Patent ID: 6877205

Claim:
A method of connecting contact sheets to form a contact body, comprising: (a) providing at least a first and second pair of corrugated contact sheets having crests and valleys, the crests having peak surfaces and the valleys having trough surfaces, each contact sheet having opposing surfaces and a plurality of projections extending outward from one surface and located on the peak surfaces of the crests and the trough surfaces of the valleys, the projections extending in the same direction from the one surface of each contact sheet, wherein each projection defines a depression on the opposite surface of the contact sheet, some of the plurality of projections being edge projections on each peak surface and each trough surface adjacent side edges of each sheet, and the rest of the plurality of projections being interior projections on each peak surface and each trough surface in the interior of the sheet away from the side edges; (b) positioning the projections of one of the contact sheets within mating depressions of an adjacent contact sheet, thereby forming projection-depression couplings, the edge projections and the interior projections of the two contact sheets of each of the first and second pair forming projection-depression couplings with corresponding projections of the adjacent sheet of the pair; and (c) mechanically deforming at least some of the projection-depression couplings comprised of the edge projections and the interior projections to form positive locks in the form of flattened interlocked rivets between at least some of the contact sheet projection-depression couplings of each pair; and (d) mechanically deforming at least some of only the edge projections of the first pair of contact sheets that form projection-depression couplings with the edge projections of the second pair of contact sheets to form positive locks in the form of flattened interlocking rivets between the first and second pairs of contact sheets.