Abstract:
In one aspect, the invention provides a method for making an electrical connector. The method may include: obtaining a part having a first end portion, a second end portion, and an interim  1  portion between the first and second end portions; flattening the second end portion; trimming the flattened second end portion; and forming a hole in the flattened second end portion.

Description:
This application claims the benefit of U.S. Provisional Patent Application No. 60/558,547, filed on Apr. 2, 2004, the disclosure of which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to electrical connectors and a method for making the same. In one aspect, the invention relates to pin shaped connectors. 
     2. Discussion of the Background 
     There is a need for a method of producing an electrical connector in a cost competitive manner. 
     SUMMARY OF THE INVENTION 
     The present invention provides an electrical connector and a method for making the same. 
     In one embodiment, a method for making an electrical connector includes: obtaining a part having a first end portion, a second end portion, and an interim portion between the first and second end portions; flattening the second end portion, wherein the second end portion has a first face and a second face; trimming the flattened second end portion; and forming a hole in the flattened second end portion, the hole extending from the first face to the second face. Advantageously, the part may be selectively plated. 
     The above and other features and advantages of the present invention, as well as the structure and operation of preferred embodiments of the present invention, are described in detail below with reference to the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings, which are incorporated herein and form part of the specification, help illustrate various embodiments of the present invention and, together with the description, further serve to explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the invention. In the drawings, like reference numbers indicate identical or functionally similar elements. Additionally, the left-most digit(s) of a reference number identifies the drawing in which the reference number first appears. 
         FIG. 1  is a flow chart illustrating a process for making an electrical connector according to an embodiment. 
         FIGS. 2A and 2B  illustrate a pin shaped part having a chamfered mating end and a second end opposite the chamfered mating end. 
         FIG. 3  is an illustration of the part shown in  FIG. 2 , wherein the end opposite the chamfered mating end is flattened. 
         FIG. 4  is an illustration of the part after the flattened end has been trimmed into a desired shape. 
         FIG. 5  is an illustration of an electrical connector according to an embodiment. 
         FIG. 6A  shows an embodiment of an electrical connector according to the present invention. 
         FIG. 6B  illustrates a flattened end portion according to an embodiment. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       FIG. 1  is a flow chart illustrating a process  100 , according to an embodiment of the invention, for making an electrical connector. Process  100  may being in step  102 , where a part  200  is obtained (see  FIG. 2A ). In some embodiments, part  200  is a wire formed pin and includes a chamfered mating end  202 , a second end  204  opposite the chamfered mating  202  end, and an interim portion  203  between ends  202  and  204 . Part  200  may also have a retention star  206  formed thereon. In some embodiments, part  200  is generally elongate, cylindrical in shape and rigid. Thus, in some embodiments, part  200  has a generally circular cross section as shown in  FIG. 2B . In embodiments where part  200  has a generally circular cross section, the diameter of the part, in some embodiments, may be generally between 0.12 to 0.03 inches. In one embodiment, the diameter is about 0.06 inches. Members  206 ( a )–( d ), which extend radially from the outer surface of part  200  and which make up star  206 , are also illustrated in  FIG. 2B . 
     In step  104 , the second end  204  is squashed, coined or otherwise flattened (see  FIG. 3 , which shows a side view of part  200 ). After step  104 , second end  204  may have a generally rectangular cross section. In some embodiments, the thickness (t) of the flattened end is between about 0.01 to 0.06 inches. In some embodiments, the preferred thickness (t) is about 0.03 inches. 
     In step  106 , the flattened second end  204  is processed into a desired shape (see  FIG. 4 , which shows a top view of part  200  and  FIG. 6B ). For example, the flattened second end may be trimmed. In step  108 , a hole  504  is created in the flattened second end  204 , wherein the hole extends from a top face  410  to a bottom face  411  of the flattened second  204 , thereby forming an eye (see  FIG. 5 , which is also a top view of part  200 ). In some embodiments, hole  504  is generally elliptical in shape. In step  110 , part  200  is selectively plated. That is, one or more selected portions of part  200  are plated. 
     Referring now to  FIG. 6A ,  FIG. 6A  illustrates part  200  according to some embodiments. In some embodiments, the length (L 1 ) of part  200  may generally range between about 1 and 4 inches and the length (L 2 ) of end portion  204  may generally range between about 0.1 and 0.5 inches. In some embodiments, L 1  is preferably about 2 inches and L 2  is about 0.2 inches. 
     Referring now to  FIG. 6B ,  FIG. 6B  illustrates flattened end portion  204  according to some embodiments. In some embodiments, flattened end portion  204  includes a first end section  602 , a second end section  606  and an interim section  604  disposed between end sections  602  and  606 . The length (L 4 ) of first end section  602 , in some embodiments, may generally range between 0.1 and 0.02 inches. In one embodiment, L 4  is about 0.045 inches. The width (W 2 ) of first end section  602 , in some embodiments, may generally range between 0.08 and 0.02 inches. In one embodiment, W 2  is about 0.04 inches. As shown in  FIG. 6B , in some embodiments, the width of section  602  is generally uniform along the entire length of section  602 . 
     The length (L 5 ) of the interim section  604 , in some embodiments, may generally range between 0.3 and 0.05 inches. In one embodiment, L 5  is about 0.15 inches. The width (W 1 ) of interim section  604 , in some embodiments, may generally range between 0.15 and 0.03 inches. In one embodiment, W 1  is about 0.07 inches. As shown in  FIG. 6B , in some embodiments, the width of section  604  is generally non-uniform along the length of section  604 . The width may be widest across the middle of section  604  as shown in the figure. The length (L 3 ) of hole  504 , in some embodiments, may generally range between 0.2 and 0.05 inches. In one embodiment, L 3  is about 0.1 inches. 
     Although the above described process is illustrated as a sequence of steps, it should be understood by one skilled in the art that at least some of the steps need not be performed in the order shown, and, furthermore, some steps may be omitted and additional steps added without departing from the scope of the invention. 
     While various embodiments/variations of the present invention have been described above, it should be understood that they have been presented by way of example only, and not limitation. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.