Abstract: A continuous electrical connector or component strip of plastic or other moldable material serving as substrates and manufactured by injection molding of axial segments in sequence by a scheme providing for interlocking or interconnecting adjacent segments. Into the surface of the plastic or moldable part and tightly bonded thereto is surface-embedded a metal pattern or other metal structure. The metal structure may be metal traces serving as active parts of circuit traces of a printed circuit, with the resultant substrate with metal traces when severed from the strip functioning as a PCB to which may be added electrical components by automatic machinery. The strip can be processed by efficient reel-to-reel techniques.

Abstract: Improved tape assemblies for delivering electrical devices to work stations at which the devices are installed. Each of the devices comprises a laminar electrical component sandwiched between two laminar metal members, and is preferably a PTC circuit protection device. In the assemblies, the electrical components are discrete components, but they are contacted by, and linked together through, laminar metal members which, after the assembly has been divided into separate devices, provide leads which contact and extend away from the electrical component. Preferably the metal members are prepared by cutting and forming a single strip of metal. Preferably the assembly is free from any longitudinally continuous carrier strip which much be discarded after the devices have been separated from each other. Preferably, the assemblies are sufficiently flexible to be wrapped around a reel and unwrapped at the work station.

Abstract: In order to allow header-less connector pins to be directly surface mounted to a PCB, using a standard pick and place machine, a novel pin holder is used to hold the pin while in pockets or holes of a reeled tape and during its pick and placement by the suction head of the pick and place machine supplied with the reel. The holder is configured to permit standard pin spacings of a row of pins to match standard female connectors, and to allow observation of the pin during the placement process. Novel pin designs for use with the holder are also described.

Abstract: A continuous molded electronic component assembly process in which a continuous line of components are supplied on reels for assembly and insertion. The supply reels of electronic components are made by an injection molding process, reeled and supplied to assembly and insertion machines. The assembly and insertion machines provide the means for removing, assembling and inserting the electronic components. Examples of the process, but not limited to, are shunts, wire end terminals and pilot posts.

Abstract: A continuous molded electronic component assembly process in which a continuous line of components are supplied on reels for assembly and insertion. The supply reels of electronic components are made by an injection molding process, reeled and supplied to assembly and insertion machines. The assembly and insertion machines provide the means for removing, assembling and inserting the electronic components. Examples of the process, but not limited to, are shunts, wire end terminals and pilot posts.

Abstract: A method and apparatus for surface mounting terminals on a substrate, in particular, pin terminals on a printed circuit board, having solder applied therein. In the first step of the method, a plurality of terminals are inserted in a holding fixture and held in alignment with each other. The holding fixture is then rotated to bring the terminals into contact with the solder on the substrate. In the next step of the method, the area of contact is heated, for example, by infra-red radiation, until reflow of the solder occurs. After heating, the heated solder is allowed to cool, i.e. solidify, thereby forming a secure connection between the terminals and the surface of the substrate.

Abstract: An endless electrical connector has a continuous header manufactured by forming axial segments in sequence. In the case of continuous extrusion, the axial segments are infinitesimal in length, whereas in the case of semicontinuous injection molding, the segments have discrete length.

Abstract: A method for bending and inserting a pin in one sequential operation includes the steps of feeding an end of a pre-notched pin wire, shearing a connector terminal from the end of the wire, clamping one part of the terminal between jaws, displacing the jaws toward a hole in a printed circuit board, displacing a bending sheet at a rate faster than the rate at which the jaws are displaced whereby the bending shoe bends the connector terminal pin while the jaws are moving, and inserting the bent terminal in the hole in the printed circuit board. The apparatus for carrying out the method includes a bending shoe ram and an insertion ram driven at different speeds and with different stroke lengths by an eccentric pin mounted on the end of a drive shaft.

Abstract: A system for coupling or connecting magnet wires to lead wires comprises terminals each having a portion upturned with an insulation displacement connector and each also having a portion with crimp connectors. The system also comprises a terminal holder with front and rear plates each having slots for supporting said connectors in a position to hold wires in an out-of-alignment orientation.

Abstract: An apparatus is disclosed for inserting elements into a workpiece. The apparatus includes reciprocating feeding means movable between first and second positions for sequentially advancing a supply strip of integrally connected preformed elements towards the workpiece. Actuating means cooperate with the reciprocating feeding means for rotating the reciprocating feeding means when the reciprocating feeding means has reached its second position. During the rotation, the supply strip of elements rotates with respect to the lead element which has been inserted into the workpiece thereby breaking the lead element from the supply strip. As the feeding means, holding the supply strip, rotates back to its initial position, the interaction of the supply strip and the lead element which has been inserted into the workpiece polishes and wipes away any burr that may have remained during the severance.

Abstract: Apparatus is disclosed for forming electrical splices from a continuous supply band. The apparatus includes feeding means for feeding a preselected length of the supply band to a forming station; clinching means positioned beneath the forming station; forming means for forming said preselected length into a generally U-shaped configuration; driving means for driving the U-shaped configuration into the clinching means; and operating means for simultaneously moving the forming means and the driving means in a forward direction for a preselected length of travel sufficient to effect formation of said U-shaped configuration by said forming means and for thereafter moving only said driving means in said forward direction to drive said U-shaped configuration into said clinching means. A removable container is also disclosed which houses the continuous supply band of electrically conductive material from which the splices are formed in the apparatus with which the container is associated.

Abstract: An apparatus and supply strip is disclosed for inserting terminal pins into an apertured workpiece. The apparatus includes reciprocating feeding means for sequentially advancing a supply strip of integrally connected preformed terminal pins toward the workpiece; shearing means for severing the leading one of said pins from the remainder of the supply strip; and driving means for inserting the severed lead one of said pins into the workpiece. The feeding means comprises grasping means operable only when the feeding means is moving in a first direction toward the workpiece to grasp the supply strip at the juncture of adjacent integrally connected preformed terminal pins.

Abstract: An endless connector is disclosed which comprises a continuous length of insulating material, the length of insulating material having electrical contacts spaced therealong and being provided with severance means intermediate said contacts for selectively severing said length of insulating material at locations intermediate said contacts. In one embodiment of the invention, the electrical contacts are imbedded in the length of insulating material, while in another embodiment, the continuous length of insulating material includes open ended cavities disposed intermediate the severance means with the contacts being disposed in the cavities.

Abstract: An apparatus and supply strip is disclosed for inserting terminal pins into an apertured workpiece. The apparatus includes reciprocating feeding means for sequentially advancing a supply strip of integrally connected preformed terminal pins toward the workpiece; shearing means for severing the leading one of said pins from the remainder of the supply strip; and driving means for inserting the severed lead one of said pins into the workpiece. The feeding means comprises grasping means operable only when the feeding means is moving in a first direction toward the workpiece to grasp the supply strip at the juncture of adjacent integrally connected preformed terminal pins.

Abstract: Apparatus is disclosed for forming electrical splices from a continuous supply band. The apparatus includes feeding means for feeding a preselected length of the supply band to a forming station; clinching means positioned beneath the forming station; forming means for forming said preselected length into a generally U-shaped configuration; driving means for driving the U-shaped configuration into the clinching means; and operating means for simultaneously moving the forming means and the driving means in a forward direction for a reselected length of travel sufficient to effect formation of said U-shaped configuration by said forming means for thereafter moving only said driving means in said forward direction to drive said U-shaped configuration into said clinching means. A removable container is also disclosed which houses the continuous supply band of electrically conductive material from which the splices are formed in the apparatus with which the container is associated.

Abstract: A method is disclosed for making an insulated splice or terminal, the method including the steps of adhering an elongated layer of non-conductive material to an elongated layer of electrically conductive material so as to form a composite supply strip; severing a predetermined length of said supply strip from the remaining supply of said strip; and crimping said length about the elements to be joined until said electrically conductive material is in electrical contact with the said elements and so that the non-conductive material forms an outer insulated layer enclosing said splice or at least a portion of said terminal. In a preferred method of the instant invention, a further step of causing the non-conductive material of the splice to "flow" is employed whereby a resultant sealed splice is produced which is impervious to moisture and other contaminants.

Abstract: Apparatus is disclosed for forming a disconnect terminal from a supply band having a continuous first portion and a plurality of second portions spaced therealong and integrally connected to the first portion. The apparatus comprises first means for shearing the continuous first portion of the supply band at a location intermediate two adjacent second portions thereof to form a predetermined length of said supply band into a predetermined shape having a terminal portion and an integrally connected connector portion. Second means are provided for bending the length into a generally U-shaped configuration. A die is provided which has first and second receptacles therein. The first receptacle has a first predetermined configuration for the reception of at least one wire therein, and the second receptacle has a second predetermined configuration for forming the terminal portion of the predetermined length of the supply band into a preselected terminal configuration.

Abstract: An apparatus and method are disclosed for applying designs to pierceable materials, such as fabrics, paper goods, leather, etc., from a continuous supply strip containing intermittent design portions equally spaced along the length of the supply strip. The apparatus comprises feeding means for intermittently feeding the supply strip to a shearing, bending, driving and clinching station positioned above a clinching die; shearing means for severing a length of said supply strip from the end thereof; bending means for bending the cut off length into an approximately U-shaped member having a bight portion and side leg portions; driving means for driving the U-shaped member into the clinching die and through any pierceable material positioned above the die; and locater means for establishing a proper start position for the supply strip so that the design portions thereof will constitute the bight portions of the U-shaped members.

Abstract: An apparatus is disclosed for applying designs to pierceable materials, such as fabrics, paper goods, leather, etc., from a continuous supply strip containing intermittent design portions equally spaced along the length of the supply strip. The apparatus comprises feeding means for intermittently feeding the supply strip to a shearing, bending, driving and clinching station positioned above a clinching die; shearing means for severing a length of said supply strip from the end thereof; bending means for bending the cut off length into an approximately U-shaped member having a bight portion and side leg portions; driving means for driving the U-shaped member into the clinching die and through any pierceable material positioned above the die; and locater means for establishing a proper start position for the supply strip so that the design portions thereof will constitute the bight portions of the U-shaped members.