Method of manufacturing a multi-wire contact assembly

Abstract

A method for manufacturing a contact assembly for an electronic component commences with providing (1) a length of wire formed into a continuous series of loops each having a pair of legs joined at a closed end, the series of loops comprising first and second pluralities of loops extending laterally in opposite directions from a longitudinal axis, each loop in one plurality axially located between the legs of a loop in the other plurality; and (2) a strip of metal having a plurality of prongs extending laterally from one side and spaced apart by the same distance as are the loops in the first plurality. The prongs are bent to form a slightly acute angle with the strip. The length of wire is attached to the strip so that each of the first plurality of loops extends into the space previously occupied by a prong before it was bent, the second plurality of loops extending outwardly from the opposite side of the strip. An upwardly convex radius is formed in the legs of the first plurality of loops near the closed ends thereof, and a downwardly convex radius is similarly formed in the legs of the second plurality of loops. The strip is cut to form a flap underlying each loop in the second plurality. The flap is folded over to superimpose each loop of the second plurality onto one of the loops in the first plurality in an overlapping relationship.