Abstract: A ribbon conductor set and related method of production and installation are provided for electrically interconnecting components in an implantable medical device, such as a heart pacemaker unit or the like. The ribbon conductor set is formed by die cutting and/or stamping a thin plate of conductive material to define a plurality of conductor ribbons supported from a frame. The ribbon set and supporting frame are shaped for seated placement into a fixture to orient the conductor ribbons in predetermined array to extend between electrical components on the fixture, such as between connector blocks and feedthrough terminals of a heart pacemaker unit. The fixture thus supports the conductor ribbons for facilitated connection to the electrical components, such as by welding, after which the resultant subassembly may be further processed as by encapsulation within a cast epoxy head or the like.

Abstract: An electrical connector terminal formed from sheet stock of desired thickness in a "T"-shaped blank. Opposite arms of the "T"-shaped blank are folded on themselves accordion-style to form an integral head portion having a thickness of several multiples of the sheet stock thickness. An electrical contact fulcrum surface is formed on the edges of the folded material of the head portion.

Abstract: An interconnection device is disclosed for providing electrical connection between two conducting elements that requires less applied force than a standard ohmic connection device of the same connection area. A surface of at least a first conducting element includes a plurality of atomically sharp projections for creating a strong electric field near the tip of each projection, each projection being disposed within a locally depressed portion of an insulating layer that serves to maintain a space between each tip and a second conducting element that contacts the insulating layer. The strong electric field at each tip induces a variety of conduction modes each contributing to an aggregate current flow from the first conducting element to the second. In an alternate embodiment, a plurality of projections are disposed on the peaks and valleys of a rough surface without an insulating layer, the projections providing a variety of conduction modes.

Abstract: A programmable insertion tool is provided for inserting the contact pins of a pin header connector into plated through holes in a printed circuit board. The tool utilizes push pins of differing lengths to position selected contact pins to selected different depths thereby providing a make first, break last capability for these contact pins when connecting or disconnecting to a mating connector half.

Abstract: An electrical plug connector comprises an insulating plastic base and a first and second series of elongate metal contact security respective opposite major faces of the base by an in-molding step so that respective back surfaces of the contacts and parts of their side surfaces are embedded in the plastic material while connecting surfaces are exposed for engagement with a complementary connector. During the in-molding process a cavity is formed between the two series of contacts at a rear end of the base by a mold member supporting rear ends of the contacts of respective series in spaced apart, parallel relation while front ends of the contacts are supported by attachment to respective carrier strips. A plug is force fitted into the cavity subsequent to molding supporting the rear ends of the contacts. Leading, front ends of the contacts have laterally extending anchoring portions and tapering, inwardly extending tips completely covered by the plastic material to ensure double securement to the base.

Abstract: An electrical connector assembly is disclosed to include at least a pair of connector housings having complementary interengaging locking devices for interlocking the connector housings with the centerlines at a first spacing. Frangible webs interconnect the connector housings with their centerlines at a second spacing. Therefore, the connector housings can be used in conjunction with each other at the second spacing, and the frangible webs can be broken to allow interlocking of the connector housings for use in conjunction with each other at the first spacing.

Abstract: A carrier web of sheet metal material joining stamped and formed components of an electrical connector is disclosed. The component is carried through the stamping and forming process by the carrier web of the sheet metal material. The component is stamped and formed from the material such that at least a portion of the component projects from one side of the original plane of the sheet metal material. The carrier web is formed into a three-dimensional configuration to reduce the spacing between adjacent components. A portion of the web may project a sufficient distance from the one side of the original plane of the sheet metal material to protect the projecting portion of the component during subsequent manufacturing operations on the component. A retaining structure may also be provided to retain the components at a predetermined spacing on the carrier web. A method of manufacturing the carrier web is also disclosed.

Abstract: An electrical connector assembly having a metal or metallized plastic housing block (10) with contact members (26) contained within channels (12) in the block (10). The metallic housing block (10) provides a shield to eliminate cross-talk between the contact members (26). The contact members (26) are directly coated with a dielectric material, except where they perform an electrical contact function, to insulate them from the metallic housing block (10).

Abstract: A lead frame is provided having a number of leads to be mechanically and electrically connected to a substrate. Retaining members are also provided with the frame to hold the substrate against the leads. The retaining member is preferably disengaged from the substrate simultaneously with the trimming of the leads from the frame after connecting to the substrate.

Abstract: A method for production of an armature device group for matrix print heads of the clapper-armature construction is based on connecting and jointly processing prefabricated parts (1, 2) such that elongated armatures with wide armature arms (4) and narrower armature arms (5) are generated. For further decreasing the production costs and for increasing the precision of the armature coordination, for facilitating mounting and for saving assembly steps, an armature circle (1) is punched out with openings (6). An annular elastic shaped plate (2) of sheet metal is then attached covering the opening (6) and the radially outer and radially inner armature arms (4, 5) are then cut out employing a method such as thermal cutting or, respectively, water-torch cutting, without damaging of the shaped plate (2).

Abstract: A connector includes a pair of housings mutually engageable integrally, and a plurality of contactors secured at their base portions to each of the housings so that the contactors of the both housings are contactable with each other respectively at their free ends when the housings are engaged integral to each other, mutually with a clicking resiliency provided by means of a sloped step made in each contactor between the base and free end portions, whereby the contactor capable of providing a reliable clicking action denoting completion of the connection is rendered manufacturable without requiring highly precise administration.

Abstract: A connector assembly (10) and a method of manufacture include a connector sheet (30) formed of a fine web of insulating strands (32, 34) woven together to define a mesh of cavities (35) containing discrete contacts (36, 40) held by an adhesive (38) to define an ordered anisotropic area of discrete contact points useful in interconnecting contact pads (24) of a component (20) to contact pads (18) of a circuit (12). A connector housing (60) is provided to clamp the component (20) to the circuit (12) with the connector sheet (30) therebetween.

Abstract: Mechanical forming apparatus and method for manufacturing planar contact projections for a flexible circuit is disclosed. A forming die includes a punch assembly configured for mating with a die plate. The punch assembly comprises a pin plate coupled to a punch plate and configured to hold adjusting pins and forming punches, respectively. Each forming punch has a tail with a contoured tip that conforms to the geometry of a desired contact projection. The die plate has a plurality of cavities configured and dimensioned for receiving the tail tips of the punches. In operation, the punch assembly and die plate are placed in a die set and installed in an open position in a punch press with a flexible circuit positioned therein. When activated, the press closes the die set, causing the punch tails to push against the flexible circuit, while circuit material flows into the die plate cavities. As the cavities fill, any excess material is compressed into peripheral areas of the die plate surrounding the cavities.

Abstract: Apparatus for taking a plurality of terminals arranged in a first spatial configuration, and rearranging them into a second spatial configuration for insertion into a stator or other electrical component, is provided. The apparatus includes a plurality of tubes, one for each terminal, which convey the terminals to new locations and, if necessary, twist along the way to change the orientations of the terminals.

Abstract: A plastic package that includes a cavity for holding an integrated circuit die. The package also includes several singel-piece leads that each have bonding pad area on one end and an area for connecting to external circuitry on the other end. The package's plastic body supports the leads, separates them from each other, and includes a ridge that substantially encircles the cavity and separates the bonding pad areas from the cavity. The package may be made by forming a first portion including alignment protrusions sized to receive lead bonding pad ends, placing the leads with their bonding pads so that they are spaced apart by the protrusions, and securing them, preferably by supplying heat to the protrusions. A second portion of the package may then be molded around the first portion, the leads, and, preferably, a heat sink.

Abstract: A programmable tool for mounting a connector to a circuit board, the tool having a guide member with a plurality of apertures therein for receiving the leading ends of terminal members disposed in thhe connector and at least one plate member having first apertures therein aligned with selected ones of those in the guide member and defining selected deeper apertures. The leading end of the tool is positioned over the terminal members and as force is applied the selected deeper apertures allow the ends of corresponding terminal members received therein to extend further back within the tool than those of the other terminal members and hence are not pushed as far, whereby upon removing the tool from the mounted connector, the terminal members are arranged in a staged array.

Abstract: A shunting system for a modular jack type connector which includes a dielectric housing defining a plug receiving cavity open at one end of the housing. A plurality of terminals are mounted in the housing, with contact portions disposed in a single row. A pair of programmable shunts substantially identically stamped and differently formed from sheet metal material are provided for engagement with the contact portions when the two shunts are mounted in different positions on the housing. Selected different ones of the contact fingers of each shunt are removed so that the remaining contact fingers engage only selected ones of the contact portions.

Abstract: A coaxial electrical connector (2) comprises a pair of half shells (4 and 6) each having a shield forming part (12) which is semi-circular in cross section and defines a swept rectangle. The half shells (4 and 6) are assembled to a dielectric insert (8) having an axial slot (34) receiving a center pin (10), so that the shield forming portions (12) of the half shells enclose the insert (8). Tabs (26) and (28) on one half shell (4) are bent down into notches (30 and 32) in the other half shell (6) to secure the half shells (4 and 6) about the insert (8). Each half shell is connected in side by side relationship with a plurality of identical half shells by means of a carrier strip (42) for conveying the half shells to an assembly station AS. One or both of the carrier strips (42) is allowed to remain connected to its respective half shells until a desired multiplicity of the connectors (2) have been assembled.

Abstract: The connector is for receiving the edge of a printed circuit board and making contact with the pads along the edge thereof. The connector has a body in which is positioned a plurality of longitudinally arranged U-shaped sockets which receive the edge of the board. Formed points are located in the sockets at a different distance from the bottom of the socket. These points are spaced so that the board may slide therebetween and then, as the board is turned in the socket, it engages the points to make assured contact.

Abstract: Erroneous insertion of a press-connecting terminal is detected, either electrically or mechanically, by providing a piece either on a rear portion of a base plate of an electrical connector, or on a wire-press connecting portion disposed behind an electric contact portion which is provided at a front end of the base plate. The erroneous insertion-detecting piece is formed in accordance with a size of the press-connecting terminal.

Abstract: An electrical interconnection, which includes a method for fabricating the device, is disclosed. The interconnection comprises two contact surfaces, on at least one of which is disposed at least one solid metal conical projection in predetermined dimension and location. Rather than necessarily being permanently cojoined, the contact surfaces are attachable and detachable when desired. The conical projections on one contact surface make ohmic contact, either by wiping with an intermeshing like structure on a second contact surface or by contacting a second contact surface which is a substantially flat contact pad. An interconnection, in this invention, is the combination of at least one contact having individual conical projections and another contact, optionally having individual conical projections. The conical projections are formed in metal by electrochemical machining in neutral salt solution, optionally in a continuous foil. The conical projections are also optionally formed on the head of a contact pin.

Abstract: An electrical connector modularly arranged wherein electrical contacts either manual or automatic assemble though a grommet assembly into retention clips.

Abstract: The present invention is a method of creating a ring surrounding a chip carrier having a lead frame premolded to a carrier body or housing. The ring is comprised of a first premolded section having a first predetermined shape and a second premolded section having a second predetermined shape. A non-conductive adhesive material is applied to a mating side of each of said sections. These first and second sections are combined to form the ring in which certain portions of the first section mate into the second section through matching holes in the metal lead frame of the chip carrier package. The resulting chip carrier ring is positioned in a short distance from the carrier body relative to the length of any of the four sides of the carrier body in order to gain mechanical strength provided by the plurality of leads, thus avoiding the substantial bending of individual leads.

Abstract: In order to improve the stability of a flat contact spring for plugs of electrical plug and socket connections which comprise connections for electrical conductors and a recess the marginal faces of which support a retaining tongue fastened to the spring housing, the contact spring is formed from a sheet metal cut-out with a first section composed of a central strip and longitudinal marginal strips which can be folded back onto the latter. The longitudinal marginal strips comprises cut-outs which extend as far as their edges and which together form an undercut recess when the longitudinal marginal strips are folded back onto the central strip.

Abstract: An interconnect or circuit device having coplanar contact bumps, and the method of manufacture thereof are presented. The coplanar contact bumps are formed against a flat reference surface whereby the resulting bumps have coplanar means.

Abstract: A method of fabricating a printed wiring substrate board to have integral contacts over the thickness of a defined connector edge in order to allow for perpendicular mating to exposed conductors on the surface of a second substrate.

Abstract: A cochlear prosthetic package having a cup-shaped titanium case with a ceramic plate; a plurality of hermetically-sealed feedthroughs are formed in the plate by sintering the plate with hollow metallic tubes located in plate holes and then sealing at least one end of each tube. An electrode cable connector is provided which allows removal and replacement of a case even in the presence of body fluids. A telemetry coil is contained in a metallic tube which extends out of the case; the coil-containing tube has its two ends hermetically-sealed to the case by ceramic insulating bushings.

Abstract: A method of forming a conductive lamina for use with and to form a bio-medical electrode device comprising the steps of providing a non-conductive base structure, providing a mixture of an electrically conductive substance and a media component, depositing the mixture onto the base structure, and curing the mixture. The method further comprises the step of mixing the electrical conductant and the media component in a closed cell, positive pressure kinetic mixer. The method further comprises the steps of combining a urethane base and a polyhydric alcohol to form the media component and delaying the mixing of the media component and the electrical conductant for a predetermined time period. In another embodiment, the method comprises the steps of combining a photo-initiator, a cross-linking agent, and low pH acrylic monomers to form a precomponent, and mixing the precomponent with the glycol to form the media component.

Abstract: A method of making a plastic terminal connector having a metal terminal set embedded therein in which the conductive contact members of the terminal set are electrically isolated from each other prior to the injection molding process. There is included a three-plated mold base which is formed from a lower movable mold plate, an intermediate mold plate, and an upper stationary mold plate. The upper mold plate includes a plurality of punches which extend through the spring-biased intermediate mold plate so as to cut connecting ties of the metal terminal set so as to form a plurality of individual electrically isolated conductive contact members when the mold is closed. The cutting operation is performed prior to the injection molding process as an integral part of loading the metal terminal set into the lower mold plate and securing the terminal set within the mold between the lower and intermediate mold plates when the mold is closed.

Abstract: A method of forming an enclosure for an electric circuit and the enclosure wherein there is provided a boat of material having a bottom and side wall, placing a material having a substantially higher thermal conductivity and a lower melting point than that of the boat in the boat bottom, heating the material to a temperature above the melting point thereof and below the melting point of the boat to cause the material to flow along the bottom to form a layer of the material thereon and join the layer to the bottom and side wall and removing a sufficient amount of the bottom of said boat to expose the layer. In accordance with a second embodiment, a depression is formed in the bottom, and when the material flows along the bottom, it fills the depression and become joined to the bottom. Plural such depressions can be provided. The exterior portion of the bottom is removed to expose the material if the depressions do not extend completely through the bottom.

Abstract: A connector is described of the type that has contacts lying in insulative material in a housing, wherein a separate positioner (24 in FIG. 2) of insulative material is molded about each contact (22) to form a terminal device (20), and the terminal devices can be arranged in a variety of configurations. Each terminal device includes an elongated metal contact with front and rear end portions and a middle, and an insulative positioner (24) molded about the middle. The terminal devices lie in the housing with the molded positioners of adjacent contact devices substantially abutting each other and holding the contact ends in a predetermined pattern, wherein the axes of all terminal devices extend parallel to each other. The middles of the contacts are hollow and include access openings (52 in FIG. 5) into which molding material can flow, so the molded material of the positioner seals the middle of the inside of each contact.

Abstract: A plurality of the terminals (42--42) are mounted in slots which open to an inner surface (75) of a well (78) of a housing (41) of a modular plug (23) to terminate conductors (22--22) of an end of a cordage (21) that has been secured within the housing. The slots communicate with a cavity in which are disposed conductors of the cordage. Each terminal includes a body portion (84) having first and second ends (87 and 88). Internal contacting portions in the form of tangs (92--92) protrude from the body portion and engage electrically the conductors of the cordage. An external contact portion (94) of each terminal protrudes from and is disposed asymmetrically along the body portion between its ends. The external contact portion of each terminal is disposed between partitions (79--79) which extend from the inner surface of the well to an exterior surface of the housing or between such a partition and a sidewall of the housing.

Abstract: A bi-level connector for making mechanical and electrical contact between a mother printed circuit board and a daughter printed circuit board. The connector comprises lower level contacts with a varied spring rate when a daughter printed circuit board is inserted. The method of manufacturing the connector comprises forming a strip of two types of contacts, upper contacts and lower contacts, on a single carry strip in alternating fashion such that both the upper and lower contacts can be simultaneously inserted into a connector housing in a single insertion process.

Abstract: A method is disclosed for easy and inexpensive fabrication of fold-up frames having diverse geometric configurations for flat packs (metal packages) for housing discrete and integrated circuit chips. The method includes a first step of cutting a piece of flat metallic stock to predetermined length and width consistent with the number of fold-up frames and the perimeter required for the specific fold-up frame configuration to be fabricated, respectively. The flat stock is then milled to form a plurality of grooves of predetermined angle lengthwise in at least one major surface thereof to define the number of sidewall members in the final configuration of the fold-up frame. The milled flat stock may then be sliced to form a plurality of individual milled frames each having the predetermined height required by the specific configuration fold-up frame. Apertures are formed in the milled frame by punching or piercing all sidewall members simultaneously in a single operation.

Abstract: A method and apparatus for making a flexible interconnect for connection between stacks of electronic components. The method includes forming a plurality of holes through a flexible insulating material, depositiong electrically conductive metal studs into the holes extending out of at least one side and preferably both sides of the flexible material, and electrically interconnecting some of the electrically conductive metal studs by interconnects supported by the flexible material. The interconnects may be supported from the outside of the flexible material or embedded therein. Dummy studs may be provided in the flexible material extending to the outside and aligned with studs extending on the other side of the insulating material which are connected to the electrical interconnects.

Abstract: A piezoelectric buzzer comprising a case having the shape of a bottomed cylinder, a piezoelectric diaphragm fixedly disposed within the case, a cover plate fitted in the open end of the case, and terminals integrally combined with the cover plate and each having one end in contact with the piezoelectric diaphragm and the other end projecting outside from the cover plate. Since the cover plate and the terminals are combined together by insert moldings, no gap is formed between the cover plate and the terminals, no sealing work for sealing gaps between the cover plate and the terminals is necessary, the manufacturing process is simplified, and the piezoelectric element is not exposed to the external atmosphere.

Abstract: A contact element such as an end-sleeve or a cable shoe, having a connecting portion and a contact portion, is produced from an originally plane blank which has a substantially rectangular first part, which in the finished product defines said connecting portion, and a second part, which in the finished product defines said contact portion. A plurality of such blanks is joined into a metallic punching band with an obverse face and a reverse face and comprising a first zone with all the first parts of the blanks, and a second zone with all the second parts of blanks. On at least the obverse face of the first zone is an insulating cover or coating applied before the individual blanks are removed from the punching band, so that the contact elements having a metallic connection portion with an insulating layer are obtained.

Abstract: An apparatus for containment and alignment of wire terminations has a wire holder with a slidable retainer. The front of the wire holder has oval-shaped holes for partially receiving several oval-shaped wire terminations to be connected to electronic equipment, and for reducing rotational motion of the wire terminations. Smaller holes connected to the oval-shaped holes receive the wires, but prohibit further movement of the wire terminations into the wire holder so that wire terminations uniformly protrude from the wire holder. Slots at the back of the wire holder receive the wires, which wires are frictionally locked into place by the retainer.

Abstract: A contact leaf bank for an electrical contactor preferably etched from a single uniform sheet of resiliently flexible, electrically conductive material comprises a ground sheet defining a plurality of uniformly-spaced, elongated, parallel slots in which are singularly disposed a plurality of resiliently flexible, elongated leaves each having and end portion adapted to be a contact finger, the tip of each contact finger preferably being rhodium-plated for hardness.

Abstract: Suggested is a grid (22) of electrically conducting sheet material for connecting especially an electromotor, said grid being a deep-drawn part so that a high density and number of conductor paths (29) positioned side by side and one upon the other can be obtained, said conductor paths extending in different planes (24, 26, 28) and, if necessary, along curved paths.

Abstract: An apparatus and method for assembling electrical connector components, including headers, connectors, and terminals, to circuit bearing substrates functions to align the terminal pins of a connector or header into a preferred position and install an annular solder preform onto each terminal pin. The pin alignment apparatus includes movable jaw plates the define a variable size aperture for encompassing each of a plurality of terminal pins, including terminal pins that are bent or skewed relative to an intended position. A carrier plate overlies the jaw plates and includes a plurality of cavities for receiving solder preforms to be installed over each of the terminal pins. The jaw plates are positioned over the terminal pins and moved to a closed position to align all the terminal pins, including any bent or skewed terminal pins, to an intended alignment.

Abstract: A thick film integrated circuit having a terminal with a plurality of parallel legs each having an angled foot portion for connection to the thick film circuit board. An elongated tie bar extends perpendicular to the legs and connects the legs to each other for stabilization. The tie bar has sufficient mass and is positioned sufficiently far from the foot so that heat can be applied to the foot to solder it to the thick film substrate. The legs are positioned in a guide bar with tapered sides to provide a self-centering feature when the terminal is coupled to a connector.

Abstract: An improved lead insertion apparatus for randomly inserting crimped wire leads one at a time into a multicircuit connector includes a pair of elongate insertion jaws for longitudinally surrounding and gripping a crimp terminated wire lead. The insertion jaws are actuable by a gripper control between a first open position, a second intermediate gripping position wherein the jaws are axially slideable along the gripped wire lead and a third closed position wherein the jaws firmly grip the lead in a non-slideable manner. The jaws and their gripper control are mounted for axial movement along the wire lead into the insertion station. A drive for the jaws moves the jaws in their intermediate wire gripping position along the wire segment until a proximity sensor senses the tips of the jaws abutting the rear end of the crimp terminal. In response to the sensor the gripper control changes the jaws to their closed position on the wire prior to insertion.

Abstract: Provided herein are novel layered elastomeric connectors, housings therefor and methods of manufacture for the connectors which includes alternating fused layers of a dielectric elastomer and electrically conductive fibrous mats coextensive with a cross section of the conductor to provide a multiplicity of conductive pathways between two electrically conductive surfaces. In order to promote a more mechanically stable connector, the fibrous mats can be exposed to a coupling agent for enhanced bonding. To enhance the electrical characteristics, the fibrous mats can be electroplated with an electrically conductive metal.

Abstract: A process for forming a contact bump in an electrically conductive contact pad having top and bottom surfaces supported on a dielectric substrate that includes the steps of removing a portion of the substrate underlying the contact pad to form an aperture and expose a portion of the bottom surface of the pad; upwardly deforming the pad by applying force to its exposed bottom surface to form the bump; and filling the aperture behind the bump with a supporting substance.

Abstract: A method of producing a plurality of individual contact spring assemblies for use in an electromagnetic relay in which movable and fixed contact springs for each assembly are held by a molded resin base comprises the steps of caulking a first set of contacts and a second set of contacts to a unitary sheet metallic blank and stamping out the movable and fixed contact springs from the metallic blank. The method further comprises the steps of bending the stamped-out movable and fixed contact springs into a predetermined configuration such that the fixed and movable contact springs are in opposition to each other and molding a base so that selected portions of the movable and fixed contact springs are embedded therein. Finally, the method comprises the step of cutting the fixed and movable contact springs from the metallic blank.

Abstract: A holder and method of forming a holder for a removable plug-in circuit element is disclosed. The fuse holder comprises an insulated base, an electrical bus member, and a plurality of terminal members which are formed from the same blank of metal as the metal bus member and which were separated from each other after that blank was mounted on the insulated base. The bus member comprises a plurality of branches joined to a common trunk with each branch having at its free end an integral terminal. Each terminal member has at one end an electrical terminal and, at an opposite end, an integral terminal which is aligned to the free end of one lateral branch. In one embodiment of the invention, the holder includes an insulated cover which is carried by the base and which has a plurality of apertures which aligned to the terminals of each branch so as to receive the ends of a removable plug-in circuit element therein.

Abstract: The present invention is directed to a ganged lamp socket device especially applicable for a bank of LED's. The apparatus includes a housing having a row of sockets with a groove and first pockets on one side of the row and a plurality of second pockets on the other side. A common terminal strip fits in the groove and first pockets, while a plurality of contact members fit in the second pockets. The apparatus is easily assembled using the common strip and plurality of contact members formed in a single conductive sheet. The strip is inserted in the groove and broken from the sheet and then the contact members which are held together by a carrier are inserted in the second pockets. The carrier is broken from the contact members and all items are pressed into place. The apparatus reduces the number of piece parts normally needed for this type of device and increases system reliability.

Abstract: A method of making a flexible interconnect for connection between stacks of electronic components. The method includes punching a plurality of holes through a flexible insulating material, plating copper studs into the holes extending out of at least one side and preferably both sides of the flexible material, and electrically interconnecting some of the plated studs by interconnects supported by the flexible material. The interconnects may be supported from the outside of the flexible material or embedded therein. Dummy studs may be provided in the flexible material extending to the outside and aligned with studs extending on the other side of the insulating material which are connected to the electrical interconnects.

Abstract: A method of manufacturing a compact switch includes steps of(a) forming a base by insert molding on terminal members such that terminal pins of the terminal members are extended downward through the base when the terminal members, one of which has a bimetallic plate-fixing portion and another of which has engaging grooves to be engaged with a movable spring member, are punched in a hoop member;(b) fixing a bimetallic plate to the fixing portion of the one terminal member, a fixed contact being attached to a free end of the bimetallic plate which is displaced when temperature of the bimetallic plate is raised;(c) bringing a movable spring member into engagement with the engaging grooves of the other terminal member, a movable contact to be faced to the fixed contact being attached to a free end of the movable spring member;(d) bringing a lower end portion of a push button member into engagement with the movable spring member;(e) cutting the terminal pins at predetermined positions from a lead frame of the hoop