Small-sized contact pin package

Claim 2

A small-sized electrical contact pin unit for engagement with an internal surface (18) of a plug socket (14) capable of being provided in a device such as a printed circuit board, said internal surface (18) having an approximately circular cross-sectional area, said contact pin unit comprising an elongate basic pin (10) having a longitudinal axis and longitudinally arranged opposite end portions, a partial section (A) being elongate over at least part of the axial length of the basic pin (10) between said longitudinally arranged opposite end portions, said partial section (A) having lateral faces (24, 26), said partial section (A) having a long cross-sectional axis (X), whose length corresponds approximately to the inside diameter of said internal surface (18) so as to provide centering of the basic pin (10) in the plug socket 14, and a short cross-sectional axis (Y), at least one (24) of said lateral faces (24, 26) being substantially perpendicular to the short cross-sectional axis (Y) within said partial section of said basic pin (10), a contact spring (20) elongate in said axial direction, said contact spring being laterally supported on said one lateral face (24) in a direction perpendicular to the longitudinal axis of the basic pin (10) without extending over either of the longitudinally extending opposite end portions of said basic pin and being conductively connected to said basic pin, said contact spring (20) being dimensioned such as to make electric contact with said internal surface (18) of said plug socket (14) with radial pressure substantially perpendicular with respect to said one lateral face (24), said contact spring (2) being formed of sheet metal and, considered in a cross-section that is perpendicular to the longitudinal axis of the basic pin (10), said contact spring (20) being curved and having a substantially concave internal side (20a), which is directed towards the basic pin (10), and a substantially convex external side (20b) which is directed towards the internal surface (18) of the plug socket (14) when the contact pin unit is mounted in the socket.

Claim 3

A contact pin unit as claimed in claim 1, wherein, considered in said cross-section perpendicular to the longitudinal axis of the basic pin, the external side (20b) has a radius of curvature which is slightly smaller than or, at the most, equal to the inside radius of the internal surface (18) of the plug socket (14).

Claim 4

A contact pin unit as claimed in claim 1, wherein the contact spring (20) extends in an arc-shaped manner along said longitudinal axis of said basic pin (10), with a concave arc curvature that is directed towards said one lateral face (24) and a convex arc curvature that is directed towards the internal surface (18) of the plug socket (14) when the contact pin is mounted in the socket.

Claim 5

A contact pin unit as claimed in claim 3, wherein, at least after the contact pin unit has been inserted into said plug socket (14), two axially spaced end portions of said contact spring (20) are supported on said one lateral face (24) of said basic pin (10).

Claim 6

A contact pin unit as claimed in claim 3, wherein the contact spring (20) is fastened to the basic pin (10) with a first end and abuts the partial section (A) of the basic pin (10) with its second end (20a) so as to be displaceable in the longitudinal direction of the latter.

Claim 7

A contact pin unit as claimed in claim 5, wherein, at its second end (20a), the contact spring (20) is opposite to a stop (34) which limits its displaceability in the longitudinal direction of the basic pin (10).

Claim 8

A contact pin unit as claimed in claim 6, wherein the stop (34) has been co-ordinated with the length of the contact spring and with the inside diameter of the plug socket (14) in such a way that the second end (20a) butts thereagainst before the contact spring (20) enters the plug socket (14).

Claim 9

A contact pin unit as claimed in claim 1, wherein the contact spring (20) has at least one axial end portion welded or soldered to the basic pin (10).

Claim 10

A contact pin unit as claimed in claim 1, wherein each of two radially opposite lateral faces (24) perpendicular to the short cross-sectional axis (Y) are each provided with a contact spring (20), said contact spring (20) being made from sheet metal.

Claim 11

A contact pin unit as claimed in claim 9, wherein a connection part (28) is U-shaped and has a web (28a), which abuts a basic pin (10) lateral surface zone (30a) that is perpendicular to the long cross-sectional axis (X) of the partial section (A), and two legs (28b) which abut the partial section (A) lateral surfaces (24) that are perpendicular to the short cross-sectional axis (Y) of the partial section (A), and in that the contact springs (20) extend from respective legs (28b).

Claim 12

A contact pin unit as claimed in claim 10, wherein the web (28a) abuts a basic pin (10) lateral surface zone (30a) that is perpendicular to the long cross-sectional axis (X) of the partial section (A) and which is set back, in relation to the associated partial section (A) lateral surface (26) that is defined by the long cross-sectional axis (X), towards the basic pin axis.

Claim 13

A contact pin unit as claimed in claim 10, wherein the web (28a) and/or at least one of the legs (28b) have been soldered or welded together with the basic pin (10) lateral surface zone which respectively butts thereagainst.

Claim 14

A contact pin unit as claimed in claim 1 wherein the lateral faces (26, 326) substantially perpendicular to said long cross-sectional axis (X) of said partial section (A) are convexly rounded towards the internal surface (18, 318) of the plug socket (14).

Claim 15

A contact pin unit as claimed in claim 1 wherein the lateral faces (126, 326) perpendicular to said long cross-sectional axis (X) of said partial section (A) converge towards each other at at least one end of said partial section (A); said one end being intended for being introduced first into said plug socket (14).

Claim 16

A contact pin unit as claimed in claim 1 wherein said partial section A has been formed by flattening a piece of wire forming the basic pin (10, 310).

Claim 17

A contact pin unit as claimed in claim 15, wherein the piece of wire (10, 310) has a square cross-sectional area with two transverse intersecting central axes, and wherein said axes (X,Y) of said flattened partial section (A) are parallel to said transverse intersecting central axes.

Claim 18

A contact pin unit as claimed in claim 15, wherein a stop (34) for the contact spring (20) is formed by the transition shoulder from the flattened partial section (A) to an adjoining undeformed wire section (C), there being, if necessary, integrally formed with this transition shoulder (34) a holding nose (36) which engages over the contact spring, at least after it has reached the stop (34).

Claim 19

A contact pin unit as claimed in claim 15 wherein the partial section (A) has, at at least one end, a flattened transition section (D), whose short cross-sectional axis corresponds in its length to the short cross-sectional axis (Y) of the flattened partial section (A) and whose long axis corresponds to the corresponding axis of the undeformed piece of wire or is smaller than this axis, and in that the connection part (28) abuts this transition section (D).

Claim 20

A contact pin unit as claimed in claim 15 wherein the legs (28b) of the connection part (28) abut, with their edges (28c) that are remote from the contact springs (20), transition shoulders (32) between the flattened partial section (A) and an adjoining section (B) of the undeformed piece of wire (10).

Claim 21

A contact pin unit as claimed in claim 1, wherein the inside diameter of said internal surface (18, 318) of said plug socket is smaller than 2.5 mm, more especially approximately 1 mm.

Claim 22

A contact pin unit as claimed in claim 1, wherein the ratio of the length of the long axis (X) of said partial section (A) to the length of the short axis (Y) of said partial section (A) is in a range of 1.5:1 to 4:1, preferably approximately 2:1 to 3:1.

Claim 23

A contact pin unit as claimed in claim 1, wherein the thickness of the sheet metal is approximately 5/100 to approximately 20/100 mm.

Claim 24

A contact pin unit as claimed in claim 1, wherein the ratio of the axial length of the partial section (A) to the inside diameter of the internal surface (18, 318) of the plug socket is about 2:1 to about 4:1, preferably approximately 3:1.

Claim 25

A contact pin unit as claimed in claim 1, wherein the plug socket is formed by a hole the internal surface of which has been metalized, more especially a tin-coated hole (18) in a printed-circuit board (16).

Claim 26

A contact pin unit as claimed in claim 1, wherein the contact spring (220, 320) has a rounded or pointed contour adjacent at least one of its ends, said at least one end being introduced first when said contact pin unit is introduced into said plug socket (14).

Claim 27

A contact pin unit as claimed in claim 1, wherein the one lateral face (24) is substantially roof-shaped and substantially perpendicular to the short cross-sectional axis (Y).

Claim 28

A contact pin unit as claimed in claim 1, wherein the one lateral face (24) is substantially trough-shaped and substantially perpendicular to the short cross-sectional axis.

Claim 29

A method for the production of a contact pin package as claimed in claim 1 wherein two contact springs (220) with a U-shaped connection piece (228) are placed, transversely to the longitudinal axis of the basic pin, on this pin and may be welded thereto.

Claim 30

A small-sized electrical contact pin unit for engagement with an internal surface (318) of a plug socket capable of being provided in a device such as a printed circuit board, said internal surface (318) having an approximately circular cross-sectional area, said contact pin unit comprising an elongate basic pin (310) having a longitudinal axis, a partial section (A) being elongate and extending over at least part of the axial length of the basic pin (319), said partial section (A) having lateral faces (324, 326), said partial section (A) having a long cross-sectional axis (X), whose length corresponds approximately to the inside diameter of said internal surface (318) so as to provide centering of the basic pin (310) in the plug socket, and a short cross-sectional axis (Y), at least one (324) of said lateral faces (324, 326) being substantially perpendicular to the short cross-sectional axis (Y) within said partial section (A) of said basic pin (310), a contact spring (320) elongate in said axial direction being supported on said at least one lateral surface (324) and being conductively connected to said basic pin (310), said contact spring (320) being dimensioned such as to make electric contact with said internal surface (318) of said plug socket with radial pressure substantially perpendicular with respect to said one lateral face (324), said contact spring (320) being formed of sheet metal and, considered in a cross-section that is perpendicular to the longitudinal axis of the basic pin (310), said contact spring (320) being curved and having substantially concave internal side (320a), which is directed towards the basic pin (310), and a substantially convex external side (320b) which is directed towards the internal surface (318) of the plug socket when the contact pin unit is mounted in the socket, said contact spring (320) also having longitudinal edge zones (320f) substantially parallel to said longitudinal axis, said longitudinal edge zones (320f) engaging said one lateral face (324) substantially over the entire length of said edge zones (320f) when said contact pin unit has been introduced into engagement with said internal surface (318) of said plug socket.

Claim 31

A small-sized electrical contact pin unit for engagement with an internal surface (318) of a plug socket capable of being provided in a device such as a printed circuit board, said internal surface (318) having an approximately circular cross-sectional area, said contact pin unit comprising an elongate basic pin (310) having a longitudinal axis, a partial section (A) being elongate and extending over at least part of the axial length of the basic pin (319), said partial section (A) having lateral faces (324, 326), said partial section (A) having a long cross-sectional axis (X), whose length corresponds approximately to the inside diameter of said internal surface (318) so as to provide centering of the basic pin (310) in the plug socket, and a short cross-sectional axis (Y), at least one (324) of said lateral faces (324, 326) being substantially perpendicular to the short cross-sectional axis (Y) within said partial section (A) of said basic pin (310), a contact spring (320) elongate in said axial direction being supported on said at least one lateral surface (324) and being conductively connected to said basic pin (310), said contact spring (320) being dimensioned such as to make electric contact with said internal surface (318) of said plug socket with radial pressure substantially perpendicular with respect to said one lateral face (324), said contact spring (320) being formed of sheet metal and, considered in a cross-section that is perpendicular to the longitudinal axis of the basic pin (310), said contact spring (320) being curved and having substantially concave internal side (320a), which is directed towards the basic pin (310), and a substantially convex external side (320b) which is directed towards the internal surface (318) of the plug socket when the contact pin unit is mounted in the socket, said contact spring (320) also having longitudinal edge zones (320f) substantially parallel to said longitudinal axis, said longitudinal edge zones (320f) engaging said one lateral face (324) substantially over the entire length of said edge zones (320f) when said contact pin unit has been introduced into engagement with said internal surface (318) of said plug socket.

Claim 32

A contact pin unit as claimed in claim 29 wherein in an untensioned state of the contact spring, a central circle of curvature (320f) of a curvature (320g) of the contact spring (320) as regarded in a plane perpendicular to said longitudinal axis, has a centre (M) outside the respective lateral face (324) which is substantially perpendicular to the short cross-sectional axis (Y) and has a radius of curvature (r) which is substantially smaller than half of the long cross-sectional axis (X).

Claim 33

A contact pin unit as claimed in claim 30, wherein the distance of the centre (M) of the central circle of curvature (320g) from the respective lateral face (324) that is vertical to the short cross-sectional axis (Y) is approximately one third to approximately two thirds, preferably approximately one half of the radius of curvature (r) of the central circle of curvature (320q).

Claim 34

A contact pin unit as claimed in claim 30, wherein the radius of curvature (r) of the central circle of curvature (320q) is approximately one third to approximately two thirds, preferably approximately one half of half the length of the long cross-sectional axis (X).

Claim 35

A contact pin unit as claimed in claim 30, wherein an internal side (320a) of the contact spring (320), when regarded in a sectional plane perpendicular to said longitudinal axis, is concavely curved in a topzone (320n) and convexly curved in an edge zone (320f).

Claim 36

A contact pin unit as claimed in claim 33, wherein the contact spring (320) abuts, with a convexly curved internal surface (320p) of the edge zone (320f), the respective lateral face (324) that is substantially perpendicular to the short cross-sectional axis (Y).

Claim 37

A contact pin unit as claimed in claim 29, wherein the respective lateral face (324) which is substantially perpendicular to the short cross-sectional axis (Y) is designed as a plane surface or roof surface.

Claim 38

A contact pin unit as claimed in claim 29, wherein the contact spring (420) abuts, with sharp edges (420m), the respective lateral face (424) that is substantially perpendicular to the short cross-sectional axis (Y).

Claim 39

A contact pin unit as claimed in claim 29, wherein the lateral face (424) which is substantially perpendicular to the short cross-sectional axis (Y) is designed as a flat-trough surface.

Claim 40

A contact pin unit as claimed in claim 29, wherein the contact spring 320, when regarded in a sectional plane perpendicular to said longitudinal axis, has an external side (320b) which is convex in an apex zone and is substantially parallel to the short cross-sectional axis (Y) in another edge zone (320ba).

Claim 41

A contact pin unit as claimed in claim 29, wherein the material of the contact spring (320), when regarded in a sectional plane perpendicular to said longitudinal axis, is oriented by having been circumferentially stressed during curve shaping.

Claim 42

A contact pin unit as claimed in claim 29, wherein the lateral faces (324, 326) of the partial section (A) merge in a substantially continuous (stopless) manner with corresponding lateral faces of the basic pin (310).

Claim 43

A contact pin unit as claimed in claim 40, wherein said basic pin (310) is provided with a wire coil (301) coiled around the basic pin at a location outside said partial section (A).

Claim 44

A contact pin unit as claimed in claim 29 wherein the basic pin (510) is provided with a plug contact part (555, 557) at at least one end.

Claim 45

A contact pin package comprising a plurality of contact pin units as claimed in claim 29, wherein the plurality of contact pin units (310) are coherent in the form of a magazine strip.

Claim 46

A contact pin package as claimed in claim 43, wherein the contact springs (320) have been made from a sheet-metal strip (317) by stamping and bending.

Claim 47

A contact pin package as claimed in claim 44 wherein pre-determined breaking points (309C, 311d, 311e) are provided between the contact springs (320) and remainders of the sheet-metal strip (317) which connect the basic pins (310) to the magazine strip.

Claim 48

A contact pin package as claimed in claim 44, wherein the basic pins (310) have been connected to the magazine strip by parts from the sheet-metal strip (317) which were left during the formation of the contact springs (320).

Claim 49

A contact pin package as claimed in claim 46, wherein pre-determined breaking points (309c, 311d, 311e) are provided between the contact springs (320) and remainders of the sheet-metal strip (317) which connect the basic pins (310) to the magazine strip.

Claim 50

A contact pin package as claimed in claim 46 wherein remainders of the sheet-metal strip (317) which connect the basic pins (310) to the magazine strip are provided with guide means (313) and/or indexing means (315) for transporting the magazine strip through processing devices.

Claim 51

A contact pin package as claimed in claim 46, wherein sheet-metal strip (317) remainders connecting the basic pins (310) to the magazine strip comprise a carrier strip (307) which extends transversely to the axial direction of the basic pins and parallel to the basic pin lateral faces (324) carrying first contact springs (320l), on one side (324l) of the basic pins (310), and in that this carrier strip (307) is connected to the contact springs (320l), which lie on the same side (324l) of the basic pins (310), via first connection strips (309) which substantially lie in a plane (E1) that is perpendicular to the longitudinal direction of the carrier strip (307) and passes through the respective basic pin (310) and is connected to second contact springs (320k), which lie on the other side (324k) of the basic pins (310), by second connection strips (311) which lie outside this plane (E1).

Claim 52

A contact pin package as claimed in claim 49, wherein the plane containing the carrier strip (307) is substantially parallel to the axial direction of the basic pins (310), and in that a first connection strip (309) has a first strip section (309a) substantially perpendicular to the plane of the carrier strip (307) and has a second strip section (309b) which is inclined towards the axial direction of the respective basic pin (310) and extends to the adjacent end of the respective contact spring (320l), there being provided a predetermined breaking point (309c) at the transition from the second strip section (309b) to the respective contact spring (320l).

Claim 53

A contact pin package as claimed in claim 49, wherein said second connection strip (311) has a strip section (311a, 311b) which is multiply angled and which, starting out from the carrier strip (307), lies in a plane (E2) that is substantially perpendicular to the longitudinal direction (LR) of the carrier strip (307) and that is laterally offset from the respective basic pin (310) and has a continuation strip section (311c) which is substantially parallel to the carrier strip (307) and connects the multiply angled strip section (311a, 311b) to the contact spring (320k), the plane of the carrier strip (307) being substantially parallel to the axial direction of the basic pins (310), and a first partial section (311a) of the multiply angled strip section (311a, 311b) adjoining the carrier strip (307) at a first angle β and projecting beyond the associated basic pin (310) lateral faces (324k) that are remote from the carrier strip, and a second partial section (311b) of the multiply angled strip section (311a, 311b) returning at a second angle γ with respect to the first partial section (311a) into the plane of the lateral face (324k) that is remote from the carrier strip (310) and adjoining the continuation strip section (311c), and predetermined breaking points (311e and 311d respectively) being provided at a transition from the carrier strip (307) to the first partial section (311a) and a transition from the continuation strip section (311c) to the respective contact spring (320k).

Claim 54

A contact pin package as claimed in claim 49 wherein the carrier strip (307) has been stiffened by tabs (313) which are angled substantially perpendicularly to its plane and result in a substantially U-shaped guide section.

Claim 55

A contact pin package as claimed in claim 49 wherein the two ends of the basic pins (310) project, in the axial direction thereof, beyond the carrier strip (307) and the connection strips (309, 311).

Claim 56

A method for the production of a contact pin package as claimed in claim 49 while using basic pins and a sheet-metal strip providing the contact springs, wherein the sheet-metal strip (317) is moved in a feed direction (LR) perpendicularly to a supply direction of the basic pins (310), and wherein there is obtained from the sheet-metal strip by stamping operations a filigree strip containing the contact springs (320l, 320k) for the respective lateral faces (324k, 324l) of the basic pin (310), the carrier strip (307) and the connection strips (309, 311), and in that the basic pins (310) are placed, with one lateral face (324l), against the respective first contact springs (320l) and wherein thereupon the second contact springs (320k) are folded onto the respective other lateral face (324k) of the basic pins (310).

Claim 57

A method for the production of a contact pin package as claimed in claim 54, wherein the basic pins (310) are fixed with the respective lateral faces (324l) to the first contact springs (320l) by one of the soldering and welding methods and in that the second contact springs (320k) are fastened to the respective lateral faces (324k) of the basic pins (310) by one of the welding and soldering methods.

Claim 58

A method for the installation of a section of a contact pin package as claimed in claim 49 into a basic pin reception carrier (349), wherein first the second connection strips (311) are cut off, and wherein the first connection strips (309 ) are broken off in one of the periods during or following the introduction of the basic pins (310) into the basic pin receptable carrier (349).

Claim 59

A method as claimed in claim 56, wherein the first connection strips (309) are broken off by displacing the basic pins (310) in their axial direction with respect to the carrier strip (307).

Claim 60

A contact pin package as claimed in claim 29, wherein the printed-circuit board (359) is designed as a multi-layer printed-circuit board, the contact spring being shaped such as to be able to contact a plurality of layers.

Claim 61

A method for the production of the contact springs for contact pin units as claimed in claim 29 wherein the contact spring, when considered in a section perpendicular to the longitudinal axis, is curved by a forming operation by which the spring material is oriented with a direction of orientation substantially parallel to the circumferential direction of the curve configuration.

Claim 62

A method as claimed in claim 59, wherein for the production of the contact springs (320) from a sheet-metal strip (317) there are provided prior to the production of the curve configuration (320 g) in the sheet-metal strip (317), at a distance from the edges of the respective contact spring (320) slots (319) in the sheet-metal strip (317), the edge zones (323a) of a material web (323) left between the slots (319) are clamped, a central zone of this material web (323) is curved and the edge zones (323a) are thereupon trimmed.

Claim 63

A contact pin unit as claimed in claim 29, wherein the contact spring (620) is provided, at least on its side that is directed towards the basic pin (610), with a coating (621) which is softer than the material of the contact spring (620) and the material of the basic pin (610) and is highly conductive, said softer layer being deformed such as to define an increased contact surface with the basic pin (610) when the contact spring (620) is operationally pressed against the basic pin (610).

Claim 64

A contact pin unit as claimed in claim 29, wherein said longitudinal edge zones (320f) engage said one lateral face (324) in the untensioned state, i.e. before inserting said contact pin unit into said plug socket (314).

Claim 65

A contact pin unit as claimed in claim 29, wherein said curved contact spring (320), when regarded in said cross-section, has a predetermined radius of curvature in an area adjacent an apex of said curved contact spring (320) in an untensioned state, i.e. before said contact pin unit is entered into said plug socket (314), said predetermined radius of curvature being increased by said radial pressure, i.e. when said contact pin unit is introduced into said plug socket (314).

Claim 66

A contact pin unit as claimed in claim 29, wherein the contact spring (320) has at least one axial end portion welded or soldered to the basic pin (310).

Claim 67

A contact pin unit as claimed in claim 29, wherein each of two radially opposite lateral faces (324) perpendicular to the short cross-sectional axis (Y) are each provided with a contact spring (320), said contact springs (320) being made from sheet metal.

Claim 68

A contact pin unit as claimed in claim 29, wherein the thickness of the sheet metal is approximately 5/100 to approximately 20/100 mm.

Claim 69

A contact pin unit as claimed in claim 29, wherein the lateral faces (326) substantially perpendicular to the long cross sectional axis (X) of the partial section (A) are convexly rounded towards the internal surface (318) of the plug socket.

Claim 70

A contact pin unit as claimed in claim 29, wherein the lateral faces (326) perpendicular to said long cross-sectional axis (X) of said partial section (A) converge towards each other at at least one end of said partial section (A); said one end being intended for being first introduced into said plug socket.

Claim 71

A contact pin unit as claimed in claim 29, wherein the partial section (A) has been formed by flattening a piece of wire forming the basic pin (310).

Claim 72

A contact pin unit as claimed in claim 69, wherein the piece of wire has a square cross-sectional area with two middle axes, and wherein said axes (X, Y) of said flattened partial section (A) are parallel to said middle axes.

Claim 73

A contact pin unit as claimed in claim 29, wherein the inside diameter of said internal surface (318) of said plug socket is smaller than 2.5 mm, more especially approximately 1 mm.

Claim 74

A contact pin unit as claimed in claim 29, wherein the ratio of the length of the long axis (X) of said partial section (A) to the length of the short axis (Y) of said partial section (A) is in a range of 1.5:1 to 4:1, preferably approximately 2:1 to 3:1.

Claim 75

A contact pin unit as claimed in claim 29, wherein the ratio of the axial length of said partial section (A) to the inside diameter of the internal surface (318) of the plug socket is about 2:1 to about 4:1, preferably approximately 3:1.

Claim 76

A contact pin unit as claimed in claim 29, wherein the plug socket is formed by a hole the internal surface of which has been metalized, more especially a tin-coated hole (318) in a printed-circuit board (316).

Claim 77

A contact pin unit as claimed in claim 29, wherein the contact spring (220) has a rounded or pointed contour adjacent at least one of its ends, said at least one end being introduced first when said contact pin unit is introduced into said plug socket.

Claim 78

A contact pin unit as claimed in claim 29, wherein said basic pin (310) is provided with a wire coil (301) coiled around the basic pin at a location outside said partial section (A).

Claim 79

A contact pin unit as recited in claim 29, wherein each of two radially opposite lateral faces (324) perpendicular to the short cross-sectional axis (Y) are each provided with a contact spring (320) being made of sheet metal.

Claim 80

A small-sized electrical contact pin unit for engagement with an internal surface (318) of a plug socket capable of being provided in a device such as a printed circuit board, said internal surface (318) having an approximately circular cross-sectional area, said contact pin unit comprising an elongate basic pin (310) having a longitudinal axis, a partial section (A) being elongate and extending over at least part of the axial length of the basic pin (310), said partial section (A) having lateral faces (324, 326), said partial section (A) having a long cross-sectional axis (X), and a short cross-sectional axis (Y), at least one (324) of said lateral faces (324, 326) being substantially perpendicular to the short cross-sectional axis (Y) within said partial section of said basic pin (310), a contact spring (320) elongate in said axial direction being supported on said at least one lateral surface (324) and being conductively connected to said basic pin (310), said contact spring (320) being dimensioned such as to make electric contact with said internal surface (318) of said plug socket with radial pressure substantially perpendicular with respect to said one lateral face (324), and said contact spring (320), adjacent at least one of its axial end portions, being three-dimensionally curved in the shape of a bath-tub (at 320g) over at least a portion of its length, the bath-tub configuration having longitudinal edge zones (320f) substantially parallel to said longitudinal axis, said longitudinal edge zones (320f) engaging the respective lateral face (324) substantially over the entire length of said edge zones (320f) when said contact pin unit has been introduced into engagement with said internal surface (318) of said plug socket.

Claim 81

A small-sized electrical contact pin unit for engagement with an internal surface (318) of a plug socket capable of being provided in a device such as a printed circuit board, said internal surface (318) having an approximately circular cross-sectional area, said contact pin unit comprising an elongate basic pin (310) having a longitudinal axis, a partial section (A) being elongate and extending over at least part of the axial length of the basic pin (310), said partial section (A) having lateral faces (324, 326), said partial section (A) having a long cross-sectional axis (X), and a short cross-sectional axis (Y), at least one (324) of said lateral faces (324, 326) being substantially perpendicular to the short cross-sectional axis (Y) within said partial section of said basic pin (310), a contact spring (320) elongate in said axial direction being supported on said at least one lateral surface (324) and being conductively connected to said basic pin (310), said contact spring (320) being dimensioned such as to make electric contact with said internal surface (318) of said plug socket with radial pressure substantially perpendicular with respect to said one lateral face (324), and said contact spring (320), adjacent at least one of its axial end portions, being three-dimensionally curved in the shape of a bath-tub (at 320g) over at least a portion of its length, the bath-tub configuration having longitudinal edge zones (320f) substantially parallel to said longitudinal axis, said longitudinal edge zones (320f) engaging the respective lateral face (324) substantially over the entire length of said edge zones (320f) when said contact pin unit has been introduced into engagement with said internal surface (318) of said plug socket.

Claim 82

A contact pin unit as claimed in claim 78, wherein the contact spring (320) is provided, at at least one end, with an end flange (320h) which continues the bath-tub configuration (320g) in the axial direction, and in that this end flange (320h) abuts the respective lateral face (324) perpendicular to the short cross-sectional axis (Y).

Claim 83

A contact pin unit as claimed in claim 79, wherein the end flange (320h) is fastened to said basic pin by one of the soldering or welding methods.

Claim 84

A contact pin unit as claimed in claim 79, wherein the end flange (320h) has a convexly curved, axially directed terminal edge.

Claim 85

A contact pin unit as claimed in claim 81, wherein said convexly curved terminal edge is located such as to be introduced first into said plug socket when said contact pin (310) is introduced into said plug socket.

Claim 86

A contact pin unit as claimed in claim 78, wherein said bath tub configuration has an apex line substantially parallel to the respective lateral face (324).

Claim 87

A contact pin unit as claimed in claim 78, wherein said bath tub configuration has a curved edge zone at at least one axial end portion thereof, said curved edge zone contacting the respective lateral face (324).

Claim 88

A contact pin unit as claimed in claim 78, wherein said bath tub configuration has, when regarded in a section perpendicular to said longitudinal axis, a radially outer convex side (320b) directed towards said internal surface (318) and having at least in a zone adjacent an apex thereof a radius of curvature smaller than the radius of curvature of said internal surface (318).

Claim 89

A contact pin unit as claimed in claim 78, wherein said bath tub configuration defines, when regarded in a section perpendicular to said longitudinal axis and located at an axially intermediate location between said axial end portions, a curve, said curve having an apex zone, said curve having a predetermined radius of curvature in said apex zone in the untensioned state, i.e. before inserting said contact pin unit into said plug socket, said predetermined radius of curvature being increased by said radial pressure, i.e. when said contact pin unit is introduced into said plug socket.

Claim 90

A contact pin unit as claimed in claim 78, wherein the lateral faces (324,326) of the partial section (A) merge in a substantially continuous manner with corresponding lateral faces of the basic pin (310).

Claim 91

A small-sized electrical contact pin unit for engagement with an internal surface (18) of a plug socket (14) capable of being provided in a device such as a printed circuit board, said internal surface (18) having an approximately circular cross-sectional area, said contact pin unit comprising an elongate basic pin (10) having a longitudinal axis and elongated opposite ends, a partial section (A) being elongate over at least part of the axial length of the basic pin (10) between said elongated opposite ends, said partial section (A) having lateral faces (24, 26), said partial section (A) having a long cross-sectional axis (X), whose length corresponds approximately to the inside diameter of said internal surface (18) so as to provide centering of the basic pin (10) in the plug socket 14, and a short cross-sectional axis (Y), at least one (24) of said lateral faces (24, 26) being substantially plane and substantially perpendicular to the short cross-sectional axis (Y) within said partial section of said basic pin (10), a contact spring (20) elongate in said axial direction, said contact spring being laterally supported on said one lateral face (24) in a direction perpendicular to the longitudinal axis of the basic pin (10) without extending over either of the elongated opposite ends of said basic pin and being conductively connected to said basic pin, said contact spring (20) being dimensioned such as to make electric contact with said internal surface (18) of said plug socket (14) with radial pressure substantially perpendicular with respect to said one lateral face (24), said contact spring (20) being formed of sheet metal and, considered in a cross-section that is perpendicular to the longitudinal axis of the basic pin (10), said contact spring (20) being curved and having a substantially concave internal side (20a), which is directed towards the basic pin (10), and a substantially convex external side (20b) which is directed towards the internal surface (18) of the plug socket (14) when the contact pin unit is mounted in the socket, said contact spring (20) also having longitudinal edge zones (20f) with sharp edges (20ff) substantially parallel to said longitudinal axis, said sharp edges (20ff) being engageable with said one lateral face (24).

Claim 92

A small-sized electrical contact pin unit for engagement with an internal surface (18) of a plug socket (14) capable of being provided in a device such as a printed circuit board, said internal surface (18) having an approximately circular cross-sectional area, said contact pin unit comprising an elongate basic pin (10) having a longitudinal axis and elongated opposite ends, a partial section (A) being elongate over at least part of the axial length of the basic pin (10) between said elongated opposite ends, said partial section (A) having lateral faces (24, 26), said partial section (A) having a long cross-sectional axis (X), whose length corresponds approximately to the inside diameter of said internal surface (18) so as to provide centering of the basic pin (10) in the plug socket 14, and a short cross-sectional axis (Y), at least one (24) of said lateral faces (24, 26) being substantially plane and substantially perpendicular to the short cross-sectional axis (Y) within said partial section of said basic pin (10), a contact spring (20) elongate in said axial direction, said contact spring being laterally supported on said one lateral face (24) in a direction perpendicular to the longitudinal axis of the basic pin (10) without extending over either of the elongated opposite ends of said basic pin and being conductively connected to said basic pin, said contact spring (20) being dimensioned such as to make electric contact with said internal surface (18) of said plug socket (14) with radial pressure substantially perpendicular with respect to said one lateral face (24), said contact spring (20) being formed of sheet metal and, considered in a cross-section that is perpendicular to the longitudinal axis of the basic pin (10), said contact spring (20) being curved and having a substantially concave internal side (20a), which is directed towards the basic pin (10), and a substantially convex external side (20b) which is directed towards the internal surface (18) of the plug socket (14) when the contact pin unit is mounted in the socket, said contact spring (20) also having longitudinal edge zones (20f) with sharp edges (20ff) substantially parallel to said longitudinal axis, said sharp edges (20ff) being engageable with said one lateral face (24).

Claim 93

A contact pin unit as claimed in claim 88, wherein, considered in said cros-section perpendicular to the longitudinal axis of the the basic pin, the external side (20b) has a radius of curvature which is slightly smaller than or, at the most, equal to the inside radius of the internal surface (18) of the plug socket (14).

Claim 94

A contact pin unit as claimed in claim 88, wherein the contact spring (20) extends in an arc-shaped manner along said longitudinal axis of said basic pin (10), with a concave arc curvature that is directed towards said one lateral face (24) and a convex arc curvature that is directed towards the internal surface (18) of the plug socket (14) when the contact pin is mounted in the socket.

Claim 95

A contact pin unit as claimed in claim 90, wherein, at least after the contact pin unit has been inserted into said plug socket (14), two axially spaced end portions of said contact spring (20) are supported on said one lateral face (24) of said basic pin (10).

Claim 96

A contact pin unit as claimed in claim 90, wherein the contact spring (20) is fastened to the basic pin (10) with a first end and abuts the partial section (A) of the basic pin (10) with its second end (20a) so as to be displaceable in the longitudinal direction of the latter.

Claim 97

A contact pin unit as claimed in claim 92, wherein, at its second end (20a), the contact spring (20) is opposite to a stop (34) which limits its displaceability in the longitudinal direction of the basic pin (10).

Claim 98

A contact pin unit as claimed in claim 93, wherein the stop (34) has been co-ordinated with the length of the contact spring and with the inside diameter of the plug socket (14) in such a way that the second end (20a) butts thereagainst before the contact spring (20) enters the plug socket (14).

Claim 99

A contact pin unit as claimed in claim 88, wherein the contact spring (20) has at least one axial end portion welded or soldered to the basic pin (10).

Claim 100

A contact pin unit as claimed in claim 97, wherein each of two radially opposite lateral faces (24) perpendicular to the short cross-sectional axis (Y) are each provided with a contact spring (20), said contact springs (20) being made from sheet metal.

Claim 101

A contact pin unit as claimed in claim 96, wherein a connection part (28) is U-shaped and has a web (28a), which abuts a basic pin (10) lateral surface zone (30a) that is perpendicular to the long cross-sectional axis (X) of the partial section (A), and two legs (28b) which abut the partial section (A) lateral surfaces (24) that are perpendicular to the short cross-sectional axis (Y) of the partial section (A), and in that the contact springs (20) extend from respective legs (28b).

Claim 102

A contact pin unit as claimed in claim 97, wherein the web (28a) abuts a basic pin (10) lateral surface zone (30a) that is perpendicular to the long cross-sectional axis (X) of the partial section (A) and which is set back, in relation to the associated partial section (A) lateral surface (26) that is defined by the long cross-sectional axis (X), towards the basic pin axis.

Claim 103

A contact pin unit as claimed in claim 97, wherein the web (28a) and/or at least one of the legs (28b) have been soldered or welded together with the basic pin (10) lateral surface zone which respectively butts thereagainst.

Claim 104

A contact pin unit as claimed in claim 97, wherein the lateral faces (26, 326) substantially perpendicular to said long cross-sectional axis (X) of said partial section (A) are convexly rounded towards the internal surface (18, 318) of the plug socket (14).

Claim 105

A contact pin unit as claimed in claim 88, wherein the lateral faces (126, 326) perpendicular to said long cross-sectional axis (X) of said partial section (A) converge towards each other at at least one end of said partial section (A); said one end being intended for being introduced first into said plug socket (14).

Claim 106

A contact pin unit as claimed in claim 88, wherein said partial section A has been formed by flattening a piece of wire forming the basic pin (10, 310).

Claim 107

A contact pin unit as claimed in claim 102, wherein the piece of wire (10, 310) has a square cross-sectional area with two transverse intersecting central axes, and wherein said axes (X,Y) of said flattened partial section (A) are parallel to said transverse intersecting central axes.

Claim 108

A contact pin unit as claimed in claim 102, wherein a stop (34) for the contact spring (20) is formed by the transition shoulder from the flattened partial section (A) to an adjoining undeformed wire section (C), there being, if necessary, integrally formed with this transition shoulder (34) a holding nose (36) which engages over the contact spring, at least after it has reached the stop (34).

Claim 109

A contact pin unit as claimed in claim 102, wherein the partial section (A) has, at at least one end, a flattened transition section (D), whose short cross-sectional axis corresponds in its length to the short cross-sectional axis (Y) of the flattened partial section (A) and whose long axis corresponds to the corresponding axis of the undeformed piece of wire or is smaller than this axis, and in that the connection part (28) abuts this transition section (D).

Claim 110

A contact pin unit as claimed in claim 102, wherein the legs (28b) of the connection part (28) abut, with their edges (28c) that are remote from the contact springs (20), transition shoulders (32) between the flattened partial section (A) and an adjoining section (B) of the undeformed piece of wire (10).

Claim 111

A contact pin unit as claimed in claim 88, wherein the inside diameter of said internal surface (18, 318) of said plug socket (14) is smaller than 2.5 mm, more especially approximately 1 mm.

Claim 112

A contact pin unit as claimed in claim 88, wherein the ratio of the length of the long axis (X) of said partial section (A) to the length of the short axis (Y) of said partial section (A) is in a range of 1.5:1 to 4:1, preferably approximately 2:1 to 3:1.

Claim 113

A contact pin unit as claimed in claim 88, wherein the thickness of the sheet metal is approximately 5/100 to approximately 20/100 mm.

Claim 114

A contact pin unit as claimed in claim 88, wherein the ratio of the axial length of the partial section (A) to the inside diameter of the internal surface (18, 318) of the plug socket is about 2:1 to about 4:1, preferably approximately 3:1.

Claim 115

A contact pin unit as claimed in claim 88, wherein the plug socket is formed by a hole the internal surface of which has been metalized, more especially a tin-coated hole (18) in a printed-circuit board (16).

Claim 116

A contact pin unit as claimed in claim 88, wherein the contact spring (220, 320) has a rounded or pointed contour adjacent at least one of its ends, said at least one end being introduced first when said contact pin unit is introduced into said plug socket (14).

Claim 117

A method for the production of a contact pin package as claimed in claim 88, wherein two contact springs (220) with a U-shaped connection piece (228) are placed, transversely to the longitudinal axis of the basic pin, on this pin and may be welded thereto.

Claim 118

A contact pin unit as claimed in claim 88, wherein the one lateral face (24) is substantially roof-shaped and substantially perpendicular to the short cross-sectional axis (Y).

Claim 119

A contact pin unit as claimed in claim 88, wherein the one lateral face (24) is substantially trough-shaped and substantially perpendicular to the short cross-sectional axis.

Claim 120

A contact pin unit as recited in claim 78, wherein each of two radially opposite lateral faces (324) perpendicular to the short cross-sectional axis (Y) are each provided with a contact spring (320) being made of sheet metal.