WO1998054801A1 - Method for covering edges on contacts, and corresponding contact - Google Patents

Method for covering edges on contacts, and corresponding contact Download PDF

Info

Publication number
WO1998054801A1
WO1998054801A1 PCT/IB1998/000780 IB9800780W WO9854801A1 WO 1998054801 A1 WO1998054801 A1 WO 1998054801A1 IB 9800780 W IB9800780 W IB 9800780W WO 9854801 A1 WO9854801 A1 WO 9854801A1
Authority
WO
WIPO (PCT)
Prior art keywords
contact
edges
contacts
produced
stamping
Prior art date
Application number
PCT/IB1998/000780
Other languages
French (fr)
Inventor
Andreas Machill
Original Assignee
The Whitaker Corporation
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by The Whitaker Corporation filed Critical The Whitaker Corporation
Priority to AU72271/98A priority Critical patent/AU7227198A/en
Publication of WO1998054801A1 publication Critical patent/WO1998054801A1/en

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R13/00—Details of coupling devices of the kinds covered by groups H01R12/70 or H01R24/00 - H01R33/00
    • H01R13/02—Contact members
    • H01R13/03—Contact members characterised by the material, e.g. plating, or coating materials
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/16—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for manufacturing contact members, e.g. by punching and by bending
    • 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
    • H01R13/10—Sockets for co-operation with pins or blades
    • H01R13/11—Resilient sockets

Definitions

  • the invention relates to a method for covering edges on contacts which are produced from metal by stamping and forming, and to a corresponding contact utilizing this method.
  • Coating a portion of the contacting region with a mixture of Teflon and tin or nickel or similar materials is envisaged in US 5,235,743.
  • the coating is provided in order to reduce the insertion forces when introducing a blade contact into a socket contact. It is disclosed to apply the coating to the metal strip before the stamping operation.
  • a drawback is that sharp edges may still be produced during punching and bending. Coating the metal strip prior to stamping and forming is unsuitable, at least with reference to the sharp punched edges. Such a coating procedure is also questionable for the bent edges, since it is not certain whether or not the coating will tear during bending.
  • Figure 2 shows a cross-section through the collective seal in the plane perpendicular to the plug-in direction, as the contact is introduced;
  • Figure 3 shows an enlargement of a detail from Figure 2;
  • Figure 4 shows the contact of Figure 1 with appropriate coatings, according to the present invention
  • Figure 5 shows a front detail view from Figure 4.
  • Figure 6 shows a side view of a contact with a single wire seal
  • Figure 7 shows a cross-section through an appropriate connector housing chamber for the contact shown in Figure 6;
  • Figure 8 shows the chamber with the contact introduced
  • Figure 9 shows a corresponding enlargement of a detail from Figure 8.
  • Figure 1 shows a side view of a socket contact 1, which is suitable for receiving a corresponding blade contact, as well as a cross-section through a collective seal 2.
  • An opening 3 in the collective seal 2 is provided through which the socket contact 1 must be brought.
  • the collective seal 2 is spread by front edges 4, 5 of the contact. After pushing the contact through the collective seal, it recloses around the trailing wire (not shown) that is fitted to the contact. Since typically it is one of the basic requirements in contact systems with collective seals 2 that the contacts 1 can be removed again, a rear edge 6 of the contact 1 must also be suitable for re-extracting from the collective seal 2.
  • a contact 1 in the region of the bent corners shown in Figure 2 may have a rough surface 8. This rough surface may correspondingly damage the collective seal 2 in the region of the cracks 7.
  • damage to the collective seal 2 can be avoided by providing: in the region of the sharp edges the contact 1, a layer 9-14 of a material to produces a smooth surface in the region of the sharp edges. Since the contacts 1 are to be introduced into corresponding contact chambers, it is typically important that the thickness of the layer is slight, for example between 0.1 and 0.2 mm. This should be sufficient to cover any damage or rough surface 8 along to the edge with a layer 9, as shown in Figure 5, for example. Corresponding additional layers 11-14 are also shown in Figure 4. In each case, they cover the sharp edges which could prove to be damaging when the contact is introduced into the collective seal 2.
  • One method uses a heated plastic, which is the sprayed by one or more nozzles onto the appropriate locations of the contact 1. By being applied by spraying to the contact, the heated plastic then cools and hardens there. Thin coatings can be achieved as a result. It is also possible, if desired, to carry out a plurality of coating operations.
  • the second method uses a thixotropic material which is applied, likewise with the aid of spray nozzles, to the appropriate locations of the contact 1. After being applied, this material is extremely viscous, and can be cured in place by means of a curing operation, for example by heat or by means of UV light.
  • a thixotropic curable adhesive can be used.
  • a possible material is LOCTITE 322 (Trademark of LOCTITE Corporation) an arcylate which is UV curable.
  • the corresponding coating and curing operations can be performed after the stamping and forming operations.
  • the contacts which are punched from a metal strip and are still located on an appropriate transport belt, can be coated immediately after they have been produced. If a heat curable thixotropic material is used, the heat produced by stamping and forming machines may be used to cure the material. This would be a very advantageous use of the dissipation heat.
  • a second problem is represented together with its solution in Figures 6 to 9.
  • a contact 15 is sealed by means of a single wire seal 16 in a chamber 17 of the housing 18.
  • the single-wire seal 16 surrounds the wire 19 and is connected by means of a crimp 20 to the contact 15.
  • Located in the region of the crimp 20 is a bend 21 at the transition from the contacting crimp region 22 into the isolation crimp 20.
  • this bend 21 is produced, the surface of the contact 15 may likewise be damaged. If this contact is introduced together with the damaged surface, at bend 21, into the chamber 17, longitudinal grooves may be produced along the chamber wall.
  • the single wire seal 16, which is then intended to provide a seal with respect to the walls of the chamber 17, cannot deform sufficiently to fill these longitudinal grooves, and the sealing integrity is thereby impaired.
  • the corresponding region 21 of the contact can now be protected by a coating 23, which prevents the formation of the longitudinal grooves in the chamber 17.
  • the coating 23 on the bend 21 of the electric contact 15 is also represented in Figure 9. The sealing integrity of the single wire seal and chamber wall interface is thus ensured by the prescribed coating process.

Landscapes

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

Abstract

A method for covering sharp edges (8) and contacts (10) is specified for the purpose of reducing damage to collective seals or chamber walls with the aid of said covering. In this case, a layer (9 to 13) made from a plastic or a thixotropically cured material is applied to the sharp edges (8) by means of at least one nozzle.

Description

METHOD FOR COVERING EDGES ON CONTACTS, AND CORRESPONDING
CONTACT
The invention relates to a method for covering edges on contacts which are produced from metal by stamping and forming, and to a corresponding contact utilizing this method.
Many electric contacts are produced from a metal strip by stamping and forming. This method of production may produce sharp edges on the contacts which can have a disadvantageous effect. Various causes of sharp edges are to be distinguished here: firstly, sharp edges produced at those points at which cut edges are present from the punching and secondly, sharp edges produced by virtue of bending the metal such that the surface is torn and burrs are thereby produced.
These sharp edges may lead to two different types of damage :
Firstly, it is customary to feed contacts through so-called collective or family seals in order to achieve environmental sealing about trailing wires in plug-in connectors. It is also customary to use seals at the face for sealing plug-in connectors. The sharp edges of the contacts may cut into these mat-like seals and impair the sealing integrity of the plug-in connector.
Secondly, however, it also happens that sharp edges scratch connector housing chamber regions as the contact is inserted such that these scratches extend mostly in a longitudinal direction corresponding to the insertion direction of the contact. If the aim is to seal the connector by means of a seal (individual or family) in the region of the chamber in which the longitudinal scratches are situated, this renders sealing difficult. It is known from US 4,169,646 to cover the contact of an insulation piercing connecting device completely with a non-conducting plastic. The procedure disclosed is suitable for contacts which are of very simple design, but is completely unsuitable, for example, for socket contacts, which comprise internal contacting springs and an external enveloping spring.
Coating a portion of the contacting region with a mixture of Teflon and tin or nickel or similar materials is envisaged in US 5,235,743. The coating is provided in order to reduce the insertion forces when introducing a blade contact into a socket contact. It is disclosed to apply the coating to the metal strip before the stamping operation. However, a drawback is that sharp edges may still be produced during punching and bending. Coating the metal strip prior to stamping and forming is unsuitable, at least with reference to the sharp punched edges. Such a coating procedure is also questionable for the bent edges, since it is not certain whether or not the coating will tear during bending.
Proceeding from the problems outlined above, it is the object of the invention to specify a method and an electric contact incorporating the results of such a procedure so that it is possible to solve the problems of damage to seals or chambers as specified above.
The object is achieved with reference to the method by one of Patent Claims 1 or 5, and with reference to the electric contact by Patent Claim 6. Advantageous developments are specified in the subclaims. The problems arising and the corresponding solutions are now to be described again with the aid of the figures, in which: Figure 1 shows a side view of an exemplary electric contact and a cross-section through a part of a corresponding collective seal;
Figure 2 shows a cross-section through the collective seal in the plane perpendicular to the plug-in direction, as the contact is introduced;
Figure 3 shows an enlargement of a detail from Figure 2;
Figure 4 shows the contact of Figure 1 with appropriate coatings, according to the present invention;
Figure 5 shows a front detail view from Figure 4;
Figure 6 shows a side view of a contact with a single wire seal;
Figure 7 shows a cross-section through an appropriate connector housing chamber for the contact shown in Figure 6;
Figure 8 shows the chamber with the contact introduced; and
Figure 9 shows a corresponding enlargement of a detail from Figure 8.
Figure 1 shows a side view of a socket contact 1, which is suitable for receiving a corresponding blade contact, as well as a cross-section through a collective seal 2. An opening 3 in the collective seal 2 is provided through which the socket contact 1 must be brought. When the socket contact 1 is inserted into the opening 3 of the collective seal, the collective seal 2 is spread by front edges 4, 5 of the contact. After pushing the contact through the collective seal, it recloses around the trailing wire (not shown) that is fitted to the contact. Since typically it is one of the basic requirements in contact systems with collective seals 2 that the contacts 1 can be removed again, a rear edge 6 of the contact 1 must also be suitable for re-extracting from the collective seal 2.
As represented in Figure 2, when the contact 1 is inserted into the collective seal 2 cracks 7 may be produced at the locations corresponding to which the bent edges of the contact pass through the collective seal 2. As a result of these cracks 7 or cuts, the collective seal 1 may not meet the required sealing requirements.
It is shown in Figure 3 that a contact 1 in the region of the bent corners shown in Figure 2 may have a rough surface 8. This rough surface may correspondingly damage the collective seal 2 in the region of the cracks 7.
As shown in Figures 4 and 5, damage to the collective seal 2 can be avoided by providing: in the region of the sharp edges the contact 1, a layer 9-14 of a material to produces a smooth surface in the region of the sharp edges. Since the contacts 1 are to be introduced into corresponding contact chambers, it is typically important that the thickness of the layer is slight, for example between 0.1 and 0.2 mm. This should be sufficient to cover any damage or rough surface 8 along to the edge with a layer 9, as shown in Figure 5, for example. Corresponding additional layers 11-14 are also shown in Figure 4. In each case, they cover the sharp edges which could prove to be damaging when the contact is introduced into the collective seal 2.
Recourse may be made to two different methods for applying these layers. One method uses a heated plastic, which is the sprayed by one or more nozzles onto the appropriate locations of the contact 1. By being applied by spraying to the contact, the heated plastic then cools and hardens there. Thin coatings can be achieved as a result. It is also possible, if desired, to carry out a plurality of coating operations.
The second method uses a thixotropic material which is applied, likewise with the aid of spray nozzles, to the appropriate locations of the contact 1. After being applied, this material is extremely viscous, and can be cured in place by means of a curing operation, for example by heat or by means of UV light. For example, an appropriate thixotropic curable adhesive can be used. A possible material is LOCTITE 322 (Trademark of LOCTITE Corporation) an arcylate which is UV curable. The corresponding coating and curing operations can be performed after the stamping and forming operations. The contacts, which are punched from a metal strip and are still located on an appropriate transport belt, can be coated immediately after they have been produced. If a heat curable thixotropic material is used, the heat produced by stamping and forming machines may be used to cure the material. This would be a very advantageous use of the dissipation heat.
A second problem is represented together with its solution in Figures 6 to 9. Here a contact 15 is sealed by means of a single wire seal 16 in a chamber 17 of the housing 18. The single-wire seal 16 surrounds the wire 19 and is connected by means of a crimp 20 to the contact 15. Located in the region of the crimp 20 is a bend 21 at the transition from the contacting crimp region 22 into the isolation crimp 20. When this bend 21 is produced, the surface of the contact 15 may likewise be damaged. If this contact is introduced together with the damaged surface, at bend 21, into the chamber 17, longitudinal grooves may be produced along the chamber wall. The single wire seal 16, which is then intended to provide a seal with respect to the walls of the chamber 17, cannot deform sufficiently to fill these longitudinal grooves, and the sealing integrity is thereby impaired.
As shown in Figure 8, the corresponding region 21 of the contact can now be protected by a coating 23, which prevents the formation of the longitudinal grooves in the chamber 17. The coating 23 on the bend 21 of the electric contact 15 is also represented in Figure 9. The sealing integrity of the single wire seal and chamber wall interface is thus ensured by the prescribed coating process.
7Λn additional advantage which is achieved by coating the contacts is that during manual assembly of contacts in the housing there is also a reduction in the risk of injury at the contacts.

Claims

1. Method for covering edges on contacts which are produced from metal by punching and bending, characterized in that a thixotropic material is applied by means of at least one spraying nozzle to the zones provided therefore and is cured thereafter by means of a curing process.
2. Method according to Claim 1, characterized in that the curing of the material is carried out with the aid of UV radiation.
3. Method according to Claim 1, characterized in that the curing of the material is carried out with the aid of heat.
4. Method according to Claim 3, characterized in that the waste heat of the stamping machines is used to cure the material.
5. Method for covering edges on contacts which are produced from a metal by stamping and forming, characterized in that liquid plastic particles are applied by means of at least one nozzle to the edges provided therefore and hardened there.
6. Electric contact which is produced from a metal by stamping and forming, characterized in that edges and corners (8) which are sharp and could therefore lead to damage to the material are partially covered by a layer (9 to 13) made from a thixotropically cured material or from a plastic.
7. Electric contact according to Claim 6, characterized in that the layer (9 to 13) has a thickness in the range of 0.1 to 0.2 mm, preferably 0.15 mm.
8. Electric contact according to one of Claims 6 or 7, characterized in that the edges produced by the stamping are partially coated.
9. Electric contact according to one of Claims 6 to 8, characterized in that the bent edges produced by bending are partially coated.
PCT/IB1998/000780 1997-05-30 1998-05-20 Method for covering edges on contacts, and corresponding contact WO1998054801A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU72271/98A AU7227198A (en) 1997-05-30 1998-05-20 Method for covering edges on contacts, and corresponding contact

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE19722800.3 1997-05-30
DE1997122800 DE19722800A1 (en) 1997-05-30 1997-05-30 Process for covering edges on contacts and corresponding contact

Publications (1)

Publication Number Publication Date
WO1998054801A1 true WO1998054801A1 (en) 1998-12-03

Family

ID=7831012

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IB1998/000780 WO1998054801A1 (en) 1997-05-30 1998-05-20 Method for covering edges on contacts, and corresponding contact

Country Status (3)

Country Link
AU (1) AU7227198A (en)
DE (1) DE19722800A1 (en)
WO (1) WO1998054801A1 (en)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102005027001A1 (en) * 2005-06-10 2006-12-21 Sks Kontakttechnik Gmbh Plug contact element and method for its preparation and apparatus for performing the method

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3701966A (en) * 1970-08-28 1972-10-31 Amp Domestic Inc Electrical connector
US4260212A (en) * 1979-03-20 1981-04-07 Amp Incorporated Method of producing insulated terminals
US4820196A (en) * 1987-10-01 1989-04-11 Unisys Corporation Sealing of contact openings for conformally coated connectors for printed circuit board assemblies
EP0457454A1 (en) * 1990-05-16 1991-11-21 Dow Corning Corporation Protective coating for electrical components
US5235743A (en) * 1990-07-11 1993-08-17 Yazaki Corporation Method of manufacturing a pair of terminals having a low friction material on a mating surface to facilitate connection of the terminals
EP0626433A1 (en) * 1993-05-26 1994-11-30 Fibre Glass-Evercoat Company, Inc. Sprayable filler composition

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE19543665A1 (en) * 1994-12-22 1996-06-27 Leonische Drahtwerke Ag Encapsulation of cables and plugs
DE19523557A1 (en) * 1995-06-28 1997-01-02 Grote & Hartmann Conductor wire crimping claw of hard material

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3701966A (en) * 1970-08-28 1972-10-31 Amp Domestic Inc Electrical connector
US4260212A (en) * 1979-03-20 1981-04-07 Amp Incorporated Method of producing insulated terminals
US4820196A (en) * 1987-10-01 1989-04-11 Unisys Corporation Sealing of contact openings for conformally coated connectors for printed circuit board assemblies
EP0457454A1 (en) * 1990-05-16 1991-11-21 Dow Corning Corporation Protective coating for electrical components
US5235743A (en) * 1990-07-11 1993-08-17 Yazaki Corporation Method of manufacturing a pair of terminals having a low friction material on a mating surface to facilitate connection of the terminals
EP0626433A1 (en) * 1993-05-26 1994-11-30 Fibre Glass-Evercoat Company, Inc. Sprayable filler composition

Also Published As

Publication number Publication date
AU7227198A (en) 1998-12-30
DE19722800A1 (en) 1998-12-03

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