Patent Publication Number: US-6669499-B2

Title: Contact for pin grid array connector and method of forming same

Description:
BACKGROUND OF THE INVENTION 
     Certain embodiments of the present invention relate to a pin grid array contact, and more particularly to an pin grid array contact that provides more efficient assembly into an electrical connector. 
     Connectors are known for interconnecting various electrical media components, such as printed circuit boards (PCB), discrete circuit components, flex circuits and the like. Many printed circuit boards are connected to pin grid substrates by way of ZIF (zero insertion force) connectors. Typically, ZIF connectors include single or double point contacts that connect conductive pins, which extend from the pin grid substrate, to traces on the printed circuit board. Typically, the pin grid substrate, the connector, and printed circuit board are compressed together in order to ensure a conductive path between the pins, contacts and the traces on the printed circuit board. 
     FIG. 1 is an isometric view of a conventional connector including pin grid substrate  10 , a printed circuit board  16  and ZIF electrical connector  20 . The pin grid substrate  10  includes a member  12  from which pins  14  outwardly extend. The circuit board  16  includes circuitry connected to plated through holes  18 . The connector  20  includes a housing  22 , contact elements  24 , a cover  26  and a lever  28 . The housing  22  carries a number of regularly spaced cavities (not shown), positioned below the pins  14 . A groove  54  is open at one end  60  to accommodate the lever  28 . 
     Two blocks  64  with holes  66  therethrough are located on each side of the housing  22 . The holes receive roll pins  68 . The blocks  64 , holes and roll pins  68  cooperate with structures on the cover  26  to hold the cover on the housing  22 . The cover  26 , preferably molded with the same material as the housing  22 , contains vertical openings  70  therethrough in the same number and on the same spacing as cavities in the housing  22 . 
     Cam block  74  extends down below the lower surface  76  of the cover  26  and is channeled along its downwardly facing surface as indicated by reference numeral  78 . One corner of the cover  26  adjacent end  80  is recessed as indicated by reference numeral  82  to provide room for the lever  28 . 
     Blocks  84  extend downwardly from opposing sides  86  and  88  of the cover  26 . Both blocks  84  are outwardly displaced relative to the vertical plane of the sides. Further, the block  84  on side  86  is displaced downwardly, relative to top surface  72 , to provide a space for the arm of lever  28 . Each block contains an aperture  90  in each end face to receive roll pin  68 . One section of the member  92  extends outwardly from that side. 
     The lever  28 , a one piece member, includes handle  96  and cam section  98 . The cam section  98  is perpendicular to the handle  96 . A short connecting piece  100  joins the handle  96  and cam section  98  and displaces one relative to the other. After loading the contact elements  24  into the cavities, the lever  28  is placed into the housing  22 . The connecting piece  100  and the handle  96  extend out of the groove through open end  60 . 
     The cover  26  is placed onto the top surface  32  so that blocks  84  slide in between blocks  64  and block  74  enters into the enlarged portion  58 . The cover  26  is slidably attached to the housing  22  by sliding the roll pins  68  into the holes  66  in blocks  64  and the apertures  90  in the blocks  84 . The cover  26  is actuated against the top surface  32  of the housing  22  by the pivoting handle  96  of the lever  28 . Thus, the lever  28  provides the actuation necessary to mate the pins  14  with the contacts  24 . 
     The contacts  24  may contact the pins  14  at a single point, or at two points. Typically, a contact  24  that contacts a pin  14  at a single point is less reliable than a contact  24  that contacts a pin  14  at two points. A contact  24  that contacts a pin  14  at two points, moreover, is a redundant contact system. A redundant contact system is more reliable than a single contact system in that if the pin is slightly out of position, while one contact may not abut the pin  14 , another contact may abut the pin  14 . In other words, two points of contact are better than one point of contact. 
     Typically, the two point contact straddles the pin  14 , thereby offering another advantage over the single point contact. That is, the two point contact ensure proper positioning of the pin  14  because the pin  14  is positioned between two contact portions of the two point contact, as opposed to touching one point of contact, as with the single point contact. 
     Typically, two point contacts are stamped, or blanked, in conjunction with a carrier strip, from a unitary piece of conductive material. The two point contact is typically stamped such that the contact portions are oriented in a straight line. That is, one contact portion is located at one end of the line, while the other contact portion is located at the other end of the line. 
     FIG. 2 is an isometric view of a conventional two point contact  24 . FIG. 3 is an illustration of a conventional preformed, blanked two point contact  24  attached to a carrier strip  140 . As shown in FIG. 3, while in the preformed, blanked state, the contact portions  122  are aligned with one another such that the top surfaces  118  of the contact portions  122  are co-linear with each other. That is, line segment AB and line segment CD may be connected by dashed line BC, wherein line AD is a straight line. In order to form the contact, the contact portions  122  are bent as shown in FIG.  2 . 
     Forming two point contacts through stamping or blanking, however, produces wasted material. As shown in FIG. 3, the stamped, preformed contact typically must be sufficiently wide to allow the proper size of the contacting portions  122 , while at the same time ensuring that the contacting portions  122  will align with, or mirror, each other when the contact is formed. As a result, a greater portion of conductive material is wasted during the stamping process as compared to the stamping of a single point contact. 
     Further, unlike single point contacts, double point contacts typically cannot be stamped the same distance apart, that is, stamped on the same pitch, as that of the cavities in the connector housing. Typical connector housing cavities, or receptacles are positioned 1.27 mm, or 0.05″, apart from one another. However, stamped double point contacts typically cannot be stamped that same distance from each other. The pitch, or spacing, between center lines of formed contacts on a carrier strip may be 0.10″. Thus, when the double point contacts are inserted into the cavities, the contacts are individually inserted into the housing cavities. Alternatively the double point contacts may be skip inserted into the contacts because the contacts may be spaced twice the distance between the cavities of the connector housing. For example, a connector housing may include a matrix of 24 cavities by 24 cavities. If the contacts are skip inserted into a row (or column) of the matrix, 12 contacts may be inserted at one time. That is, the double point contacts may be stamped on double the pitch as that of the cavities. 
     Thus a need has existed for a more efficient way of method of stamping, or blanking double point micro pin grid array contacts. Further, a need has existed for a more efficient method of inserting double point pin grid array contacts into cavities or receptacles of a connector housing. 
     BRIEF SUMMARY OF THE INVENTION 
     In accordance with certain embodiments of the present invention, A pin grid array contact has been developed that comprises a planar main body defining, and arranged within, a primary contact plane. The main body has edges along opposed sides and along opposed ends. The contact also includes first and second spring beams integral with the main body and extending from a common one of the edges by different first and second lengths, respectively. The first length being longer than the second length. The first and second spring beams are aligned with the primary contact plane while the second spring beam may aligned in the primary contact plane. Optionally the second spring beam may be aligned with the primary contact plane, but may be bent toward the first spring beam, such that the second spring beam is no longer in the primary contact plane. The contact further comprises a paddle integral with and extending from one of the edges of the main body. The paddle is configured to adhere to a solder ball. The main body includes first and second radial positioners configured for positioning the main body into a cavity, or receptacle of a connector housing. 
     The first spring beam includes a first contacting portion located at a distal end of the first spring beam remote from the main body. The first and second contacting portions lie in different planes; and the first contacting portion is bent into alignment with the second contacting portion. Also, the second spring beam includes a second contacting portion located at a distal end of the second spring beam remote from the main body. The first and second spring beams are shifted laterally from one another with respect to a center line of the main body. The lateral shift is in a direction parallel to the primary contact plane. 
     While in the flat, stamped state, the second spring beam is offset from the first spring beam by a predetermined angle. The stamped double contacts are coplanar with the carrier strip. Then, the first and second spring beams are bent such that the first and second spring beams lie in different first and second planes, while the first contacting portion remains laterally aligned with the second contacting portion. 
     Certain embodiments of the present invention provide a method of forming a pin grid array contact. The method comprises stamping a contact having a main body formed with first and second spring beams from a planar single sheet of conductive material, in which the first and second spring beams have different first and second lengths that extend along first and second longitudinal axes, respectively. The first and second spring beams are aligned at an acute angle with one another and initially oriented in a primary contact plane defined by the main body. The method also comprises bending the second spring beam with respect to the main body until the second spring beam is located in a second beam plane that is separate from the primary contact plane. Additionally, the method comprises shifting the first and second spring beams laterally from one another with respect to a center line of the main body. The shifting step occurring in a direction parallel to the primary contact plane. Also, the method comprises aligning a first contacting portion of the first spring beam into alignment with a second contacting portion of the second spring beam. 
     Certain embodiments of the present invention also provide the following steps: providing a carrier strip integral with a plurality of the contacts in the primary contact plan; positioning adjacent contacts so that a distance between center lines of the adjacent contacts corresponds to a distance between two cavities located on a connector housing; and stamping a paddle on the main body and bending the paddle to be perpendicular to the main body of each contact. 
    
    
     BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS 
     FIG. 1 is an isometric view of a conventional connector with a pin grid substrate, a printed circuit board and a ZIF (zero insertion force) electrical connector. 
     FIG. 2 is an isometric view of a conventional two point contact. 
     FIG. 3 illustrates a conventional preformed, blanked two point contact attached to a carrier strip. 
     FIG. 4 is a front view of a carrier strip carrying a plurality of flat blanked contacts formed in accordance with an embodiment of the present invention. 
     FIG. 5 is an end view of a carrier strip carrying a plurality of flat blanked contacts formed in accordance with an embodiment of the present invention. 
     FIG. 6 is a front view of a contact formed in accordance with an embodiment of the present invention. 
     FIG. 7 is a side view of a contact formed in accordance with an embodiment of the present invention. 
     FIG. 8 is a top view of a contact formed in accordance with an embodiment of the present invention. 
     FIGS. 9 and 10 are isometric views of a contact formed in accordance with an embodiment of the present invention. 
     FIG. 11 is a front view of a carrier strip carrying a plurality of flat blanked contacts formed in accordance with an alternative embodiment of the present invention. 
     FIG. 12 is an end view of a carrier strip carrying a plurality of flat blanked contacts formed in accordance with an alternative embodiment of the present invention. 
     FIG. 13 is a front view of a contact formed in accordance with an alternative embodiment of the present invention. 
     FIG. 14 is a side view of a contact formed in accordance with an alternative embodiment of the present invention. 
     FIG. 15 is a top view of a contact formed in accordance with an alternative embodiment of the present invention. 
     FIGS. 16 and 17 are isometric views of a contact formed in accordance with an alternative embodiment of the present invention. 
     FIG. 18 is a side view of a contact and a carrier strip prior to insertion of the contact into the connector housing according to an embodiment of the present invention. 
     FIG. 19 is a side view of a contact positioned within a cavity of a connector housing according to an embodiment of the present invention. 
     FIG. 20 is a cross-sectional view of a cavity formed in accordance with an embodiment of the present invention. 
     FIG. 21 is a cross-sectional view of a cavity formed in accordance with an embodiment of the present invention. 
     FIG. 22 is a front view of a carrier strip carrying a plurality of flat blanked contacts formed in accordance with an embodiment of the present invention. 
     FIG. 23 is an end view of a carrier strip carrying a plurality of flat blanked contacts, formed in accordance with an embodiment of the present invention. 
     FIG. 24 is a side view of a contact formed in accordance with an embodiment of the present invention. 
     FIGS. 25 and 26 are isometric views of a contact formed in accordance with an embodiment of the present invention. 
     FIG. 27 is a side view of a contact and a carrier strip prior to insertion of the contact into the connector housing according to an embodiment of the present invention. 
     FIG. 28 is an isometric view of a contact and carrier strip prior to insertion of the contact into the connector housing according to an embodiment of the present invention. 
    
    
     The foregoing summary, as well as the following detailed description of certain embodiments of the present invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there is shown in the drawings, certain embodiments. It should be understood, however, that the present invention is not limited to the arrangements and instrumentality shown in the attached drawings. 
     DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 4 is a front view of a carrier strip  240  carrying a plurality of flat blanked contacts  202  formed in accordance with an embodiment of the present invention. FIG. 5 is an end view of a carrier strip  240  carrying a plurality of flat blanked contacts  202  formed in accordance with an embodiment of the present invention. The carrier strip  240  and the flat blanked contacts  202  are formed from a unitary, planar piece of conductive material, such as a copper alloy having a suitable plating, such as tin, lead or nickel. The carrier strip  240  includes cavities  236  and connection joints  234  that join the carrier strip  240  to the flat blanked contacts  202 . The connection joints  234  may be perforated to facilitate the release of the individual contacts  202  from the carrier strip  240 . 
     Each flat blanked contact  202  is coplanar with the carrier strip  240 . Each contact  202  includes a paddle  204 , first radial positioners  208 , second radial positioners  210 , a main body  206 , a first spring beam  212 , a second spring beam  214 , a first contacting portion  216  connected to the first spring beam  212 , and a second contacting portion  218  connected to the second spring beam  214 . The main body  206  has opposed side edges  246 ,  247  and opposed end edges  248 ,  249 . The first and second spring beams  212  and  214  are stamped integral with, and extend outward from end edge  249 . The first spring beam  212  extends a length  250  from the end edge  249 , while the second spring beam  214  extends a length  251  from the same end edge  249 . The first and second spring beams  212  and  214  are shifted laterally in the direction of arrow  213  from one another on opposite sides of the center line  230 . The lateral shift is parallel to the primary contact plane. The center line of each contact  202  is denoted by reference line  230  that is contained within a primary contact plane. The width of the carrier strip  240  and the contacts  202  in the preformed blanked state, as shown in FIG. 5, is denoted by W S . The distance (D C ) represents the distance between the center lines  230  of adjacent contacts  202 . The contacts  202  may be flat blanked such that the distance (D C ) between their center lines  230  is less than or equal to 1.27 mm, or 0.05′ apart from one another. 
     The carrier strip  240  and the contacts  202  are stamped, or blanked, from a single planar sheet, coil, or slab of conductive material. As shown in FIG. 4, while in the blanked, preformed state, the first spring beam  212  is longer than the second spring beam  214 . In the preformed state, the first spring beam  212  and the second spring beam  214  are aligned in the primary contact plane, which is defined by the main body  206 . Once stamped, the second spring beam  214  is angled away, or offset, from the first spring beam  212  by approximately 20°. Further, the first contacting portion  216  and the second contacting portion  218  are not aligned with one another while in the blanked, preformed state. Also, the lengths of the first contacting portion  216  and the second contacting portion  218  do not lie on a common straight line. Because the first and second spring beams  212  and  214  are oriented as shown in FIG. 4 while in the blanked, preformed state, adjacent contacts  202  may be blanked, or stamped, closer to one another than previously blanked contacts. Thus, the contacts  202  may be blanked, or stamped, such that the distance (D C ) between respective center lines  230  is the same distance between connector housing cavities, or receptacles. For example, the distance (D C ) between the center lines  230  of adjacent contacts  202  may be 1.27 mm, or 0.05″, which is also the same distance between the centers of connector housing receptacles, or cavities, into which the contacts are eventually positioned. 
     Further, because the contacts  202  are stamped or blanked closer together, more of the original sheet of conductive material is utilized, thereby producing less wasted conductive material than in previous blanking processes. The forming process, which includes a series of bends and cants of the contacts  202  by way of a forming die, as described below with respect to FIGS. 6-10, enables the contacts  202  to be blanked within a close spacing, such as 1.27 mm, or 0.05″, from one another. 
     FIG. 6 is a front view of a contact  202  formed in accordance with an embodiment of the present invention. FIG. 7 is a side view of the contact  202  formed in accordance with an embodiment of the present invention. FIG. 8 is a top view of the contact  202  formed in accordance with an embodiment of the present invention. FIGS. 9 and 10 are isometric views of the contact  202  formed in accordance with an embodiment of the present invention. The formed contact  202  is similar to the flat blanked contact  202  except that the formed contact  202  has been bent, canted and otherwise formed through a die. The contact  202  may be formed while still on the carrier strip  240 . 
     During the forming process, the first spring beam  212  is bent out from the plane of the main body  206  at bend  312 . The first spring beam  212  is bent to be parallel with, but no longer coplanar with, the plane of the main body  206  (and therefore the carrier strip  240 ). Further, the second spring beam  214  is canted, at bend  314 , toward the first spring beam  212  such that the first contacting portion  216  and the second contacting portion  218  are aligned with each other, that is, the first contacting portion  216  is parallel, but not coplanar, with the second contacting portion  218 . While the second spring beam  214  is canted toward the first spring beam  212 , the second spring beam  214  remains in the same plane as the main body  206  (and the carrier strip  240 , when the contact  202  is formed while it is still attached to the carrier strip  240 ). That is, the second spring beam  214  remains aligned in the primary contact plane, while the first spring beam  212  is aligned with, but not in, the primary contact plane. The bending and canting of the spring beams  212  and  214  allows the spring beams  212  and  214  to be stamped closer to one another, than in previous stamping, or blanking processes. 
     Additionally, the first contacting portion  216  and the second contacting portion  218  are formed such that first and second contacting tips  316  and  318  are bent outward from the plane of the main body  206 , that is, the primary contact plane. Additionally, during the forming process, the paddle  204  is bent at bend  307  such that the plane of the paddle  204  is perpendicular to the plane of the main body  206 . 
     If the contacts  202  are formed while still connected to the carrier strip  240 , adjacent contacts  202  remain the distance D C  from one another. Thus, an entire row, or column, of contacts  202  may be inserted into cavities of a connector housing because the distance (D C ) between the center lines  230  of adjacent contacts  202  remains the same as the distance between the centers of connector housing receptacles, or cavities, into which the contacts  202  are eventually positioned. For example a connector housing may be oriented in a pin grid array that is 25 cavities by 25 cavities. Because the contacts  202  may be formed on the carrier so that they are the same distance apart as the cavities, the contacts  202  may be inserted simultaneously from the carrier strip  240  into a row or column of cavities. 
     FIG. 18 is a side view of a contact  202  and a carrier strip  240  prior to insertion of the contact  202  into the connector housing according to an embodiment of the present invention. In order to fasten the contacts  202  within the cavities of the connector housing (such as housing  22 , shown in FIG. 1) upon mass insertion of the formed contacts  202  into the cavities, solder balls may be positioned on the paddles  204 . For example, a solder ball having a diameter of approximately 0.03″ may be attached to the bottom of the paddle  204 . After forming, the paddles  204  may be oriented in a plane that is perpendicular to the carrier strip  240 . That is, the contacts  202  may be bent at the connection joints  234  such that the main bodies  206  of the contacts  202  are perpendicular to the carrier strip  240 . The solder balls may be attached to the paddles  204  before insertion, or the solder balls may be positioned within the cavities prior to insertion of the contacts  202  into the cavities. 
     FIG. 19 is a side view of a contact  202  positioned within a cavity  704  of a connector housing  701  according to an embodiment of the present invention. A solder ball  702  is positioned between the paddle  204  and the cavity base  703 . Prior to insertion into the connector housing  701 , each paddle  204  is oriented in a plane that is parallel to the surface of the connector housing  701 . Once the contacts  202  are inserted into cavities  704  to a depth at which the carrier strip  240  abuts against or is closest to the connector housing  701 , the carrier strip  240  is severed from the contacts  202  at the connection joints  234 . Optionally, the carrier strips  240  may be severed shortly after the first and second contacting portions  216  and  218  are started into the cavities  704  (if inserted upward) or shortly after the paddle  204  is started into the cavities  704  (if inserted downward). Alternatively, the carrier strip  240  may be severed from the contacts  202  before insertion, in which case a separate insertion strip may engage the contacts  202  by the contacting portions  216  and  218  and position the contacts  202  into the cavities  704 , or receptacles of the connector housing  701 . In each case, individual positioning of the contacts  202  is not required. For example, if the contacts  202  are bent in the carrier strip  240 , all of the contacts  202  may be mass inserted into the cavities  704  of the connector housing  701 . Alternatively, if the contacts  202  are first severed from the carrier strip  240 , a separate insertion strip may attach to the first and second contacting portions  216  and  218 , such as by an electromagnetic force, while the contacts  202  are severed from the carrier strip. In both cases, the contacts  202  remain the same distance (D C ) from one another. Therefore, the insertion process is more efficient than previous insertion processes. 
     As the contacts  202  are inserted into the cavities  704  of the connector housing  701 , the first radial positioners  208  engage the interior walls of the cavities  704  and facilitate proper alignment of the contacts  202  during the assembly stroke, that is, the insertion process. As the contacts  202  are further inserted into the cavities  704 , the second radial positioners  210  engage the interior walls of the cavities such that there are four points of contact between each contact  202  and the interior walls of the cavity  704  into which the contact  202  is inserted. Thus, each cavity  704  within the connector housing  701  receives a contact  202  and retains the contact  202  through the first and second radial positioners  208  and  210 . Further, each paddle  204  rests on a base  703  of a cavity  704  such that an attached solder ball  702  is positioned between the base  703  of the cavity  704  and the paddle  204 . As mentioned above, solder balls  702  may be attached directly to the paddles  204 . Alternatively, solder balls  702  may be inserted into the cavities  704  before the contacts  202  are inserted into the cavities  704 . Also alternatively, instead of utilizing a paddle  204 , the contact  202  may include a solder pin, which receives a solder ball  702 . Once the contacts  202  are positioned within the cavities  704 , the base of the connector housing  701  is heated in order to solder the paddles  204  to the bases of the cavities. 
     After the contacts  202  are inserted, the connector housing  701 , the printed circuit board and the pin grid substrate may be compressed together. Upon compression, or actuation of the cover against the connector housing  701  (similar to the connector housing  22  shown in FIG.  1 ), conductive pins, such as pins  14  shown in FIG. 1, are received by the first and second contacting portions  216  and  218  of the contacts  202 . During the mating of the pins  14  to the contacts  202 , the mating surface of each pin  14  is laterally slid between the first and second contacting portions  216  and  218  (such as in the direction of arrow  317  of FIG.  9 ). The tips  316  and  318  (as shown in FIG. 9) of the first and second contacting portions  216  and  218  are bent outward in order to facilitate proper insertion of a pin. That is, the orientation of the tips  316  and  318  decreases the possibility of a pin  14  stubbing, or otherwise not being fully engaged with, the first and second contacting portions  216  and  218 . The actuation provided by an actuation mechanism, such as lever  28  in FIG. 1, slides the pins  14  between the first and second contacting portions  216  and  218 . When the pins  14  are fully engaged through the actuation provided by the lever, each pin  14  is contacted on opposite sides by a contact  202 . That is, the first contacting portion  216  and the second contacting portion  218  of a contact  202  simultaneously contact one pin  14 . 
     FIG. 20 is a cross-sectional view of a connector housing  801  having a cavity  706  and housing base  710  formed in accordance with an embodiment of the present invention. In this example, the contact  202  may be inserted from the cavity base  703  when the housing base  710  is removed. After the contact  202  is positioned within the cavity  706 , the housing base  710  is attached to the cavity  706 . 
     FIG. 21 is a cross-sectional view of a connector housing  802  having a cavity  712  formed in accordance with an embodiment of the present invention. The connector housing  802  includes a base  803  and a channel  804 . The channel  804  may be used as a path to deliver a solder ball and/or a conductive path to electrical elements (not shown) and/or traces (not shown) within the connector housing. 
     FIGS. 11-17 illustrate contacts  402  formed in accordance with an alternative embodiment of the present invention. Common reference numerals have been assigned to common structure of the contacts  402  of FIGS. 11-17 and the contact  202  of FIGS. 4-10. The contact  402 , however, includes a solder depression  604 , instead of the paddle  204  of the contact  202  as shown in FIGS. 4-10. Thus, when the contact  402  is inserted into a cavity of the connector housing, the solder depression  604  contacts a solder ball positioned on the base of the cavity. 
     FIG. 22 is a front view of a carrier strip  1240  carrying a plurality of flat blanked contacts  1202  formed in accordance with an embodiment of the present invention. FIG. 23 is an end view of a carrier strip  1240  carrying a plurality of flat blanked contacts  1202  formed in accordance with an embodiment of the present invention. A comparison between FIGS. 22 and 23 with FIGS. 4 and 5 show that the first spring beam  1212  may be slightly longer and narrower than the spring beam  212 . Also, the second spring beam  1214  may be slightly narrower than the spring beam  214 . Also, the angle of the offset between spring beam  1214  and spring beam  1212  may be slightly more than that between spring beam  214  and spring beam  212 . The same beam configuration may be used with contacts  402 . 
     FIG. 24 is a front view of a contact  1202  formed in accordance with an embodiment of the present invention. FIGS. 25 and 26 are isometric views of the contact  1202  formed in accordance with an embodiment of the present invention. As shown in FIGS. 24-26, the second spring beam  1214  may be bent toward the first spring beam  1212 . FIGS. 27 and 28 show the contact  1202  and a carrier strip  1240  prior to insertion of the contact  1202  into the connector housing according to an embodiment of the present invention. 
     Various embodiments of the present invention provide a more efficient method of blanking, or stamping, micro pin grid array contacts, and provide a more efficient method of inserting the contacts into cavities of a connector housing. 
     While the invention has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.