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Патент USA US3071851

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Jan- 8, 1963
R. T. KRAUSE ETAL
3,071,844
METHOD OF MAKING A TERMINAL
Filed Aug. 5, 1959
INVENTORS 20
E/CIJA 12D 77 KEA use,
#mzou: aKALMAz AM»
BY F-EAA/K A. Kuzm
haw, ?eas“ Mic/(926W
4T7'OkA/E-Y5.
United States Patent O?tice
3,071,844
Patented Jan. 8, 1963
1
2
3,071,844
‘FIG. 7 is an enlarged sectional view taken along line
7-7 of FIG. 6;
METHOD OF MAKING A TERMINAL
FIG. 8 is a perspective view of the terminal of FIG. 6
Richard T. Krause, Morton Grove, Harold B. Kalmar,
Des Plaines, and Frank A. Kukla, Riverside, [1]., as
signors to Malco ‘Manufacturing Company, Chicago,
and the reworking tools used in the third step of the
method of the present invention;
iFIG. 9 is a perspective view of the terminal of FIG. 6
after the third step of the method of the present invention;
Filed Aug. 5, 1959, Ser. No. 831,853
and
4 Claims. (Cl. 29—155.55)
FIG. 10 is an enlarged, perspective view taken along
The present invention relates to a method of making 10 line 10—10 of ‘FIG. 9.
Referring now to the drawing, FIGS. 1 through 10
electrical terminals and, in particular, relates to a method
illustrate the various steps embodied in the method of
of making terminals of the round pin type. i
the present invention. Brie?y, the method is employed
It is an object of the present invention to provide a
to transform rectangular pin type terminals into round
new and improved method of making an electrical ter
15 pin type terminals and comprises three steps that can be
minal.
'
practiced by automatic machinery. Consequently the
It is another object of the present invention to provide
round pin terminals can be quickly, easily, and inexpen
a new and improved method for making a round pin type
sively fabricated. It has been observed that round pin
terminal from a rectangular pin type terminal.
It is a further object of the present invention to make 20 terminals made in accordance with the method of the
present invention are perfectly rounded and exhibit
a round pin type terminal having a perfectly continuous
better electrically conductive characteristics than round
and uninterrupted pin surface.
pin terminals made by existing or prior art methods.
It is yet a further object of the present invention to
Attention is directed to FIG. 1 wherein a rectangular
provide in a new and improved method the step of re
pin
terminal is illustrated in perspective and is identi?ed
working the surface material of a round pin terminal to
Ill., a partnership
eliminate any surface roughness or unevenness.
It is yet another object of the present invention to pro
vide a new and improved method for making a round pin
25 generally by reference numeral 10.
The rectangular pin
terminals are readily stamped out of stock material, for
example, brass or the like, by suitable automatic ma
chinery. The rectangular pin terminal 10 is satisfactorily
terminal from a rectangular pin terminal including the
step of effecting an axial plastic flow of the surface ma 30 used in many installations and, in this connection, may be
mounted with a bushing (not shown) to a support (not
terial of the round pin terminal, thereby producing a ter
shown) in accordance with, for example, the method
minal having a smooth, continuous, and highly conductive
described
and illustrated in the Alex Just et al. Patent
surface.
No. 2,995,617, entitled “Self Locking Terminal,” and
The above and other objects are realized in accordance
assigned to the same assignee as the present application.
with the present invention by providing a new and im~ 35
As shown in FIG. 1, the terminals’s upper portion com
proved method of making an electrical terminal. In the
prises a wire-wrap shank 12 of generally rectangular
practice of the method, a rectangular pin type terminal
cross section for accommodating an electrically conduc
is deformed in successive steps into a round pin type
tive, bare wire. The extreme upper end of the wire-wrap
terminal having a highly conductive surface offering a
shank 12 is beveled, as indicated at 14, to facilitate inser
lower electrical resistance to the transfer of electrical en 40 tion of the shank 12 into suitable wire-wrap machinery
ergy between the round pin terminal and a female ter
which winds the ‘bare wire tightly around the shank 12.
minal. In the initial step of the method, the rectangular
Adjacent the lower end of the wire-wrap shank 12 is a
‘pin is transformed into a generally rounded pin having
gripping shank 16 which is adapted to coact with the
?ashing or the like extending outwardly. Thereafter, the
above-referred to ‘bushing (not shown) as described in
?ashing is removed to provide a substantially rounded 45 ‘the above-identi?ed application. A pair of inwardly ex
pin having an uneven and‘ rough surface resulting from
tending, locking notches 18 is located at the lower end
the ?ashing removal step. To eliminate the surface rough?
of the shank 16 to accommodate the parts of the bushing
ness, the material adjacent the surface of the round pin
(not shown) that are expanded during mountingof the
is reworked, to obtain a perfectly smooth and highly con
terminal to the above-referred to support (not shown).
50 As clearly seen, a pair of laterally extending ?anges 20
ductive surface.
The invention, both as to its organization and method
are located intermediate the locking notches >18 and a rec
of operation, taken with further objects and advantages
tangular pin 22.
.
thereof, will best be understood by reference to the fol
The rectangular pin 22 depends downwardly or axially
lowing description taken in connection with the accom
from the laterally extending ?anges 20 and lies in the
panying drawing, in which:
‘
55 same plane as the wire-wrap shank 12, the gripping
1FIG. 1 is a perspective view of a rectangular pin type
terminal before it is deformed into a round pin type ter
minal in accordance with the method of the present in
tangular in section throughout substantially its entire
vention.
length, with the exception of a pair of opposite end cor~
_
shank 16, and the ?anges 20. The pin 22 is relatively
short compared with the shanks 12 and 16 and is rec
'FIG. 2 is a perspective view of the terminal of FIG. 1
and deforming tools used in a ?rst step of the method of
ners which are beveled, as indicated at 24,'to facilitate
the present invention;
(not shown).
.
FIG. 3 is a side elevational view of the terminal of
FIG; 2 after the ?rst step;
.
FIG. 4 is an enlarged sectional view taken along line
4-4 of FIG. 3;
_
‘
FIG. 5 is a perspective view of the terminal of FIG. 3
and shearing tools used in the second step of the method
of the present invention;
,
‘FIG. 6 is anrelevational view of the terminal of FIG.
5 after the second step;
'
the nesting of the pin 22 with a suitable female terminal
_
In the practice of the method of the present invention,
the terminal 10 is moved to three stations wherein in
65 three steps the rectangular pin 22 is transformed .to a
round pin. At the ?rst station, shown fragmentarily in
FIG. 2, the'shank of the pin 22 is changed from its rec
tangular section to a generally circular section while the
lower end of the pin 22 is changed from an angulated
construction to a generally semi~spherical construction.
The deformation of the pin '22 is effected by a die-form
ing punch 30 and a ‘die-forming block 32, hereinafter '
3,071,844
3
referred to collectively as die-forming tools, which are
movable relative to one another by suitable apparatus
(not shown). The apparatus (not shown) generates an
impact force adequate to cause the rectangular pin 22
to be deformed as described above.
vMore speci?cally, the terminal 10 is 'moved to the ?rst
station and is suitably held in an upright position with its
pin 22 depending downwardly between the die-forming
tools 30 and 32.
Actually, the terminal 10 is ‘located
immediately adjacent to the stationary die-forming block
4
control of suitable apparatus (not shown). Particularly,
the terminal 10 when at the second station is maintained
in an upright position by suitable holding means (not
shown) with its pin 42 depending downwardly between
the die-shearing tools 50 and 52. Actually, the terminal
10 is located immediately adjacent to the stationary die
shear-ing block 52 so that the ?ashing 44 is sheared off
when the die-shearing punch 50 moves toward and mates
with the die-shearing block 52.
As shown, the die
10 shearing block 52 is of elongated construction, as con
32 so that the desired deformation of the pin 22 occurs
when the die-forming punch 30 moves toward and mates
with the die-forming block 32. As shown, the die-form
trasted to the generally rectangular construction of the
die-forming tools 30 and 32. The die-shearing block 52
includes a coacting or mating face 54 entirely compris
ing punch 30 is of generally rectangular con?guration and
ing a recess 55. The recess 55 extends vertically and
opens onto the upper surface 53 of the block 52 to de
?ne an arcuate cutaway portion 55a, in contrast to the
includes a coacting or mating face 34 in which is de?ned
a generally semi-cylindrical recess 36. The recess 36 ex
tends vertically in the face 34 and opens onto the upper
surface 35, thereby de?ning a semi-circular cut-away por
above-referred to semi-circular cutaway portions 36a and
40a. This result obtains since the recess 55 includes ap
proximately 130 degrees of recessed surface instead of
the approximately 180 degrees recessed surface of the
tion 36a. The bottom 36b of the recess 36 is somewhat
spherical to impart a semi-spherical end to the pin 22.
recesses 36 and 40. Similar to the recesses 36 and 40,
The die-forming block 32 is of identical construction and
the bottom 55b of the recess 55 is somewhat spherical
‘likewise includes a coacting or mating face 38 in which
to coact with the bottom portion of the pin 42.
‘is de?ned a semi-cylindrical recess 40. Identically to the
On the other hand, the die-shearing punch 50 is of
recess 36, the recess 40 opens onto the upper surface 39
to form a semi-circular cutaway portion 40a and includes 25 generally rectangular construction and includes a mating
face 56 in which is de?ned a vertically extending recess
a somewhat spherical bottom 4012. It will be appreciated
58. The recess 58‘ has a con?guration best shown in FIG.
that the die-forming tools 30 and 32 are so related to
5 and is substantially deeper than the recesses 36 and 40.
one another by the above-referred to apparatus that,
In any event the recess 58 speci?cally comprises a slot-like
'when the faces 34 and 38 mate, the recesses 36 and 40
portion 60 having a curved ‘bottom 66a and an adjacent
coact together to de?ne a generally cylindrical recess
generally semi-cylindrical rear portion 62 including a
having a semi-spherical bottom. In accordance with the
somewhat spherical bottom portion 62a. The portions 60
‘?rst step of the method, the terminal 10 is properly po
and 62 de?ne a smooth and continuous recess surface and
sitioned adjacent to ‘the die~forming block 32, i.e., with
open onto the upper surface 63 to de?ne an arch-like cut
the lower surfaces of the terminal ?anges 20 slightly
spaced above the upper surface 38 and with the pin 22 35 away portion -58a. In this connection, the slot-like por
tion 60 also de?nes at the mating face 56 an arch-like
partially located within the recess 40. In this position,
shearing edge ‘64 for coacting with the ?ashing 44. The
only the pin 22 is located between the die-forming tools
slot-like portion 60 is so constructed that the shearing
30 and 32. Thereafter, the above-referred to apparatus
edge 64 generally conforms to the cross section of the
associated with the die-forming punch 36 is operated to
pin 42, exclusive of the ?ashing 44.
‘cause the punch 30 to move toward the block 32. The
In the practice of the second step of the method, the
punch 30 engages or strikes the pin 22 with such impact
terminal 10 is positioned adjacent to the die-shearing
that the entire pin 22 is deformed.
block 52 so that the right side 42a of the pin 42, as seen
As a result of the deforming blow of the punch 32, the
"rectangular pin 22, as seen in FIGS. 1 and 2, is trans
in FIG. 5, mates with the recess 54. In this position, the
formed into a substantially cylindrical pin, indicated by 45 ?ashing 44 extends generally perpendicular to the elon
gated shearing block 52, and by virtue of the approxi
reference numeral 42, as seen in FIGS. 3 and 4. As
mate 130 degree surface of the recess 54, only those por
"shown in FIGS. 3 and 4, the pin 42 is not cylindrical
or rounded in any sense since it includes surplus mate
tions immediately adjacent to the ?ashing 44 are not sup
‘rial ‘or ?ashing 44 extending outwardly along the plane
of the mating faces 34 and 38. The ?ashing 44 extends
ported by the die-shearing block '52. Thereafter, with the
pin 42 of the terminal '10’ being supported by the block
entirely around the pin 42, i.e., along opposite sides and
‘along the bottom of the pin 42. Although it is desirable
that all of the material of the rectangular pin 22 be
52 as described above, the apparatus (not shown) asso
ciated with the die-shearing punch 50 is operated to cause
the die-shearing punch 50 to move toward the die-shear
transformed exactly into a cylindrical pin which has no
?ashing, such an objective cannot be achieved because
of the variations in size and dimension of the rectangular
pins 22 due to tolerances or the like and, further, because
of the variations in the vertical positions of the pins 22
ing block 52. During this movement, the shearing edge
64 engages the ?ashing 44 immediately adjacent the body
of the pin 42, thereby shearing and removing the entire
?ashing 44 from the pin 42. Because of the relative di
mensions of the die-shearing tools 50 and 52, the die
shearing punch 59 telescopes about the die-shearin g ‘block
ferent amounts of ?ashing 44- are obtained on each of 60 52. ‘Speci?cally, after the ?ashing 44 is sheared from
the pins 42 that are deformed as described above. In
the pin 42, the shearing edge 64 moves by the pin 42, as
this connection, it should be appreciated that the recesses
well as the opposite sides 66 ‘and 68 of the block 52.
36 and 40 in the die-forming tools 30 and 32 are not
As a result of the shearing step, the pin 42 is changed
exactly semi-cylindrical but are somewhat less than semi
into a substantially cylindrical pin 72 as illustrated in
cylindrical. ‘For example, instead of 180 degrees of re
FIGS. 6 and 7. The pin ‘72 is not truly cylindrical, as
cessed surface, only 178 degrees or 179 degrees of re
best seen in FIG. 7, since the area adjacent the base of
cessed surface is provided to compensate for the width
the ?ashing 44 is somewhat rough and uneven. Although
of the ?ashing ‘44.
the shearing edge 64 on the punch 50 is accurately di
The terminal 10 shown in FIGS. 3 and 4 is then moved
.mensioned, unevenness is developed at the juncture be
to the second station, shown fragmentarily in FIG. 5,
tween the pin 72 and the ?ashing 44. As shown, the
whereat all of the ?ashing 44 is removed in a single
rough and broken area, identi?ed as '70, extends along
Step. The removal of the ?ashing 44 is effected by a
the opposite sides and bottom of the pin '72 and provides
die-shearing punch 50 and a die-shearing block 52, here
a discontinuous surface which is undesirable and unsat
inafter referred to collectively as die-shearing tools, which
are relatively movable toward one another under ‘the 75 isfactory since it produces a poor contact surface for
relative to the die-forming block 32. Accordingly, dif
3,071,844
5
transmitting electrical energy to a female or the like ter
What is desired to be claimed and secured by Letters
Patent of the United States is:
To smooth out the surface of the pin 72, the termi
1. A method of making a rectangular pin type termi
nal 10 is moved into the third station, shown fragmen
nal having a round pin terminal portion, said method
tarily in FIG. 8, whereat the rough and uneven area 7.0 5 comprising the steps of forming a pin terminal having a
on the pin 72 is removed. The terminal 10 is axially
generally rectangular cross-section, deforming the lower
aligned with a burnishing tool 74 and, thereafter, the
end of the terminal into a generally round terminal por
terminal 10 and the burnishing tool 74 are moved rela
tion having ?ashing extending outwardly, removing the
tive to one another. The engagement of the burnishing
?ashing to produce a generally round terminal surface
'tool 74' and the terminal 101 causes the material adja 10 having discontinuities, and reworking the surface mate
minal.
cent‘the surface of the pin 72 to be reworked so that
the uneven strip 70‘ is smoothed out.
Speci?cally, the terminal 10, when at the third station,
is grasped by suitable apparatus (not shown) which re
strains the pin '72 against axial movement and aligns
it with the burnishin-g tool 74. Suitable apparatus (not
shown) associated with the burnishing tool 74 is op
rial of the round terminal portion to ?ll up and smooth
out the discontinuities, thereby producing a terminal hav
ing a smooth and continuous surface.
2. A method of making a rectangular pin type termi
nal having a round pin terminal portion, said method
comprising the steps of forming a pin terminal having a
generally rectangular cross-section, deforming the lower
erated to cause the tool to move axially toward the pin
end of the terminal into a generally round pin terminal
72. As shown, the tool 74 is generally cylindrical in
portion having ?ashing extending outwardly, removing
construction and includes a perfectly cylindrical, axially 20 the ?ashing to produce a generally round terminal sur
extending bore 76 that opens onto a face 77. As shown
face having discontinuities, and causing metal ?ow of
in FIG. 8, the mouth of the axial bore 76 is rounded,
the surface material of the terminal portion to smooth out
as indicated at 78‘ to facilitate entry of the pin 72 into
the discontinuities by moving a tool axially along the
the bore 76. The diameter of the bore 76 is slightly less
than the diameter of the pin 72 so that as the tool 74
mates with the pin 72 a relatively great pressure is ap
plied to the pin 72. As the tool 74 moves along the pin
72, the surface material is reworked to cause the rough
ness in the area 70‘ to be smoothed out.
More particu
terminal surface.
‘
3. A method of making a pin terminal, said method
comprising the steps of forming from a metallic blank a
pin terminal having a generally rectangular cross-section,
deforming the lower end of the terminal into a terminal
portion having a generally curvilinear cross-section, said
larly, a “plastic flow” of the surface material is obtained, 30 terminal portion having ?ashing extending outwardly,
with the result that the entire surface of the pin 72 con
removing the flashing to produce a terminal portion having
forms to the contour of the bore 76 which, as indicated
a generally curvilinear cross-section provided with dis
above, is perfectly cylindrical.
continuities, and reworking the surface material of the
Hence, after the third step, a perfectly smooth and
terminal portion by moving a tool axially of the termi
uniform pin, identi?ed by reference numeral 82, is ob 35 nal portion to produce a terminal having a smooth and
tained. As shown best in FIGS. 9 and 10, the body of
continuous surface.
the pin 82 is perfectly cylindrical, i.e., has a circular
‘ 4. A method of making a solid pin terminal, said meth
section, while the lower end of the pin is perfectly semi
od comprising the steps of forming from a solid blank
spherical. Consequently, a terminal 10 having the above
material a solid pin terminal having generally rectangular
described round pin 82 can be mounted in a predetermined 40 cross-section, deforming the lower end of the terminal to
axial manner and, irrespective of its relative rotary posi
produce a solid generally round terminal portion having
tion, the pin 82 satisfactorily mates with a female termi
?ashing extending outwardly, removing the ?ashing to
nal. In addition, the perfectly cylindrical con?guration
produce a generally round terminal surface having dis
of the body of the pin 82 provides a good contacting
continuities, and reworking only the outer surface mate
surface and, consequently, a good electrical connection 45 rial of the terminal portion to smooth out the discontinui
is obtained between the terminal 10 and a female termi
ties, thereby producing a solid terminal portion havng
nal (not shown).
'
Although the present method has been described in
connection with the making of a round pin having a cir
cular section, it will be appreciated that the method can 50
also be practiced to produce a round pin having an oval
or elliptical section. To this end, it is only necessary
that appropriate forming tools, shearing tools and bur
nishing tools be substituted for the above-described form
ing tools 30 and 32, shearing tools ‘50 and 52, and bur 55
nishing tool 74.
_
While the method described herein is at present con
sidered to be preferred, it is understood that various
modi?cations and improvements may be made therein,
and it is intended to cover in the appended claims all 60
such modi?cations and improvements as fall within the
true spirit and scope of the invention.
a smooth and continuous surface.
References Cited in the ?le of this patent
UNITED STATES PATENTS
774,242
Gates ________________ __ Nov. 8, 1904
1,391,365
11,813,539
1,883,205
2,057,580
Carlson _____________ __ Sept. 20,
Hurley _______________ __ July 7,
Whitehead ____________ __ Oct. 18,
Layton ______________ _._ Oct. 13,
2,390,651
2,614,465
2,744,309
2,939,100
Iseman ____________ __ Dec.
Markert et al. ________ __ Oct.
‘Graham _______ _,______ May
Watts ______________ .._ May
1921
1931
1932
1936
11, 1945
21, 1952
8, 1956
31, 1960
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