Patent Publication Number: US-2020295490-A1

Title: One-piece socket contact

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit and priority of U.S. Provisional Application No. 62/817,408 titled “ONE-PIECE SOCKET CONTACT,” filed on Mar. 12, 2019, the entire contents of this application is hereby incorporated by reference herein. 
    
    
     BACKGROUND 
     1. Field of the Invention 
     This specification relates to electrical contacts, and more particularly, to one-piece socket contacts. 
     2. Description of the Related Art 
     Electrical socket contacts are used to electrically couple a pin contact to a wire termination. Conventional electrical socket contacts come in two forms, a long service life form and a short service life form. Both forms suffer from several inherent drawbacks. The long service life form generally has an outer diameter of 2.4 times the outer diameter of the pin contact it is configured to couple with. The long service life form is typically expensive to build due to the large number of components. For example, hyperboloid socket contacts are constructed from a minimum of eight individual components. The long service life form is also rigid and is unable to compensate for misalignment with pin contacts. This misalignment, as well as high mating forces, causes damage to the socket contacts which in turn decreases their service life. 
     The short service life form generally has a split front round barrow to compensate for misalignment with pin contacts. However, the short service life form has poor durability. For example, the short service life form inherently creates a narrow force concentration on the pin contact which results in gold plating being stripped off of the electrical socket contact. Both forms of electrical socket contacts are also not designed to engage with wires sizes that are 40 AWG or smaller. 
     Thus, there is a need for an electrical socket contact that compensates for misalignment with mating pins, has satisfactory durability, can engage with fragile wire sizes that are 40 AWG or smaller, and can be manufactured from a minimum number of components. 
     SUMMARY 
     In general, one aspect of the subject matter described in this specification may be embodied in a one-piece socket contact. The one-piece socket contact includes a body extending along a longitudinal axis and having a first end and a second opposite the first end. The second end defining a cavity therein and configured to receive a wire having a wire termination. The one-piece socket contact includes a ring configured to receive a pin contact. The one-piece socket contact includes one or more beams extending longitudinally between the ring and the first end of the body. The one or more beams having a radially inward facing curvature and being configured to engage with and apply pressure to the pin contact. 
     These and other embodiments may optionally include one or more of the following features. At least a portion of the one-piece socket contact may be plated with a conductive material. The one-piece socket contact may further include at least one aperture extending between the cavity and an outer surface of the body. The at least one aperture may be configured to allow soldering of the wire termination to the body. The at least one aperture may be configured to crimp the insulated portion of the wire to the body. The second end of the one-piece socket contact may be configured to receive a wire termination that is less than or equal to 40 AWG in size. 
     The one or more beams may be at least partially flexible. A portion of the body located adjacent to the second end may be configured to be crimped onto a portion of the wire. The ring may have an inner diameter larger than an outer diameter of the pin contact to compensate for misalignment between the one-piece socket contact and the pin contact. The ring may have a flared opening to compensate for misalignment between the one-piece socket contact and the pin contact. The second end may have a flared opening to facilitate easier entry of the wire termination into the cavity. 
     In another aspect, the subject matter may be embodied in a one-piece socket contact. The one-piece socket contact includes a body extending along a longitudinal axis and having a first end and a second end opposite the first end. The one-piece socket contact includes a solder tail coupled to the second and extending longitudinally away from the body. The one-piece socket contact includes a ring configured to receive a pin contact. The one-piece socket contact includes one or more beams extending longitudinally between the ring and the first end of the body. The one or more beams having a radially inward facing curvature and being configured to engage with and apply pressure to the pin contact. 
     In another aspect, the subject matter may be embodied in a one-piece solder cup contact. The one-piece solder cup contact includes a body extending along a longitudinal axis and having a first end and a second end opposite the first end. The second end defining a cavity therein and configured to receive a wire having a wire termination. The one-piece solder cup contact includes a pin contact coupled to the first end and extending longitudinally away from the body. 
    
    
     
       BRIEF DESCRIPTION OF THE D WINGS 
       The features and advantages of the embodiments of the present disclosure will become more apparent from the detailed description set forth below when taken in conjunction with the drawings. Naturally, the drawings and their associated descriptions illustrate example arrangements within the scope of the claims and do not limit the scope of the claims. Reference numbers are reused throughout the drawings to indicate correspondence between referenced elements. 
         FIG. 1A  is a perspective view of a one-piece socket contact according to an aspect of the invention. 
         FIG. 1B  is a cross sectional view along line A-A in  FIG. 1A  of the one-piece socket contact shown in  FIG. 1A . 
         FIG. 1C  is a cross sectional view along line B-B in  FIG. 1B  of the one-piece socket contact shown in  FIG. 1B . 
         FIG. 2A  is a perspective view of a one-piece socket contact according to an aspect of the invention. 
         FIG. 2B  is a cross sectional view along line A-A in  FIG. 2A  of the one-piece socket contact shown in  FIG. 2A . 
         FIG. 2C  is a cross sectional view along line B-B in  FIG. 2B  of the one-piece socket contact shown in  FIG. 2B . 
         FIG. 3A  is a perspective view of a one-piece socket contact according to an aspect of the invention. 
         FIG. 3B  is a cross sectional view along line A-A in  FIG. 3A  of the one-piece socket contact shown in  FIG. 3A . 
         FIG. 3C  is a cross sectional view along line B-B in  FIG. 3B  of the one-piece socket contact shown in  FIG. 3B . 
         FIGS. 4A-4B  show a perspective view of the one-piece socket contact of  FIGS. 1A-1C  and a wire according to an aspect of the invention. 
         FIG. 4C  is a cross sectional view of the one-piece socket contact and the wire shown in  FIGS. 4A-4B . 
         FIG. 5  shows a one-piece socket contact according to an aspect of the invention. 
         FIG. 6  shows a one-piece solder cup contact the pin according to an aspect of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     In the following detailed description, numerous specific details are set forth to provide an understanding of the present disclosure. It will be apparent, however, to one of ordinarily skilled in the art that elements of the present disclosure may be practiced without some of these specific details. In other instances, well-known structures and techniques have not been shown in detail to avoid unnecessarily obscuring the present disclosure. 
       FIG. 1A  shows a one-piece socket (Arkaloid) contact  100 . The one-piece socket contact  100  includes a body  101  extending along a longitudinal axis and having a first end  103  and a second end  105 . The second end  105  defines a cavity  107  therein and is configured to receive a wire having a wire termination (as depicted in  FIGS. 4A-4C ). The one-piece socket contact  100  includes a ring  109  configured to receive a pin contact. The one-piece socket contact  100  includes one or more beams  111  extending longitudinally between the ring  109  and the first end  103  of the body  101 . The one or more beams  111  have a radially inward facing curvature and are configured to engage with and apply pressure to the pin contact. The pressure on the pin contact may result from the radially inward facing curvature of the one or more beams  111  having an inner diameter that is smaller than an outside diameter of the pin contact. 
     The one-piece socket contact  100  is formed from a single piece of conductive spring material. For example, the one-piece socket contact  100  may be formed from a single piece of copper based spring alloy. However, other conductive spring materials may be used interchangeably according to various embodiments. At least a portion of the one-piece socket contact  100  may be plated with a conductive material. For example, the one-piece socket contact  100  may be plated with a non-oxidized metal. However, other conductive materials may be used interchangeably according to various embodiments. 
     The one or more beams  111  may be at least partially flexible. The flexibility of the one or more beams  111  may compensate for misalignment between the one-piece socket contact  100  and the pin contact. For example, the flexibility of the one or more beams  111  may allow for a pitch of less than or equal to 1.0 mm. However, the one or more beams  111  may be configured to allow other pitch distances interchangeably according to various embodiments. 
     In some embodiments, the one-piece socket contact  100  may include at least one aperture  113  extending between the cavity  107  and an outer surface of the body  101 . The at least one aperture  113  may be configured to allow soldering of the wire to the body  101 . The second end  105  may be configured to receive a wire termination that is less than or equal to 40 AWG in size. In some embodiments, a portion of the body  101  located adjacent to the second end  105  may be configured to be crimped onto a portion of the wire (as depicted in  FIGS. 4A-4C ). For example, a stripped portion of the wire (wire termination) may be soldered to the body  101  via the at least one aperture  113  and a portion of the body  101  located adjacent to the second end  105  may be crimped onto an insulated portion of the wire (as depicted in  FIGS. 4A-4C ). The soldered wire to the body  101  may facilitate electrical conductivity between the wire and the body  101  and the insulated portion of the wire under the crimp may facilitate mechanical durability to the soldered wire/body  101  pair. 
     The ring  109  may provide axial and radial stability to the one or more beams  111  from deformations in the axial and radial directions. The ring  109  may have an inner diameter larger than an outer diameter of the pin contact to compensate for misalignment between the one-piece socket contact  100  and the pin contact. In some embodiments, the ring  109  may have a flared opening to compensate for misalignment between the one-piece socket contact  100  and the pin contact. In some embodiments, the second end  105  may have a flared opening to facilitate easier entry of the wire termination into the cavity  107 . 
     In some embodiments, the one-piece socket contact  100  may be at least partially formed by swaging. For example, the radially inward facing curvature of the one or more beams  111  may be formed by swaging after the body  101 , the ring  109 , and the one or more beams  111  have already been formed. In another example, the radially inward facing curvature of the one or more beams  111  may be formed by swaging before the body  101 , the ring  109 , and the one or more beams  111  have been formed. However, other manufacturing methods may be used interchangeably according to various embodiments. 
       FIG. 1B  shows a cross sectional view along line A-A in  FIG. 1A  of the one-piece socket contact  100  shown in  FIG. 1A .  FIG. 1C  shows a cross sectional view along line B-B in  FIG. 1B  of the one-piece socket contact  100  shown in  FIG. 1B .  FIG. 1C  depicts the one or more beams  111  having four beams ( 111   a ,  111   b ,  111   c , and  111   d ), however any number beams may be used interchangeably according to various embodiments. 
       FIG. 2A  shows a one-piece socket (Arkaloid) contact  200 . The one-piece socket contact  200  includes a body  201  extending along a longitudinal axis and having a first end  203  and a second end  205 . The second end  205  defines a cavity  207  therein and is configured to receive a wire having a wire termination (as depicted in  FIGS. 4A-4C ). The one-piece socket contact  200  includes a ring  209  configured to receive a pin contact. The one-piece socket contact  200  includes one or more beams  211  extending longitudinally between the ring  209  and the first end  203  of the body  201 . The one or more beams  211  have a radially inward facing curvature and are configured to engage with and apply pressure to the pin contact. The pressure on the pin contact may result from the radially inward facing curvature of the one or more beams  211  having an inner diameter that is smaller than an outside diameter of the pin contact. 
     The one-piece socket contact  200  is formed from a single piece of conductive spring material. For example, the one-piece socket contact  200  may be formed from a single piece of copper based spring alloy. However, other conductive spring materials may be used interchangeably according to various embodiments. At least a portion of the one-piece socket contact  200  may be plated with a conductive material. For example, the one-piece socket contact  200  may be plated with a conductive non-oxidized metal. However, other conductive materials may be used interchangeably according to various embodiments. 
     The one or more beams  211  may be at least partially flexible. The flexibility of the one or more beams  211  may compensate for misalignment between the one-piece socket contact  200  and the pin contact. For example, the flexibility of the one or more beams  211  may allow for a pitch of less than or equal to 1.0 mm. However, the one or more beams  211  may be configured to allow for other pitch distances interchangeably according to various embodiments. 
     In some embodiments, the one-piece socket contact  200  may include at least one aperture  213  extending between the cavity  207  and an outer surface of the body  201 . The at least one aperture  213  may be configured to allow soldering of the wire to the body  201 . The second end  205  may be configured to receive a wire termination that is less than or equal to 40 AWG in size. In some embodiments, a portion of the body  201  located adjacent to the second end  205  may be configured to be crimped onto an insulated portion of the wire (as depicted in  FIGS. 4A-4C ). For example, a stripped portion of the wire (wire termination) may be soldered to the body  201  via the at least one aperture  213  and a portion of the body  201  located adjacent to the second end  205  may be crimped onto an insulated portion of the wire (as depicted in  FIGS. 4A-4C ). The soldered wire to the body  201  may facilitate electrical conductivity between the wire and the body  201  and the insulated portion of the wire under the crimp may facilitate mechanical durability to the soldered wire/body  201  pair. 
     The ring  209  may provide axial and radial stability to the one or more beams  211  from deformations in the axial and radial directions. The ring  209  may have an inner diameter larger than an outer diameter of the pin contact to compensate for misalignment between the one-piece socket contact  200  and the pin contact. In some embodiments, the ring  209  may have a flared opening to compensate for misalignment between the one-piece socket contact  200  and the pin contact. In some embodiments, the second end  205  may have a flared opening to facilitate easier entry of the wire termination into the cavity  207 . 
     In some embodiments, the one-piece socket contact  200  may be at least partially formed by swaging. For example, the radially inward facing curvature of the one or more beams  211  may be formed by swaging after the body  201 , the ring  209 , and the one or more beams  211  have already been formed. In another example, the radially inward facing curvature of the one or more beams  211  may be formed by swaging before the body  201 , the ring  209 , and the one or more beams  211  have been formed. However, other manufacturing methods may be used interchangeably according to various embodiments. 
       FIG. 2B  shows a cross sectional view along line A-A in  FIG. 2A  of the one-piece socket contact  200  shown in  FIG. 2A .  FIG. 2C  shows a cross sectional view along line B-B in  FIG. 2B  of the one-piece socket contact  200  shown in  FIG. 2B .  FIG. 2C  depicts the one or more beams  211  having two beams ( 211   a  and  211   b ), however any number of beams may be used interchangeably according to various embodiments. 
       FIG. 3A  shows a one-piece socket (Arkaloid) contact  300 . The one-piece socket contact  300  includes a body  301  extending along a longitudinal axis and having a first end  303  and a second end  305 . The second end  305  defines a cavity  307  therein and is configured to receive a wire having a wire termination (as depicted in  FIGS. 4A-4C ). The one-piece socket contact  300  includes a ring  309  configured to receive a pin contact. The one-piece socket contact  300  includes one or more beams  311  extending longitudinally between the ring  309  and the first end  303  of the body  301 . The one or more beams  311  have a radially inward facing curvature and are configured to engage with and apply pressure to the pin contact. The pressure on the pin contact may result from the radially inward facing curvature of the one or more beams  311  having an inner diameter that is smaller than an outside diameter of the pin contact. 
     The one-piece socket contact  300  is formed from a single piece of conductive spring material. For example, the one-piece socket contact  300  may be formed from a single piece of copper based spring alloy. However, other conductive spring materials may be used interchangeably according to various embodiments. At least a portion of the one-piece socket contact  300  may be plated with a conductive material. For example, the one-piece socket contact  300  may be plated with a conductive non-oxidized metal. However, other conductive materials may be used interchangeably according to various embodiments. 
     The one or more beams  311  may be at least partially flexible. The flexibility of the one or more beams  311  may compensate for misalignment between the one-piece socket contact  300  and the pin contact. For example, the flexibility of the one or more beams  311  may allow for a pitch of less than or equal to 1.0 mm. However, the one or more beams  311  may be configured to allow for other pitch distances interchangeably according to various embodiments. 
     In some embodiments, the one-piece socket contact  300  may include at least one aperture  313  extending between the cavity  307  and an outer surface of the body  301 . The at least one aperture  313  may be configured to allow soldering of the wire to the body  301 . The second end  305  may be configured to receive a wire termination that is less than or equal to 40 AWG in size. In some embodiments, a portion of the body  301  located adjacent to the second end  305  may be configured to be crimped onto a portion of the wire (as depicted in  FIGS. 4A-4C ). For example, a stripped portion of the wire (wire termination) may be soldered to the body  301  via the at least one aperture  313  and a portion of the body  301  located adjacent to the second end  305  may be crimped onto an insulated portion of the wire (as depicted in  FIGS. 4A-4C ). The soldered wire to the body  301  may facilitate electrical conductivity between the wire and the body  301  and the insulated portion of the wire under the crimp may facilitate mechanical durability to the soldered wire/body  301  pair. 
     The ring  309  may provide axial and radial stability to the one or more beams  311  from deformations in the axial and radial directions. The ring  309  may have an inner diameter larger than an outer diameter of the pin contact to compensate for misalignment between the one-piece socket contact  300  and the pin contact. In some embodiments, the ring  309  may have a flared opening to compensate for misalignment between the one-piece socket contact  300  and the pin contact. In some embodiments, the second end  305  may have a flared opening to facilitate easier entry of the wire termination into the cavity  307 . 
     In some embodiments, the one-piece socket contact  300  may be at least partially formed by swaging. For example, the radially inward facing curvature of the one or more beams  311  may be formed by swaging after the body  301 , the ring  309 , and the one or more beams  311  have already been formed. In another example, the radially inward facing curvature of the one or more beams  311  may be formed by swaging before the body  301 , the ring  309 , and the one or more beams  311  have been formed. However, other manufacturing methods may be used interchangeably according to various embodiments. 
       FIG. 3B  shows a cross sectional view along line A-A in  FIG. 3A  of the one-piece socket contact  300  shown in  FIG. 3A .  FIG. 3C  shows a cross sectional view along line B-B in  FIG. 3B  of the one-piece socket contact  300  shown in  FIG. 3B .  FIG. 3C  depicts the one or more beams  311  having one beam  311   a , however any number of one or more beams  311  may be used interchangeably according to various embodiments. 
       FIGS. 4A-4B  show a perspective view of the one-piece socket (Arkaloid) contact  100  of  FIGS. 1A-1C  and a wire  415  according to an aspect of the invention. As shown, a portion of the body  101  located adjacent to the second end  105  is crimped onto an insulated portion of the wire  415 . 
       FIG. 4C  show a cross sectional view of the one-piece socket contact  100  and the wire  415  shown in  FIGS. 4A-4B . The wire  415  has a stripped portion (wire termination end)  417  that is threaded into the cavity  107  and is accessible through the one or more apertures  113 . The wire termination end  417  may be soldered to the body  101  of the one-piece socket contact  100  to allow conduction between a pin contact engaged with the ring  109  and the one or more beams  111  and the wire termination end  417 . 
       FIG. 5  shows a one-piece socket (Arkaloid) contact  500  according to an aspect of the invention. The one-piece socket contact  500  includes a body  501  extending along a longitudinal axis and having a first end  503  and a second end  505 . The one-piece socket contact  500  includes a solder tail  519  is coupled to the second end  505  and extends longitudinally away from the body  501 . The one-piece socket contact  500  includes a ring  509  configured to receive a pin contact. The one-piece socket contact  500  includes one or more beams  511  extending longitudinally between the ring  509  and the first end  503  of the body  501 . The one or more beams  511  have a radially inward facing curvature and are configured to engage with and apply pressure to the pin contact. The pressure on the pin contact may result from the radially inward facing curvature of the one or more beams  511  having an inner diameter that is smaller than an outside diameter of the pin contact. 
     The one-piece socket contact  500  is formed from a single piece of conductive spring material. For example, the one-piece socket contact  500  may be formed from a single piece of copper based spring alloy. However, other conductive spring materials may be used interchangeably according to various embodiments. At least a portion of the one-piece socket contact  500  may be plated with a conductive material. For example, the one-piece socket contact  500  may be plated with a conductive non-oxidized metal. However, other conductive materials may be used interchangeably according to various embodiments. 
     The one or more beams  511  may be at least partially flexible. The flexibility of the one or more beams  511  may compensate for misalignment between the one-piece socket contact  500  and the pin contact. For example, the flexibility of the one or more beams  511  may allow for a pitch of less than or equal to 1.0 mm. However, the one or more beams  511  may be configured to allow for other pitch distances interchangeably according to various embodiments. 
     The ring  509  may provide axial and radial stability to the one or more beams  511  from deformations in the axial and radial directions. The ring  509  may have an inner diameter larger than an outer diameter of the pin contact to compensate for misalignment between the one-piece socket contact  500  and the pin contact. In some embodiments, the ring  509  may have a flared opening to compensate for misalignment between the one-piece socket contact  500  and the pin contact. 
       FIG. 6  shows a one-piece solder cup contact  600  according to an aspect of the invention. The one-piece solder cup contact  600  includes a body  601  extending along a longitudinal axis and having a first end  603  and a second end  605 . The second end  605  defines a cavity  607  therein and is configured to receive a wire having a wire termination (as similarly depicted in  FIGS. 4A-4C ). The one-piece solder cup contact  600  includes a pin contact  621  coupled to the first end  603  of the body  601 . 
     The one-piece solder cup contact  600  is formed from a single piece of conductive material. For example, the one-piece solder cup contact  600  may be formed from a single piece of copper. However, other conductive materials may be used interchangeably according to various embodiments. At least a portion of the one-piece solder cup contact  600  may be plated with a conductive material. For example, the one-piece solder cup contact  600  may be plated with a conductive non-oxidized metal. However, other conductive materials may be used interchangeably according to various embodiments. 
     In some embodiments, the one-piece solder cup contact  600  may include at least one aperture  613  extending between the cavity  607  and an outer surface of the body  601 . The at least one aperture  613  may be configured to allow soldering of the wire to the body  601 . The second end  605  may be configured to receive a wire termination that is less than or equal to 40 AWG in size. In some embodiments, a portion of the body  601  located adjacent to the second end  605  may be configured to be crimped onto an insulating portion of the wire (as similarly depicted in  FIGS. 4A-4C ). For example, a stripped portion of the wire (wire termination) may be soldered to the body  601  via the at least one aperture  613  and a portion of the body  601  located adjacent to the second end  605  may be crimped onto an insulated portion of the wire (as depicted in  FIGS. 4A-4C ). The soldered wire to the body  601  may facilitate electrical conductivity between the wire and the body  601  and the insulated portion of the wire under the crimp may facilitate mechanical durability to the soldered wire/body  601  pair. In some embodiments, the second end  605  may have a flared opening to facilitate easier entry of the wire termination into the cavity  607 . 
     Exemplary embodiments of the methods/systems have been disclosed in an illustrative style. Accordingly, the terminology employed throughout should be read in a non-limiting manner. Although minor modifications to the teachings herein will occur to those well versed in the art, it shall be understood that what is intended to be circumscribed within the scope of the patent warranted hereon are all such embodiments that reasonably fall within the scope of the advancement to the art hereby contributed, and that scope shall not be restricted, except in light of the appended claims and their equivalents.