Contact with anti-skiving feature

Abstract: A contact (10), insertable into an insulative housing of a connector (100), has a mating end (11) for receiving a mating contact; a retention portion (21) for insertion into the connector; and a mounting end (13) opposite the mating end. The mounting end has a transition area (19) adapted to pass through the insulative housing without substantially skiving the insulative housing.

Description: Background of the Invention 1. Field of the Invention The present invention relates to a contact with an anti-skiving feature. More specifically, the present invention relates to a contact capable of insertion within a connector housing without substantial skiving of the connector housing. The invention also comprises a method of making said contact, a connector and a carrier strip. 2. Brief Description of Earlier Developments When separating contacts from a carrier strip, a cutting tool typically creates a severed edge with a burred region. When the cut-off travels through the connector housing during insertion, the burr skives a layer of material from the retention portion of the connector housing. The skiving of the connector housing may reduce the amount of retention force imparted by the connector housing to retain the contact. In addition, the portion of the housing skived.by the burr may remain on the contact after passing through the connector housing. To remove the skived portion from the contact, the connector assembly process requires an additional step. The connector assembly could use, for example, a brushing step to remove the skived portion from the contact prior to securing a fusible element to the contact. The additional step increases manufacturing costs. Without removal, the skived portion may interfere with the proper attachment of the fusible element to the contact. Thus, the presence of the skived portion is unacceptable, especially in automated applications. Clearly, there is room for improvement in the art. DE-A-3 936 414 A1 discloses an electrical connector comprising a plastic housing and several blade-type contacts. Said blade-type contacts are inserted into slots in said housing. In order to fix said contacts, said housing comprises barb-like latching means which engage apertures in said contacts. It is a disadvantage of said electrical connector that said barb-like latching means and said contacts with said suitable apertures have to be produced with low tolerance to provide an exact fitting. Particularly, this aspect causes an expensive production. Furthermore, in case of a failure of said contacts, they cannot be replaced after their insertion in the housing without damaging or destroying said latching means of the housing. Therefore, it is always necessary to change the whole electrical connector in case of a failure of one blade-type contact. It is therefore the problem of the present invention to provide a contact of simple construction which can be easily inserted and exchanged in an electrical connector. In view of the prior art, it is a further problem to provide a less expensive method of making said contact. Finally, it is another problem of the present invention to provide a connector being less complex in construction than the known connectors. Summary of the Invention The above problems are solved by the subject-matters of independent claims 1, 7, 12 and 20 disclosing a contact, a method of making said contact, a connector and a carrier strip. The contact is insertable into an insulative housing of a connector and has a mating end for receiving a mating contact; a retention portion for insertion into the connector; and a mounting end opposite the mating end. The mounting end has a transition area adapted to pass through the insulative housing without substantially skiving the insulative housing. The carrier strip includes: a sheet of material having an edge; and at least one contact. The contact has a mounting end extending from said edge and including a window; a retention portion extending from the mounting end; and a mating end extending from the retention portion. The connector has an insulative housing with at least one aperture therethrough; and a contact insertable within said aperture. The contact has a mating end for receiving a mating contact; a retention portion for engaging the connector; and a mounting end opposite the mating end and having a die controlled region adjacent the retention portion. The die controlled region can pass through the insulative housing of the connector without substantially skiving the insulative housing. The method of making a contact includes the steps of: providing a sheet of material; stamping the sheet to form a carrier strip having an edge and a plurality of contacts, each having a mounting end extending from said the of the carrier strip; placing a window in the mounting ends of the contacts; and removing the contacts from said carrier strip. Brief Description of the Drawings Other uses and advantages of the present invention will become apparent to those skilled in the art upon reference to the specification and the drawings, in which: Figure 1 is an elevational view of one alternative embodiment of a contact of the present invention; Figure 2 is a an elevational view of a series of contacts of the present invention on a carrier strip; Figure 3 is an enlarged view of a portion of the carrier strip and contact shown in Figure 2; Figure 4 is a cross-sectional view of a portion of the carrier strip and contact taken along line IV-IV of Figure 3; Figure 5 is a plan view of a portion of connector housing capable of receiving a contact of the present invention; Figure 6 is a cross-sectional view of a portion of the connector housing taken along line VI-VI of Figure 5; Figure 7 is a plan view of the portion of the connector housing shown in Figure 5 with a contact of the present invention inserted therein; and Figure 8 is a cross-sectional view of the portion of the connector housing and contact taken along line VIII-VIII in Figure 7. Detailed Description of the Preferred Embodiments Figure 1 displays one alternative embodiment of a contact 10 of the present invention. As discussed in more detail below, contact 10 is part of a connector 100. Contact 10 has a mating end 11 that extends from connector 100 to interact with a corresponding contact (not shown) extending from a mating connector (not shown). As an example, the blade-type contact shown in Figure 1 preferably interacts with a dual beam contact on the mating connector. However, any type of contact could be used with the present invention. A mounting end 13 opposes mating end 11 of contact 10. Mounting end 13 preferably includes a notch 15 flanked by arms 17. The wall that defines notch 15 includes a generally smooth transition area 19. Transition area 19 is an area of reduced thickness, and preferably has a beveled or an arcuate shape as seen in Figure 4. Preferably, transition area 19 is located on an-area of the wall of notch 15 closest to mating end 11. The benefits of notch 15 and transition area 19 will become more apparent below. A retention portion 21 extends between mating end 11 and mounting end 13 of connector 10. Retention portion 21 is the portion of contact 10 that interference fits within connector 100. Retention portion 21 may include anti-wicking apertures 23 that helps prevent the possible wicking of solder towards mating end 11 during later manufacturing steps. The steps of making contact 10 will now be described with reference to Figures 2-4. Machines, such as conventional stamping machines, form a series of contacts 10 on a carrier strip 200. Carrier strip 200 is a sheet of suitable conductive material. In addition to forming the outline of contact 10 and punching anti-wicking apertures 23, the stamping process also forms a window 25 in contact 10. The portion of the wall that forms window 25 and is located adjacent retention portion 21 is deformed to create transition area 19. Preferably, transition area 19 is a die controlled region. A coining operation preferably forms transition area 19. However, other methods of creating transition area 19 could be used. After the coining step, a cutting step severs contacts 10 from carrier strip 200, creating discrete contacts. When cut from carrier strip 200, window 25 of contact 10 becomes notch 15. Contacts 10 are placed into connector 100 after severing using known techniques. Connector 100 will now be described with reference to Figures 5-8. Connector 100 includes an insulative housing 101 with an array of apertures 103 extending between a mating surface 105 and a mounting surface 107. Adjacent mating surface 105, each aperture 103 preferably has lead-in surfaces 109, 111. Lead-ins 109, 111 help align contacts 10 with apertures 103 during assembly of connector 100. Apertures 103 also include a reduced width portion between mating surface 105 and mounting surface 107 as seen in Figures 6 and 8. The reduced width portion forms a retention zone 113 that retains contact 10 using an interference fit. As shown in Figures 5 and 7, retention zone 113 can be a rib that projects inwardly from the walls that form aperture 103. Retention zone 113 can also extend axially along a length of aperture 103. Although shown as a rib, other protuberances could be used to form the reduced width portion. Since the mating connector preferably has dual beam contacts that mate with contacts 10, insulative housing 101 can include a pair of beam receiving notches 117 that communicate with each aperture 103. Receiving notches 117 can receive the distal ends of the dual beams during mating with contacts 10. Receiving notches 117 are sized to accommodate the deflection of the dual beams when the dual beam contacts mate with contacts 10. Connector 100 preferably surface mounts to a substrate (not shown) using reflow techniques, preferably Ball Grid Array (BGA) technology. To assist surface mounting, aperture 103 can have an enlarged portion 115 adjacent mounting surface 107. As shown in Figure 8, enlarged portion 115 is dimensioned to receive at least a portion of a fusible element 117, such as a solder ball. International Publication number WO 98/15989 (International Application number PCT/US97/18066), describes methods of securing a solder ball to a contact. The insertion of contact 10 into connector 100 will now be described with reference to Figures 7 and 8. The insertion of contact 10 into connector 100 occurs, using known techniques, after contact 10 is severed from carrier strip 200. Mounting portion 13 of contact 10 enters aperture 103 first. Legs 17 of contact 10 freely pass by retention zone 113 of connector 100 since legs 17 are not aligned with retention zone 113. Transition area 19 of contact 10, however, is aligned with, and engages, retention zone 113 during insertion. Further insertion of contact 10 into connector 100 brings retention portion 21 into engagement with retention zone 113. Due to its shape, transition area 19 does not skive retention zone 113 during insertion. The insertion of contact 10 into connector 100 can be accomplished with automated techniques. With contact 10 properly seated in connector 100, fusible element 117 can be attached to contact 10 using, for example, the techniques described in International Publication number WO 98/15989 described above. With the present invention, fusible element 117 can attach to contact 10 without the need for an intermediate step of preparing contact 10, such as brushing the skived portion from contact 10. Dual arms 17 and notch 15 can help improve the security and placement of fusible element 117 on contact 10. First, dual arms 17 and notch 15 provides more surface area upon which fusible element 117 can attach than with conventional contacts. A larger surface area can increase the bonding force between fusible elements 117 and contacts 10. In addition, notch 15 can help align fusible element 117 on contact 10. During reflow, fusible element 117 flows into the void area formed by notch 15 even if fusible element 117 is not properly centered on contact 10. The reflow of a portion of fusible element 117 into the void causes the displacement of the remainder of fusible element 117 towards the void area. In other words, fusible element 117 moves towards a centered position during reflow. This helps provide a more uniform connector 100. While the present invention has been described in connection with the preferred embodiments of the various figures 1 to 8, it is to be understood that other similar embodiments may be used or modifications and additions may be made to the described embodiment for performing the same function of the present invention without deviating therefrom. Therefore, the present invention should not be limited to any single embodiment, but rather construed in breadth and scope in accordance with the recitation of the appended claims.

Claims: A contact (10) insertable into an insulative housing (101) of a connector (100), comprising: a. a mating end (11) for receiving a mating contact; b. a retention portion (21) for insertion into said insulative housing (101) of said connector (100); and c. a mounting end (13) opposite said mating end (11) and having a transition area (19), characterized in that d. said transition area (19) formed in a wall of a notch (15) of said contact (10) adjacent said retention portion (21) has a beveled or an arcuate shape adapted to pass through said insulative housing (101) of said connector (100) without substantially skiving said insulative housing (101). The contact (10) according to claim 1, characterized in that said transition area (19) comprises an area of reduced thickness compared to the thickness of the remaining contact (10). The contact (10) according to claim 2, characterized in that said transition area (19) is coined. The contact (10) according to claim 3, characterized in that said transition area (19) is substantially smooth. The contact (10) according to claim 4, characterized in that said transition area (19) is tapered or rounded. The contact (10) according to claim 1, characterized in that said mounting end (13) further comprises a notch (15) defined by a wall and a pair of arms (17) flanking said transition area (19). A method of making a contact (10) according to claim 1 comprising the steps of: a. providing a sheet of material; b. stamping said sheet to form a carrier strip (200) having an edge and a plurality of contacts (10), each contact (10) having a mounting end (13) extending from said edge of said carrier strip (200); c. placing a window (25) in said mounting ends (13) of said contacts (10); d. removing said contacts (10) from said carrier strip (200), characterized by further comprising e. the step of die controlling a region of said window (25) to form a transition area (19) adjacent a retention portion (21) opposite said mounting end (13). The method of making a contact (10) according to claim 7, characterized by further comprising the step of deforming said transition area (19). The method of making a contact (10) according to claim 8, characterized in that said step of deforming comprises the step of coining a region of said window (25). The method of making a contact (10) according to claim 9, characterized in that said deforming step comprises the step of smoothing said transition area (19) or that said deforming step comprises the step of tapering said transition area (19). The method of making a contact (10) according to claim 7, characterized in that said removing step comprises cutting said contacts (10) across said mounting ends (13), wherein the cut passes through said windows (15). A connector (100) having an insulative housing (101) with at least one aperture (103) therethrough; and a contact (10) insertable within said aperture (103) comprising: a. a mating end (11) for receiving a mating contact; b. a retention portion (21) for insertion into said insulative housing of said connector (100); and c. a mounting end (13) opposite said mating end (11) and having a transition area (19), characterized in that d. said transition area (19) formed in a wall of a notch (15) of said contact (10) adjacent said retention portion (21) has a beveled or an arcuate shape adapted to pass through said insulative housing (101) of said connector (100) without substantially skiving said insulative housing (101). The connector according to claim 12, characterized in that said transition area (19) comprises an area of reduced thickness compared to the thickness of the remaining contact (10). The connector according to claim 13, characterized in that said transition area (19) is coined. The connector according to claim 14, characterized in that said transition area (19) is tapered or rounded and that said transition area (19) is substantially smooth. The connector according to claim 15, characterized in that said mounting end (13) further comprises a notch (15) defined by a wall and a pair of arms (17) flanking said transition area (19). The connector according to claim 12, characterized by further comprising a fusible element (117) attachable to said contact (10) wherein said fusible element (117) is a solder ball. The connector according to claim 12, characterized in that said insulative housing (101) comprises a mating side (105) and a mounting side (107) and a pattern of said apertures (103) through said insulative housing (101) from said mating side (105) to said mounting side (107), said apertures (103) having generally parallel side walls and a first width near said mating side (105) and having a retention bump protruding into the aperture (103) near the mounting side (107) such that the aperture (103) has a second smaller width. The connector according to claim 18, characterized in that said aperture (103) comprises a first section for receiving said transition area (19) and a second section for receiving said pair of arms (17) and said solder ball (117) whereby any skived plastic is prevented from interfering with a solder joint between said solder ball (117) and said pair of arms (17). A carrier strip (200), comprising a sheet of material having an edge and at least one contact (10), comprising: a. a mating end (11) for receiving a mating contact; b. a retention portion (21) for insertion into an insulative housing (101) of a connector (100); and e. a mounting end (13) opposite said mating end (11) and having a transition area (19), characterized in that f. said transition area (19) formed in a wall of a window (25) of said contact (10) adjacent said retention portion (21) has a beveled or an arcuate shape adapted to pass through said insulative housing (101) of said connector (100) without substantially skiving said insulative housing (101). The carrier strip (200) according to claim 20, characterized in that said transition area (19) comprises an area of reduced thickness compared to the thickness of the remaining contact (10). The carrier strip (200) according to claim 21, characterized in that said transition area (19) is coined. The carrier strip (200) according to claim 22, characterized in that said transition area (19) is substantially smooth. The carrier strip (200) according to claim 23, characterized in that said transition area (19) is tapered or rounded. The carrier strip (200) according to claim 24, characterized in that said mounting end (13) further comprises a notch (15) defined by a wall and a pair of arms (17) flanking said transition area (19).

Inventors: STANSBURY ALAN L, STANSBURY, ALAN L.
Applicants: FRAMATOME CONNECTORS INT, FCI
Application year: 1999
Main classification: H01R13
IPC codes: H01R24, H01R13