Miniature insulation displacement electrical contact

Claim 2

A contact terminal for establishing an insulation displacement interconnection to an insulated conductor, comprising: two parallel plates, each plate having a slot extending inwardly from one end thereof; two sidewalls, each sidewall extending transversely past one edge of each plate, the plates and the sidewalls extending upwardly from a common base; a plurality of embossments projecting arcuately from a planar section of the sidewall, sheared edges of the embossments being adjacent opposite faces of each plate, each sheared edge being adjacent to a peripheral edge on each end thereof, each peripheral edge remaining joined to the sidewall, each plate being held in position between embossments on opposite sides thereof.

Claim 3

The contact terminal of claim 1 wherein a strap in the plane of the sidewall remains between sheared edges of adjacent embossments, the strap being juxtaposed to the edge of the plate located between the sheared edges of the embossments.

Claim 4

The contact terminal of claim 2 wherein adjacent embossments are formed outwardly from the plane of the sidewall by a forming tool means having convex die surfaces.

Claim 5

The contact terminal of claim 3 wherein opposed sidewalls are formed upwardly from opposite radiused edges of the common base and two parallel plates are formed upwardly from the common base between the opposed sidewalls.

Claim 6

The contact terminal of claim 4 wherein a single central embossment extends between the two parallel plates on each sidewall, the central embossment having sheared edges at spaced ends thereof, each central embossment being joined to the respective sidewall, above and below the sheared edges, between the spaced ends.

Claim 7

The contact terminal of claim 5 wherein outer embossments are formed on each sidewall on both ends of each central embossment, each outer embossment being spaced from the most adjacent sheared edge of the central embossment by a distance at least equal to the thickness of the plates.

Claim 8

The contact terminal of claim 6 wherein each outer embossment has a generally ellipsoidal shape.

Claim 9

The contact terminal of claim 7 wherein a pin contact section is formed on one end of the terminal and a strain relief section is formed on the other end of the terminal, the plates and the sidewalls being located between the pin contact section and the strain relief section.

Claim 10

A contact terminal for establishing an insulation displacement interconnection to an insulated conductor, comprising; at least one plate having a slot extending inwardly from one end thereof, each plate being stamped from a flat blank prior to upwardly forming the plate, material being removed from portions of the flat blank subsequently forming a common base to form the profile of the plate, side edges of each plate being straight; sidewalls formed upwardly from the common base, each sidewall extending transversely past an adjacent side edge of each plate; and a plurality of embossments in each sidewall adjacent opposite faces of each plate, the embossments being formed outwardly from a planar section of the sidewall, first edges of each embossment, adjacent first edges of other embossments, being sheared from the sidewall, second edges of each embossment extending from opposite ends of the first edges remaining joined to the sidewall, first sheared edges of adjacent embossments being spaced apart by a distance at least equal to the thickness of the plate, so that the plate is held stationary between first sheared edges of adjacent embossments.

Claim 11

A contact terminal for establishing an insulation displacement interconnection to an insulated conductor, comprising; at least one plate having a slot extending inwardly from one end thereof, each plate being stamped from a flat blank prior to upwardly forming the plate, material being removed from portions of the flat blank subsequently forming a common base to form the profile of the plate, side edges of each plate being straight; sidewalls formed upwardly from the common base, each sidewall extending transversely past an adjacent side edge of each plate; and a plurality of embossments in each sidewall adjacent opposite faces of each plate, the embossments being formed outwardly from a planar section of the sidewall, first edges of each embossment, adjacent first edges of other embossments, being sheared from the sidewall, second edges of each embossment extending from opposite ends of the first edges remaining joined to the sidewall, first sheared edges of adjacent embossments being spaced apart by a distance at least equal to the thickness of the plate, so that the plate is held stationary between first sheared edges of adjacent embossments.

Claim 12

The contact terminal of claim 9 wherein the sidewall includes a strap in the planar section of the sidewall extending between the sheared edges of adjacent embossments, the sheared edges projecting from the plane of the sidewall.

Claim 13

The contact terminal of claim 10 wherein opposed sidewalls are formed upwardly from opposite radiused edges of a common base and two parallel plates are formed upwardly from the common base between the opposed sidewalls, convex surfaces of the embossments being located on the interior of the sidewalls folded upwardly from from the common base.

Claim 14

The contact terminal of claim 11 wherein the two parallel plates are stamped from a flat blank prior to upwardly forming the plates and the sidewalls, material being removed from portions of the flat blank subsequently forming the common base and the sidewalls to stamp the profile of the plates, the side edges of the plates being straight.

Claim 15

The contact terminal of claim 12 wherein the embossments extend inwardly from the sidewall for a distance greater than the spacing between the side edges of each plate and the interior of the adjacent sidewall.

Claim 16

The contact terminal of claim 13 wherein a single central embossment on each sidewall extends between the two parallel plates, the central embossment having sheared edges at spaced ends thereof, each central embossment being joined to the respective sidewall, above and below the sheared edges, between the spaced ends.

Claim 17

The contact terminal of claim 14 wherein outer embossments are formed on each sidewall on both ends of each central embossment, each outer embossment being spaced from the most adjacent sheared edge of the central embossment by a distance at least equal to the thickness of the plates.

Claim 18

The contact terminal of claim 15 wherein each outer embossment has a generally ellipsoidal shape.

Claim 19

The contact terminal of claim 9 wherein the embossments are formed in the sidewall without removal of material.

Claim 20

The contact terminal of claim 17 wherein a pin contact section is formed on one end of the terminal and a strain relief section is formed on the other end of the terminal, the plates and the sidewalls being located between the pin contact section and the strain relief section.

Claim 21

A contact terminal for establishing an insulation displacement interconnection to an insulated conductor, comprising; at least one plate having a slot extending inwardly from one end thereof, each plate being stamped from a flat blank prior to upwardly forming the plate, material being removed from portions of the flat blank subsequently forming a common base to form the profile of the plate including the profile of side edges of the plate, the side edges of each plate being straight; sidewalls formed upwardly from the common base, each sidewall extending transversely past an adjacent side edge of each plate; and a plurality of embossments in each sidewall adjacent opposite faces of each late, the embossments comprising portions of the sidewalls formed from planar sections of the sidewwall by a shallow drawing operation, portions of the embossments adjacent other embossments being sheared from the sidewall, opposite portions of each embossment extending from the sheared portions thereof remaining joined to the sidewall.

Claim 22

A contact terminal for establishing an insulation displacement interconnection to an insulated conductor, comprising; at least one plate having a slot extending inwardly from one end thereof, each plate being stamped from a flat blank prior to upwardly forming the plate, material being removed from portions of the flat blank subsequently forming a common base to form the profile of the plate including the profile of side edges of the plate, the side edges of each plate being straight; sidewalls formed upwardly from the common base, each sidewall extending transversely past an adjacent side edge of each plate; and a plurality of embossments in each sidewall adjacent opposite faces of each late, the embossments comprising portions of the sidewalls formed from planar sections of the sidewwall by a shallow drawing operation, portions of the embossments adjacent other embossments being sheared from the sidewall, opposite portions of each embossment extending from the sheared portions thereof remaining joined to the sidewall.