ELECTRICAL CONTACT PIN
Provided is a contact pin with a solder cup. The solder cup is formed directly from the contact pin by a manufacturing process. The manufacturing process includes the steps of providing a wire, securing the wire in a carrier structure, cutting the wire to a predetermined length to form a contact, coining a first end of the contact to a predetermined thickness and forming the first end of the contact into a solder cup.
1 . A method for manufacturing an electrical contact having a solder cup comprising the steps of:
providing a wire;
securing the wire in a carrier structure;
cutting the wire to a predetermined length to form a contact; and
forming the first end of the contact into a solder cup.
2 . The method of claim 1 , comprising the step of coining a first end of the contact to a predetermined thickness.
3 . The method of claim 2 , wherein the step of coining a first end of the contact to a predetermined thickness comprises flattening the first end of the contact.
4 . The method of claim 2 , comprising the step of trimming the first end of the contact to a predetermined shape.
5 . The method of claim 4 , wherein the predetermined shape is a rectangular geometry.
6 . The method of claim 4 , wherein the predetermined shape is a square geometry.
7 . The method of claim 4 , wherein the step of forming the first end of the contact into a solder cup further comprises bending opposite sides of the contact upward to form a “U” shape.
8 . The method of claim 1 , wherein the step of cutting the wire to a predetermined length to form a contact is repeated to form a plurality of contacts.
9 . The method of claim 1 , wherein the step of forming the first end of the contact into a solder cup uses substantially all of the material from the first end.
10 . A method for manufacturing an electrical contact having a solder cup comprising the steps of:
providing wire on a carrier structure;
cutting the wire to a predetermined length to form a contact;
repeating the step of cutting the wire to a predetermined length to form a contact until the desired number of contacts are formed; and
forming a first end of each contact of the plurality of contacts into a solder cup.
11 . The method of claim 10 , further comprising the step of coining a first end of each contact to a predetermined thickness.
12 . The method of claim 11 , further comprising the step of trimming the first end of each contact to a predetermined shape.
13 . The method of claim 11 , wherein the step of coining a first end of each contact to a predetermined thickness comprises flattening the first end of each contact.
14 . The method of claim 12 , wherein the predetermined shape is a rectangular geometry.
15 . The method of claim 12 , wherein the predetermined shape is a square geometry.
16 . The method of claim 12 , wherein the step of forming the first end of each contact into a solder cup further comprises bending opposite sides of the coined and trimmed contact upward to form a “U” shape.
17 . The method of claim 10 , wherein the step of forming the first end of the contact into a solder cup uses substantially all of the material from the first end.
18 . An electrical contact with a solder cup manufactured by the process comprising the steps of:
providing a wire;
securing the wire in a carrier structure;
cutting the wire to a predetermined length to form a contact;
coining a first end of the contact to a predetermined thickness; and
forming the first end of the contact into a solder cup.
19 . The electrical contact of claim 18 , wherein the process comprises the step of trimming the first end of the contact to a predetermined shape.
20 . The electrical contact of claim 18 , wherein the step of cutting the wire to a predetermined length to form a contact is repeated to form a plurality of contacts.