CA1149898A - Electrical contact - Google Patents
Electrical contactInfo
- Publication number
- CA1149898A CA1149898A CA000370334A CA370334A CA1149898A CA 1149898 A CA1149898 A CA 1149898A CA 000370334 A CA000370334 A CA 000370334A CA 370334 A CA370334 A CA 370334A CA 1149898 A CA1149898 A CA 1149898A
- Authority
- CA
- Canada
- Prior art keywords
- holes
- sleeve
- contact
- electrical contact
- conductor
- 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
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
- H01R13/10—Sockets for co-operation with pins or blades
- H01R13/11—Resilient sockets
- H01R13/111—Resilient sockets co-operating with pins having a circular transverse section
-
- 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
- H01R13/15—Pins, blades or sockets having separate spring member for producing or increasing contact pressure
- H01R13/187—Pins, blades or sockets having separate spring member for producing or increasing contact pressure with spring member in the socket
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
- H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
- H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
-
- 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
Landscapes
- Connections Effected By Soldering, Adhesion, Or Permanent Deformation (AREA)
- Manufacturing Of Electrical Connectors (AREA)
Abstract
ELECTRICAL CONTACT
ABSTRACT OF THE DISCLOSURE
An electrical contact (100) for terminating an elec-trical conductor including an inner sleeve member (10) stamped from a flat sheet of conducting material and formed in a cylindrical shape, with its rear portion (16) including a plurality of round holes (19) extending through the sleeve member and internal circumferential grooves. The round holes are arranged in radially spaced portions, each including a closely-adjacent pair of axially spaced holes (19a, 19b) and a third hole (19c) spaced axially from the pair of holes. The internal grooves or grooved indentations (18) extend circum-ferentially around the inside periphery of the formed cylindrical contact sleeve. The grooved indentations are located in the rear conductor-receiving portion (16) of the sleeve, preferably forwardly of the rear-most holes (19c). A conductor, inserted into the rear end of the formed sleeve member at least as far forward as the is crimped into tight contact within the sleeve by a crimping apparatus having a plurality of radially spaced bi-lobed crimping members positioned for crimping the sleeve member in the region of the holes and grooves.
The bi-lobed crimping members are positioned to have one lobe in the region of the pair of holes (19a, 19b), the other in the region of the third hole (19c). One of the crimper lobes is also preferably in the region of the grooved indentations (18). The finished contact pre-ferably includes a second (liner) sleeve (30) surrounding the crimped sleeve and a forward hood 140) mounted to the contact to form a three piece contact assembly (100).
ABSTRACT OF THE DISCLOSURE
An electrical contact (100) for terminating an elec-trical conductor including an inner sleeve member (10) stamped from a flat sheet of conducting material and formed in a cylindrical shape, with its rear portion (16) including a plurality of round holes (19) extending through the sleeve member and internal circumferential grooves. The round holes are arranged in radially spaced portions, each including a closely-adjacent pair of axially spaced holes (19a, 19b) and a third hole (19c) spaced axially from the pair of holes. The internal grooves or grooved indentations (18) extend circum-ferentially around the inside periphery of the formed cylindrical contact sleeve. The grooved indentations are located in the rear conductor-receiving portion (16) of the sleeve, preferably forwardly of the rear-most holes (19c). A conductor, inserted into the rear end of the formed sleeve member at least as far forward as the is crimped into tight contact within the sleeve by a crimping apparatus having a plurality of radially spaced bi-lobed crimping members positioned for crimping the sleeve member in the region of the holes and grooves.
The bi-lobed crimping members are positioned to have one lobe in the region of the pair of holes (19a, 19b), the other in the region of the third hole (19c). One of the crimper lobes is also preferably in the region of the grooved indentations (18). The finished contact pre-ferably includes a second (liner) sleeve (30) surrounding the crimped sleeve and a forward hood 140) mounted to the contact to form a three piece contact assembly (100).
Description
8~3 The present inven-tion is related to and an improve-ment upon the invention disclosed in U.S. Patent ~,120,556, issued October 17, 1978 and entitled "Electrical Contact Assembly". This patent is assignecl by inventors C. R. Waldron et al. to the assignee oE the present invention, and is herein sometimes referred to as the "Three-Piece Contact Patent".
The present invention is also rela-ted to U.S. Patent 4,072,39~ to C. R. Waldron et al., for "Electrical Contact Assembly". This patent is also assigned to assignee of the present invention and is sometimes referred to as the "Alternate Three-Piece Contact Patent".
The invention disclosed in copending Canadian Patent Application, Serial No. 370,335, filed on February 6r 1981 date, of D. L. Pfendler and E. J. Bright and which is sometimes referred to as the "Pfendler/Bright Patent".
TECHNICAL FIELD
This invention relates to electrical connectors of the type having an outer shell or housing; a plurality of electrical contacts, each of which are electrically a dielectric insert or insert assembly mounted to the housing ~or either fixedly or removably mounting the electrical contacts in the shell electrically isolated from other conductors. This invention is more particularly related to an improved electrical contact assembly.
- 1 - ~1~ ;
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B~1~3 BACKGROUND OF THE INVENTION
A variety of electrical contacts have been suggested in the prior art. A variety of methods of making such contact also have been suggested in the prior art. Ad-vantageously the contact will be inexpensive and simple to manufacture and assemble, having superior electrical properties, and have good mechanical characteristics (resistance to conductor "pull out" or undesirable con-tact disassembly).
10The Three-Piece Contact Patent describes an elec-trical contact (and method of making it) somewhat similar to the present invention. The electrical contact described therein, however, presents possible - manufacturing and assembly difficulties which could lead to quality and reliability problems in electrical or mechanical properties. The contacts in that patent are shown to have four elongated slots~ Typically, the four slot sleeve ~shown therein) is crimped in place by a crimping mechanism having four radially spaced crimper 20members. Tbe elongated slots could coact with the equal number of crimpers to provide an unreliable mechnical and electrical connection.
The Pfendler/Bright patent addresses this problem by providing an arrangement of slots unequal to the number of crimpers and provides internal grooves in the sleeve.
While such a design works well, the removal of so much mateiral (to Eorm slots) may be undesirable in some i~ instances by reducing mechani~cal and electrical `~ characteristics of the contact.
30In other embodiments, electrical contacts are machined from cylindrical metal stock. In these machined -~ contacts, very close manufacturing tolerances ~0.002 inches or less) are frequently desired to avoid oversized .
: - 2 -.~` ~
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., . - :
~:L43898 contact parts. An oversized contact may not be insert-able into connector apertures designed to receive the contacts. Further, an insufficient clearance, caused by either an undersized or oversized part, could prevent proper electric or mechanical operation of the contact.
Machined contacts are also generally relatively ex--pensive to manufacture when machine and operator costs are considered. Further, the weight of a machined con-tact is typically greater than the weight of a stamped and formed contact as descr;bed in present invention.
While individual contact weight is generally small, an aircraft requires a very large number of contacts and every extra gram of aircraft equipment (e.g., in the con-tacts) displaces a gram of potential load, since the maximum weight for equipment and load is specified for the aircraft.
Machined contacts are also disadvantageous in that the machines producing them are time-consuming and diffi-cult to set up and inherently produce a parts output which have a relatively wide dimensional range. This dimensional range requires a costly post-manufacture in-spection, at which a significantly number of machined parts may be rejected or discarded as not meeting speci-fications. The reject problem significantly raises the costs of good parts.
Some prior art electrical contacts which are stamped and formed into a shape having a seam which is welded or brazed together. The added step of welding or brazing the seam adds an extra step to the manufacturing process and the step is difficult to accomplish accurately in view of the small dimensions which are involved in contact manu-facture.
Examples of such prior art contacts are shown in U.S. Patents 2,689,337; 2,804,602; 3,125,396; 3,137,925;
3,314,044; 3,316,528; 3,317,887; 3,6~8,224; 3~660,805;
:.
, . . . ~
.
.
.
, , 9~9~
3,721,943; 3,920,310; French paten~ 1,447,759 and German Patent 60,347.
Accordingly, the prior art contacts present various and sundry limitation and disadvantages (depending on the type of contact selected).
According to the present invention there is pro~ided an electrical contact assembly which has a tu~ular liner with a front mating portion, a reàr wire receiving portion and a center portion with the rear wire receiving portion including a plurality of axially spaced grooves extending around the internal periphery thereof and having a plurality of holes extending therethrough. The holes are arranged in an axial and - radial pattern in the rear wire receiving portion. A sleeve is telescopically mounted oYer at least one portion of the tubular liner and is secured thereon.
The present contact assem~ly includes the sleeve stamped to have an arrangement of holes in a conductor-receiving rear portion and advantageously includes a plurality of internal grooved indentations extending circumferentially around the conductor-receiving portion forwardly of some, but preferably not all of the holes. More specifically, the holes are arranged in sets of a pair of axially-spaced closely adjacent holes, with a third hole spaced axially at a signifi~antly greater distance. Sets of holes are repeated at several (e.g. four) radial locations. In a specific embodiment, the holes are small and round and of uniform size, allowing the sleeve to be easily crimped whlle retaining su~stantial sleeve portions for mechanical (conductor retention~ and electrical (current and signal transmission) purposes.
~3B~f3 The electrical contact of the present invention has the advantage that it is lower weight and higher quality than that of prior art machined contacts.
The present invention also has the advantage that it has better electrieal and meehanieal eharaeteristies that the eontaet deseribed in the Three-Pieee Contaet Patent or the Alternate Three-Pieee Contact patents referred above.
~;'` `` ' .
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The preferred embodiment of the present invention is a three-piece electrical contact assembly including a sleeve that is stamped and fol-med from a piece of sheet metal and is characterized by a tubular inner sleeve which has an unwelded seam and twelve holes arranged in a pattern of four holes symmetr:ically radially at each of three axial location in the rear of the sleeve when formed into a tubular shape. A conductor is secured within the sleeve by ~eing crimped in place with crimps engaging each of the sets of holes.
It is also an object of the present invention to re-place the expensive machine contacts with a less expen-sive, yet high quality, stamped and formed contact of the present invention.
It is also an object of the invention to provide an electrical contact which, when stamped from sheet metal, formed into a cylindrical shape and crimped to a conduc-tor, makes a good mechanical attachment and good electri-cal connection to the conductor.
It is still another object of this invention to pro-vide an electrical contact which can be fabricated rather easil~ in large ~uantities at low cost with relatively low number of unacceptable parts.
It is still a further object of the present inven-tion to provide an inexpensive electrical contact which is of lower weight than machined electrical contacts.
The foregoing and other objects, advantages and fea-tures of the present invention will become apparent to those skilled in the art, in view of the following des-cription and claims, taken in conjunction with the accompanying drawings which form a part of this appli-cation.
39l3 BRIEF DESCRIPTION OF THE DRAWINGS
FIGURE 1 is a top view of a contact sleeve stamped as a flat piece, prior to forming into a three-dimension-al cylindrical shape.
FIGURE 2 iS a partial cross-sectional view of the contact sleeve of FIGURE 1, aEter it has been formed to its tubular or three-dimensional shape.
FIGURE 3 iS a partial cross-sectional view of a second piece of the contact assembly of the present in-vention.
FIGURE 4 is a partial cross-sectional view of a third piece of the electrical contact assembly of the present invention.
FIGURE 5 shows a subassembly of the first and second pieces of the electrical contact assembly of the present invention.
FIGURE 6 is a partial cross-sectional view of the assembly of FIGURE 5, looking along the line VI-VI, looking in the direction of the arrows.
FIGURE 7 is a top view of the assembly portion of FIGURE 6, looking along the line VII-VII, looking in the direction of the arrows.
FIGURE 8 is a partial cross section of the three-piece assembly.
FIGURE 9 iS an alternate embodiment of the sleeve of FIG~RE 1.
FIGURE 10 is another alternate embodiment of the sleeves of FIGURES 1 and 9.
DETAILED DESCRIPTION OF THE DRAWINGS
FIGURE 1 is a top view of a one-piece contact sleeve member 10 showing elements of the present invention. The ?
sleeve member 10 is shown as it is initlally formed, a . ~ , .
, ~98~3 flat piece of sheet metal or other electrically con-ducting material, stamped in substantially the shape shown.
irhe sleeve member 10 includes a forward contact section 12, a medial section 14, and a rear conductor-receiving section 16. The forward contact section 12 in-cludes two (or, alternatively a plurality of) projections 13 which taper to narrower forward ends. The projections become spring fingers for receiving a male or pin-type electrical contact in both mechanical contact and an electrical circuit relationship after the sleeve member is formed into its three-dimensional cylindrical shape.
The medial section 14 spatially connects and elec-trically joins the forward contact section 12 and the rear conductor-receiving section 16. The rear conduc-tor-receiving portion 16 includes a plurality of grooved depressions or indentations 18 extending transverse to the length of the sleeve member 10 and transverse to the axis of the cylindrically-shaped sleeve member 10 (when formed). These grooves 18 are formed on the inside side of the sleeve member 10 when it is formed into its three-dimensional cylindrical shape.
The rear section 16 also includes a plurality of holes generally circular and of small diameter with respect to the width of the sleeve member 10. At each of four radial locations (when the sleeve is formed into its cylindrical shape) there are three axially spaced holes l9a, l9b, l9c, with two holes (19a, l9b) being spaced closely, for example by approximately 1-2 times the hole diameter, and the third hole being spaced by a greater distance, for example by three or more hole diameters.
When the sleeve member 10 is formed into its cylindrical shape, a set of holes is formed along the seam, as first hole halves l9d cooperates with second hole halves l9e to form a single set of holes. These radially spaced holes - :
8~38 and hole portions are separated by a unifor~ lateral spacing to provide a uniform angular (radial) separation of the hole sets when the contact sleeve portion is formed into its cylindrical shape.
FIGURE 2 shows the contact sleeve member 10 ~ormed into a cylindrical shape by forming the sleeve 10. The sleeve member 10 is symmetrical about an axis which is parallel to the length of the sleeve portion and the slots. The forward contact section 12 has the spring fingers 13 converging to its forward end for receiving the pin-type contact therein. The grooved indentations 18 are shown in the cut-away portion extending circum-ferentially around the inside portion of the sleeve member 10 of FIGURE 2. The grooves 18 are preferably located forwardly of at least the rear holes (19a, l9b) but within the rear contact receiving section 16.
A rear end portion 21 of the contact body is flared radially outwardly for more ease in inserting an elec-trical conductor therein. The hole halves l9d, l9e meet at a seam 22 to form a single set of holes, generally similar in shape to the other hole sets 19.
The contact sleeve portion 10 is crimped after a conductor is inserted into the rear end thereof to retain the conductor therein. Existing crimping apparatus are well known and generally have a plurality of radially spaced crimping elements, including four bi-lobed elements spaced 90 degrees apart in the preferred embodiment. Applicants preferred structure is specifically disclosed to have holes axially arranged to fall under or near each of the lobes, as, for example, holes l9c falling near one lobe with the other lobe falling near holes l9a and/or holes l9b. The present invention, therefore, provides arrangement in which the crimps of the sleeve made by the crimping apparatus will deform the sleeve into contact with in the region of the . .
holes l9c and either holes l9a or l9b (or both) as well as the grooves 18 are deformed into the conductor slots.
In this way, applicants insure that a significant solid portion of the sleeve in the region of the holes will be crimped into the conductor to thereby retain the con-ductor within the contact sleeve. The contact sleeve is positioned within the crimping members to insure that a portion of the crimping members extends into the region occupied by the grooved portions 18 to further retain the conductor within the sleeve member. By crimping the sleeve member 10 within the region of the groove portions 18, the conductor and groove portions 18 cooperate to additionally prevent external forces from pulling the conductor out of the sleeve member 10.
FIGURES 3 and 4 illustrate the second (liner) and third (hood) members 30, 40, respectively, of the three-piece contact of the present invention. These members 30, 40 are generally similar in structure and function to the members disclosed in the Three-Piece Contact and Alternate Three-Piece Contact patents. The structure of the members 30, 40 are not particularly relevant to the present invention, except that the present invention has preferred and alternate embodiments as described in the Three-Piece Contact and Alternate Three-Piece Contact patents, respectively Reference should be made thereto for a fuller understanding of the present invention and its environment. The liner 30 includes a radial enlargement 32.
FIGURE 5 shows an initial (partial) assembly of the contact pieces 10, 30 in the present invention. Wall portions 11, 31 of the members 10, 30, respectively, are punched and bent inwardly to form an inspection aperture 50.
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.
FIGURE 6 shows a cross-sectional view of the assembly of FIGURE 5. The sleeve 10 and the member 30 are shown, and have the inspection aperture 50 and indentations 52 shown. The aperture 50 allows a visual inspection of an inserted conductor to insure its proper preparation and positioning.
FIGURE 7 shows a top view of the member 30 in the vicinity of the inspection a]perture 50 and better show the preferred shape of the aperture.
FIGURE 8 shows a partial cross-sectional view of the entire assembly of a contact 10 showing the inner sleeve 10, the liner 30 and the hood 40. The hood 40 extends rearwardly to (and over) the radial enlargement 32.
FIGURE 9 shows an alternate structure for a sleeve 10'. The alternate sleeve 10' has the same general configuration, to include the grooved portions 18. The holes l9a', l9b', l9c', however, are uniformly spaced but do not include a set of holes which is formed (split) along the seam, by including half on one side, half on the other. The five set of holes are fully defined in the material even in its flat state.
FIGURE 10 shows a second alternate structure for a sleeve 10", including 18 holes arranged in three axial rows l9a", l9b", l9c" of six holes spaced radially around the sleeve.
While a preferred embodiment of the present inven-tion has been disclosed with some particularity, it will be apparent to those skilled in the art that changes may be made to the present preferred embodiment without departing from the spirit of the present invention. In some instances, certain features of the present invention may be used to advantage without the corresponding use of other features. For example, ~he number and shape of holes is not important. Instead of a pair of closely spaced holes in the rear with a spaced hole forwardly ~in , -, .
' . . :
. .
each radial set~, the pair of holes could be forwardly, with the single hole rearwardly (in each radial set).
The grooves can be between the sets of holes, or overlap one of both sets. Additionally, the grooved portions need neither be continuous nor extend completely cir-cumferentially around the body. Accordingly, it is intended that the illustrative and descriptive materials herein be used merely to illust:rate the principles of the present invention and not to limit the scope thereof which is described solely by the appended claims.
. . .
The present invention is also rela-ted to U.S. Patent 4,072,39~ to C. R. Waldron et al., for "Electrical Contact Assembly". This patent is also assigned to assignee of the present invention and is sometimes referred to as the "Alternate Three-Piece Contact Patent".
The invention disclosed in copending Canadian Patent Application, Serial No. 370,335, filed on February 6r 1981 date, of D. L. Pfendler and E. J. Bright and which is sometimes referred to as the "Pfendler/Bright Patent".
TECHNICAL FIELD
This invention relates to electrical connectors of the type having an outer shell or housing; a plurality of electrical contacts, each of which are electrically a dielectric insert or insert assembly mounted to the housing ~or either fixedly or removably mounting the electrical contacts in the shell electrically isolated from other conductors. This invention is more particularly related to an improved electrical contact assembly.
- 1 - ~1~ ;
, pc/ ~
:: ~
B~1~3 BACKGROUND OF THE INVENTION
A variety of electrical contacts have been suggested in the prior art. A variety of methods of making such contact also have been suggested in the prior art. Ad-vantageously the contact will be inexpensive and simple to manufacture and assemble, having superior electrical properties, and have good mechanical characteristics (resistance to conductor "pull out" or undesirable con-tact disassembly).
10The Three-Piece Contact Patent describes an elec-trical contact (and method of making it) somewhat similar to the present invention. The electrical contact described therein, however, presents possible - manufacturing and assembly difficulties which could lead to quality and reliability problems in electrical or mechanical properties. The contacts in that patent are shown to have four elongated slots~ Typically, the four slot sleeve ~shown therein) is crimped in place by a crimping mechanism having four radially spaced crimper 20members. Tbe elongated slots could coact with the equal number of crimpers to provide an unreliable mechnical and electrical connection.
The Pfendler/Bright patent addresses this problem by providing an arrangement of slots unequal to the number of crimpers and provides internal grooves in the sleeve.
While such a design works well, the removal of so much mateiral (to Eorm slots) may be undesirable in some i~ instances by reducing mechani~cal and electrical `~ characteristics of the contact.
30In other embodiments, electrical contacts are machined from cylindrical metal stock. In these machined -~ contacts, very close manufacturing tolerances ~0.002 inches or less) are frequently desired to avoid oversized .
: - 2 -.~` ~
. .. , , : - , . ' ': " ' ' ' ~ ' '. ,' .
., . - :
~:L43898 contact parts. An oversized contact may not be insert-able into connector apertures designed to receive the contacts. Further, an insufficient clearance, caused by either an undersized or oversized part, could prevent proper electric or mechanical operation of the contact.
Machined contacts are also generally relatively ex--pensive to manufacture when machine and operator costs are considered. Further, the weight of a machined con-tact is typically greater than the weight of a stamped and formed contact as descr;bed in present invention.
While individual contact weight is generally small, an aircraft requires a very large number of contacts and every extra gram of aircraft equipment (e.g., in the con-tacts) displaces a gram of potential load, since the maximum weight for equipment and load is specified for the aircraft.
Machined contacts are also disadvantageous in that the machines producing them are time-consuming and diffi-cult to set up and inherently produce a parts output which have a relatively wide dimensional range. This dimensional range requires a costly post-manufacture in-spection, at which a significantly number of machined parts may be rejected or discarded as not meeting speci-fications. The reject problem significantly raises the costs of good parts.
Some prior art electrical contacts which are stamped and formed into a shape having a seam which is welded or brazed together. The added step of welding or brazing the seam adds an extra step to the manufacturing process and the step is difficult to accomplish accurately in view of the small dimensions which are involved in contact manu-facture.
Examples of such prior art contacts are shown in U.S. Patents 2,689,337; 2,804,602; 3,125,396; 3,137,925;
3,314,044; 3,316,528; 3,317,887; 3,6~8,224; 3~660,805;
:.
, . . . ~
.
.
.
, , 9~9~
3,721,943; 3,920,310; French paten~ 1,447,759 and German Patent 60,347.
Accordingly, the prior art contacts present various and sundry limitation and disadvantages (depending on the type of contact selected).
According to the present invention there is pro~ided an electrical contact assembly which has a tu~ular liner with a front mating portion, a reàr wire receiving portion and a center portion with the rear wire receiving portion including a plurality of axially spaced grooves extending around the internal periphery thereof and having a plurality of holes extending therethrough. The holes are arranged in an axial and - radial pattern in the rear wire receiving portion. A sleeve is telescopically mounted oYer at least one portion of the tubular liner and is secured thereon.
The present contact assem~ly includes the sleeve stamped to have an arrangement of holes in a conductor-receiving rear portion and advantageously includes a plurality of internal grooved indentations extending circumferentially around the conductor-receiving portion forwardly of some, but preferably not all of the holes. More specifically, the holes are arranged in sets of a pair of axially-spaced closely adjacent holes, with a third hole spaced axially at a signifi~antly greater distance. Sets of holes are repeated at several (e.g. four) radial locations. In a specific embodiment, the holes are small and round and of uniform size, allowing the sleeve to be easily crimped whlle retaining su~stantial sleeve portions for mechanical (conductor retention~ and electrical (current and signal transmission) purposes.
~3B~f3 The electrical contact of the present invention has the advantage that it is lower weight and higher quality than that of prior art machined contacts.
The present invention also has the advantage that it has better electrieal and meehanieal eharaeteristies that the eontaet deseribed in the Three-Pieee Contaet Patent or the Alternate Three-Pieee Contact patents referred above.
~;'` `` ' .
~ !
- .:
- \
The preferred embodiment of the present invention is a three-piece electrical contact assembly including a sleeve that is stamped and fol-med from a piece of sheet metal and is characterized by a tubular inner sleeve which has an unwelded seam and twelve holes arranged in a pattern of four holes symmetr:ically radially at each of three axial location in the rear of the sleeve when formed into a tubular shape. A conductor is secured within the sleeve by ~eing crimped in place with crimps engaging each of the sets of holes.
It is also an object of the present invention to re-place the expensive machine contacts with a less expen-sive, yet high quality, stamped and formed contact of the present invention.
It is also an object of the invention to provide an electrical contact which, when stamped from sheet metal, formed into a cylindrical shape and crimped to a conduc-tor, makes a good mechanical attachment and good electri-cal connection to the conductor.
It is still another object of this invention to pro-vide an electrical contact which can be fabricated rather easil~ in large ~uantities at low cost with relatively low number of unacceptable parts.
It is still a further object of the present inven-tion to provide an inexpensive electrical contact which is of lower weight than machined electrical contacts.
The foregoing and other objects, advantages and fea-tures of the present invention will become apparent to those skilled in the art, in view of the following des-cription and claims, taken in conjunction with the accompanying drawings which form a part of this appli-cation.
39l3 BRIEF DESCRIPTION OF THE DRAWINGS
FIGURE 1 is a top view of a contact sleeve stamped as a flat piece, prior to forming into a three-dimension-al cylindrical shape.
FIGURE 2 iS a partial cross-sectional view of the contact sleeve of FIGURE 1, aEter it has been formed to its tubular or three-dimensional shape.
FIGURE 3 iS a partial cross-sectional view of a second piece of the contact assembly of the present in-vention.
FIGURE 4 is a partial cross-sectional view of a third piece of the electrical contact assembly of the present invention.
FIGURE 5 shows a subassembly of the first and second pieces of the electrical contact assembly of the present invention.
FIGURE 6 is a partial cross-sectional view of the assembly of FIGURE 5, looking along the line VI-VI, looking in the direction of the arrows.
FIGURE 7 is a top view of the assembly portion of FIGURE 6, looking along the line VII-VII, looking in the direction of the arrows.
FIGURE 8 is a partial cross section of the three-piece assembly.
FIGURE 9 iS an alternate embodiment of the sleeve of FIG~RE 1.
FIGURE 10 is another alternate embodiment of the sleeves of FIGURES 1 and 9.
DETAILED DESCRIPTION OF THE DRAWINGS
FIGURE 1 is a top view of a one-piece contact sleeve member 10 showing elements of the present invention. The ?
sleeve member 10 is shown as it is initlally formed, a . ~ , .
, ~98~3 flat piece of sheet metal or other electrically con-ducting material, stamped in substantially the shape shown.
irhe sleeve member 10 includes a forward contact section 12, a medial section 14, and a rear conductor-receiving section 16. The forward contact section 12 in-cludes two (or, alternatively a plurality of) projections 13 which taper to narrower forward ends. The projections become spring fingers for receiving a male or pin-type electrical contact in both mechanical contact and an electrical circuit relationship after the sleeve member is formed into its three-dimensional cylindrical shape.
The medial section 14 spatially connects and elec-trically joins the forward contact section 12 and the rear conductor-receiving section 16. The rear conduc-tor-receiving portion 16 includes a plurality of grooved depressions or indentations 18 extending transverse to the length of the sleeve member 10 and transverse to the axis of the cylindrically-shaped sleeve member 10 (when formed). These grooves 18 are formed on the inside side of the sleeve member 10 when it is formed into its three-dimensional cylindrical shape.
The rear section 16 also includes a plurality of holes generally circular and of small diameter with respect to the width of the sleeve member 10. At each of four radial locations (when the sleeve is formed into its cylindrical shape) there are three axially spaced holes l9a, l9b, l9c, with two holes (19a, l9b) being spaced closely, for example by approximately 1-2 times the hole diameter, and the third hole being spaced by a greater distance, for example by three or more hole diameters.
When the sleeve member 10 is formed into its cylindrical shape, a set of holes is formed along the seam, as first hole halves l9d cooperates with second hole halves l9e to form a single set of holes. These radially spaced holes - :
8~38 and hole portions are separated by a unifor~ lateral spacing to provide a uniform angular (radial) separation of the hole sets when the contact sleeve portion is formed into its cylindrical shape.
FIGURE 2 shows the contact sleeve member 10 ~ormed into a cylindrical shape by forming the sleeve 10. The sleeve member 10 is symmetrical about an axis which is parallel to the length of the sleeve portion and the slots. The forward contact section 12 has the spring fingers 13 converging to its forward end for receiving the pin-type contact therein. The grooved indentations 18 are shown in the cut-away portion extending circum-ferentially around the inside portion of the sleeve member 10 of FIGURE 2. The grooves 18 are preferably located forwardly of at least the rear holes (19a, l9b) but within the rear contact receiving section 16.
A rear end portion 21 of the contact body is flared radially outwardly for more ease in inserting an elec-trical conductor therein. The hole halves l9d, l9e meet at a seam 22 to form a single set of holes, generally similar in shape to the other hole sets 19.
The contact sleeve portion 10 is crimped after a conductor is inserted into the rear end thereof to retain the conductor therein. Existing crimping apparatus are well known and generally have a plurality of radially spaced crimping elements, including four bi-lobed elements spaced 90 degrees apart in the preferred embodiment. Applicants preferred structure is specifically disclosed to have holes axially arranged to fall under or near each of the lobes, as, for example, holes l9c falling near one lobe with the other lobe falling near holes l9a and/or holes l9b. The present invention, therefore, provides arrangement in which the crimps of the sleeve made by the crimping apparatus will deform the sleeve into contact with in the region of the . .
holes l9c and either holes l9a or l9b (or both) as well as the grooves 18 are deformed into the conductor slots.
In this way, applicants insure that a significant solid portion of the sleeve in the region of the holes will be crimped into the conductor to thereby retain the con-ductor within the contact sleeve. The contact sleeve is positioned within the crimping members to insure that a portion of the crimping members extends into the region occupied by the grooved portions 18 to further retain the conductor within the sleeve member. By crimping the sleeve member 10 within the region of the groove portions 18, the conductor and groove portions 18 cooperate to additionally prevent external forces from pulling the conductor out of the sleeve member 10.
FIGURES 3 and 4 illustrate the second (liner) and third (hood) members 30, 40, respectively, of the three-piece contact of the present invention. These members 30, 40 are generally similar in structure and function to the members disclosed in the Three-Piece Contact and Alternate Three-Piece Contact patents. The structure of the members 30, 40 are not particularly relevant to the present invention, except that the present invention has preferred and alternate embodiments as described in the Three-Piece Contact and Alternate Three-Piece Contact patents, respectively Reference should be made thereto for a fuller understanding of the present invention and its environment. The liner 30 includes a radial enlargement 32.
FIGURE 5 shows an initial (partial) assembly of the contact pieces 10, 30 in the present invention. Wall portions 11, 31 of the members 10, 30, respectively, are punched and bent inwardly to form an inspection aperture 50.
-'.
.
FIGURE 6 shows a cross-sectional view of the assembly of FIGURE 5. The sleeve 10 and the member 30 are shown, and have the inspection aperture 50 and indentations 52 shown. The aperture 50 allows a visual inspection of an inserted conductor to insure its proper preparation and positioning.
FIGURE 7 shows a top view of the member 30 in the vicinity of the inspection a]perture 50 and better show the preferred shape of the aperture.
FIGURE 8 shows a partial cross-sectional view of the entire assembly of a contact 10 showing the inner sleeve 10, the liner 30 and the hood 40. The hood 40 extends rearwardly to (and over) the radial enlargement 32.
FIGURE 9 shows an alternate structure for a sleeve 10'. The alternate sleeve 10' has the same general configuration, to include the grooved portions 18. The holes l9a', l9b', l9c', however, are uniformly spaced but do not include a set of holes which is formed (split) along the seam, by including half on one side, half on the other. The five set of holes are fully defined in the material even in its flat state.
FIGURE 10 shows a second alternate structure for a sleeve 10", including 18 holes arranged in three axial rows l9a", l9b", l9c" of six holes spaced radially around the sleeve.
While a preferred embodiment of the present inven-tion has been disclosed with some particularity, it will be apparent to those skilled in the art that changes may be made to the present preferred embodiment without departing from the spirit of the present invention. In some instances, certain features of the present invention may be used to advantage without the corresponding use of other features. For example, ~he number and shape of holes is not important. Instead of a pair of closely spaced holes in the rear with a spaced hole forwardly ~in , -, .
' . . :
. .
each radial set~, the pair of holes could be forwardly, with the single hole rearwardly (in each radial set).
The grooves can be between the sets of holes, or overlap one of both sets. Additionally, the grooved portions need neither be continuous nor extend completely cir-cumferentially around the body. Accordingly, it is intended that the illustrative and descriptive materials herein be used merely to illust:rate the principles of the present invention and not to limit the scope thereof which is described solely by the appended claims.
. . .
Claims (3)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. An electrical contact assembly comprising:
a tubular liner having a front mating portion, a rear wire receiving portion and a center section, said rear wire receiving portion including a plurality of axially spaced grooves extending around the internal periphery thereof and having a plurality of holes extending therethrough, said holes being arranged in an axial and radial pattern in the rear wire receiving portion; and a sleeve telescopically mounted over at least one portion of the tubular liner and secured thereon.
a tubular liner having a front mating portion, a rear wire receiving portion and a center section, said rear wire receiving portion including a plurality of axially spaced grooves extending around the internal periphery thereof and having a plurality of holes extending therethrough, said holes being arranged in an axial and radial pattern in the rear wire receiving portion; and a sleeve telescopically mounted over at least one portion of the tubular liner and secured thereon.
2. An electrical contact of the type described in claim 1 wherein the pattern of holes includes a plurality of radially spaced sets of holes, each set including a pair of closely spaced holes axially separated and a third hole axially spaced by a relatively greater separation than between the pair of holes.
3. An electrical contact of the type described in claim 2 wherein the grooves are located between the pair of holes and the third hole.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US15865580A | 1980-06-11 | 1980-06-11 | |
| US158,655 | 1980-06-11 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1149898A true CA1149898A (en) | 1983-07-12 |
Family
ID=22569103
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000370334A Expired CA1149898A (en) | 1980-06-11 | 1981-02-06 | Electrical contact |
Country Status (3)
| Country | Link |
|---|---|
| EP (1) | EP0041903A1 (en) |
| JP (1) | JPS5727579A (en) |
| CA (1) | CA1149898A (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5955506A (en) * | 1996-04-03 | 1999-09-21 | Centaur Pharmaceuticals, Inc. | Benzamides for neurodegenerative disorder treatment |
| JP2010010000A (en) * | 2008-06-27 | 2010-01-14 | Autonetworks Technologies Ltd | Terminal metal fixture and wire with terminal |
| JP5412142B2 (en) * | 2009-02-27 | 2014-02-12 | 矢崎総業株式会社 | Crimp terminal |
Family Cites Families (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2452932A (en) * | 1944-04-10 | 1948-11-02 | Aircraft Marine Prod Inc | Electrical connector |
| US2685076A (en) * | 1951-05-05 | 1954-07-27 | Aircraft Marine Prod Inc | Electrical connector |
| GB1164100A (en) * | 1967-09-13 | 1969-09-10 | Amp Inc | Terminal for Connection to Aluminium Wire |
| US4120556A (en) * | 1976-03-01 | 1978-10-17 | The Bendix Corporation | Electrical contact assembly |
| US4278317A (en) * | 1979-08-31 | 1981-07-14 | The Bendix Corporation | Formed socket contact with reenforcing ridge |
-
1981
- 1981-02-06 CA CA000370334A patent/CA1149898A/en not_active Expired
- 1981-06-11 JP JP9018781A patent/JPS5727579A/en active Pending
- 1981-06-11 EP EP81400926A patent/EP0041903A1/en not_active Withdrawn
Also Published As
| Publication number | Publication date |
|---|---|
| JPS5727579A (en) | 1982-02-13 |
| EP0041903A1 (en) | 1981-12-16 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |