Abstract: A machine for attaching wire leads to cans for housing electrical components. The machine includes a plurality of split dies mounted on the spokes of a rotatable spindle for receiving and holding wire leads, and an index drive for rotatably indexing the spindle and split dies to a plurality of work stations, including a wire feed station, a wire upsetting station, a can staking station and a discharge station. At the wire feed station, a plurality of reciprocating plungers feed wire leads of predetermined length to the split dies so that one end of the wires project from the face of the split dies. At the wire upsetting station, a plurality of reciprocating punches upset and head the wire leads at a location spaced from their ends while at the can staking station a plurality of reciprocating punches feed cans having bottom holes over the headed ends of the wire leads as far as the heads and stake the ends of the wire leads to attach the leads to the cans.

Abstract: The present invention is an improved machine for inserting a plurality of pins from a continuous webbing of pins into a motherboard. The machine has a pair of plier-like jaws with interior confronting surfaces for grasping and holding the pins when the jaws are closed. The two jaws, which extend downward, are separated from each other above the confronting surfaces to provide an opening through the jaws. The continuous webbing is fed through this opening with the pins extending down between the confronting surfaces of the jaws. When the desired number of pins are between the jaws, the jaws close to grasp the pins and the carrier strip is then separated from the pins. The jaws are then moved downward to insert the pins into the motherboard with the opening preventing interference with the carrier strip.

Abstract: A plurality of components are force-fitted into a workpiece simultaneously, by the following steps: preparing a dummy workpiece with tool supports fixed thereto in a predetermined pattern, each tool support being removably surmounted by a component insertion tool; placing the dummy workpiece beneath a magnetic chuck on the platen of a hyrdraulic press; lowering the platen so that the tools are magnetically secured to the chuck; raising the platen to remove the tools from the tool supports; replacing the dummy workpiece by an actual workpiece with the components arranged thereon in said predetermined pattern; lowering the platen so that each tool on the chuck force-fits the component therebeneath into the workpiece; raising the platen with the tools thereon; and removing the actual workpiece from the press.

Abstract: A tool facilitates the hand insertion of wire wrap square sectioned pins from a fanning metal strip into plated through holes of a wire-wrap printed circuit board. The tool includes a solid cylindrical tip which is mounted within a handle member which includes an automatic anvil. An end portion of the tip has a portion with stepped profile which contains a round hole. The hole is slightly larger than the square section of the pin and has a predetermined depth for positioning the pin in a vertical direction during an insertion operation. The sizes of the individual steps are selected to enable the pins to be ejected completely from the band portions of the strip into the holes of the board at a predetermined depth without damaging the strip or the areas surrounding the holes.

Abstract: A screw terminal (14) is formed on a circuit board (12) by inserting a typical terminal screw (22) in a thread-forming operation into a tube (27) of a rim-like seat (21). The screw (22) is inserted into the tube (27) to a predetermined depth which is equal to or greater than the thickness of the circuit board (12). After the insertion of the screw (22) into the seat (21), the seat (21) is inserted into an aperture (16) in the circuit board (12). The aperture (16) is of circular cross section of a diameter such that the wall of the aperture engages the edges of the tube (27) in interfering contact. In a preferred embodiment, the wall of the aperture (16) is metallized and the seat (21) is of a copper coated, low carbon steel. After insertion of the seat (21) into the aperture (16), the seat (21) is soldered to the aperture (16) in an operation which fills any gaps between the circuit board and the seat and fixes the position of the walls with the confines of the circuit board.

Abstract: A flexible plug-to-socket connection firming-up device which is at least partly foldable from an initially substantially flat and inoperative state to at least a partly folded operative state includes an adhesive strip adapted for being connected to at least a holder of the socket, and flaps connected to the adhesive strip, and adapted to be at least partially wrapped around the plug so as to restrain the plug from being unintentionally unplugged from the socket.

Abstract: A through-hole pin connection for laminated circuit elements and method of connection are presented. The laminated circuit element consists of a plurality of individual circuit elements, each element having a land area about the periphery of the through-hole. The through-hole pin has at least one ridged region located along the direction of insertion into the through-hole. Upon insertion, the pin guides a solder into the land areas and the ridged region effects electrical and mechanical contact between the through-hole pin and each of the land areas of the laminated circuit element.

Abstract: Contact insertable in a metallized hole of a printed circuit card containing two ends (1, 2) designed to project on both sides of the card in position of insertion of the contact and to facilitate the electric connection of any devices. The contact includes a median part (3) joining the ends (1, 2) which assures the electrical connection of the contact with the, metallized interior surface of the hole and at the same time its mechanical retention in the hole. The median part (3) comprises a spiral structure of a rectangular section, the verticles of which define the edges (4) of that spiral structure.

Abstract: An electrical connector is disclosed for making electrical connections to a large area visual display in the form of a substrate having a plurality of spaced-apart contact pads arranged in parallel rows along the edges on one surface. The connector includes a base in the form of a rectangular frame for supporting the edges of the substrate, and having spaced-apart parallel rows of cavities formed in each side of the base. A plurality of contact assemblies each containing a row of electrical contacts are provided which are designed to fit within a respective one of the cavities. A cover is also provided which fits over one side of the substrate and fastens to the base in a manner which applies pressure to the substrate edges to maintain connection between the contact pads and the contacts. The connector includes alignment elements for positioning the substrate so that the contact pads are aligned with the contacts.

Abstract: A machine for forming a head and a bulge on a copper pin and to connect the pin to a ceramic substrate by a single application of impact force at high velocity and controlled energy conditions includes an air cylinder within which a piston of controlled mass moves due to the effect of compressed air stored in an accumulator. A die block includes a two dimensional array of holes into which are fitted pin blanks that extend above the surface of the die block and on which is fitted a substrate having an identical array of pin holes formed therein. The pins are fitted within the die block and on the substrate such that a predetermined length of the pin blank extends above the surface of the substrate and a controlled length of the pin blanks extends between the substrate and the die block. The pins are retained within the die against axial movement and the holes in the substrate and die block provide radial restraint to the pins following the application of the impact force.

Abstract: An apparatus (10) and method for the automatic insertion of terminals (84) into cavities (16) of a ceramic substrate (15). A continuous carrier web (80) is advanced from a reel (90), into an automatic terminal insertion apparatus (10) simultaneously with the automatic advancement of substrates (15) along a trackway (20). As a substrate (15) is secured by a securement and lateral transmission apparatus (170) and moved laterally from the trackway (20) to align the substrate cavities (16) with associated transmittal barrels (162), a web hold down apparatus (130) secures web portion (82) of carrier web (80) and the cut-off blade (146) of a separation block (144) moves downwardly to separate a predetermined number of terminals (84) from the web portion (82) and locate the terminals in transmittal slots (152) located in a subjacent pressure pad (150).

Abstract: An insertion head (80) for inserting a contact (30) having opposed tines (34--34) into a connector cavity (28) having opposed ribs (49--49) protruding from the inner wall thereof. The insertion head (80) severs a contact (30) from a spine (44) of contact strip (42) and the contact (30) is then moved laterally, away from the strip, to a vertically aligned position above the cavity (28). A punch (128) pushes the contact (30) into the cavity (28) while simultaneously spreading the tines (34--34) apart to straddle the opposed ribs (49--49).

Abstract: An adaptor for electrically connecting an irregular array of terminals of a circuit device to be tested to a regular array of terminals of a universal test fixture for automatic testing equipment. The adaptor includes a top plate having an aperture pattern that corresponds to the terminal pattern of the circuit device, a bottom plate having an aperture pattern that corresponds to the universal test fixture, and an alignment plate intermediate the top and bottom plates having apertures so disposed as to guide rigid probes extending from individual ones of the apertures in the top plate into preselected ones of the apertures in the bottom plate. A method for fabricating the adaptor is also disclosed.

Abstract: Various permutations of plugs (13) are inserted in keying holes (12) formed in a connector 10 secured to an edge of a printed circuit board (11). A carrier nest (16) is loaded with a permutation array of plugs (13) at a load station (20), advanced to an insert station where the array is checked, and then advanced to an unload station (22) where a group of insert pins act through carrier nest holes (17) to seat the plugs in the connector holes (12). At the inspect station, checks are made for missing plugs and plugs in wrong holes. If plugs in wrong holes are detected, the plugs are dumped from the carrier nest and a new array of plugs are loaded into the carrier nest (16). If a missing plug is detected, the carrier nest is returned to the load station and a plug is loaded into the proper nest hole (17).

Abstract: A method for mounting one or a plurality of multilead components (25-28) on a circuit board (20) is herein disclosed. The method comprises the steps of loading a releasable template (32) with the component/components to be mounted, positioning the releasable template proximate to the board, releasing the component/components from the template onto the board such that each lead of each component is proximate to a corresponding aperture in the board, and imparting a vibratory motion (via 29 and 23) to the board thereby inserting the component/components into the board. Also disclosed are various embodiments of an apparatus for achieving this mounting method using a programmable robotic arm (FIG. 2).

Abstract: A contact insertion machine (50) having a base (52) with an X, Y, .theta. table (54) thereon and a superstructure (56) hingeably mounted on the base for movement towards and away from the table (54). The superstructure (56) has a plurality of contact strip feed reels (78) which sequentially feeds the strips (42) to each of a plurality of insertion heads (80). A tray (68) containing a multitude of connector housings (16) is positioned on the X, Y, .theta. table (54) and the superstructure (56) moved towards the tray until the heads (80) are in close, spaced relation to the connectors in the tray. The heads (80) are activated to simultaneously insert a contact (30) into each of a plurality of different connector housings (16). The contacts (30) are simultaneously inserted sequentially into a different sector of connectors until contacts have been inserted into predetermined cavities 28--28 in the connector housings (16).

Abstract: A terminal strip 10 (see FIG. 7) is assembled by the method and apparatus so that two tiers of pins 11 are forced fitted into blind holes 13 formed in a plastic strip 12. Two tiers of terminal pins are advanced by two rows of pusher rods 41 and 42 from stacks 16 of pins through holes 31 and 32 in a slide bar 28 into passageways 26 and 27 of a loader block 21 so that the leading end of the pins project from the block while the trailing ends are fully seated within the passageway. The slide block 28 is shifted to block the rear end of the passageways 26 and 27. Next, a work holder nest 51 loaded with a plastic strip 12 is moved toward the now held pins 11 to force seat the pins into the blind holes 13. The nest is withdrawn, and cleats 63, 64 and 58 pull the plastic strip 12 to withdraw the pins 11 from the passageway to permit the subsequent removal of the assembled terminal strip 10.

Abstract: A circuit assembly and method of making the same involves locating a flat flexible circuit member with an electrically conducting region defined thereon between a pair of opposed, relatively rigid wafers with a pin conductor inserted through the member and the wafers. Each wafer includes an aperture extending through the wafer, the aperture of one wafer aligned with the aperture of the other wafer and arranged to abut with the conducting region at the point of desired termination. The pin conductor is forced into and is retained within each aperture in each wafer, piercing the conducting region on the flat flexible circuit member in the process and making electrical contact with the conducting region. A portion of the pin conductor extends outwardly of one of the wafers for electrical connection to a female connector.

Abstract: A method for mounting elongated pin connectors 10 which have a connector body 11 and pin contact elements 5, wherein the pin contact elements are pressed, preferably in a single operation, into openings 7 of a circuit board 8 and into openings 90 of body 11 arranged below circuit board 8. A pressing tool 1 is provided for contact element combs 2 which have a pilot strip 6 to which contact elements 5 are attached. A clamping section 3 of the tool 1 is designed so that it severs pilot strip 6 when the contact elements are pressed into contact with circuit board 8. The connector body 11 has cams 93,94 adjacent slots 90 for forming an upper surface with their upper sides.

Abstract: A method and apparatus are provided for consistently handling, inserting, and driving wire pins of reduced cross-section into circuit board holes and the like while retaining control of the pins and avoiding breakage of the apparatus due to constraints imposed thereon by such reduced cross-section.

Abstract: The integral interconnect socket and flexible board assembly accepts an electronic module having a plurality of leads arranged in a predetermined pattern. The assembly includes a flexible printed circuit (PC) board having a plurality of conductors and a first set of holes disposed to respectively intersect the conductors. A substantially rigid platform is mounted to the PC board and has a second set of holes. The first and second set of holes are in alignment and define common apertures arranged in the predetermined pattern to receive the leads of the modules. A layer of metal plating formed within the apertures makes electrical connections with the respective conductors. Jacks are mounted to each aperture for receiving the leads and making electrical connections between the leads and the conductors.

Abstract: A printed circuit board interconnection system interconnects a pair of printed circuit boards in parallel planes so that all of the board components can be assembled in a standard fashion using standard connectors. The system includes an assembly having a spacer member positioned between the two circuit boards and a pair of ejector members which attach to each end of the spacer member. Each ejector member includes vertical and horizontal arm portions positioned to provide a predetermined mechanical advantage for separating the connectors mounted on each board as standard components.

Abstract: A plurality of pins (20) are supported by a shuttle (42) with shanks (21) of the pins extending freely from the shuttle. The shuttle (42) is manipulated to insert the shanks (21) into a pin-insertion head (127). The shuttle (42) is then withdrawn from the pins (20) whereby shanks (22) of the pins extend freely from the head (127). The head (127) is then moved toward a board (24) to insert the pins (20) into apertures (23) of the board.

Abstract: Ceramic substrates are pinned using powdered metallurgy pins formed in situ on the substrate.

Abstract: A multiplicity of integrated circuit connector contact sockets mounted to a plurality of carrier strips are moved between pairs of orientation rollers with tails of the contacts protruding upwardly whereby an upper socket portion of one contact is aligned with an upper socket portion of a contact on a carrier strip in an adjacent row. A plurality of integrated circuit connector insulators having socket receiving apertures formed therein are held together in an array and placed over the contact tails with one tail being received within each aperture of an insulator. The carrier strips are simultaneously advanced beneath a work station wherein a tool presses the insulators downwardly to tightly fit the contact socket portions into the receiving apertures in the insulators. A shearing tool then severs the insulators in the array from one another except for the continued affixation of the contact sockets to the parallel carrier strips.

Abstract: A plurality of pins (20) are supported and held within a pin supporting shuttle (54) by wedging the shank portion (24) of each of the pins between a respective one of a plurality of spaced parallel channels (58) and a ramp (62). The shuttle (54) is then moved to place a free end of each of the pins (20) in a gripped position within an insertion apparatus (55). The shuttle (54) is manipulated so that the shank portion (24) is allowed to return to a normal axis of each respective pin (20). The shuttle (54) is then removed from about the pins (20).

Abstract: A coordinate array of terminal pins are straightened and aligned in precise rows and columns by flexing one-half of the pins in one direction while flexing the other half of the pins in an opposite direction. This coordinate alignment is attained by inserting first rows of pins (13) into apertures (31) formed in a first set of slide bars (36) and second rows of pins (13) into apertures (32) formed in a second set of slide bars (37) which are interleaved with the first bars. A pair of air cylinders (81 and 89) are programmed to operate to reciprocate the slide bars (36 and 37) in opposite directions to flex the terminal pins beyond elastic limits and back to their origin point. The flexing operation is effective to align the pins in a coordinate array without introduction of detrimental stresses in a terminal pin support, such as a connector housing (11) or a printed circuit board (102).

Abstract: The present invention relates to an applicator tool capable of picking up loose miniature spring sockets and inserting them into holes in a printed circuit board. More particularly, the tool has dual air lines, one being connected to a compressed air supply and the other being connected to a vacuum. With the sockets laying on the work surface, vacuum pulls a socket into the tool nozzle. The tool is then placed into alignment with a hole and the trigger squeezed to activate the air supply to drive a ram which drives the socket out of the tool and into the hole in the board.

Abstract: The invention relates to a method and a contact strip for the production of gas-tight connections for printed backwall wirings. Heretofore, the difficulty in the production of such connections has been that the posts of the relatively small and delicate plug connectors had to be pressed into the through-contacted bores under high pressure. The invention solves this problem in that, in pressing in, use is made of a contact strip housing which, during the pressing operation, presses not on the plug connectors themselves, but on their mount, with which the individual plug connectors are firmly held together.

Abstract: The disclosed invention is an improvement to a card edge connector insertion tool. More particularly, the improvement includes a spring loaded guide block mounted on the insertion tool which enables the tool to be machine drivable for semi-automatically mounting a connector onto a printed circuit board.

Abstract: A method and apparatus for pull fitting contacts. Contacts tails initially are placed through apertures on a mounting member. A support member having a pair of clamping jaws which clamp the contact ends encloses an actuation plate which after the tails are clamped pushes the mounting member relative to the support member thereby inserting the contacts completely into an insulative housing.

Abstract: First end portions (22c) of terminal pins (22) are gripped in a gripping means (54) on one side of a substrate (24) and intermediate portions (22cs) of the pins then are inserted into the substrate. In the insertion operation, second opposite end portions (22i) of the pins are extended into a straightening means (74) on the opposite side of the substrate (24). Tip portions of the first pin end portions (22c) then are disposed in the gripping means (54) and tip portions of the second pin end portions (22i) are disposed in the straightening means (74). To straighten the pins (22), relative reciprocating movement then is caused between the pin intermediate portions (22cs) and the pin tip portions to flex and coldwork the first and second pin end portions (22c and 22i) in a lateral direction simultaneously.

Abstract: A connector mounting press includes a vertically moveable insertion head and a moveable bed which supports a printed circuit board including a plurality of press fit connectors. The bed is indexable to locate a selected connector under the insertion head. Alignment pins on the insertion head accurately position the connector for receipt of a pair of combs which engage and individually press the contacts of the connector into the printed circuit board.

Abstract: An apparatus and technique are provided to automatically align an insert for insertion into a hole of a predrilled board. The hole is located by a retractable centering pin on the apparatus to ensure an accurate alignment with the insert, and, once aligned, the insert is inserted into the hole with a force axially applied by the apparatus.

Abstract: Terminal pins (18) in a terminal pin strip (16) are integrally interconnected by webs (22) located intermediate free insertion ends (18i) and free connector ends (18c) of the pins so that when the webs are severed to separate the terminal pins, the severing operation does not disrupt the integrity of smooth finished surfaces on the connector ends of the pins. Each terminal pin (18) also is formed with an intermediate push shoulder (18ps) for applying pressure on the pin to insert the pin into an aperture (20a) in a support structure, such as a printed wiring board (20), without damaging the connector end (18c) of the pin. Assembly of the terminal pins (18) into the printed wiring board (20), utilizing terminal pin strips (16) on respective supply reels (24), is accomplished with apparatus comprising a pair of pin transporter mechanisms (26), a pair of web-severing punch-and-die mechanisms (28), and a pin insertion mechanism 30.

Abstract: A universal circuit board probe assembly connects a variety of circuit board types to a diagnostic system. The probe assembly is an integrated system which includes a general purpose perforate platform having perforations in a uniform grid pattern, a plurality of floating connector pins of the type having an opposing double-action movement, a removable backing plate which confronts the platform, pin displacement modules which removably mount to the backing plate and are disposed to abut to the connector pins, means for aligning the backing plate with the platform and circuit board test points, means for urging the modules in contact with connector pins to activate the connector pins for testing, and means for causing the activated connector pins to engage test points on a circuit board to be tested.

Abstract: A method of forming a ceramic circuit substrate allowing mounting of high integration density semiconductor elements. The method provides a multilayered ceramic circuit substrate having via holes formed with high accuracy and high integration density wiring patterns by forming metallic conductive balls to connect the conductive wiring patterns of upper and lower layers; a ball arranging plate having many holes placing on a green sheet uniformly in close contact; filling the holes of the plate with the embedding the conductive balls by pressure into the green sheet; and thereafter baking the green sheet individually or in a stacked layered arrangement.

Abstract: A machine for inserting terminal pins into a printed-circuit board under programmed control has a pin-insertion head which is charged with pins from a reciprocating shuttle that executes only one stroke in response to each pin-insertion operation. The head is charged with a pin from one of two passages in the shuttle at the end of each stroke while the other passage is being loaded with a pin ready for translation to the head to recharge it, during the next stroke. The machine further includes apparatus for feeding the pins from a pin storage means to the shuttle.

Abstract: Manual mounting of large high density lead insertion connectors (1) onto circuit boards (3) is achieved by simultaneously engaging all connector leads (2) with a comb (9), sliding the engaged leads into alignment with receiving passageways (4) in the circuit board and pressing the connector leads into the receiving passageways. The comb has an exterior surface forming channels (10) corresponding in spatial relationship to the lead receiving passageways. A connector lead insertion apparatus (5, 6, 7, 8, 9, 10) is utilized in conjunction with the lead insertion method to hold the circuit board and connector in fixed position with respect to each other. The apparatus further permits the comb to be guided into proper position prior to engaging the connector leads.

Abstract: A photoflash device circuit board assembly including a dielectric substrate and at least one switching element and conductor die-stamped therein. To assure that the delicate switch is not severed by the die's cutting edge during die-stamping, a relief means (e.g., slot) is provided within the substrate so that a segment of the switch can be aligned therewith. As an alternative, it is taught to provide stepped portions within the die's cutting edge to align with preselected portions of the switch and thus prevent total severance thereof.

Abstract: A method and apparatus is provided for aligning and press-fitting connector terminals into a substrate. The terminals are initially supported together by a bandolier strip, and an alignment tool aligns the terminals with apertures in the substrate to which the terminals will be press-fitted. A pressing tool engages the shanks of the terminals to fold the bandolier away from the terminals and thereafter press the terminals into the apertures.

Abstract: A ram tip component for inserting terminal posts in a wiring board includes an elongated body having an end face and a terminal post receiving passageway extending into the body through the end face and having outer and inner portions with respect to the end face. A terminal post entry slot extends laterally through the body and the end face and opens into the outer portion of the passageway, and a retaining spring is positioned in the inner portion of the passageway to bias the terminal post in the passageway against a wall thereof. The end of the body opposite the end face is provided with a bore communicating with the inner portion of the passageway, and terminal post stop pins of varying axial length are adapted to be supported in the bore to limit displacement of a terminal post axially inwardly of the passageway.

Abstract: An apparatus for driving pins into a printed circuit board and the like which comprises: table means for receiving and retaining a board into which the pins are to be driven; magazine means for holding a supply of the pins in a position parallel to the plane of the table, and receiver means, pivotally movable to receive the pin from the magazine means in one pivotal position and to pivot the pin into transverse relation with the table means in a second pivoting position. Loading means are provided for inserting the pins into the receiver means. Means are also provided for moving the receiver means while in the second pivoting position to drive the pin inserted in it into the board.

Abstract: Interconnect sockets (10) are assembled with substrates, such as printed circuit cards (12), to connect the leads (17) of electrical components (18) to conductive pads (14) deposited on the substrate. Each socket has an end section (19)inserted into a mounting hole (11) in the substrate, for gripping portions of the walls of the hole to mount the socket to the board; a midsection (13) for contacting the conductive pad; and a lead-engaging section (16) for gripping the component lead and connecting it to the pad through the socket. Preferably, the socket is a tubular member of a conductively plated spring metal, with spring members (20, 22, 30) for resiliently engaging the walls of the hole, the contact pad, and the lead. The sockets are especially useful with thermosetting conductive-particle/resin conductors, such as silver-epoxy or -acrylic resin "thick-film " conductive inks.

Abstract: A solderless electrical connector comprising a printed circuit board and electrical contact terminals mounted therein. A printed circuit board is fabricated to the construction stage wherein conductive circuitry interconnects plated through holes formed therethrough. The exposed circuitry and plated through holes are covered with a conformal coating of insulative material which seals the outer surfaces of the conductive materials from the environment and its effects. The insulative coating obviates the need for solder to protect the conductive materials as well as precludes the use of solder for electrical interconnection therewith. The plated through holes are constructed for press fit insertion of contact terminals in tight frictional engagement therein. The press fit insertion of a contact having an angular edge portion effectively penetrates the insulative coating by deforming it away from that portion of the plated through hole brought to bear against the contact.

Abstract: A machine to assemble electrical contact retention clips automatically in an insulator including a slotted tube expandable by a tapered plunger to embed an electrical connector retention clip in a heated and softened insulator after having been inserted into an insulator bore by a ferrule slidable on the tube.