US2116269A - Method of forming electrical contacts - Google Patents

Method of forming electrical contacts Download PDF

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Publication number
US2116269A
US2116269A US121106A US12110637A US2116269A US 2116269 A US2116269 A US 2116269A US 121106 A US121106 A US 121106A US 12110637 A US12110637 A US 12110637A US 2116269 A US2116269 A US 2116269A
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strip
forming
contact
punch
punching
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US121106A
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Kobzy Steven
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/36—Making other particular articles clips, clamps, or like fastening or attaching devices, e.g. for electric installation
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49204—Contact or terminal manufacturing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49204—Contact or terminal manufacturing
    • Y10T29/49208—Contact or terminal manufacturing by assembling plural parts
    • Y10T29/49222—Contact or terminal manufacturing by assembling plural parts forming array of contacts or terminals

Definitions

  • the primary object of this invention is to provide an improved method for producing electrical contacts from strips of sheet metal through a series of operations which will involve less time and less waste of material. This is accomplished by utilizing a series of spaced stationary dies and registering, punching, forming and embossing dies carried -by the stationary and movable jaws, respectively, of a punch press, and so arranged that a strip of sheet metal advanced a predetermined distance at each actuation of the punch press will form the contact by a series of operations of the dies. This strip may be fed b-y hand or mechanically.
  • Figure 1 is a perspective of one end of a metal strip indicating the several operations to which the strip is subjected as it advances endwise, a completed contact being shown as severed from the forward end of the strip;
  • Fig. 2 is a plan view partly in sectiononline 2-2 of Fig. 3 showing the various punching, forming, notching, shearing, and embossing dies used in forming this electrical contact from a strip of sheet metal; v
  • Fig. 3 is a partial vertical section on broken line 3-3 of Fig. 2;
  • Fig. 4 is a partial vertical section on line 4-4 of Fig. 2 showing a slitting die
  • Fig. 5 is a partial vertical section on line 5 5 of Fig. 2 showing a forming die in operation
  • Fig. 6 is a partial section on line 6-6 of Fig. 2 showing two forming dies in operation simultaneously;
  • Figs. 7 and 8 are two partial sections on lines I-l and 8 8, respectively, of' Fig. 2, showing forming dies in operation, Fig. 8 also having an embossing die operating simultaneously therewith; and
  • Fig. 9 is an enlarged perspective of the finished electrical contact.
  • the electrical contact for which my improved method of production has been devised is such as may advantageously be-employed to receive engagement from one of the prongs of a vacuum tube.
  • this contact C is made of sheet metal having requisite spring prop-V (Cl. zei-4155.55)
  • the terminal lug is a clip c whose angled 4body is sufllciently wide to provide for turned sides c and c2 which face each other whereby to grip between them and the clip body, the prong (not shown) of a vacuum tube or other electrical instrument.
  • Ears d may be extended outwardly from the clip sides at a point adjacent the mounting plate, as shown.
  • the mechanism illustrated for punching and forming this contact from a strip of metal comprises a series of dies, the stationary element of each die being carried by the stationary jaw ill of a conventional punch press while the movable members are carried by its movable jaw Il.
  • a punch press is well known, further ydescription thereof is unnecessary. It is understood, however, that at each actuation of the punch press the movable jaw II descends a predetermined distance toward the stationary jaw III and then returns to its initial position wherein all of the movable parts ofthe die are above the strip.
  • Two punches I2, I3 which are preferably round pass through suitable guides I4 and coact with registering openings I5, I6 in a die block I1 which is carried by the stationary jaw IIJ to form the holes b', b2.
  • the guide I4 is separated from the die block I1 leaving a passage I8 through which the metal strip S may be fed endwise either manually, or by means of mechanism not shown, a definite amount at each step.
  • the sides of passage I8 serve also to guide the strip laterally, or, if desired, other guide means may be used.
  • a punch I9 which is secured to the movable x jaw II coacts with a corresponding opening in the die block.
  • This latter punch is preferably rectangular in form with a recessed portion which leaves an ear 20.
  • the ear is slitted centrally along the line 2
  • a notching punch 23 the center of which is preferably in line with the line 2l removes a portion of the left side of the strip so as to outline a portion of the lugs b of the finished contacts b ut leaving a narrow bar 24 to connect adjacent contact blanks.
  • the upper edge of the strip S (Fig. 2) is referred lto as the right side and the lower as the left ⁇ side.
  • the first forming punch 25 serves to bend down the slitted ears 20 to the position 20'.
  • the lower end of this punch is rounded to serve as a pilot punch for the entire group.
  • the second forming punch 26 coacts with a stationary forming die 21, as shown in Fig. 3 to cause the parallel slitted portions 28 to be bent vertically into the position 28'.
  • a plunger 28 is slidably mounted in the block 21 and is pressed by means of a spring 30, the spring resting upon a screw 3
  • Another forming punch 32 serves to curve the lug b as shown in Fig. 6 on the curved die surface 21h.
  • a third forming punch 33 descends it presses the right hand end of the contact down against a stationary block 35 and, as it continues to descend, forces the edges 28* inwardly from the dotted line position to the full line position 28h, as shown beneath lthe punch 33 completing the clip c.
  • the block 35 is provided with a spring pressed plunger- 36 similar to the plunger 29.
  • the plunger 36 is pressed down, as shown, against the action of a spring 31, but as soon as the die rises, the spring 31 will push the plunger 38 up, lifting the right hand end of the formed contact out of the block 35.
  • the strip As the strip is advanced one more step it reaches the position shown by the section line 1-1 of Fig. 2 wherein the right hand end falls beneath a fourth forming punch 38 .which passes between the inwardly bent edges 28h and bends the clip c down over a ledge 39 until it assumes a position 28e substantially at right angles to tionary ledge 40 by means of a fth forming punch 4
  • the body oi' the contact is embossed to form the button b3 by means of an embossing punch 42, as shown in Fig. 3,'cooperating with a depression 43 in a stationary die 44 which carries the ledge 40.
  • the contacts in question may be produced economically as regards the material used and the time consumed.
  • the method of forming contacts of the class described from a sheet metal strip comprising arranging a series of punching and forming dies in spaced alignment, the steps in order comprising punching the left side of the strip in what is later one end of the contact, punching out an intermediateportion midway to outline portions of two contacts leaving therebetween an inwardly extending ear, slitting from the right edge of the strip through said ear, notching the left side of the strip. passing a f tact from each other, and severing the last contact from the strip.
  • the method of forming contacts of the class described from a sheet metal strip comprising arranging a series of punching and forming dies in spaced alignment, f the steps in order comprising punching the left side of the strip in what is later one end of the contact, punching out an intermediate portion midway between two contacts leaving therebetween an inwardly extending ear, slitting from the right edge of the strip through said ear, notching the left side of the strip, passing a forming die through the punched opening in the intermediate portion to bend down the slitted ear, bending up two slitted portions from the right side of the strip including said ears, simultaneously bending up the left hand end of the contact, bending said portions toward each other, bending the right hand end of the strip about a second line parallel to the first line and at the left thereof so as to space the two end portions of the contact from each other, and severing the last contact from the strip.
  • the method of forming contacts o f the class described from a sheet metal strip comprising arranging a series of punching and forming out an intermediate portion midway between two contacts leaving therebetween an inwardly extending ear, slitting from the right edge ot the strip through said ear, notchingthe left side of ⁇ the strip so as to leave only n.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing Of Electrical Connectors (AREA)

Description

May 3, 1938.- s. KoEszYl 2,115,269
` METHOD OF FORMING ELECTRICAL CONTACTS Filed Jan. 18, 1957 2 Sheets-Sheet 2 www Patented May 3, 1938 NUNITED STATES PATENT OFFICE METHOD OF FORMING ELECTRICAL CONTACTS Claims.
The primary object of this invention is to provide an improved method for producing electrical contacts from strips of sheet metal through a series of operations which will involve less time and less waste of material. This is accomplished by utilizing a series of spaced stationary dies and registering, punching, forming and embossing dies carried -by the stationary and movable jaws, respectively, of a punch press, and so arranged that a strip of sheet metal advanced a predetermined distance at each actuation of the punch press will form the contact by a series of operations of the dies. This strip may be fed b-y hand or mechanically.
A mechanism suitable for carrying out this invention is fully described in the following specification in conjunction with the accompanying drawings wherein:
Figure 1 is a perspective of one end of a metal strip indicating the several operations to which the strip is subjected as it advances endwise, a completed contact being shown as severed from the forward end of the strip;
Fig. 2 is a plan view partly in sectiononline 2-2 of Fig. 3 showing the various punching, forming, notching, shearing, and embossing dies used in forming this electrical contact from a strip of sheet metal; v
Fig. 3 is a partial vertical section on broken line 3-3 of Fig. 2;
Fig. 4 is a partial vertical section on line 4-4 of Fig. 2 showing a slitting die;
Fig. 5 is a partial vertical section on line 5 5 of Fig. 2 showing a forming die in operation;
Fig. 6 is a partial section on line 6-6 of Fig. 2 showing two forming dies in operation simultaneously;
Figs. 7 and 8 are two partial sections on lines I-l and 8 8, respectively, of' Fig. 2, showing forming dies in operation, Fig. 8 also having an embossing die operating simultaneously therewith; and
Fig. 9 is an enlarged perspective of the finished electrical contact.
The electrical contact for which my improved method of production has been devised is such as may advantageously be-employed to receive engagement from one of the prongs of a vacuum tube. As shown best in Fig. 9, this contact C is made of sheet metal having requisite spring prop-V (Cl. zei-4155.55)
the terminal lug, is a clip c whose angled 4body is sufllciently wide to provide for turned sides c and c2 which face each other whereby to grip between them and the clip body, the prong (not shown) of a vacuum tube or other electrical instrument. Ears d may be extended outwardly from the clip sides at a point adjacent the mounting plate, as shown. l
The mechanism illustrated for punching and forming this contact from a strip of metal comprises a series of dies, the stationary element of each die being carried by the stationary jaw ill of a conventional punch press while the movable members are carried by its movable jaw Il. Inasmuch as a punch press is well known, further ydescription thereof is unnecessary. It is understood, however, that at each actuation of the punch press the movable jaw II descends a predetermined distance toward the stationary jaw III and then returns to its initial position wherein all of the movable parts ofthe die are above the strip.
Two punches I2, I3 which are preferably round pass through suitable guides I4 and coact with registering openings I5, I6 in a die block I1 which is carried by the stationary jaw IIJ to form the holes b', b2. The guide I4 is separated from the die block I1 leaving a passage I8 through which the metal strip S may be fed endwise either manually, or by means of mechanism not shown, a definite amount at each step. The sides of passage I8 serve also to guide the strip laterally, or, if desired, other guide means may be used.
A punch I9 which is secured to the movable x jaw II coacts with a corresponding opening in the die block. This latter punch is preferably rectangular in form with a recessed portion which leaves an ear 20.
At the next operation, when the strip has been advanced toward the left side of the sheet one step, the ear is slitted centrally along the line 2| by means of a punch 22, as shown in Fig. 4, to form the ears d. At the vsame time a notching punch 23 the center of which is preferably in line with the line 2l removes a portion of the left side of the strip so as to outline a portion of the lugs b of the finished contacts b ut leaving a narrow bar 24 to connect adjacent contact blanks. For the sake of convenience, the upper edge of the strip S (Fig. 2) is referred lto as the right side and the lower as the left` side.
At the next stage, and when the strip has been advanced one space, the first forming punch 25 serves to bend down the slitted ears 20 to the position 20'. The lower end of this punch is rounded to serve as a pilot punch for the entire group.
The second forming punch 26 coacts with a stationary forming die 21, as shown in Fig. 3 to cause the parallel slitted portions 28 to be bent vertically into the position 28'. A plunger 28 is slidably mounted in the block 21 and is pressed by means of a spring 30, the spring resting upon a screw 3|. This spring is suillciently strong to force the edge portions 28' out of the die block 21 as the punch 26 recedes. It will be observed also that the upper surface of the die block 21 is slightly raised. so that as the strip is advanced it slides up over the surface 21. Another forming punch 32 serves to curve the lug b as shown in Fig. 6 on the curved die surface 21h. As the strip is again advanced one step, the edge portions 28* of the right hand end -are engaged by a third forming punch 33 whose lower surface is provided with a V-notch v34. As the forming punch 33 descends it presses the right hand end of the contact down against a stationary block 35 and, as it continues to descend, forces the edges 28* inwardly from the dotted line position to the full line position 28h, as shown beneath lthe punch 33 completing the clip c.
The block 35 is provided with a spring pressed plunger- 36 similar to the plunger 29. During this forming operation the plunger 36 is pressed down, as shown, against the action of a spring 31, but as soon as the die rises, the spring 31 will push the plunger 38 up, lifting the right hand end of the formed contact out of the block 35.
As the strip is advanced one more step it reaches the position shown by the section line 1-1 of Fig. 2 wherein the right hand end falls beneath a fourth forming punch 38 .which passes between the inwardly bent edges 28h and bends the clip c down over a ledge 39 until it assumes a position 28e substantially at right angles to tionary ledge 40 by means of a fth forming punch 4| carried by the movable jaw Il. At the same time the body oi' the contact is embossed to form the button b3 by means of an embossing punch 42, as shown in Fig. 3,'cooperating with a depression 43 in a stationary die 44 which carries the ledge 40.
At the same time the finished contact C is completed by means of a shear 45 which cuts away the bar 24 connecting the last contact with the next adjacent contact as indicated by the dotted lines 24.
According to the method of procedure herein described, the contacts in question may be produced economically as regards the material used and the time consumed.
I claim:
l. The method of forming contacts of the class described from a sheet metal strip comprising arranging a series of punching and forming dies in spaced alignment, the steps in order comprising punching the left side of the strip in what is later one end of the contact, punching out an intermediateportion midway to outline portions of two contacts leaving therebetween an inwardly extending ear, slitting from the right edge of the strip through said ear, notching the left side of the strip. passing a f tact from each other, and severing the last contact from the strip.
2. The method of forming contacts of the class described'from a sheet metal strip comprising arranging a series of punching and forming dies in spaced alignment, the steps in order comprising punching the left side of the strip in what is later one end of the contact, punching out an intermediate portion midway between two contacts leaving therebetween an inwardly extending ear, slitting from the right edge of the strip through said ear, simultaneously notching the left side of the strip, passing a forming die through the punched opening in the intermediate portion to bend down the slitted ear, bending up two slitted portions from the right side of the strip including said ears, bending said por- 'tions toward each other, bending the right hand end of the contact about a first line parallel to the edge of the strip, bending the right hand end of the strip about a second line parallel to the first line and at the left thereof so as to space the two end portions of the contact from each other,
and severing the last contact from the strip.
3. The method of forming contacts of the class described from a sheet metal strip comprising arranging a series of punching and forming dies in spaced alignment, f the steps in order comprising punching the left side of the strip in what is later one end of the contact, punching out an intermediate portion midway between two contacts leaving therebetween an inwardly extending ear, slitting from the right edge of the strip through said ear, notching the left side of the strip, passing a forming die through the punched opening in the intermediate portion to bend down the slitted ear, bending up two slitted portions from the right side of the strip including said ears, simultaneously bending up the left hand end of the contact, bending said portions toward each other, bending the right hand end of the strip about a second line parallel to the first line and at the left thereof so as to space the two end portions of the contact from each other, and severing the last contact from the strip.
4. The method of forming contacts of the class described froma sheet metal strip comprising arranging a series of punching and forming dies in spaced alignment, the steps in order comprising punching the left side of the strip in what is later o'ne end of the contact, punching out an intermediate portion midway between two contacts leaving therebetween an inwardly extending ear, slitting from the rightedge of the strip through said ear, notching the left side of the strip passing a forming die through the punched opening in the', intermediate portion to bend down the slitted ear, bending up two slitted portions from the right side of the strip including said ears.' simultaneously bending up the left hand end of the con- 7 left thereof so as tnspace thel two end portions u of the contact from each other, embossing, and
`severing the last contact from the strip.
5. The method of forming contacts o f the class described from a sheet metal strip comprising arranging a series of punching and forming out an intermediate portion midway between two contacts leaving therebetween an inwardly extending ear, slitting from the right edge ot the strip through said ear, notchingthe left side of` the strip so as to leave only n. narrow bar connecting the adjacent contacts, passing a forming die through the punched opening in the intermediate portion to bend down the slitted ear, bending up two slitted portions from the right side of the strip, bending said portions toward each other, bending the right hand end 'of the contact about a iirst line parallel to the edge of the strip, bending the right hand end of the strip about a second line parallel to the iirst line and at the left thereof so as to space the two lend portions oi the contact from each other, and cutting out the connecting bar thereby severing the last contact from the strip.
STEVEN KOBZY.
US121106A 1937-01-18 1937-01-18 Method of forming electrical contacts Expired - Lifetime US2116269A (en)

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Cited By (20)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2558052A (en) * 1948-03-04 1951-06-26 Heyman Mfg Company Process of making solderless blades for electrical plug caps
US2610390A (en) * 1947-06-10 1952-09-16 Louis P Locke Method of making electrical terminals
US2694188A (en) * 1950-04-20 1954-11-09 Illinois Tool Works Sheet metal terminal connector
US2711466A (en) * 1951-10-09 1955-06-21 Harry Z Marx Machine for making and attaching electric terminals
US2716741A (en) * 1951-06-29 1955-08-30 Continental Copper & Steel Ind Strain relief device
US2727299A (en) * 1953-02-27 1955-12-20 Heyman Mfg Company Process for making electrical terminals
US2835959A (en) * 1954-08-20 1958-05-27 Martines Rene Method of forming a plug for electrical conductors
US2932880A (en) * 1955-02-24 1960-04-19 Western Electric Co Method of making electrical switching devices
US2953247A (en) * 1955-05-12 1960-09-20 Johnson Matthey Co Ltd Manufacture of electrical contacts
US2976607A (en) * 1959-02-16 1961-03-28 Charles J Obst Method of making telescopic bracelet inner box elements
US3420087A (en) * 1963-02-18 1969-01-07 Amp Inc Electrical connector means and method of manufacture
FR2463959A1 (en) * 1979-08-23 1981-02-27 Malosse Louis Identifying tag to clip on to poultry wing etc. - is mass produced by pressing from intermittently advanced sheet metal
DE3447582A1 (en) * 1983-12-30 1985-07-11 Piher Navarra, S.A., Tudela, Navarra METHOD FOR PRODUCING METAL CONTACTOR ELEMENTS FOR ELECTRONIC COMPONENTS
US4539748A (en) * 1982-07-30 1985-09-10 At&T Technologies, Inc. Methods of making an electrical connector
DE3542953A1 (en) * 1984-12-25 1986-04-24 Alps Electric Co Ltd Method for producing micro-platelets for an electrical switch
US4777720A (en) * 1986-12-24 1988-10-18 Precision Concepts, Inc. Method for manufacturing multiple-wire brush contact
US4847993A (en) * 1988-09-20 1989-07-18 Lin Mei Mei Cost-saving process for making plug blades directly from a linear strip
US4872262A (en) * 1988-08-15 1989-10-10 Cooper Industries, Inc. Holder for a blade-type circuit element
US5306181A (en) * 1993-03-01 1994-04-26 Rogers Corporation Planer fuse panel
US5476395A (en) * 1993-03-01 1995-12-19 Methode Electronics, Inc. Planar fuse panel

Cited By (21)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2610390A (en) * 1947-06-10 1952-09-16 Louis P Locke Method of making electrical terminals
US2558052A (en) * 1948-03-04 1951-06-26 Heyman Mfg Company Process of making solderless blades for electrical plug caps
US2694188A (en) * 1950-04-20 1954-11-09 Illinois Tool Works Sheet metal terminal connector
US2716741A (en) * 1951-06-29 1955-08-30 Continental Copper & Steel Ind Strain relief device
US2711466A (en) * 1951-10-09 1955-06-21 Harry Z Marx Machine for making and attaching electric terminals
US2727299A (en) * 1953-02-27 1955-12-20 Heyman Mfg Company Process for making electrical terminals
US2835959A (en) * 1954-08-20 1958-05-27 Martines Rene Method of forming a plug for electrical conductors
US2932880A (en) * 1955-02-24 1960-04-19 Western Electric Co Method of making electrical switching devices
US2953247A (en) * 1955-05-12 1960-09-20 Johnson Matthey Co Ltd Manufacture of electrical contacts
US2976607A (en) * 1959-02-16 1961-03-28 Charles J Obst Method of making telescopic bracelet inner box elements
US3420087A (en) * 1963-02-18 1969-01-07 Amp Inc Electrical connector means and method of manufacture
FR2463959A1 (en) * 1979-08-23 1981-02-27 Malosse Louis Identifying tag to clip on to poultry wing etc. - is mass produced by pressing from intermittently advanced sheet metal
US4539748A (en) * 1982-07-30 1985-09-10 At&T Technologies, Inc. Methods of making an electrical connector
DE3447582A1 (en) * 1983-12-30 1985-07-11 Piher Navarra, S.A., Tudela, Navarra METHOD FOR PRODUCING METAL CONTACTOR ELEMENTS FOR ELECTRONIC COMPONENTS
DE3542953A1 (en) * 1984-12-25 1986-04-24 Alps Electric Co Ltd Method for producing micro-platelets for an electrical switch
US4777720A (en) * 1986-12-24 1988-10-18 Precision Concepts, Inc. Method for manufacturing multiple-wire brush contact
US4872262A (en) * 1988-08-15 1989-10-10 Cooper Industries, Inc. Holder for a blade-type circuit element
US4847993A (en) * 1988-09-20 1989-07-18 Lin Mei Mei Cost-saving process for making plug blades directly from a linear strip
US5306181A (en) * 1993-03-01 1994-04-26 Rogers Corporation Planer fuse panel
WO1994021009A1 (en) * 1993-03-01 1994-09-15 Rogers Corporation Planer fuse panel
US5476395A (en) * 1993-03-01 1995-12-19 Methode Electronics, Inc. Planar fuse panel

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