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Method of manufacturing an interconnected foil contact array

  • US 7,987,594 B1
  • Filed: 11/02/2007
  • Issued: 08/02/2011
  • Est. Priority Date: 11/08/2006
  • Status: Active Grant
First Claim
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1. A method for manufacturing a foil contact assembly having a plurality of circuits, comprising the steps of:

  • providing a housing having an upper surface and a lower surface, the housing further having substantially opposed first and second sides, each side of a pair of opposed sides including a plurality of apertures having an upper portion and a lower portion, the apertures on each side of the pair of opposed sides corresponding substantially to apertures on the opposed side;

    providing a plurality of contacts, each contact having an upper portion and a lower portion;

    inserting the plurality of contacts into the apertures from the upper surface to the lower surface on opposed sides of the housing so that the upper portion of each contact is positioned in the upper portion of the aperture, while the lower portion of the contact extends through the lower portion of the aperture, a portion of the lower portion of each contact extending through the housing opposite the upper portion of the contact;

    providing a metallic foil having a plurality of strips of predetermined thickness,providing a first beam, the beam having a plurality of fingers extending from a beam surface, the beam further including a latch mechanism;

    placing the foil between the first beam and the housing so that a strip of the plurality of strips extend across apertures on at least the first side of the housing;

    capturing the foil in the contacts by inserting the plurality of fingers of the first beam into the apertures so that the fingers are captured within the upper portion of the contacts on the first side of the housing and electrically connecting the plurality of strips to the plurality of contacts on the first side;

    providing a mandrel;

    providing a second first beam, the beam having a plurality of fingers extending from a beam surface, the beam further including a latch mechanism;

    positioning the metallic foil so that each strip of the plurality of strips extend over apertures on the second side of the housing;

    while maintaining the mandrel in contact with the foil, inserting the second beam so that the plurality of fingers capture the foil in the contacts by inserting the plurality of fingers of the second beam into the apertures on the second side of the housing wherein the fingers are captured within the upper portion of the contacts on the second side of the housing and electrically connecting the plurality of strips to the plurality of contacts on the second side; and

    ;

    removing the mandrel from contact with the strips of metallic foil.

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