Electrical probe contact

Claim 1

A stamped and formed sheet metal probe contact for an electrically conducting lead including an outer insulating cover carried by an inner electrical conductor, said cover defining an insulating cover diameter, and said conductor defining a conductor diameter smaller than said insulating cover diameter, comprising: a discrete probe tip portion having a generally cylindrical base and an elongated metal pin extending from said tip portion base; and a coupling portion comprising: an elongated body portion; a first set of opposed, bendable arms integrally formed with said body portion for mechanically grasping said insulating cover; a second set of opposed bendable arms integrally formed with said body portion for electrically and mechanically grasping said inner electrical conductor, said first and second set of arms being in laterally offset relation along said body portion with each other; and a third set of opposed, bendable arms integrally formed with said body portion, said third set of arms spaced from said second set, said second set of arms being disposed between said first and third sets of arms, said third set of arms including interlocking means for interconnecting said third set of arms to form a tubular tip portion receiving receptacle electrically coupled to said first and second set of arms, for electrically and mechanically grasping said probe tip portion, said first set of arms and said body portion defining a first channel for receiving said insulating cover, and said second set of arms and said body portion defining a second channel for receiving said electrical conductor, said second channel including a plurality of strength providing ribs, and said first channel having an internal cross sectional diameter adapted for receiving said insulating cover and said second channel having an internal cross sectional diameter smaller than said first channel diameter and adapted for receiving said electrical conductor, said third set of arms and said body portion defining a third channel for receiving said probe tip portion, said probe tip base being staked within said third channel by inwardly bending said body portion against said probe tip base to form a staking indentation, said body portion including structure defining an aperture communicating with said third channel at said staking indentation to facilitate said inward bending, said third set of arms being swaged on to the cylindrical base of said probe tip portions to form a frusto-conical probe tip base crimping portion.