Method of making a contact assembly
First Claim
1. A method for making a contact assembly, comprising the steps of:
- forming first and second contact pieces having beams of contact sections thereon and respective board engaging posts thereon, and further forming a gap between said first and said second contact pieces,using said gap to separate a first beam of said beams on a first contact section of said contact sections from a second beam of said beams on said first contact section,positioning said first beam and said second beam adjacent each other for receiving a pin into connection therewith, and for the pin to make an electrical connection between said first beam and said second beam, andimbedding said first and second contact pieces in insulating material with said posts protruding from said insulating material to make connections to a board, and with said first beam and said second beam protruding from said insulation material to make an electrical connection to said pin, whereby, upon said first beam and said second beam of said first contact section making connection to said pin, an electrical connection is established between said first contact piece and said second contact piece.
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Accused Products
Abstract
A contact assembly (90) includes separate conductive members (42,54) with insulative material (90) molded about body sections (50,64) to define an integral unit for handling during connector assembly. The method includes stamping the conductive members (656,658,660,662) from a common blank (680) to have beams (610,612,614,616) associated in pairs to define sockets (606,608), second contact sections (648,650,652,654) at other ends, and body sections (656,658,660,662) joining the respective beams and second contact sections (648,650,652,654). Final separation of the conductive members may occur after molding of the insulative material (670), prior to which the conductive members may be retained on carrier strip facilitating the stamping, plating and molding processes. One contact assembly (604) provides sockets (606,608) having pairs of beams (610,612 and 614,616) with the beams defined on separate conductive members (640,642,644,646) and is inserted into a housing doubling the contact density of the connector without increasing the size of the housing.
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Citations
15 Claims
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1. A method for making a contact assembly, comprising the steps of:
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forming first and second contact pieces having beams of contact sections thereon and respective board engaging posts thereon, and further forming a gap between said first and said second contact pieces, using said gap to separate a first beam of said beams on a first contact section of said contact sections from a second beam of said beams on said first contact section, positioning said first beam and said second beam adjacent each other for receiving a pin into connection therewith, and for the pin to make an electrical connection between said first beam and said second beam, and imbedding said first and second contact pieces in insulating material with said posts protruding from said insulating material to make connections to a board, and with said first beam and said second beam protruding from said insulation material to make an electrical connection to said pin, whereby, upon said first beam and said second beam of said first contact section making connection to said pin, an electrical connection is established between said first contact piece and said second contact piece. - View Dependent Claims (2, 3, 4, 5, 6)
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7. A method for making a contact assembly, comprising the steps of:
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forming first and second contact pieces having portions of contact sections thereon and respective board engaging posts thereon, and further forming a gap between said first and said second contact pieces, using said gap to separate a first portion of a first contact section from a second portion of said first contact section, positioning said first portion of said first contact section and said second portion of said first contact section adjacent each other for receiving a pin into connection therewith, and for the pin to make an electrical connection between said first portion of said first contact section and said second portion of said first contact section, and imbedding said first and said second contact pieces in insulating material, with said posts protruding from said insulating material for connection to a board, and with said first portion and said second portion protruding from said insulation material for making connection to said pin, whereby, upon said first portion and said second portion of said first contact section making connection to said pin, an electrical connection is established between said first contact piece and said second contact piece. - View Dependent Claims (8, 9, 10, 11, 12, 13, 14, 15)
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Specification