding claim, further comprising placing the socket in a protective sleeve configured to be placed between the socket and the outer shank, and/or
   further comprising closing the socket using complementary means provided on the sheet of conductive material.
10. The method of any of the two preceding claims, further comprising attaching the socket to the outer shank with a ring, optionally wherein the ring is attached to the outer shank and/or wherein the ring is formed by curving a free extremity of the outer shank.
11. The method of any of the preceding claims, further comprising placing the socket in an insulator to form a connector, optionally wherein a pitch p between successive sockets in a connector comprising a plurality of sockets is such that: $$0.5\mathrm{mm}\le \mathrm{p}\le 5\mathrm{mm}\mathrm{.}$$

    
12. The method of any of the preceding claims, wherein attaching the plurality of wires com prises:

    attaching at least 3 wires, and/or

    attaching wires comprising gold plated beryllium copper, and/or

    attaching the plurality of wires such that they are slanted by an angle α such that: $$3°\le \mathrm{\alpha }\le 15°\mathrm{.}$$

    
13. A female electrical contact comprising:

    a tubular conductive socket having a longitudinal axis, and

    a plurality of conductive wires, each conductive wire comprising two extremities and being attached to the socket at the two extremities,

    wherein the plurality of wires are slanted with respect to the longitudinal axis of the socket to define a hyperboloid receiving space for a male electrical contact, and

    wherein the socket is configured to form a structure which is folded around the longitudinal axis.
14. The contact of the preceding claim, comprising at least 3 wires, and/or

    wherein the plurality of wires comprises a gold plated beryllium copper wire, and/or

    wherein the plurality of wires is such that they are slanted by an angle α such that: $$3°\le \mathrm{\alpha }\le 15°\mathrm{.}$$

    
15. A female electrical contact manufactured by performing the method of any of claims 1 to 12.

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