Method of manufacturing a press-fit contact

1. A method of forming an electrically conductive contact that is adapted for mounting to a substrate having a hole formed therein, the method comprising:

providing a work piece of conductive metal, the work piece having a longitudinal axis;

forming a precursor configuration in the work piece, the precursor configuration including a free end portion and a precursor retention portion connected to a remaining portion of the work piece, the precursor retention portion including a pair of precursor beams separated by a precursor slot defined by a precursor interior surface having opposing side portions forming parts of the precursor beams, respectively, the side portions of the precursor interior surface being joined at opposing first and second precursor junctures, the first precursor juncture being located toward the free end portion;

forming a fastening section from the precursor configuration, the step of forming the fastening section comprising: applying a pair of first forces F 1 to opposing exterior sides of the precursor beams at a location along the longitudinal axis that is aligned with the first precursor juncture, and applying a pair of second forces F 2 to opposing exterior sides of the precursor beams at a location along the longitudinal axis that is aligned with the second precursor juncture;

wherein the step of forming the fastening section is performed so as to transform the precursor slot into a finished slot and transform the precursor beams into finished beams, wherein the finished slot is defined by a finished interior surface having opposing side portions forming parts of the finished beams, respectively, the side portions of the finished interior surface being joined at opposing first and second finished junctures and being bowed so as to diverge from each other as they extend away from the first and second finished junctures, respectively; and

wherein the finished slot is at least 5% longer than the precursor slot in the direction of the longitudinal axis.

2. The method of claim 1 , wherein the first and second precursor junctures correspond to the first and second finished junctures, respectively, the first precursor juncture being arcuate and having a radius of curvature R 1 and the first finished juncture being arcuate and having a radius of curvature R 2 ; and

wherein the step of forming the fastening section is performed so that R 2 is from about 20% to about 150% less than R 1 .

3. The method of claim 2 , wherein R 2 is less than 50 microns.

4. The method of claim 2 , wherein the finished slot of the fastening section has a maximum width WS 2 ; and

wherein the step of forming the fastening section is performed so that the ratio WS 2 /R 2 is at least about 5/1.

5. The method of claim 2 , wherein the second finished juncture is arcuate and has a radius of curvature R 2 ′; and

wherein the step of forming the fastening section is performed so that R 2 is less than R 2 ′.

6. The method of claim 1 , wherein the conductive metal is selected from the group consisting of copper, a copper alloy, aluminum and an aluminum alloy.

7. The method of claim 1 , wherein the step of forming the precursor configuration comprises forming a barrel-shaped portion in the work piece.

8. The method of claim 7 , wherein the step of forming the precursor configuration further comprises flattening the barrel-shaped portion to form a flattened ellipsoid-like portion and then punching a slot in the flattened ellipsoid-like portion, thereby forming the precursor retention portion and the precursor slot.

9. The method of claim 8 , wherein the work piece comprises a length of metal wire having a rectangular cross-section.

10. The method of claim 1 , wherein the first forces F 1 are applied by moving a pair of oppositely-directed first press elements toward each other, and the second forces F 2 are applied by a moving a pair of oppositely-directed second press elements toward each other.

11. The method of claim 1 , wherein the first forces F 1 and the second forces F 2 are applied by moving a pair of oppositely-directed singular press elements toward each other.

12. The method of claim 11 , wherein each singular press element is configured to have a topography with first and second portions, wherein the first portion applies the first force F 1 to the exterior side of one of the precursor beams and the second portion applies the second force F 2 to the exterior side of the one of the precursor beams.

13. The method of claim 1 , wherein the finished slot is from about 5% to about 20% longer than the precursor slot in the direction of the longitudinal axis.