Electrical connectors – Contact terminal
Reexamination Certificate
2002-07-26
2003-12-09
Paumen, Gary (Department: 2833)
Electrical connectors
Contact terminal
Reexamination Certificate
active
06659813
ABSTRACT:
BACKGROUND OF THE INVENTION
The invention relates to a male contact having a male contact section formed by bending both sides of a metal plate inward, and a method of manufacturing the same.
DESCRIPTION OF THE PRIOR ART
The contacts shown in
FIG. 6
(see Japanese Patent Application Laid-Open No. H7-192793) and
FIG. 7
(see Japanese Patent Application Laid-Open No. H8-162191) are known as conventional male contacts that have male contact sections formed by bending both sides of a metal plate inward.
Shown in FIG.
6
(A), male contact
100
comprises a male contact section
101
that contacts a mating terminal (not shown), an electrical wire termination portion
102
connected to an electrical wire (not shown), and a securing portion
103
disposed between the male contact section
101
and the electrical wire termination portion
102
that is attached to a connector housing (not shown). Shown in FIG.
6
(B), the male contact section
101
is formed by bending both sides of a stamped metal plate
104
so that joining faces
105
are positioned on an upper side in the approximate center with respect to the direction of width of the metal plate
104
. The cross-sectional shape of the male contact section
101
is a substantially oval shape in the direction of width. Upper and lower surfaces of the male contact section
101
form substantially flat contact surfaces
106
,
107
, respectively, that contact a mating female contact (not shown). Curved sections
108
are formed on the four corners of the cross-sectional plane of the male contact section
101
. The radius of the curved sections
108
is substantially equal to the thickness of the metal plate
104
.
Shown in FIG.
7
(A), male contact
200
comprises a male contact section
201
that contacts a mating terminal (not shown), an electrical wire termination portion
202
connected to an electrical wire (not shown), and a securing portion
203
disposed between the male contact section
201
and electrical wire termination portion
202
that is secured to a connector housing (not shown). Shown in FIG.
7
(B), the male contact section
201
is formed by bending one side of a stamped metal plate
204
so that joining faces
205
are positioned at a side portion with respect to the direction of width of the metal plate
204
. The cross-sectional shape of the male contact section
201
is a substantially oval shape in the direction of width. Upper and lower surfaces of the male contact section
201
form substantially flat contact surfaces
206
,
207
, respectively, that contact a mating female contact (not shown). Curved sections
208
are formed on the four corners of the cross-sectional plane of the male contact section
201
. The curved sections
208
have a radius that is greater than the thickness of the metal plate
204
.
Electrical connectors, such as the male contacts
100
,
200
shown in
FIGS. 6 and 7
, are commonly used in industrial fields, such as the automotive field. In recent years there has been a demand for multi-pole connectors. As a result of this demand for multi-pole connectors, a need has arisen for contacts having male contact sections with a small width, for example 0.64 mm square posts.
When male contact sections are formed with a small width, by bending both sides of a stamped metal plate
104
or one side of a metal plate
204
in the same manner as the male contact sections
101
,
201
of the male contacts
100
,
200
, an insufficient area of contact with the mating female contact (not shown) arises due to the fact that the curved sections
108
,
208
formed on the four corners of the cross-sectional plane of the male contact sections
101
,
201
have radii substantially equal to the thicknesses of the metal plates
104
,
204
. If a sufficient area of contact with the mating female contact (not shown) can not be obtained, the contact pressure between the contacts is unstable, resulting in unstable contact.
It is therefore desirable to provide a male contact having a sufficient area for contact with a mating female contact in cases where the width of the male contact section formed by bending both sides of a metal plate inward is small. It is further desirable to develop a method of manufacturing the same.
SUMMARY OF THE INVENTION
This and other objects of the present invention are solved by a contact part having an electrical wire termination portion, a metal contact part, and a securing portion disposed between the male contact section and the electrical wire termination portion. The male contact section is formed from a metal plate and has a rectangular cross-sectional shape. Curved sections are formed at corners of the cross-sectional shape that have a radius that is equal to or less than ⅓ of the thickness of the metal plate.
The male contact section is formed by bending both sides of the metal plate inward, and then shaping the cross-sectional shape into a substantially rectangular shape by forging so that the curved sections on the four corners of the cross-sectional plane have a radius that is equal to or less than ⅓ of the thickness of the metal plate.
REFERENCES:
patent: 3288915 (1966-11-01), Hatfield
patent: 5083944 (1992-01-01), Pitts
patent: 5649842 (1997-07-01), Ohsumi
patent: 5989080 (1999-11-01), Tsuji et al.
patent: 6077131 (2000-06-01), Fukuda et al.
patent: 6398599 (2002-06-01), Irikura et al.
patent: 6402575 (2002-06-01), Suzuki
patent: 07192793 (1995-07-01), None
patent: 08162191 (1996-06-01), None
Barley Snyder
Paumen Gary
Tyco Electronics AMP K.K.
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