US3564709A - Process of making a connector - Google Patents

Process of making a connector Download PDF

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Publication number
US3564709A
US3564709A US688255A US3564709DA US3564709A US 3564709 A US3564709 A US 3564709A US 688255 A US688255 A US 688255A US 3564709D A US3564709D A US 3564709DA US 3564709 A US3564709 A US 3564709A
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US
United States
Prior art keywords
tube
pins
blank
synthetic resin
lead
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 - Lifetime
Application number
US688255A
Inventor
Raymond Hickton
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ZF International UK Ltd
Original Assignee
Lucas Industries Ltd
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Filing date
Publication date
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Publication of US3564709A publication Critical patent/US3564709A/en
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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/46—Bases; Cases
    • H01R13/50—Bases; Cases formed as an integral body
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/28—Contacts for sliding cooperation with identically-shaped contact, e.g. for hermaphroditic coupling devices
    • 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
    • Y10T29/4922—Contact or terminal manufacturing by assembling plural parts with molding of insulation
    • 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
    • Y10T29/49826—Assembling or joining
    • Y10T29/49908—Joining by deforming
    • Y10T29/49925—Inward deformation of aperture or hollow body wall
    • Y10T29/49927—Hollow body is axially joined cup or tube
    • Y10T29/49929—Joined to rod

Definitions

  • a method of manufacturing a connector unit which in use constitutes one part of a plug and socket connector including the step of placing a plurality of conductive pins in a mould, injecting synthetic resin around the pins, and allowing the resin to set, is characterised in that each pin is formed by shaping a conductive blank so that the two opposite edges of the blank are in mutual contact, and the blank forms an open ended tube, inserting a lead into one end of the tube, and deforming said one end of the tube so as to simultaneously connect the tube to the lead, and close said one end of the tube, thereby minimising loss of synthetic resin through the pins during the moulding operation.
  • This invention relate to a method of manufacturing connector units which in use constitute one part of a plug and socket connector.
  • a method according to the invention comprises placing a plurality of pins in a mould, injecting synthetic resin around the pins, and allowing the resin to set, characterised in that each pin is formed by shaping a conductive blank so that two opposite edges of the blank are in mutual contact and the blank forms an open-ended tube, inserting a lead into one end of the tube, and deforming said one end of the tube so as to simultaneously connect the tube to the lead and close said one end of the tube, thereby minimising loss of synthetic resin through the pins.
  • FIG. 1 is a plan view of a blank which is utilized to form a conductive pin in one example of a method according to the invention
  • FIG. 2 is a perspective view of a pin formed from the blank shown in FIG. 1
  • FIG. 3 is a perspective view of a connector unit manuactured in accordance with said one example of a method according to the invention, for use in a plug and socket connector
  • FIG. 4 is a view similar to FIG. 3 showing a modified form of connector unit.
  • a plurality of pins are formed from a sheet of metal by stamping from the sheet a series of generally rectangular blanks 10. The blanks are then rolled and shaped to engage a pair of long sides 10a of the blank together along their whole length so that they constitute hollow substantially cylindrical pins 11. As the pins 11 are rolled, each has a respective lead 12 secured thereto. One end of each lead 12 is stripped of insulation and one end of the respective pin is crimped to electrically interconnect the pin 11 and lead 12, the stripped portion of the lead 12 extending through the crimped portion of the respective pin to ensure that the crimped portion of the pin 11 is sealed.
  • Each pin is formed at said one with a pair of deformable tags 17 which in use are bent to grip the insulating cover of the lead 12. It will be appreciated that the pins so formed are hollow but are substantially closed with the exception of a small hole at the end of each pin remote from its respective lead 12. Between the tags 17 and the body of each pin there is defined a tapering portion 18. Prior to rolling the pin the edges of the blank which constitute the portion 18 are chamfered so that when the pin is rolled the chamfered edges will overlap slightly thereby ensuring that the portion '18 is closed.
  • a plurality of pins so formed are then secured in a mould together with a plurality of hollow conductive socket members 14, the axial passage of the members 14 being closed by posts integral with the mould.
  • the leads 12 of the pins and the leads 15 of the members 14 extend from one side of the mould while the free ends of the pins 11 extend from the opposite side of the mould.
  • Synthetic resin is now introduced into the mould and allowed to solidify to form a flexible body 16, the mould being such that the pins 11 and the socket members 14 will be engaged in the mould body 16 (FIG. 3).
  • the other ends of the pins 11 and socket members 14 extend from one end of the body 16 while their respective leads 12, 15 extend from the opposite end of the body, the exterior projecting parts of the socket members 14 being encased in respective synthetic resin sleeves 19.
  • the posts integral with the mould are of sufiicient axial length to close the passages of the members 14 throughout their length so that substantially no synthetic resin enters the members 14.
  • a suitable synthetic resin material for moulding the flexible body 16 i polyvinylchloride.
  • the socket members 14 project from the body 16 and are encased only by their respective individual synthetic resin sleeves 19, the members 14 can be moved relative to one another, which would not be possible if the socket members were set into a block of synthetic resin material.
  • the freedom of movement of the socket members 14 relative to one another facilitates engagement with the connector unit of a corresponding connector unit wherein the pins of the corresponding unit, which engages the members 14, are misaligned with respect to one another.
  • a connector unit form ing part of a plug and socket connector, comprising,
  • each pin by, forming a conductive blank having two edges, at least a portion of each of which is chamfered, shaping said conductive blank so that said two edges of the blank are in mutual contact and the blank constitutes an open ended tube with said chamfered portions overlapping slightly, inserting a lead into one end of the tube, and, deforming said one end of the tube so as to simultaneously connect the tube to the lead and close said one end of the tube, thereby minimising loss of synthetic resin through pins during the moulding operation.
  • a method as claimed in claim 1 including the step of placing at least one conductive socket member in the mould with the pins so that the resultant connector unit includes pins and at least one socket.
  • a method as claimed in claim 1 wherein said synthetic resin material is polyvinylchloride.

Landscapes

  • Manufacturing Of Electrical Connectors (AREA)
  • Coupling Device And Connection With Printed Circuit (AREA)
  • Connector Housings Or Holding Contact Members (AREA)

Abstract

A METHOD OF MANUFACTURING A CONNECTOR UNIT WHICH IN USE CONSTITUTES ONE PART OF A PLUG AND SOCKET CONNECTOR, INCLUDING THE STEPS OF PLACING A PLURALITY OF CONDUCTIVE PINS IN A MOULD, INJECTING SYNTHETIC RESIN AROUND THE PINS, AND ALLOWING THE RESIN TO SET, IS CHARACTERISED IN THAT EACH PIN IS FORMED BY SHAPING A CONDUCTIVE BLANK SO THAT THE TWO OPPOSITE EDGES OF THE BLANK ARE IN MUTUAL CONTACT, AND THE BLANK FORMS AN OPEN ENDED TUBE, INSERTING A LEAD

INTO ONE END OF THE TUBE, AND DEFORMING SAID ONE END OF THE TUBE SO AS TO SIMULTANEOUSLY CONNECT THE TUBE TO THE LEAD, AND CLOSE SAID ONE END OF THE TUBE, THEREBY MINIMISING LOSS OF SYNTHETIC RESIN THROUGH THE PINS DURING THE MOULDING OPERATION.

Description

Feb. 23, 1971 I HICKTON 3,564,709
' 7 v PROCESS 0F MAKING A CONNECTOR 3 meme. 5. 1967 INV TOR i United States Patent US. Cl. 29629 3 Claims ABSTRACT OF THE DISCLOSURE A method of manufacturing a connector unit which in use constitutes one part of a plug and socket connector, including the step of placing a plurality of conductive pins in a mould, injecting synthetic resin around the pins, and allowing the resin to set, is characterised in that each pin is formed by shaping a conductive blank so that the two opposite edges of the blank are in mutual contact, and the blank forms an open ended tube, inserting a lead into one end of the tube, and deforming said one end of the tube so as to simultaneously connect the tube to the lead, and close said one end of the tube, thereby minimising loss of synthetic resin through the pins during the moulding operation.
This invention relate to a method of manufacturing connector units which in use constitute one part of a plug and socket connector.
A method according to the invention comprises placing a plurality of pins in a mould, injecting synthetic resin around the pins, and allowing the resin to set, characterised in that each pin is formed by shaping a conductive blank so that two opposite edges of the blank are in mutual contact and the blank forms an open-ended tube, inserting a lead into one end of the tube, and deforming said one end of the tube so as to simultaneously connect the tube to the lead and close said one end of the tube, thereby minimising loss of synthetic resin through the pins.
In the accompanying drawings FIG. 1 is a plan view of a blank which is utilized to form a conductive pin in one example of a method according to the invention, FIG. 2 is a perspective view of a pin formed from the blank shown in FIG. 1, FIG. 3 is a perspective view of a connector unit manuactured in accordance with said one example of a method according to the invention, for use in a plug and socket connector, and FIG. 4 is a view similar to FIG. 3 showing a modified form of connector unit.
Referring tfirst to FIGS. 1 and 2 a plurality of pins are formed from a sheet of metal by stamping from the sheet a series of generally rectangular blanks 10. The blanks are then rolled and shaped to engage a pair of long sides 10a of the blank together along their whole length so that they constitute hollow substantially cylindrical pins 11. As the pins 11 are rolled, each has a respective lead 12 secured thereto. One end of each lead 12 is stripped of insulation and one end of the respective pin is crimped to electrically interconnect the pin 11 and lead 12, the stripped portion of the lead 12 extending through the crimped portion of the respective pin to ensure that the crimped portion of the pin 11 is sealed. Each pin is formed at said one with a pair of deformable tags 17 which in use are bent to grip the insulating cover of the lead 12. It will be appreciated that the pins so formed are hollow but are substantially closed with the exception of a small hole at the end of each pin remote from its respective lead 12. Between the tags 17 and the body of each pin there is defined a tapering portion 18. Prior to rolling the pin the edges of the blank which constitute the portion 18 are chamfered so that when the pin is rolled the chamfered edges will overlap slightly thereby ensuring that the portion '18 is closed.
A plurality of pins so formed are then secured in a mould together with a plurality of hollow conductive socket members 14, the axial passage of the members 14 being closed by posts integral with the mould. The leads 12 of the pins and the leads 15 of the members 14 extend from one side of the mould while the free ends of the pins 11 extend from the opposite side of the mould. Synthetic resin is now introduced into the mould and allowed to solidify to form a flexible body 16, the mould being such that the pins 11 and the socket members 14 will be engaged in the mould body 16 (FIG. 3). The other ends of the pins 11 and socket members 14 extend from one end of the body 16 while their respective leads 12, 15 extend from the opposite end of the body, the exterior projecting parts of the socket members 14 being encased in respective synthetic resin sleeves 19. The posts integral with the mould are of sufiicient axial length to close the passages of the members 14 throughout their length so that substantially no synthetic resin enters the members 14.
It will be appreciated that since each pin 11 is closed except for the hole 13 in its end remote from its respective lead 12, and the member 14 are closed by posts integral with the mould, there will be no loss of synthetic resin from the mould through the pins 11 or the members 14 during the moulding operation.
A suitable synthetic resin material for moulding the flexible body 16 i polyvinylchloride.
Since the socket members 14 project from the body 16 and are encased only by their respective individual synthetic resin sleeves 19, the members 14 can be moved relative to one another, which would not be possible if the socket members were set into a block of synthetic resin material. The freedom of movement of the socket members 14 relative to one another facilitates engagement with the connector unit of a corresponding connector unit wherein the pins of the corresponding unit, which engages the members 14, are misaligned with respect to one another.
In the modified form of connector unit shown in FIG. 4 the spacing between the socket members has been reduced to a level wherein the respective sleeves 19 of the members 14 are connected at points on their peripheries of the sleeves of adjacent members 14. It should be noted however that the members 14 can still be moved relative to one another as permitted by deformation of their respective synthetic resin sleeves.
Having thus described my invention what I claim as new and desire to secure by Letters Patent is:
1. In a method of manufacturing a connector unit form ing part of a plug and socket connector, comprising,
placing a plurality of pins in a mould, injecting synthetic resin around the pins, and, allowing the resin to set, the improvements comprising forming each pin by, forming a conductive blank having two edges, at least a portion of each of which is chamfered, shaping said conductive blank so that said two edges of the blank are in mutual contact and the blank constitutes an open ended tube with said chamfered portions overlapping slightly, inserting a lead into one end of the tube, and, deforming said one end of the tube so as to simultaneously connect the tube to the lead and close said one end of the tube, thereby minimising loss of synthetic resin through pins during the moulding operation.
3 *2. A method as claimed in claim 1 including the step of placing at least one conductive socket member in the mould with the pins so that the resultant connector unit includes pins and at least one socket.
3. A method as claimed in claim 1 wherein said synthetic resin material is polyvinylchloride.
References Cited UNITED STATES PATENTS 4 3,275,423 9/1966, Klumpp, Jr. 3,328,512 7/1967 Lembke et al. 29-629 FOREIGN PATENTS 1,105,275 10/1955 France.
812,933 5/1959 Great Britain.
JOHN F. CAMPBELL, JR., Primary Examiner R. W. CHURCH, Assistant Examiner US. Cl. X.R. 18-5; 29-628, 517; 113-119; 174-74, 75, 77; 264-
US688255A 1966-12-12 1967-12-05 Process of making a connector Expired - Lifetime US3564709A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB55490/66A GB1210681A (en) 1966-12-12 1966-12-12 Electrical connector units

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US3564709A true US3564709A (en) 1971-02-23

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US688255A Expired - Lifetime US3564709A (en) 1966-12-12 1967-12-05 Process of making a connector

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DE (1) DE1640987A1 (en)
ES (2) ES348655A1 (en)
GB (1) GB1210681A (en)

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3667101A (en) * 1970-04-13 1972-06-06 Amp Inc Improved connectors and guide means for electrical harness making
US3675188A (en) * 1970-09-23 1972-07-04 Amp Inc Multiple cold crimp sleeve plug and socket
US3725845A (en) * 1971-03-30 1973-04-03 Hughes Aircraft Co Environment proof connector
US3725825A (en) * 1971-06-14 1973-04-03 Amp Inc Filtered socket for electronic circuit board
US4236689A (en) * 1979-06-11 1980-12-02 Lyall Electric, Inc. Connector mold with flexible wire guide
US4477136A (en) * 1982-10-29 1984-10-16 Mark Products Incorporated Takeout connector
US4493529A (en) * 1982-07-30 1985-01-15 Hughes Aircraft Company Electromagnetic energy signal-carrying connector having secure strain-relief mechanism
US4540962A (en) * 1984-05-29 1985-09-10 General Motors Corporation Solenoid coil wire termination
US4586245A (en) * 1984-05-29 1986-05-06 General Motors Corporation Solenoid coil wire termination
US4707045A (en) * 1985-11-15 1987-11-17 Amp Incorporated Shielded microminiature multi-pin connector
US20040232592A1 (en) * 2003-05-22 2004-11-25 Hsu John S. Method of making hermetic seals for hermetic terminal assemblies

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2428582C2 (en) * 1974-06-14 1983-11-17 kabelmetal electro GmbH, 3000 Hannover Socket for an electrical connection line
DE3644038A1 (en) * 1985-12-21 1987-06-25 Schaltbau Gmbh Housing part for, in particular, multipole plug connectors

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3667101A (en) * 1970-04-13 1972-06-06 Amp Inc Improved connectors and guide means for electrical harness making
US3675188A (en) * 1970-09-23 1972-07-04 Amp Inc Multiple cold crimp sleeve plug and socket
US3725845A (en) * 1971-03-30 1973-04-03 Hughes Aircraft Co Environment proof connector
US3725825A (en) * 1971-06-14 1973-04-03 Amp Inc Filtered socket for electronic circuit board
US4236689A (en) * 1979-06-11 1980-12-02 Lyall Electric, Inc. Connector mold with flexible wire guide
US4493529A (en) * 1982-07-30 1985-01-15 Hughes Aircraft Company Electromagnetic energy signal-carrying connector having secure strain-relief mechanism
US4477136A (en) * 1982-10-29 1984-10-16 Mark Products Incorporated Takeout connector
US4540962A (en) * 1984-05-29 1985-09-10 General Motors Corporation Solenoid coil wire termination
US4586245A (en) * 1984-05-29 1986-05-06 General Motors Corporation Solenoid coil wire termination
US4707045A (en) * 1985-11-15 1987-11-17 Amp Incorporated Shielded microminiature multi-pin connector
US20040232592A1 (en) * 2003-05-22 2004-11-25 Hsu John S. Method of making hermetic seals for hermetic terminal assemblies
US7695663B2 (en) * 2003-05-22 2010-04-13 Ut-Battelle, Llc Method of making hermetic seals for hermetic terminal assemblies

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ES348653A1 (en) 1969-03-16
ES348655A1 (en) 1969-03-16
GB1210681A (en) 1970-10-28
DE1640987A1 (en) 1971-09-16

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