Патент USA US3091848код для вставки
June 4, 1963 H. F. HILD ETAL METI-IOD FOR SECURING TERMINALS Filed Oct. 2, 1959 ' 3,091,838 2 Sheets-Sheet 1 .1284 k/44 '//////,/,a a 34 I32 30-’; 20 ', v > 5 I72 I i I O | I m I. I I I l I I I I I l l I I I I l N. Io:l : l .L_ _ June 4, 1963 H. F. HILD ETAL 3,091,838 METHOD FOR SECURING TERMINALS '2 Sheets-Sheet 2 Filed 00’0- 2, 1959 | L__________________J United States Patent 0 M1C6 1 3,091,838 METHQD FOR SECURING TERMINALS Henry F. Hild and Siegfried E. Manecke, Indiana, Pa., as signors to Robertshaw-Fulton Controls Company, Richmond, Va., a corporation of Delaware Filed Oct. 2, 1959, Ser. No. 844,100 3,091,838 Patented June 4, 1963 2 such as brass, and may have various con?gurations, one of which is shown in FIG. 1. The terminal 10, shown in FIG. 1, has a male connector portion 16 extending upwardly of the aperture 12 in the casing 14. The male connector 16 has a length and width of suitable dimen sions, which dimensions are primarily determined by the female connector (not shown) that will be used in the electrical circuit. This invention relates to method for securing terminals A main body portion 18 of the terminal 10‘ is located to a casing and, more particularly, to securing ?at plate 10 beneath the male connector portion 16 of the terminal male terminals to a molded plastic casing. 10 and substantially between the sidewalls 20 of the aper It has been the practice to secure a ?anged electrical ture ‘12. The main body portion 18 has a width which terminal to a relatively thin-walled casing by overlapping is slightly greater than the base width of the male con portions of the terminal so as to engage one surface of nector portion 16. The depth of the main body portion a wall. Generally, this practice of securing a terminal 15 18 of the terminal 10 is greater than the thickness of the 4 Claims. (Cl. 29-15555) to a casing has been referred to as “staking.” To secure the ?anged terminal to an aperture in the casing, 21 sharp-edged punch is used to overlap a portion of the body of the terminal, closely adjacent to the pe riphery of the aperture in the casing wall, so as to form outwardly extending ?anges which secure the terminal to the wall. However, as the terminal is generally made of a malleable metal, such as brass, it is relatively soft and easily split when subjected to shearing stresses. In addition, the sharp-edged punch used for peeling the wall of the casing 14. A small area on each side of the main body portion 18 extends above the upper sur~ face 22 of the wall of the casing 14, to form shoulders 24. Beneath the main body portion 18 of the terminal are oppositely disposed ?ange portions 26 which extend out~ wardly from the longitudinal length of the terminal 10. The ?ange portions 26 of the terminal '10 are of su?icient width and depth to prevent the terminal 10 from being inserted completely through the aperture 12 in the thin wall of the casing 14. Beneath the main body portion 18 and the ?anged portions 26 of the terminal ‘'10, there is a downwardly extending projection. This projection of the terminal 10 terminal is not resiliently mounted and, therefore, trans mits a high impact shock to the terminal when the sharp edged punch is actuated. Another di?iculty in staking terminals to a thin-walled is the terminal connector 28 to which electrical conduc casing is the extreme accuracy with which the sharp 30 tors (not shown) can be secured by numerous means, one edged punch must be positioned prior to actuation. Gen of which is soldering. The terminal connector 28 can erally, the punch has at least two edges that engage sub have numerous con?gurations, but for representative stantially oppositely disposed side portions of the termi nal. If the punch is not properly positioned, one edge will engage the associated side portion of the terminal; while the other edge will engage the surface of the wall of the casing. In this event, the casing can easily be broken by the impact. Also, should the punch initially be positioned to unevenly engage opposite sides of the terminal, then uneven stresses will be imposed upon the terminal upon impact. These uneven stresses will be transmitted to the casing to crack the thin wall upon which the terminal is mounted. purposes is substantially rectangular. A jig 30 is shown by dotted line con?guration in FIG. 1. The jig 30 can be of any known type and is used primarily to support and position the terminal 10 in the aperture .12 so that the upper edges 32 of the ?anges 26 of the terminal abut against the lower surface 34 of the thin-walled casing 14. As shown in FIG. 2, a cylindrical punch 36, having a concentric cylindrical cavity 38 bored in the central por tion of the punch 36, is depicted as being partially low ered over the male connector portion 16 of the termi nal 10. Edge 40 is formed at the junction of a cylindrical sur onto the surface of the casing. face 39 of the cavity 38 and a bottom beveled surface 42 Another object of this invention is to spin a shoulder of punch 36. Beveled surface 42 is of frusto-conical portion of a terminal onto the upper surface of a thin form being inclined at a slight angle relative to a plane walled casing under a relatively light, uniformly distrib normal to the axis of rotation of the punch 36. The an 50 gular inclination of the beveled surface 42 will depend uted impact operation. A further object of this invention is to fasten electri upon the material from which the terminal is made. cal terminals to a thin-walled casing in a rapid, inexpen Edge 40 will engage the upper edge 44 of the shoulder sive manner. 24 immediately adjacent to the base width of the male Other objects and advantages will be apparent from connector portion 16, when there is a downward motion the following description of the invention taken in con 55 of punch 36. Edge 40 will cut into shoulder 24, and nection with the accompanying drawings wherein: beveled surface 42 will peel the cut metal outwardly. FIG. 1 is an elevation view, partly in section, of a It will also be apparent that the cavity 38 of the punch terminal positioned in a thin-walled casing; 36 must be cylindrical in form. The diameter of the FIG. 2 is a view similar to FIG. 1 of the terminal and cavity 38 is determined by the amount of material to punch; 60 to be peeled from the shoulder 24 of the terminal 110, FIG. 3 is a view of the terminal and punch in operative and the width of the male connector 18 of the terminal 10. An object of this invention is to secure terminals to a thin-walled casing by peening a portion of the terminal 45 relationship; In FIG. v2, the circular punch 36 is diagrammatically shown as being resiliently mounted by means of spring FIG. 4 is an end view, partly in section, of the terminal and punch after the spinning and peening operation; and FIG. 5 is a plan view of the terminal after the spinning 46. Punch 36 is mounted to a drive mechanism (not and peening operation. speeds; and, in addition, the drive mechanism impartsv Referring more particularly to FIG. 1, there is shown a ?at terminal post 10 inserted and positioned in a slit aper ture 12 of a thin-walled casing 14. Thin-walled casing 14 can be molded from any known phenolic plastic hav ing good structural and electrical insulation properties. The terminal 10 is stamped out of a ?at sheet material, shown) that will rotate or spin punch 36 at variable a rectilinear reciprocating motion to punch 36 so that: the punch has rapid longitudinal movement in two directions. The spring 46 will limit the impact pressure of punch 36 in the downward direction to a constant value.. As shown in FIG. 3, a quick, rapid, light impact blow of punch 36 in the downward direction combined with 3,091,838 4 peen the shoulder portion 24 of the main body 18 of the terminal .10 away from the male connector portion 16. The beveled edge 42 of the punch 36 will curl the peeled ing the terminal with the flange abutting against the eas ing wall and the terminal post projecting through the aperture and outwardly of the wall, simultaneously cut ting and spinning the projecting portion of the terminal shoulder portion 24over so as to form an upper ?ange post away from the main body thereof until the spun 48 to the main body 24 of the terminal 10. It is to be noted that the curled and peened shoulder 24 will form a ?ange 48 on the upper surface 22 of the wail of the portion engages the casing wall, and further cutting and spinning the projection portion while simultaneously peening the spun portion into evenly stressed engagement with the casing wall. the spinning action of punch 36 will evenly peel and casing 14. 2. The method of securing a ?anged terminal post in The jig 30 will force the ?ange 26 of the terminal 10 10 an a ertured casing wall which comprises, positioning into engagement with the lower surface 34 of the thin the terminal with the ?ange abutting against the casing walled casing ‘14 to insure proper engagement with the ‘ wall'and the terminal post projecting through the aper lower surface 34 of the wall. vIn addition, the peeling ture and outwardly of the wall, simultaneously cutting and spinning action of the punch 36 will draw as much of the shoulder portion 24 of the main body 18 of the 15 and spinning the projecting portion of the terminal post until the spun portion curls toward and engages the cas terminal 10 out'of the aperture 12 as is exposed to fur ther insure a tight engagement between the upper sur face 32 of the terminal ?ange 26 and. the lower surface '34 of the thin-walled casing 14. The action of the resilient spring 46 on the punch will equalize the pressure on the bevelededge 42 to thereby insure that each peened shoulder 48 will be subjected to the same light oscillatory ing wall and further cutting and spinning the projecting portion while simultaneously peening the spun and curled portion of the terminal post into evenly stressed engage ment with the casing wall. 7 3. The method of securing a ?at plate ?anged terminal post in a slit aperture in a casing wall which comprises, positioning the terminal with the ?ange abutting against the casing wall and the terminal post projecting through The male terminal .10 is shown‘ in FIG. 4, with the 25 the aperture and outwardly of the wall, simultaneously cutting and spinning oppositely disposed projecting por punch 36 partially withdrawn from its. lowermost stroke. impact motion of the punch 36; and, in addition, to the spinning motion of the punch. tions of the terminal post until the spun portions engage said casing wall, to overlap the longitudinal ends of the slit aperture, and further cutting and spinning the project to form a tab 50 which is not in alignment with the flat 30 ing portions while simultaneously peening the spun por tions of the terminal post into evenly stressed engage surface of the terminal 10. For purposes of representa ment with the casing wall closely adjacent to the longitu tion, the peened shoulders in FIGS. 3 and 4 have been dinal ends and sides of the slit aperture. enlarged relative to their true representations. In actu 4.7 The method of securing a ?at plate flanged terminal ality, the uppermost portion 52 of the peened shoulder It is to be noted that the peened shoulder 48, due to the spinning action, overlaps the upper surface 22 of the casing 14 immediately adjacent to the aperture 12 so as is substantially level with the upper surface 22 of the casing @14 and could be considered as being flared into the upper surface of the casing. ‘ As shown in FIG. 5, the peened shoulder 48 is spread out over'the adjacent surface of the thin-walled casing 14, and is, in e?ect, twisted slightly from the ?at plane of terminal 10 so that the terminal 10 cannot be with drawn from the aperture 12. Although not shown in the drawings, it will readily be apparent that a substantially circular terminal having a ‘circular shoulder about the male connector portion of the terminal could also be subjected to the action of the post in a slit aperture in a casing wall which comprises, positioning the terminal with the ?ange abutting against the casing wall and the terminal post projecting through the aperture and outwardly of the wall, simultaneouslyr cutting and spinning oppositely disposed shoulder por tions of the terminal post until the spun portions curl toward and engage the casing wall, to overlap the longi tudinal ends of the slit aperture, and further cutting and spinning the projecting portions while simultaneously peening the spun and curled portions of the terminal post into evenly stressed engagement with the casing wall. punch as previously described. The circular terminal will have its shoulder spread out to overlap the area im mediately adjacent to a circular aperture in the thin References’ Cited in the ?le of this patent UNITED STATES PATENTS walled casing. In addition, it is to be realized that numerous terminals can be mounted in a single jig, so that each terminal is inserted through an appropriate aperture in the casing. In this manner, several punches can be mounted on one drive mechanism so that the numerous terminals can be 55 fastened to the casing in one operation. While only one embodiment of the invention has been shown and described herein, it will be apparent that nu merous modi?cations and changes can be made without departing from the scope of the invention as de?ned in, the appended claims. We claim: 1. The method of securing a ?anged terminal post in an apertured casing wall which comprises, position 4. ‘ 1,234,395 2,396,082 ‘2,404,051 Schmidt _____________ __ July 24, 1917 Bugg _________________ __ Mar. 5, 1946 Ginter ______________ __ July 16, 1946 2,524,420 Blampin _.___' _________ __ Oct. 3, 1950 2,682,849 Wright ______________ __ July 6, 1954 2,692,422 2,779,998 ‘2,782,392 Pierce _______________ __ Oct. 26, 1954 Bailey ________________ __ Feb. 5, 1957 Stolle ________________ __ Feb. 19, ‘1957 2,802,257 2,914,745 Holtzapple __________ __ Aug. 13, 1957 Krol et a1. __________ __ Nov. 24, 1959 . 625,654 FOREIGN PATENTS Germany ____________ __ Feb. 13, 1936 .iha_.