The Whitaker Corporation

Amp LLC

Edward L Pentz

John Mark Myer

Gary R Marpoe, Jr

Marpoe, Jr Gary R

Integral terminals are formed on the bare ends 4, 24, 64, 84 of insulated wires 2, 22, 62, 82. Male and female terminal configurations are stamped and formed on the wires. When necessary the bare wire ends are upset to increase the width of the portion of the bare wire on which the terminals are formed. Cylindrical pins 10 can be formed by removing material and cylindrical sockets 8 can be formed by drilling and reaming the end of a wire that may have been upset by a cold heading operation. Retention flanges 38 can be formed to retain pins 30 and sockets 28 in a connector housing 40. Hermaphroditic blade terminals 62 can also be formed on bare wire ends. Quick disconnect tabs 92 can be formed by forming a flat blank from the bare wire 84 or from an upset section 88.

Insulated wire with integral terminals

An electrical pin contact (10) having a wire insulation gripping section (11), a wire conductor gripping section (12), a transition section (14), a shank section (16), a retention section (20), and a pin contact section (30). The retention section (20) includes a shoulder (26) with latching projections (26a) formed thereon for engagement with a latching arm of a connector housing when the pin contact (10) has been inserted therein. Latching projections (26a) are formed by seams in the shoulder (26). Projections (26a) will increase the frictional retention of contact (10) in an electrical connector housing.

Single piece pin contact

A protective sleeve (100) for a pair of cantilevered spring contacts (15, 16) is formed by a blanking, forming and bending process (rather than a deep-drawn process) thereby providing a superior product at less cost. During the blanking process, a hole (104) is pierced within a transverse end wall (103) formed between respective first and second sleeve portions (101, 102). These sleeve portions (101, 102) are bent into semi-cylindrical shapes and are then bent towards each other and at right angles to the wall (103) to form the cylindrical sleeve (100). The hole (104) is sized to accommodate a given pin (20) but prevents an oversized pin (20') from being inserted therethrough, thereby preventing inadvertent damage to the contacts (15, 16) or to the sleeve (100). In an alternate embodiment, a barrel (107) is formed on a sleeve (100') rearwardly of the respective sleeve portions (101, 102), and the barrel (107) has a pair of lanced-out outwardly-extending ears (108, 109) received in an opening (11) on a contact assembly (13), thereby mounting the sleeve (100') on the contact (13). The sleeve 100' is also crimped on to a second diametrically-opposite opening (12) on the contact (13).

Protective sleeve for cantilevered spring contacts and method of making

An insulation displacement terminal having a pair of slotted plates retained in a nest formed by embossments on sidewalls extending past the edges of slotted plates. The sidewalls and the slotted plates are formed orthogonally upward from a common base. Outer ellipsoidal embossments are formed on opposite sides of a cylindrical embossment. The embossments are formed by a shallow drawing process without removal of material from the planar sidewalls. Adjacent edges of the embossments are sheared to form a nest receiving the side edges of the slotted plates.

Growing community of inventors

Greensboro, NC, United States of America

Edward L Pentz