Abstract:
Methods and apparatus are provided for removing plating from a device. The method and apparatus may be used for preparing an electrical connector for connecting at least one wire or other terminus thereto where the electrical connector has at least one electrical contact with a metal coating thereon. The method includes the steps of applying molten solder to the electrical contact whereby the coating dissolves into the molten solder to thereby create a molten coating-solder mixture and rotating the electrical connector whereby the molten coating-solder mixture is removed from the electrical contact.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates to electrical connectors and, more specifically, to a tool and method for extracting solder from the solder cups of the electrical connectors.  
       BACKGROUND OF THE INVENTION  
       [0002]     Electrical connectors are used in myriad applications for joining wires and electrical components to one another. Typically, an electrical connector includes a housing and a plurality of electrical contact pins that extend through the housing. In some configurations, the electrical contact pin includes a contact end and a wire input end. The wire input end is typically shaped like a cup and when the electrical connector is joined to a wire, the wire is placed in the cup and molten solder is utilized to join the two together. Hence, the wire input end is referred to in the art as a “solder cup”.  
         [0003]     In order to prevent oxidation and wear of the contact pins and the solder cups, an oxidation-resistant material, such as gold, may be plated on to both. However, when the molten solder is applied to the solder cups during a soldering process, the plated gold melts and dissolves into the solder. The gold contaminates the solder, thereby compromising the strength of the soldered joint between the wire and the contact pin. Therefore, as part of the wire joining process, the gold plating is desirably removed from the solder cup.  
         [0004]     Conventionally, the gold plating has been removed by first pre-tinning the solder cup and then manually extracting the excess solder from each individual solder cup. Typically, a technician first applies molten solder to each of the solder cups. Next, the technician uses a soldering iron to apply heat to one of the soldered solder cups to melt the solder within the solder cup. The melted solder causes the gold plating to melt and dissolve into the solder. A solder wick is then used to draw the molten solder and gold out of the cup.  
         [0005]     Although the conventional method is effective, it may be time-consuming, and thus potentially costly. For example, manual extraction of the gold plating from one solder cup may take up to a minute. If an electrical connector has over one hundred electrical contacts, a technician may spend over an hour and a half on the extraction step alone.  
         [0006]     Hence, there is a need for a method of soldering a wire to a wire connector that addresses one or more of the above-noted drawbacks. Namely, a soldering method is needed that is more time-efficient and simple to implement, and thus less costly than present methods. The present invention addresses one or more of these needs.  
       BRIEF SUMMARY OF THE INVENTION  
       [0007]     A method is provided for preparing an electrical connector for connecting at least one wire thereto, where the electrical connector having at least one electrical contact with a coating thereon. The method includes the steps of applying molten solder to the electrical contact whereby the coating dissolves into the molten solder to thereby create a molten coating-solder mixture and rotating the electrical connector whereby the molten coating-solder mixture is removed from the electrical contact.  
         [0008]     In another embodiment of the invention, an apparatus for use in removing a coating from a coated electrical contact of an electrical connector is also provided. The apparatus includes a shaft, a plate assembly, and a motor. The plate assembly is coupled to the shaft, and has a first side and a second side and an aperture extending at least partially therebetween. The aperture is configured to receive the electrical contact of the electrical connector. The motor is coupled to the shaft and configured to supply rotational energy to thereby rotate the shaft and the plate assembly.  
         [0009]     In yet another embodiment of the invention, an apparatus for use with a rotatable shaft in removing a coating from a coated electrical contact of an electrical connector is provided. The apparatus includes a plate assembly, an aperture, and at least one fastener opening. The plate assembly has first and second sides and is configured to couple to the rotatable shaft. The aperture is formed between the plate first and second sides, and is configured to receive the contact end of the electrical contact. The at least one fastener opening is configured to receive a fastener for fastening the electrical connector to the plate assembly. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0010]     The present invention will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and  
         [0011]      FIG. 1  is a perspective view of an electrical connector;  
         [0012]      FIG. 2  is an exploded side view of an exemplary tool with the electrical connector illustrated in  FIG. 1  that may be used for an exemplary embodiment of the method;  
         [0013]      FIG. 3  is a top view of an exemplary cradle that may be used with the exemplary tool illustrated in  FIG. 2 ;  
         [0014]      FIG. 4  is a top view of an exemplary insert that may be used with the exemplary tool illustrated in  FIG. 2  and the exemplary cradle illustrated in  FIG. 3 ; and  
         [0015]      FIG. 5  is a flowchart illustrating an exemplary embodiment of the inventive method. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0016]     The following detailed description of the invention is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any theory presented in the preceding background of the invention or the following detailed description of the invention. Although the invention is described as being used for extracting solder from solder cups on an electrical connector, it will be appreciated that the invention may also be used with any other type of component having plating or a soluble contaminate thereon that may need to be removed.  
         [0017]     Turning now to  FIG. 1 , an exemplary electrical connector  100  is shown. The electrical connector  100  includes a housing  102  and a plurality of electrical contacts  104 . The housing  102  has a plurality of sidewalls  106  and top and bottom walls  108  and  110 , respectively. The top wall  108  is coupled to the sidewalls  106  such that it forms a well  111  with the sidewalls  106 . Additionally, a plurality of apertures  112 ,  114  are formed in the top and bottom walls  108 ,  110 . Each aperture  112  formed in the top wall  108  is aligned with a corresponding aperture  114  on the bottom wall  110 . The apertures  112 ,  114  are each configured to receive one of the plurality of electrical contacts  104 .  
         [0018]     Each electrical contact  104  is generally tubular and is constructed of an electrically conductive material. The electrical contact  104  has a contact end  116  and a wire joint end  118 . The electrical contacts  104  are placed within the housing  102  such that the contact end  116  extends out from the top wall  110  of the housing  102 , while the wire joint end  118  extends out from the bottom wall  108  of the housing  102 . The wire joint end  118  includes a cup  120  that is configured to receive a wire end or other terminus within its interior. Each electrical contact  104 , hence, the cup  120 , is plated with an oxidation-resistant metal, such as, for example, gold.  
         [0019]     Before a wire is joined to each electrical contact  104 , the plated metal is preferably removed from the contact  104 . Referring now to  FIG. 2 , an exploded view of a tool  200  that may be used to remove the plated metal is illustrated. For context, an electrical connector  100  is also in  FIG. 2 . In general, the tool  200  includes a shaft  202 , a plate assembly  204 , a motor  206 , and a housing  208 . In the depicted embodiment, the shaft  202  is generally cylindrical and has a first end  210  and a second end  212 . The shaft first end  210  is configured to couple to the plate assembly  204 , and the shaft second end  212  is coupled to the motor  206 .  
         [0020]     The plate assembly  204  is generally configured to allow the electrical connector  100  to temporarily mount thereto. Any one of numerous configurations may be employed in this regard. In one exemplary embodiment, such as the one illustrated in  FIG. 2 , the plate assembly  204  includes a cradle  214  and an insert  216 . As illustrated in further detail in  FIG. 3 , the cradle  214  has four walls  215  arranged in a generally rectangular configuration to form a slot  218  therebetween. An appendage  219  extends perpendicularly from one of the walls  215 , and is configured to couple to the shaft first end  210 . The cradle  214  also has a plurality of fastener openings  220  that are each configured to receive a fastener.  
         [0021]     As shown in  FIG. 4 , the insert  216  is generally rectangular in shape and includes a plurality of cavities  222  that extend at least partially through the insert  216 . The cavities  222  are preferably arranged in substantially the same pattern in which the electrical contacts  104  are arranged on the particular electrical connector  100  being processed. In addition, each cavity  222  is sized and shaped to receive the wire joint ends  118  of the electrical contacts  104 . Thus, when the electrical connector  100  is attached to the tool  200 , the wire joint ends  118  of the electrical contacts  104  will be positioned radially outward from the shaft  202 . As  FIG. 4  also shows, the insert  216  also preferably includes at least one fastener opening  224 . Each fastener opening  224  is collocated with one of the fastener openings  220  in the cradle  214  and is configured to receive a fastener for fastening the electrical connector  100  to the plate assembly  204  and the insert  216  to the cradle  214 .  
         [0022]     Although the plate assembly  204  is described above as having both the cradle  214  and the insert  216 , it will be appreciated that in other exemplary embodiments of tool  200 , the insert  216  may be coupled to the shaft  202  without the cradle  214  or the cradle  214  may be coupled to the shaft  202  without the insert  216 . Additionally, although the plate assembly  204 , cradle  214 , and insert  216  are described herein as generally rectangular, it will be appreciated that any other suitable shape may be employed as well.  
         [0023]     Returning to  FIG. 2 , the motor  206  has a rotor  230  coupled to the shaft second end  212 . The motor  206  is also coupled to a power source  228 . The power source  228  supplies energy to the motor  206  to spin the rotor  230 , and thus, the shaft  202  and plate assembly  204 . Any one of numerous devices configured to provide power may be utilized. In one exemplary embodiment, the power source  228  is a plug (shown in phantom) that is electrically coupled to a power outlet. In another exemplary embodiment, the tool  200  itself is mounted to a power outlet (not shown). In yet another exemplary embodiment, the power source  228  is a battery (not shown) configured to provide sufficient energy to the motor  206  to thereby spin the shaft  202  and plate assembly  204 . In yet another exemplary embodiment, the power source  228  uses pneumatics, such as compressed gas, or hydraulics, such as pumped liquid, to energize the motor  206 .  
         [0024]     In another exemplary embodiment, the shaft  202  and motor  206  can be at least partially disposed within a housing  208 . The housing  208  is preferably dimensioned to fit in a hand and/or provide a surface for the operator to grip the tool  200 . In still yet another exemplary embodiment, the plate assembly  204  is configured to attach to and detach from a conventional rotary tool. The plate assembly  204  can be an accessory that is preferably configured to fit with any type of rotary tool, such as, for example, a drill. In yet other exemplary embodiments, the tool  200  may be incorporated into a robotic machine for use in an automated process.  
         [0025]     In yet another exemplary embodiment of the tool  200 , an indicator  229  may be included on the tool  200  that provides a mark to indicate an appropriate dipping depth. The indicator  229  may be any type of marking formed on the plate  204 .  
         [0026]     With reference to  FIG. 5 , an exemplary embodiment of the method ( 500 ) by which the plating metal is removed from a solder cup will now be described. First, the electrical connector  100  is coupled to the tool  200  ( 510 ). Then, molten solder is applied to the electrical connector  100  ( 520 ). Next, the electrical connector  100  is rotated ( 530 ). These steps will now be discussed in further detail.  
         [0027]     The step of coupling the electrical connector  100  to the tool  200  ( 510 ) is achieved in any one of numerous fashions, depending upon the particular configuration of the tool  200 . For example, if the exemplary tool  200  depicted in  FIG. 2  is used, an operator first inserts the wire joint ends  118  of the electrical connector  100  into corresponding cavities  222 . Then, the electrical connector  100  is fastened to the plate assembly  204  using any one of numerous types of fasteners, such as a screw, clip, spring clamp, or other mechanical mechanism, or alternatively, via magnetic or adhesive fasteners.  
         [0028]     Returning to  FIG. 5 , once the electrical connector  100  is coupled to the tool  200 , molten solder ( 520 ) is applied to one or more of the electrical contacts  104 . The molten solder may be contained in any one of numerous types of containers that maintains the solder in its molten state. For example, any one of numerous conventional molten solder pot could be used. In one exemplary embodiment, the operator dips at least the electrical contacts  104  into the molten solder so that an appropriate amount of molten solder is applied thereto. In this regard, the operator may rely on the indicator  229  to determine how deep the tool  200  should be dipped into the molten solder. In yet another exemplary embodiment, the molten solder container is raised to contact the electrical contacts  104  within the molten solder. In yet another exemplary embodiment, solder is applied manually using a conventional solder gun or solder iron.  
         [0029]     No matter the particular method that is used to apply solder to the electrical contacts  104 , when this is done, the gold plating on the electrical contacts  104  melts and dissolves into the molten solder. To remove the solder/gold mixture from the electrical contacts  104 , the electrical connector  100  is then spun about an axis ( 530 ). In one exemplary embodiment, the tool  200 , or at least a portion thereof, is inserted into a protective container (not shown). The tool motor  206  is then energized causing it to rotate the plate assembly  204  and attached electrical connector  100 . The centrifugal force generated by this spinning motion slings the solder/gold mixture off of the connector  100  and into the protective container. This step is preferably performed immediately after the molten solder is applied to the gold plating so that the solder/gold mixture is still molten and readily removable from the electrical connector  100 . Alternatively, heat may be applied to the electrical contacts  104  using radiation, conduction, convection, or any other suitable means from any suitable heat source to maintain the solder in its molten state.  
         [0030]     In another exemplary embodiment of the method, the electrical contacts  104  are cleaned before the molten solder is applied to the electrical connector  100  ( 540 ). In one exemplary embodiment, solder flux is applied to the electrical contact  104 , via spraying, dipping or brushing the flux onto the wire contact ends  118  of the electrical contacts  104  using any suitable device to do so.  
         [0031]     Thus, a simple, time-efficient method of removing plating from has been provided. The method may be used to remove plating from an electrical connector, and more particularly, from the solder cups of an electrical connector. Moreover, the method may be used to remove plating from any device needing plating removed therefrom. An apparatus for use in the removing plating that is simple to use is provided as well.  
         [0032]     While at least one exemplary embodiment has been presented in the foregoing detailed description of the invention, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the invention. It being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the invention as set forth in the appended claims.