Metal working – Method of mechanical manufacture – Electrical device making
Reexamination Certificate
1999-08-11
2001-07-17
Arbes, Carl J. (Department: 3729)
Metal working
Method of mechanical manufacture
Electrical device making
C029S882000, C029S884000, C439S751000, C439S823000, C439S873000
Reexamination Certificate
active
06260268
ABSTRACT:
BACKGROUND OF THE INVENTION
This invention generally relates to solid compliant electrical connector contacts and more specifically to a method for forming a compliant portion of such contacts.
Compliant connector contacts are commonly used to achieve a secure mechanical and electrical connection when the contacts are plugged into openings, such as on a circuit board, without the need for soldering or other securing steps. An example of such a compliant connector contact is shown in my U.S. Pat. No. 5,329,697. Contacts of this type are frequently grouped together in an insulator body to form an electrical connector. Compliant connector contacts have compliant portions with lateral dimensions greater than the diameter of the hole into which they are to be inserted. These compliant portions are weakened, generally by removal of material, to permit elastic deformation of the contact in the compliant region. The act of inserting the contact into the hole causes portions of the contact to be resiliently deformed upon entering the hole, making the compliant portion small enough to fit into the hole. The outward bias of the deformed portions acts to hold the contact in the hole and to maintain good electrical contact without soldering or other secondary connections.
The type of connector contact to which the present invention generally relates is a solid connector contact, which is machined from solid cylindrical bar stock. Solid connector contacts have current carrying capacity and strength which are superior to contacts formed by stamping and rolling. Solid connector contacts permit greater flexibility in choice of material because they are machined. Thus, materials having better electrical properties may be used. However, machined connector contacts take longer to make and are more expensive than stamped connector contacts. The step of making the connector contacts with a compliant portion adds further time and manufacturing cost to the production of solid connector contacts.
SUMMARY OF THE INVENTION
Among the several objects and features of the present invention may be noted the provision of a method for forming a compliant connector contact which requires few manufacturing steps; the provision of such a method which can be carried out inexpensively; the provision of such a method which limits the number of cuts made in the connector contact; and the provision of such a method which is easy to carry out.
Generally, a compliant connector contact of the present invention is formed by turning generally cylindrical bar stock to have a contact end for insertion into an opening and another end opposite the contact end. The contact end has a guide portion and a contact portion, the contact portion having a larger radial dimension than the guide portion. A slot is formed in the contact portion of the contact end to a depth less than a full lateral dimension of the contact portion. The step of forming the slot comprises plunging a cutter having a circular blade rotating about a center of the blade into the contact portion and removing the circular blade from the contact portion to form the slot to have a generally arcuate shape corresponding to the shape of the circular blade. The contact portion is resiliently deformable upon insertion into the opening for exerting a radially outward force within the opening to hold the contact in electrical contact with the opening.
Other objects and features will be in part apparent and in part pointed out hereinafter.
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Arbes Carl J.
Positronic Industries, Inc.
Senniger Powers Leavitt & Roedel
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