U.S. patent number 3,676,926 [Application Number 05/039,089] was granted by the patent office on 1972-07-18 for method for manufacturing connector terminals.
This patent grant is currently assigned to Elfab Corp.. Invention is credited to Jerry A. Kendall.
United States Patent |
3,676,926 |
Kendall |
July 18, 1972 |
METHOD FOR MANUFACTURING CONNECTOR TERMINALS
Abstract
A plurality of electrical connector terminals are formed as part
of a common metal strip. The terminals are first inserted into
prepunched holes in a mounting board while they are still attached
to one another as part of the strip. The terminals are next all
press fit simultaneously into the mounting board holes. The strip
which connects them together is then broken free and discarded to
separate the terminals from one another and leave the individual
connector terminals mounted in the board.
Inventors: |
Kendall; Jerry A. (Carrollton,
TX) |
Assignee: |
Elfab Corp. (Dallas,
TX)
|
Family
ID: |
21903607 |
Appl.
No.: |
05/039,089 |
Filed: |
May 20, 1970 |
Current U.S.
Class: |
29/882; 29/564.6;
29/739 |
Current CPC
Class: |
H01R
43/205 (20130101); H05K 13/0478 (20130101); Y10T
29/49218 (20150115); Y10T 29/53174 (20150115); Y10T
29/5142 (20150115) |
Current International
Class: |
H01R
43/20 (20060101); H05K 13/04 (20060101); H05k
013/04 () |
Field of
Search: |
;29/23B,23S,625,63R |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Annear; R. Spencer
Claims
What is claimed is:
1. A method for rigidly mounting electrical terminals in receiving
apertures comprising:
inserting a plurality of terminals joined together by a common
support strip into said receiving apertures;
press fitting said terminals down into the receiving apertures to
secure them rigidly in said apertures; and
severing the common support strip to separate the terminals from
one another.
2. A method for rigidly mounting electrical connector terminals in
receiving apertures comprising:
forming a plurality of terminals from a single sheet of conductive
material having a longitudinal dimension greater than its
transverse dimension, said terminals being formed extending
transversely of said sheet with a common support strip extending
longitudinally along one edge of said sheet and connecting the
terminals to one another;
press fitting the terminals into receiving apertures to secure them
rigidly in said apertures; and
removing the common support strip to separate the terminals from
one another.
3. A method for rigidly mounting electrical connector terminals in
receiving apertures as set forth in claim 2 wherein said forming
step includes the steps of:
stamping a plurality of terminals from a single elongate sheet of
conductive material, said terminals being stamped to extend
transversely of said sheet with a common support strip connecting
the terminals to one another; and
plating the stamped terminals with at least one layer of metal.
4. A method for rigidly mounting electrical connector terminals
into receiving apertures as set forth in claim 2 wherein said press
fitting step includes the steps of:
supporting a circuit board having holes formed therein at
preselected locations; and
applying a longitudinal force to the terminals to press fit them
into the holes and secure them rigidly and motionlessly within the
circuit board.
5. A method for rigidly mounting terminals into receiving apertures
in a circuit board comprising:
forming a long strip of connector terminals from a common elongate
sheet of conductive material, said terminals extending transversely
of said sheet and being joined together by a common support strip
left intact along one edge of said sheet of material, said support
strip being joined to each of said terminals by a narrow reduced
section;
severing a preselected number of contact terminals to be inserted
from the long strip;
press fitting the terminals into the receiving apertures in said
circuit board to secure them rigidly in said apertures; and
flexing said support strip while holding said terminals stationary
to sever said reduced section and remove the support strip from the
contact terminals to separate each of the terminals from one
another.
6. A method for rigidly mounting terminals as set forth in claim 5
which includes the additional steps of:
supporting the severed strip of terminals in alignment in a linear
array; and
inserting the shank portions of the terminals in the receiving
apertures while they are being supported in alignment and prior to
press fitting them.
7. A method for rigidly mounting terminals as set forth in claim 5
wherein the forming step includes the steps of:
stamping a long strip of connector terminals from a common elongate
sheet of conductive material, said terminals extending transversely
of said sheet and being joined together by a common support strip
left intact along one edge of said sheet of material, said support
strip being joined to each of said terminals by a narrow reduced
section; and
plating the stamped terminals with at least one layer of metal.
8. A method for rigidly mounting terminals into holes in a circuit
board comprising the steps of:
inserting a plurality of connector terminals formed to extend
transversely of a common elongate sheet of conductive material and
joined together by a common support strip left intact along one
edge of said sheet of material and connected to each terminal by a
narrow reduced section, into said holes in the circuit board;
press fitting the terminals into said holes in the circuit board to
secure them rigidly in said holes; and
severing said reduced sections to remove the support strip from the
contact terminals and separate each of the terminals from one
another.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a method and apparatus for mounting a
plurality of connector terminals on a board and, more particularly,
to a rapid and inexpensive technique for simultaneously press
fitting a plurality of contacts into prepunched holes in a circuit
board.
2. History of the Prior Art
In the past, the principal way in which electrical connector
terminals have been manufactured and inserted into circuit boards
is by first stamping the terminals from a sheet of metal and
separating them from one another. The terminals are then barrel
plated and ready for insertion into holes in a board. At this
point, the loose terminals may be handled in one of several
manners. First, the terminals may be fed to an automatic machine
which collects and orientates the terminals and then inserts them
one at a time into holes in a circuit board. The disadvantages of
this first method is that the automatic machinery is very complex
and extremely expensive. Further, these machines are also
relatively slow in performing the insertion process. For example,
one such machine which is presently in common use in the industry
inserts and press fits terminals into prepunched printed circuit
boards at a rate of 100 terminals per minute.
A second method of handling loose terminals is that of first
loading them into a workholding fixture prior to insertion. This
loading is done either by hand or by an automatic machine. The
manual loading process is extremely slow and therefore costly in
terms of labor. The automatic loading technique requires a
relatively complex and costly piece of machinery and even then does
not perform the task very quickly.
Once the loose terminals have been loaded into holding fixtures,
they may be inserted into a circuit board one at a time by an
automatic machine or may all be inserted simultaneously.
Additionally, the terminals held in alignment in a fixture may all
be bonded to a plastic strip for subsequent simultaneous insertion
into a board or shipment prior to insertion.
As can be seen once the terminals are separated from one another
for plating, or other reasons, a great deal of processing is
required to place and hold the terminals in an array for
simultaneous insertion into a circuit board.
The method and apparatus of the present invention overcomes the
disadvantages of prior art terminal handling and insertion
techniques by forming the terminals on a separable common support
strip and not separating them from one another until the insertion
step has been completed. The method thereby eliminates the
unnecessary and expensive process of placing the individual
terminals in a workholding fixture and the expensive equipment
necessary for individual insertion into a board.
While techniques for plating terminals while they are attached to a
common strip and then simultaneously processing a plurality of the
terminals is known, these methods have generally been of the type
which mold a plurality of connected terminals into an insulative
housing and then clip away the interconnecting metal portions to
separate the terminals from one another. Other methods have sought
to simultaneously separate and crimp finished terminals onto wires
to form cable connectors. These techniques for group bonding of
joined terminals are relatively slow and cannot be adapted to the
problems of press fitting contacts into a circuit board.
SUMMARY OF THE INVENTION
The invention relates to a method and apparatus for simultaneously
inserting a plurality of electrical terminals formed on a common
support strip into preformed holes in a printed circuit board,
press fitting those contacts into the board and then removing the
common strip. More particularly, one aspect of the invention
pertains to a method for inserting terminals into holes in a
circuit board including the step of forming a long strip of
connector terminals from a common sheet of conductive material. The
terminals are formed joined together by a common support strip left
intact on the sheet and joined to each of the terminals by a narrow
reduced section. A preselected number of contact terminals to be
inserted is severed from the long strip and then press fitted into
the holes in the circuit board. The support strip is then flexed
while holding the terminals stationary to sever the reduced section
and remove the support strip to separate each of the terminals from
one another.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and for
further objects and advantages thereof, reference may now be had to
the following description taken in conjunction with the
accompanying drawings in which:
FIG. 1 is a perspective view of a backing board and a circuit board
having a plurality of common connected terminals inserted through
the board;
FIG. 2 is a perspective view of a strip of common connected
terminals used in conjunction with the invention;
FIG. 3 is a perspective view of a plurality of common connected
terminals being press fitted into holes in a printed circuit
board;
FIG. 4 is a perspective view of common connected terminals which
have been press fit into the circuit board showing the reduced
portion adjacent the common connecting strip;
FIG. 5 is a perspective view showing the press fitted terminals
being separated from one another by breaking away the common
connecting strip;
FIG. 6 is a plurality of connector terminals which have been press
fitted into the board and then separated from one another to form
the finished separate terminal array; and
FIG. 7 is a perspective view of a plurality of common connected
terminals being held in alignment with one another prior to
insertion.
DETAILED DESCRIPTION
Referring to FIG. 1, there is shown a backing plate 10 having a
plurality of guide holes 11 drilled therethrough and a number of
upstanding alignment pins 12 mounted along the edge. A circuit
board 13 into which terminals are to be inserted is placed upon the
surface of the backing plate 10. The board 13 is preferably formed
of a G-10 material such as a fiberglass impregnated with epoxy
resin. The backing plate 10 may also be made of G-10 material or
any other fairly durable substance. The plate has a thickness
greater than the length of the shanks of the terminals to be
inserted in the circuit board. The circuit board 13 has alignment
holes 14 formed along its edges which are located to receive the
alignment pins 12 and hold the board 13 in proper alignment upon
the backing. The board 13 has a plurality of apertures or holes 15
formed therein by punching or drilling at preselected locations
where connector terminals are to be mounted. When the board 13 is
properly positioned on the surface of the backing plate 10 by the
engagement of the alignment holes 14 with the pins 12, the holes 15
in the circuit board 13 are in alignment with the guide holes 11 in
the backing plate 10. As is shown in FIG. 1, the backing plate 10
is capable of accommodating either six boards of the size and
configuration as that shown or it can accommodate fewer boards of
larger size. Of course, a backing plate of any configuration could
be used to support other sizes and arrangements of printed circuit
boards preparatory to insertion of terminals. Its principal
functions are to serve as a workholding surface for the circuit
boards and provide guide holes for the contact shanks during
insertion.
Referring now to FIG. 2, a strip of contact terminals 21 are shown
formed into a roll. The contact terminals are preferably made from
a single long thin strip of metal such as a phosphor-bronze.
Finished terminals are formed by next plating them first with a
layer of nickel and then with a layer of gold. The contacts may be
stamped or pressed into the proper shape and configuration. The
stamped contacts, while still on the strip, are plated and then
conveniently rolled up for easy shipping and storage as shown in
FIG. 2. When the terminals are to be inserted, a section of the
strip is unrolled and the proper number is cut from the roll by
severing the edge of the support strip 26 which holds the contacts
together.
Each one of the metal contact terminals 21 comprises a connector
portion 22 and a shank portion 23 which are separated by a shoulder
24 and an enlarged neck section 25. The neck section is greater in
width than the shank portion. The contact receiving holes 15 in the
board 13 are slightly larger than the shank portion 23 so that it
will readily pass into a mounting hole. The neck section 25 is
enlarged to such a width that when longitudinal force is applied
and the contact is press fitted down into a hole, there is a snug,
rigid engagement between the neck section and the walls of the
hole. The shoulder 24 limits the depth to which a contact 21 may be
pressed into a hole in a board. The shank portion 23 of the contact
21 is substantially square in cross section to permit termination
by such techniques as wire wrapping. The connector portion 22 of
the contact is preferably recessed from one surface of the contact
by coining. The upper end of the connector portion 22 is slightly
beveled as will be more fully explained below.
Referring now to FIG. 3, there is shown a plurality of contact
terminals which have been unrolled and cut from the coil of contact
terminals shown in FIG. 2. A circuit board 13 in which the contacts
are to be inserted has been placed down upon the backing plate 10
so that the holes 15 are in alignment with the guide holes 11 in
the backing plate. The strip of contacts 27 which is to be inserted
has been placed so that the shank portions 23 of the contacts 21
pass throuGh the holes 15 and extend down into the guide holes 11
in the backing plate 10. Because the enlarged neck sections 25 are
slightly larger than the holes 15, the contacts come to rest in the
position shown in FIG. 3 with the terminals supported by engagement
of the enlarged neck sections 25 with the edges of the holes
15.
When the contact strip 21 is in place, insertion tool 31 is brought
into engagement. The insertion tool 31 has a plurality of fingers
33 which extend from a recessed section 32. Each of the fingers 33
is of a slightly smaller width than the distance between adjacent
contactor portions 22 of the contact terminals 21. The fingers also
have beveled faces 34 so that the tool may be readily inserted
between adjacent ones of the contact terminals 21. Additionally,
each of the fingers 33 have beveled top sections 35, the function
of which will be explained more fully later. The bottom sections of
the fingers 33 are flat so that each finger engages the upper edge
of the shoulders 24 of the contact terminals 21. That is, each
finger engages one upper edge of one shoulder of one contact and
the other upper edge of the shoulder of the next adjacent contact.
The insertion tool 31 has an additional lower recessed portion 36
which prevents the lower edge of the tool from damaging the
contacts. The height of the recessed portion 36 is slightly greater
than the height of the contact shoulders 24 so that the recessed
portion provides an abutting surface against the board 10 and stops
the downward movement of the tool 31 when the contacts are fully
inserted.
When the insertion tool 31 is in place, the recessed section 32
fits adjacent the surface of the contacts and the support strip 26.
The fingers 33 of the insertion tool engage the shoulders 24 of the
contacts 21. The insertion tool 31 is connected to the piston 37 of
an air cylinder 38. When force is applied to the insertion tool 31
by the cylinder 38, longitudinal force is applied to the contacts
21 and the neck sections 25 are press fit down into the receiving
holes 15 in the circuit board 13. The lower edges of the shoulders
24 of the contact terminals 21 limit the depth to which the contact
terminals are inserted down into the holes 15 of the board 13.
Tight frictional engagement between the enlarged neck sections 25
and the inside walls of the holes 15 firmly hold the contacts in
position with the body of the circuit board 13.
When the piston 37 is withdrawn again into the air cylinder 38, the
upper beveled edges 35 of the finger sections 33 serve as camming
surfaces and force the support strip 26, along with the contacts
21, away from the insertion tool 31 so that the fingers are
automatically removed from the interstices between the terminals
21.
FIG. 4 shows the contact terminals which are still joined to the
support strip 26 after insertion into the holes 15 of the circuit
board 13. FIG. 4, however, shows the reverse side of the contact
terminals and support strip from that shown in FIG. 3. From this
view of the back side, it can be seen that the upper edges of the
contactor portions 22 of the terminals 21 are slightly beveled to a
reduced section 41 where the contact terminals are connected to the
support strip 26. It is this reduced section 41 by which each of
the contact terminals 21 are connected to the support strip 26.
After the contacts 21 have been press fit into the circuit board,
the support strip 26 is no longer needed and must be removed in
order to electrically and physically disconnect each one of the
contact terminals from the others. Referring to FIG. 5, there is
shown a breaking tool which comprises a flat metal strip 42 having
a groove 43 cut along the length of one edge. The width of the
groove is slightly larger than the thickness of the support strip
26 and the depth of the groove is approximately the same as that
from the edge of the support strip 26 to the reduced section 41.
The tool 42 is used by placing it over the array of contact
terminals so that the support strip 26 is received up within the
groove 43. By flexing the tool 42 about an axis parallel to that of
the strip 26, the reduced sections 41 are fatigued and severed and
the strip is detached from the contact terminals. As can be seen in
FIG. 6, what remains is a plurality of individual, electrically
isolated contact terminals 21 mounted in circuit board 13.
The separation of the support strip 26 could be accomplished, of
course, in other fashions. For example, the reduced section 41
could be eliminated and the strip cut away to separate the
contacts. As can be seen, one of the principal advantages of the
present method is that terminals can be inserted quickly since a
plurality of terminals are placed in at once. For example, a rate
of 200-300 terminals per minute is achieved with relative ease.
Automation of the present process should increase the speed of
insertion even more. Further, the equipment required to practice
the method of the present invention is much simpler and more
trouble-free than the individual insertion machines of the prior
art.
Since the contact terminals are formed in a long strip and often
coiled or rolled for packaging purposes, there may be a slight warp
or bow in the strip of terminals after it has been cut from the
long row. In this event, there will be a slight misalignment of the
shank portions 23 of the terminals and they will not precisely fit
into the holes of the circuit board 13. A tool 51 is shown which is
used to align warped terminals prior to inserting them into the
holes of the circuit board. The tool 51 comprises a flat portion 52
having fingers 53 extending therefrom which pass in the interstices
between adjacent ones of the terminals 21. The tool 51 is utilized
by pressing the support strip 26 up adjacent the flat surface 52 so
that any bow or warp in the terminal strip is removed. The shank
portions 23 of the terminals 21 are now in an evenly spaced, linear
array and may be easily inserted into the receiving holes 15 in the
circuit boards 13. In addition to straightening warped terminal
strips, the tool 51 speeds the insertion process even for straight
strips.
As can be seen by the above description, the method of the
invention comprises forming a plurality of electrical connector
terminals on a common support strip, plating the contacts and then
press fitting those contacts into receiving holes in a circuit
board. Once the contacts are mounted in the circuit board, the
support strip is broken away to leave electrically isolated contact
terminals.
This technique can be readily applied to the manufacture of a
number of different electrical devices. For example, the contact
terminals utilized in the integrated circuit connector disclosed
and claimed in U.S. Pat. No. 3,624,586 to Frederick T. Inacker
assigned to the assignee of the present invention, or in the
application on a printed circuit board connector Ser. No. 38,989
filed May 20, 1970 in the names of Frederick T. Inacker and John
Preston Ammon, and assigned to the assignee of the present
inventions, can be inserted using the method of the present
invention.
Having described the invention in connection with certain specific
embodiments thereof, it is to be understood that further
modifications may now suggest themselves to those skilled in the
art and it is intended to cover such modifications as fall within
the scope of the appended claims.
* * * * *