Abstract:
Provided is a contact pin with a solder cup. The solder cup is formed directly from the contact pin by a manufacturing process. The manufacturing process includes the steps of providing a wire, securing the wire in a carrier structure, cutting the wire to a predetermined length to form a contact, coining a first end of the contact to a predetermined thickness and forming the first end of the contact into a solder cup.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention is directed to electrical contact pins. More specifically, the present invention is directed to a method and system for manufacturing an electrical contact pin having a solder cup. 
       BACKGROUND OF THE INVENTION 
       [0002]    Solder cups are commonly used with contact pins for electrical applications. Solder cups provide a means for applying solder and securing the contact pin to a wire that allows connection to an electrical device or other suitable device or component. Solder cups may be manufactured directly from an end of the contact pin by a machining process. The machining process to form the solder cup from the contact pin is time consuming and undesirable waste is generated from the material removed from the contact pin to form the solder cup. Solder cups may also be manufactured by stamping flat material into a predetermined shape and rolling it into a round pin. This process involves the removal of significant amounts of material during manufacturing. These known manufacturing methods are inefficient and costly. 
         [0003]    Thus, there is an ongoing need for an efficient and low cost manufacturing process for manufacturing a contact pin having a solder cup. What is further needed is a manufacturing process that generates little or no waste when forming or manufacturing the solder cup. 
       SUMMARY OF THE INVENTION 
       [0004]    The present invention is directed to a method for manufacturing an electrical contact having a solder cup. The method includes the steps of providing a wire, securing the wire in a carrier structure, cutting the wire to a predetermined length to form a contact and forming the first end of the contact into a solder cup. 
         [0005]    The present invention is also directed to a method for manufacturing an electrical contact having a solder cup. The method includes the steps of providing wire on a carrier structure, cutting the wire to a predetermined length to form a contact, repeating the step of cutting the wire to a predetermined length to form a contact until the desired number of contacts are formed, and forming a first end of each contact of the plurality of contacts into a solder cup. 
         [0006]    The present invention is further directed to an electrical contact with a solder cup manufactured by a process. The process includes the steps of providing a wire, securing the wire in a carrier structure, and cutting the wire to a predetermined length to form a contact. The process also includes the steps of coining a first end of the contact to a predetermined thickness and forming the first end of the contact into a solder cup. 
         [0007]    An advantage of the present invention is a solder cup formed on the end of an electrical contact pin by a manufacturing process that generates minimal waste. 
         [0008]    Another advantage of the present invention is that the contact pin is disposed on a carrier, and the solder cup is formed from the contact pin, thereby providing a means for automated manufacturing. 
         [0009]    Yet another advantage of the present invention is the solder cup may be coated with a tin coating or other suitable coating without coating the remaining portion of the contact pin. 
         [0010]    Additional features and aspects of the present invention will become apparent to those of ordinary skill in the art upon reading and understanding the following detailed description of the exemplary embodiments. As will be appreciated by the skilled artisan, further embodiments of the invention are possible without departing from the scope and spirit of the invention. Accordingly, the drawings and associated descriptions are to be regarded as illustrative and not restrictive in nature. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    The accompanying drawings, which are incorporated into and form a part of the specification, schematically illustrate one or more exemplary embodiments of the invention and, together with the general description given above and detailed description given below, serve to explain the principles of the invention, and wherein: 
           [0012]      FIG. 1  shows a plan view of an apparatus forming electrical contact pins according to an embodiment of the disclosure. 
           [0013]      FIG. 2  shows an enlarged view of the apparatus in  FIG. 1 . 
           [0014]      FIG. 3  shows an enlarged view of the apparatus forming the solder cups on an end of the contact pins in  FIG. 2 . 
           [0015]      FIG. 4  shows an enlarged view of an electrical contact pin according to an embodiment of the disclosure. 
       
    
    
       [0016]    Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0017]    Exemplary embodiments of the present invention are now described with reference to the figures. Reference numerals are used throughout the detailed description to refer to the various elements and structures. In other instances, well-known structures and devices are shown in block diagram form for purposes of simplifying the description. Although the following detailed description contains many specifics for the purposes of illustration, anyone of ordinary skill in the art will appreciate that many variations and alterations to the following details are within the scope of the invention. Accordingly, the following embodiments of the invention are set forth without any loss of generality to, and without imposing limitations upon, the claimed invention. 
         [0018]      FIG. 1 . shows a carrier  10  with contact pins  28  having solder cups  14  formed on one end. Carrier  10  is formed from a strip of material  16 , such as metal (e.g. brass or steel) or other suitable material. Carrier sections  24  may be formed by a stamping process, where material  16  is stamped into a predetermined shape  20 , and the edges  22  of predetermined shape  20  are bent or formed upward to form a carrier structure  18 . Predetermined shape  20  may include slots  12  or other suitable receivers for accepting and securing contact pins  28  once contact pins  28  are inserted into carrier structure  24 . A wire strip  26  from a reel (not shown) or other suitable source is advanced into a carrier structure  18 , and wire strip  26  is cut to a predetermined length to form a contact pin  28 . Contact pin  28  is formed from wire strip  26  by cutting the wire strip  26  to a predetermined length. The remaining portion of wire strip  26  is advanced into the next carrier structure  18 , and then is cut to the same predetermined length to form a second contact pin  28  secured in carrier structure  18 . The process of forming contact pins  28  is repeated until the desired number of contact pins  28  are formed. 
         [0019]    Referring now to  FIG. 2 , once contact pin  28  is cut to the predetermined length and secured in carrier structure  18 , one end of contact pin  28  is coined to a predetermined thickness by a coining process  50 . Coined edge  30  may be trimmed to a predetermined shape  32  with predetermined dimensions by a trimming process  52 . Predetermined shape  32  may be for example, a rectangular configuration, and more specifically, a square configuration. While a rectangular configuration is described, it is appreciated that any suitable predetermined shape may be used. Next, predetermined shape  32  is formed into a solder cup  14 , by having the edges  34  of predetermined shape  32  folded or formed upward during a forming process  54 . When edges  34  are formed upward during forming process  54 , a “U” shaped configuration is formed. While  FIG. 2  shows solder cup  14  being manufactured by a three step process including coining process  50 , trimming process  52 , and forming process  54 , it is known that solder cup  14  may be formed by a two step process including coining process  50  and forming process  54 . 
         [0020]      FIG. 3  shows an enlarged view of the forming process  54  of solder cup  14  on the end of contact pin  28 . A coined and trimmed contact pin  28  is formed into solder cup  14 . A bottom form  36  presses into the underside or bottom side of predetermined shape  32  of coined and trimmed contact pin  28 . A top form  38  presses into the topside of predetermined shape  32  of coined and trimmed contact  28  substantially simultaneously with bottom form  36 . As top form  38  and bottom form  36  meet as they press into predetermined shape  32  of contact pin  28 , predetermined shape  32  is formed into solder cup  14 . When solder cup  14  is formed, little or no waste is generated. It is appreciated that bottom form  36  and top form  38  may form solder cup  14  from contact pin  28  after coining process  50 , and without trimming process  52 . It is also appreciated that bottom form  36  and top form  38  may form solder cup  14  from contact pin  28  without the coining process  50  and the trimming process  52 . 
         [0021]      FIG. 4  shows an enlarged view of contact pin  28  with solder cup  14  formed on one end. On the opposite end of contact pin  28 , a tip  42  is formed, having no sharp edges, but being formed with tapered surfaces. Tip  42  may be formed when contact pin  28  is cut from wire strip  26  ( FIG. 1 ), or tip  42  may be formed by a separate forming or trimming process. Zone  44  is the portion of contact pin  28  that is placed and secured in carrier structure  24  ( FIG. 1 ) of carrier  10  ( FIG. 1 ). Disposed on contact pin  28  substantially near the bottom of zone  44  is a retention feature  41 . Retention feature  41  facilitates a secure retention of contact pin  28  in a suitable device in which contact pin  28  is inserted for use after manufacture. 
         [0022]    A transition zone  46  connects solder cup  14  to contact pin  28 . Transition zone  46  is a tapered surface that gradually tapers from contact pin  28  to the base  48  of solder cup  14 . While any suitable dimensions may be used, solder cup may be 2.35 mm in length and 0.45 mm in height. When coined, contact pin  28  may have a thickness of 0.2 mm thick and solder cup may be 0.65±0.04 mm wide when formed. Wire  26  ( FIG. 1 ) may be a pre-plated material or wire  26  may be unplated when solder cup  14  is formed. Unplated pins  28  may then be plated with materials (e.g. nickel, then gold) across the entire pin  28 . Conversely, they may be entirely plated with a material (e.g. nickel). Plating suited for the function of each area may be applied only to those areas. For example, solder cup  14  may be plated with a material (e.g. tin) that would facilitate soldering of a wire. An area extending back from tip  42  could be plated with a different material (e.g. gold) in the area intended as a separable interface. Using multiple platings provides the best finish for the application of each end of the pin and helps control cost. The manufacturing process for the contact pin  28  with solder cup  14  may facilitate a process in which greater than on thousand contact pins  28  with solder cups  14  may be formed in one minute. It is also appreciated that less than one thousand contact pins may be formed per each minute, if desired. 
         [0023]    While the present invention has been illustrated by the description of exemplary embodiments thereof, and while the embodiments have been described in certain detail, it is not the intention of the Applicant to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the invention in its broader aspects is not limited to any of the specific details, representative devices and methods, and/or illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the Applicant&#39;s general inventive concept.