US3924917A

US3924917A - Flat cable termination method and apparatus

Info

Publication number: US3924917A
Application number: US465593A
Authority: US
Inventors: Kenneth Munshower
Original assignee: Elco Corp
Current assignee: Amphenol Corp; Elco Corp
Priority date: 1974-04-30
Filing date: 1974-04-30
Publication date: 1975-12-09
Anticipated expiration: 1992-12-09
Also published as: DE2519437A1; FR2269798A1; NL7504914A; BE828324A; ES446415A1; JPS50147587A; CA1038612A; ES446416A1; FR2269798B3; DK165675A; ES436792A1; GB1512432A; IT1032761B

Abstract

A termination method and apparatus for flexible flat conductor cable utilizing a contact having a pair of cable penetrating prongs for penetrating completely through a conductor of the flexible cable and a pair of biased abutment surfaces cooperable with the prongs for forming a crimp at a location remote from the penetration is disclosed. The prongs may be arranged in a manner to form a biased contact bridge therebetween after the connector has been attached to the cable. A die is employed to enforce cable penetration and bending of the prongs in a single movement lancing operation, while simultaneously swaging lower portions of the prongs to form prong projections engaging the conductor therebetween.

Description

United States Patent [191 Munshower FLAT CABLE TERMINATION METHOD AND APPARATUS Inventor: Kenneth Munshower, Norristown,

Assignee: Elco Corporation, Willow Grove,

Filed: Apr. 30, 1974 Appl. No.: 465,593

[56] References Cited UNITED STATES PATENTS 3,840,840 10/1974 Worth 339/17 F X Dec. 9, 1975 [57] ABSTRACT A termination method and apparatus for flexible flat conductor cable utilizing a contact having a pair of cable penetrating prongs for penetrating completely through a conductor of the flexible cable and a pair of biased abutment surfaces cooperable with the prongs for forming a crimp at a location remote from the penetration is disclosed. The prongs may be arranged in a manner to form a biased contact bridge therebetween after the connector has been attached to the cable. A die is employed to enforce cable penetration and bending of the prongs in a single movement lancing operation, while simultaneously swaging lower portions of the prongs to form prong projections engaging the conductor therebetween.

14 Claims, 2 Drawing Figures US. Patent Dec. 9, 1975 Alli 50 FIG] FLAT CABLE TERMINATION METHOD AND APPARATUS RELATED APPLICATION This application is related to commonly assigned application Ser. No. 465,594 filed concurrently herewith for Method and Apparatus for Flat Conductor Cable Termination'by Charles E. Baker and Abraham Silverweig.

BACKGROUND OF THE INVENTION The present invention relates to multiple contact connectors. More particularly, the invention relates to improvements in multiple contact connectors'for the termination of flexible flat conductor cable and the like of the type set forth in the above-mentioned application.

As pointed out therein, flexible flat conductor cable conventionally has a plurality of flat ribbon-like conductors embedded in an insulati'ng'medium, e.g;, polyester, wherein the conductors lie generally parallel to each other in a single plane. I

Flexible flat conductor cable is being used in wiring applications to an increasing extent as a result of its compactness and advantageous electrical characteristics. For example, it has been found that this type of cable may very easily be replaced and/or installed under relatively crowded conditions which would render other conventional wiring arrangements costly, burdensome, and subject to wiring errors. However, the commercial utility of flexible flat cable has been hampered by the lack of a particularly suitable termina tion contact.

In the past, connector devices for flat conductor cable have been provided which utilize both crimp-type terminations and solder-type terminations. In the case of many of these devices, it has been necessary to prepare a portion of the cable in order to receive the connector. For example, in many instances it is necessary to strip the insulation from the end of the cable prior to application of the contact to the cable. In other instances, the cable may require a pre-perforation to accommodate a portion of the contact (see e.g., US. Pat. Nos. 3,675,180 or 3,768,062).

In the use of yet other devices, it is not necessary to remove a portion of the insulation material. The insulation may be pierced by a contact which straddles a conductor of the cable. The contact may then be crimped to the conductor to effect an electrical connection (see US. Pat. No. 3,395,381). Potential drawbacks of this prior art arrangement are set forth in the aforementioned commonly assigned application.

The present invention falls into the category of tenninating devices for flexible flat conductor cable wherein the insulation is pierced and substantially no prior preparation of the cable is necessary at the location chosen to terminate the cable.

There has been suggested in the prior art aterminal for flexible circuits'which has tangs intended to penetrate the full thickness of the flexible circuit in order to thereby staple the terminal onto the flexible circuit at a pre-perforated location (see US. Pat. No. 3,768,062);

The device disclosed in the U. S. Pat. No. 3,768,062, proposes a terminal for flexible circuits which rests on a rim portion of the terminal extending generally normal to a generally planar base portion. According to this proposal, tangs, which are formed from an extension of the rim, penetrate the full thickness of the flexible circuit at a pre-p'erforated zone of enlarged width on the flexible circuit. After penetrating through the circuit, the tangs are bent against an outer layer of the circuit. It has been further suggested that, if desired, these tangs upon attachment of the terminal could be driven against an anvil of suitable configuration to provide reentry of the tangs into the flexible circuit.

It will be appreciated that these and other crimpable connecting devices for flat conductor cable in the prior art require that some extraordinary preparation be made in the cable or circuit being terminated to accommodate the connector, or that a cable having relatively wide interspaces between the conductors be chosen to prevent adjacent connectors from making electrical contact. These factors may significantly limit the utility of the cable or circuit used and, in addition, impose substantial economic restraints on the utilization of the cable or circuit. Moreover, these prior art connectors may form an electrical contact which may have certain undesirable characteristics. For example, the electrical contact made between prior art connecting devices and the conductor cable may occur over an insufficient number of points to perform satisfactorily. In addition, these prior art connectors may not provide a sufficiently tight mechanical engagement of the conductor to produce a satisfactory electrical contact over a relatively long life.

The above-mentioned commonly assigned application sets forth a novel method and apparatus for terminating flexible flat conductor cables which minimizes or reduces at least the problems of the type previously noted in connection with prior art devices. The present invention is directed to an improvement in such method and apparatus according to which particularly acceptable mechanical and electrical connections are obtained.

OBJECTS AND SUMMARY OF A PREFERRED EMBODIMENT OF THE INVENTION Accordingly, an object of the present invention is to provide a novel improvement in a method and apparatus for terminating flexible flat conductor cable, and more particularly, one which may be utilized in conjunction with relatively small conductor spacings.

Another object of the present invention is to provide a novel improvement in a method and apparatus for terminating flat conductor cable which provides an instantaneous termination of a conductor at any point along a length of flexible flat conductor cable.

A particular object of the present invention is to provide a novel improvement in a method and apparatus of the type set forth in the above-mentioned commonly assigned application (the disclosure of which is hereby incorporated by reference) according to which improvement particularly acceptable mechanical and electrical connections are obtained.

SUMMARY OF A PREFERRED EMBODIMENT OF THE INVENTION A method and apparatus for terminating flexible flat conductor cable according to a preferred embodiment of the invention intended to substantially accomplish the foregoing objects includes a cable penetrating device, according to the aforesaid application, for penetrating completely through a conductor portion of a flat conductor cable to provide thereat a first electrical and 3 mechanical'contact between the conductor portion and the contact apparatus. An engagement device is provided for also engaging the conductor portion at a loca: tion remote from the penetration of the conductor. This engagement device may include a bent-around portion of the cable penetrating device and an abutment body for providing a reaction surface against which the bent-around portion is operable to press the conductor. The bent-around portion of the penetrating device and the abutment body are cooperable to penetrate at least a portion of the .insulative covering of the conductor portion to crimp the conductor at that location remote from the penetration. There is provided at the crimp a second electrical and mechanical contact between the conductor and the connector and mechanical contact between the conductor and the connector apparatus. Moreover, the crimp formed by the bentaround portion of the penetrating device and the abutment body may isolate or trap a portion of conductor between the location of penetration and the crimp. The abutment body may be carried by a pair of spring arms integral with the connector device. These spring arms may be operable to provide a relatively constant force tending to urge the bent-around portion of the penetrating device tightly against the conductor of the cable. t

The penetrating device may include a pair of sharpened prongs. These prongs may be sharpened in such a manner as to provide a biased conductor bridge therebetween when the contact is attached to the conductor cable. At the location of this conductor bridge, swaged, oppositely facing, projection of the prongs are provided to grip the conductor cable segment of the bridge.

The method of the present invention includes the steps of penetrating at a first location a conductor of a flexible flat conductor cable with a contact. The contact is then crimped between a penetrating device and an abutment surface at a second location to provide a secure electrical and mechanical contact between the conductor and the contact at a second location. This crimping action may isolate or trap portions of the conductor to provide an improved electrical contact.

Preferably a die is employed to effect cable penetration and prong bending. The die includes a bending surface cooperable with the prongs. The bending surface may be comprised of arcuate surfaces positioned adjacent one another to define a die nose receivable between the prongs.

With the prongs positioned to extend generally perpendicular to the direction of extent of the cable to a location adjacent the cable, and with the die positioned in general alignment with the contact, relative movement of the die and contact toward one another enforces; complete penetration of the prongs through a conductor portion of the cable; bending of prongs, under control of the die bending surfaces, away from one another and into an orientation with an opposite direction of extent, and engagement of the bent prongs with a conductor of the cable crimped-between the prongs and the contact abutment surfaces; and formation and positioning of the bridge projections of the prongs. Where the cable includes insulation layers on both sides of the conductor, the single lancing operation enforces prong penetration through the insulations layers, penetration of the reverse bent prongs back into one layer and penetration of the abutment surfaces into the other insulation layer.

4 Other objects and advantages of the present invention will become apparent with reference to the following detailed description of a preferred embodiment theeof in connection with the accompanying drawings wherein like reference numerals have been applied to like elements in which:

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is.- a schematic elevational view depicting a connector oriented with respect to a staking die prior to attachment of the connector to a conductor of a flat conductor cable in accordance with the present invention; and

FIG. 2 is a schematic elevational view showing the termination according to the present invention.

DETAILED DESCRIPTION With reference to FIG. 1, there may be seen a contact 10 for flexible flat conductor cable 12, which contact is, in its initial form, identical to a contact disclosed in the above-mentioned copending application. During a staking or lancing operation, in accordance with the present invention, the contact 10 is fashioned into the form shown in FIG. 2. The contact 10 is operable to penetrate completely through a conductor -13 embedded in the cable and to additionally form a crimp in the conductor. The contact 10 may include at one end 14 a solder tab or lug 16, or another matable contact 16 for mating with a member of another connector (not shown).

The cable 12 may be any conventional flexible flat conductor cable comprised of a plurality of parallel and spaced-apart conductors 13, which are generally rib.- bon-like. These ribbon-like conductors are embedded in an insulating film 15 of a polyester or similar material. Mylar (polyethylene terephthalate), Kapton (a polyimide) and Teflon (polytetraflouroethylene) are typically used as an insulating material. It is envisioned that these and a variety of other simila'r materials would be suitable.

To effect the penetration of the conductor 13, there are provided at another end 18 of the contact 10 a pair of prongs 20. These prongs are carried by a base portion 21 of the contact and have a sharpened or pointed end 22. The prongs are operable to displace the insulation of the cable and penetrate completely through the conductor embedded therein. As will be pointed out with greater particularity below, the periphery of stems 26 of both of these prongs 20 make electrical contact with the conductor 13 when the cable is penetrated thereby.

Each prong 20 comprises an elongate stem 26 and the end 22. That end 22 of each prong is preferably sharpened by the fashioning of an interior chamfer.28 and an exterior chamfer 30 at the end or distal terminus of the elongate stem 26. These chamfers or bevels are conventionally formed in such a manner that a relatively sharp top cutting or penetrating edge 32 is provided. Preferably, the exterior chamfer 30 is larger than the, interior chamfer 28, i. e., the sharpened edge appears displaced from a central longitudinal axis 29 of each prong in a direction generally towards the opposing prong.

Each of the prongs is bendable outwardly, preferably in a plane passing through the longitudinal axis of the conductor. The plastically deformed prongs may be made to contact the conductor again by penetrating through a top side 39 of the insulating material 15 on the flat conductor cable 12.

An abutment means for the bent-around or deformed prongs is preferably provided to support the flat conductor cable 12 against the piercing or penetrating action of the re-entering cutting edge 32. In this connection, a pair of abutments 34 are provided on the contact apparatus.

These abutments 34 have a reacton surface 35 defined by an interior chamfer on back-up or abutment arms 50. This interior chamfer is cooperable with an exterior chamfer 36 on the abutment 34 to provide a sharp top edge 38.

This sharp edge 38 of the abutment 34 is spaced relative to the remaining contact portions so as to be operable to penetrate the insulation 15 on a bottom side 40 of the cable 12 and contact the conductor 13 when the cable is pressed thereagainst by the re-entry of the bent-around prongs as may be seen in FIG. 2.

The force used to bend the prongs 20 around to a position to squeeze the cable 12 between the end 22 of the prong and the abutment 34 should be regulated so as to effect a penetration of the insu ating material 15 and contact with the conductor 13 but not necessarily a penetration through the conductor 13. The cutting edges 32 and 38, after initial penetration of the cable, may be pressed generally obliquely against the cable at the crimping locations. That is to say, the crimped portion 27 of theconductor may be displaced out of the former plane of the conductor 13. As a result, a portion of the conductor 13 is tightly crimped by the end of the bent-around prong and the abutment of the contact.

It will be appreciated that electrical contact is made between the conductor 13 and the contact 10 at several engaging locations, viz., between each of the bentaround prongs and the conductor 13 adjacent its top surface 49 and between each of the reaction surfaces or chamfers 35 and the conductor 13 adjacent its bottom surface 51. The exact nature of the electrical contact between the prongs and the conductor and between the reaction surfaces and the conductor may vary depending upon circumstances. At any rate, surface contact, edge contact and/or point contact with the conductor is provided at the several engaging locations.

As noted above, electrical contact and mechanical connection occurs between the prongs 20 and the conductor at the apertures 24 where the prongs have penetrated the cable initially. It will be appreciated that electrical contact occurs around substantially the entire periphery of the prong 20.

Thus, in the practice of the present invention, as in the case of the invention of the above-mentioned commonly assigned application, electrical contact is made between the contact and the conductor at at least six distinct locations or zones. Each of the penetrating prongs 20 makes peripheral electrical contact with the conductor, and each set of engaging means makes electrical contact at the top and bottom of the crimp found formed thereby.

As may be seen in FIG. 2, the sharpened edge 22 of each of the penetrating prongs 20 may deform slightly as the prong is being bent around with the result that the surface of each of the interior chamfers 28 is stretched slightly. This phenomenon serves both to facilitate re-entry of the prongs into the cable and enhance the area of the interior chamfers 38 available to make electrical contact with the conductor after the prong has been bent around.

In any event, it is desirable that the

chamfers

35 and 28 be fashioned in a manner to facilitate a substantial coextensiveness of these surfaces subsequent to a bending around of the prong 20 and deformation of the face thereof. This arrangement results in a sandwiching" action on the portion 27 of the conductor which defines the location of the crimp formed by the contact 10.

The sharpened edges 32 of the penetrating prongs 20 slice a length of conductor having a slightly greater length than the distance between the interior walls 42 of the stems 26 of the prongs. As the conductor 13 and prongs are pressed together, the sliced portion of the conductor is forced to occupy a slightly less space with a result that a conductor bridge 44 is formed by the slice. It will be appreciated that this conductor bridge must bend or buckle slightly to squeeze or cram into the slightly shorter distance between the prongs. The formation of this conductor bridge 44, illustrated in FIG. 2 as downwardly concave, provides an advantageous flexing of the

insulation material

46 and 48 above and below the particular sliced portion of the conductor. The tensile and compressive forces set up on the flexed insulation serve to bias the conductor bridge 44 against the interior walls 42 of the prongs 20.

In addition to the biasing action of the

insulation material

46 and 48 covering conductor bridge 44, the conductor of the bridge itself may provide an additional spring action which enhances the biasing action.

As hereinafter more fully described, oppositely facing projections 47 are, according to the present invention, provided on the prongs to grip the conductor cable located at the bridge.

A portion 45 of the conductor 13 may be isolated or trapped between the crimpand an exterior wall 43 of the stem 26 of the prong 20. As will be appreciated from the drawing of FIG. 3, the trapped portion 45 may be urged towards or crammed against the exterior wall 43, as a result of the cooperation of the prong and reaction surface 35.

The abutment arms 50, provided in conjunction with the abutment surfaces 34 are preferably rendered springy. In this connection, as may be seen in the drawings, a pair of spring arms 50 is provided. These spring arms preferably are integral with the base portion 21 of the contact and are arranged to urge the abutment surfaces 34 against the conductor 13. The spring action provided by these spring arms also may improve the insulation stripping action of the

respective cutting edges

38 and 32 of the reaction surfaces and the bent-around penetrating prong ends when the contact is attached to a conductor.

It will be appreciated that the spring arms exert a continuous bias against the prongs after they have been bent-around to form the crimp, thereby establishing biased, positive, electrical contact. Thus, there may be provided a continuously biased pair of edges or faces 28 and 35 which are counterposed to sandwich the crimped portion of the conductor therebetween when the contact is attached.

Although the illustrated contact 10 includes the elongate matable contact 16 extending therefrom, a variety of mating contacts formed integrally therewith may be employed as mentioned in the above-noted copending application.

It will also be appreciated that in many instances, it may be desirable to utilize the apparatus and method of the present invention in conjunction with an insulative 7 housing (not shown) in order to form a convenient plug assembly that may be disposed at a midpoint or end of a length of flexible flat conductor cable.

It has been suitable to fashion the contact 10 of the present invention from copper alloy. Phosphor bronze or other materials may also be employed. It is also envisioned that a conventional coating such as gold over nickel or suitable non-noble metal would be satisfactory.

With renewed referenceto FIGS. 1 and 2, one preferred form of attachment of a contact to the cable according to the present invention may be more fully appreciated. Therein the contact 10 is shown as being held in a fixed position by a suitable jig or fixture indicated in section at 64. In this position, the spaced, bendable prongs are initially oriented to extend generally perpendicular to the direction of extent of the cable 12 to a location adjacent that cable.

A die, indicated in section at 66 is positioned above the cable 12 and prongs 20 in general alignment with the prongs. This die includes bending surfaces in the form'ofarcuate surfaces 68 positioned adjacent one another to define a die nose 70 receivable between the prongs. As illustrated the configuration of the arcuate bending surfaces 68 is such as to establish the final prong configuration.

A lancing operation is accomplished by effecting relative movement of the die 66 and the contact 10 toward one another. In this connection a ram (not shown) attached to the die or the jig 64, or one ram to each, may be employed.

As will be appreciated, a single lancing operation will enforce initial prong penetration as earlier discussed and prong bending under control of the bending surfaces 68, as well as repenetration of the bent around prongs through the upper insulation layers and penetration of the abutment surfaces 34 into the lower insulation layer. At the same time, the die nose 70 is operable to force the conductor. portion of the cable and the insulation between the prongs into crimped engagement with the prongs. Simultaneous terminations may be effected. 1

In addition, the die, primarily through the agency of the die nose 70, functions as a swaging tool to form the prong projections 47 adjacent the connector bridge. In addition, it will be appreciated that the die nose is provided with square corners 71 and has a lateral extent greater than the distance between the generally parallel faces 72 of the spaced prongs, as depicted by the arrows in FIG. 1 as the prongs are bent around under control of the arcuate bending surfaces 68 toward their final positions, the die nose 70 swages or shaves lower portions of the prongs to form the generally triangularly configured projections or nubs 47.

The lower face 73 of the die nose presses the projections to their final illustrated positions. In those positions those projections of the prongs envelop the bridge, making contact with the conductor 13.

In practice, a die nose with a lateral extent of 0.028 inches and a prong spacing of 0.025 inches have been employed effectively. During lancing, the prongs give up to a certain point as they are rolled outwardly, but eventually these size differences account for formation of the nubs by cutting of the prongs. A die made from suitable gauge steel has been successfully employed for this purpose.

In this fashion, an improved mechanical and electrical connection is formed at the conductor bridge. Par- 8 ticularly, creep or relaxation of the insulation which might otherwise effect the quality of the connection (more often when Mylar insulation material is employed) is positively resisted by the nubs 47 essentially encapsulating the bridge and crimping the material of the bridge into an envelope defined by the nubs and the web joining the bridge.

It has been found that the interface resistance of the connections according to the present invention starts out lower for a given energy input (as represented by the height from which the die is lowered) and remains relatively constant for extended elapsed times after the connection is made.

Thus, it is apparent that there has been provided, in accordance with the present invention, a method and apparatus for terminating a flexible flat conductor means such as flexible cable, flexible circuits, etc. which method and apparatus substantially satisfies the objects and advantages set forth above. Although the present invention has been described in conjunction with specific forms thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art in light of the foregoing disclosure of the invention. Accordingly, it is intended that all such alternatives, modifications, and variations which fall within the spirit and scope of the invention as defined in the appended claims be embraced thereby.

What is claimed is: 1. A contact apparatus for flexible flat conductor means comprising:

penetrating means for penetrating completely through a conductor portion of the said flat conductor means at any preselected location on said flat conductor means to provide thereat a first electrical contact between said conductor portion and said contact apparatus; and conductor engagement means for engaging said conductor portion at a location remote from said penetration at said preselected location, said engagement means comprising: a remote engagement portion of said penetrating means; abutment means for providing a reaction surface against which said flexible flat conductor means may be supported when said engagment portion engages said conductor portion; said engagement portion and said abutment means being operable to penetrate at least a portion of an insulative covering of said conductor portion at said remote location to provide thereat a second electrical contact between said conductor portion and said contact apparatus; I

said penetrating means including nub means projecting therefrom and establishing said first electrical contact.

2. The contact apparatus of claim 1 wherein said penetrating means comprises a pair of sharpened prongs and said nub means comprises projections on said prongs facing one another.

3. A method of terminating flexible flat conductor means the method comprising:

positioning (a) a contact having spaced, bendable prongs and abutment surfaces cooperable with the prongs and (b) the flexible flat conductor means in a position wherein the prongs extend generally perpendicular to the direction of extent of the flat conductor means to a location adjacent that flat conductor means;

9 positioning a die, including bendingsurface means cooperable with the prongs and prong swaging means, in a position in general alignment .with,the

tion; and v v I relatively moving the die and the contact toward one another to enforce I complete penetration of the prongs through a conductor portion of the flat conductor means, bending of the prongs, under control of the bending means of the die bending surface, generally away from one another and into an orientation with a direction of extent generally opposite said direction of extent, engagement of the bent prongs with a conductor of the cable crimped between the prongs and the cooperable abutment surfaces of the contact, and swaging of inner adjacent lower portions of the prongs to form prong projections engaging the conductor therebetween.

4. The method of claim 3 wherein the prong projections are positioned to essentially encapsulate and crimp the conductor between the prongs.

5. Apparatus for terminating a flexible flat conductor means with a contact having spaced, bendable prongs and abutment surfaces cooperable therewith, the apparatus comprising:

die means movable relative to said contact and including bending surface means cooperable with said prongs;

said bending surface means comprising arcuate surfaces positioned adjacent one another to define a die nose receivable between said prongs and having an extent greater than the distance between said spaced prongs;

said arcuate surfaces, upon relative movement of said die means toward said contact prongs with a flat conductor means between the prongs and the arcuate surfaces, being operable to controllably enforce penetration of the prongs through a conductor portion of the flat conductor means and bending of the prongs into engagement with the conductor of the cable crimped between the prongs and said cooperable abutment surfaces of the contact; and

said die nose including swaging means operable,

upon such relative movement, to form projections on inner adjacent lower portions of said prongs crimping a portion of the conductor between the prongs.

6. A contact apparatus for flexible flat conductor means comprising:

penetrating means for penetrating completely through a conductor portion of said flat conductor means at any preselected location on said flat conductor means to provide thereat a first electrical contact between said conductor portion and said contact apparatus; and

conductor engagement means for engaging said conductor portion at a location remote from said penetration at said preselected location to provide at said remote location additional electrical contact between said conductor portion of said flat conductor means and said contact apparatus;

said conductor engagement means including a remote engagement portion of said penetrating means operable to penetrate at least a portion of an insulative covering of said conductor portion of prongs and the adjacent flat conductor means por- 10 said flat'conductor means at said remote location;

said penetrating means including nubmeans projecting therefrom andestablishing said first electrical contact. v

7. The contactapparatus of claim 6 wherein said penetrating means comprises a pair of sharpened prongs and, said nub means comprises projections on said prongs facing one another.

8. The contact apparatus of claim 6 including means cooperable with said remote engagement portion of said penetrating means at said remote location to provide said additional electrical contact between said conductor portion of said flat conductor means and said contact apparatus.

9. The contact apparatus of claim 8 wherein said penetrating means comprises a pair of sharpened prongs and said nub means comprises projections on said prongs facing one another.

10. A method of terminating flexible flat conductor means the method comprising:

positioning (a) a contact having spaced, bendable prongs and (b) the flexible flat conductor means in a position wherein the prongs extend generally perpendicular to the direction of extent of the flat conductor means to a location adjacent that flat conductor means; positioning a die, including bending surface means cooperable with the prongs and prong swaging means, in a position in general alignment with the prongs and the adjacent flat conductor means portion; and relatively moving the die and the contact toward one another to enforce complete penetration of the prongs through a conductor portion of the flat conductor means,

bending of the prongs, under control of the bending means of the die bending surface, generally away from one another and into an orientation with a direction of extent generally opposite said direction of extent,

engagement of the bent prongs with a conductor of the cable at locations remote from the location of prong penetration before bending, and

swaging of inner adjacent lower portions of the prongs to form prong projections engaging the conductor therebetween. 11. The method of claim 10 wherein the prong projections are positioned to essentially encapsulate and crimp the conductor between the prongs.

12. The method of claim 10 wherein the relative movement of the die and contact toward one another enforces engagement of the bent prongs with conductor portions of the cable at said remote locations disposed between said prongs and means cooperable therewith to provide additional electrical contact at said remote locations.

13. The method of claim 12 wherein the prong projections are positioned to essentially encapsulate and crimp the conductor between the prongs.

14. Apparatus for terminating a flexible flat conductor means with a contact having spaced, bendable prongs, the apparatus comprising:

said arcuate surfaces, upon relative movement of said die means toward said contact prongs with a flat conductor means between the prongs and the arcuate surfaces, being operable to controllably enforce penetration of the prongs through a conductor por- '12 tion of the flat conductor means and bending of the prongs into engagement with the conductor; and said die nose including swaging means, operable upon such relative movement, to form projections on inner adjacent lower portions of said prongs crimping a portion of the conductor between the prongs.

Claims

1. A contact apparatus for flexible flat conductor means comprising: penetrating means for penetrating completely through a conductor portion of the said flat conductor means at any preselected location on said flat conductor means to provide thereat a first electrical contact between said conductor portion and said contact apparatus; and conductor engagement means for engaging said conductor portion at a location remote from said penetration at said preselected location, said engagement means comprising: a remote engagement portion of said penetrating means; abutment means for providing a reaction surface against which said flexible flat conductor means may be supported when said engagment portion engages said conductor portion; said engagement portion and said abutment means being operable to penetrate at least a portion of an insulative covering of said conductor portion at said remote location to provide thereat a second electrical contact between said conductor portion and said contact apparatus; said penetrating means including nub means projecting therefrom and establishing said first electrical contact.

3. A method of terminating flexible flat conductor means the method comprising: positioning (a) a contact having spaced, bendable prongs and abutment surfaces cooperable with the prongs and (b) the flexible flat conductor means in a position wherein the prongs extend generally perpendicular to the direction oF extent of the flat conductor means to a location adjacent that flat conductor means; positioning a die, including bending surface means cooperable with the prongs and prong swaging means, in a position in general alignment with the prongs and the adjacent flat conductor means portion; and relatively moving the die and the contact toward one another to enforce complete penetration of the prongs through a conductor portion of the flat conductor means, bending of the prongs, under control of the bending means of the die bending surface, generally away from one another and into an orientation with a direction of extent generally opposite said direction of extent, engagement of the bent prongs with a conductor of the cable crimped between the prongs and the cooperable abutment surfaces of the contact, and swaging of inner adjacent lower portions of the prongs to form prong projections engaging the conductor therebetween.

5. Apparatus for terminating a flexible flat conductor means with a contact having spaced, bendable prongs and abutment surfaces cooperable therewith, the apparatus comprising: die means movable relative to said contact and including bending surface means cooperable with said prongs; said bending surface means comprising arcuate surfaces positioned adjacent one another to define a die nose receivable between said prongs and having an extent greater than the distance between said spaced prongs; said arcuate surfaces, upon relative movement of said die means toward said contact prongs with a flat conductor means between the prongs and the arcuate surfaces, being operable to controllably enforce penetration of the prongs through a conductor portion of the flat conductor means and bending of the prongs into engagement with the conductor of the cable crimped between the prongs and said cooperable abutment surfaces of the contact; and said die nose including swaging means operable, upon such relative movement, to form projections on inner adjacent lower portions of said prongs crimping a portion of the conductor between the prongs.

6. A contact apparatus for flexible flat conductor means comprising: penetrating means for penetrating completely through a conductor portion of said flat conductor means at any preselected location on said flat conductor means to provide thereat a first electrical contact between said conductor portion and said contact apparatus; and conductor engagement means for engaging said conductor portion at a location remote from said penetration at said preselected location to provide at said remote location additional electrical contact between said conductor portion of said flat conductor means and said contact apparatus; said conductor engagement means including a remote engagement portion of said penetrating means operable to penetrate at least a portion of an insulative covering of said conductor portion of said flat conductor means at said remote location; and said penetrating means including nub means projecting therefrom and establishing said first electrical contact.

7. The contact apparatus of claim 6 wherein said penetrating means comprises a pair of sharpened prongs and said nub means comprises projections on said prongs facing one another.

10. A method of terminating flexible flat conductor means the method comprising: positioning (a) a contact having spaced, bendable prongs and (b) the flexible flat conductor means in a position wherein the prongs extend generally perpendicular to the direction of extent of the flat conductor means to a location adjacent that flat conductor means; positioning a die, including bending surface means cooperable with the prongs and prong swaging means, in a position in general alignment with the prongs and the adjacent flat conductor means portion; and relatively moving the die and the contact toward one another to enforce complete penetration of the prongs through a conductor portion of the flat conductor means, bending of the prongs, under control of the bending means of the die bending surface, generally away from one another and into an orientation with a direction of extent generally opposite said direction of extent, engagement of the bent prongs with a conductor of the cable at locations remote from the location of prong penetration before bending, and swaging of inner adjacent lower portions of the prongs to form prong projections engaging the conductor therebetween.

11. The method of claim 10 wherein the prong projections are positioned to essentially encapsulate and crimp the conductor between the prongs.

14. Apparatus for terminating a flexible flat conductor means with a contact having spaced, bendable prongs, the apparatus comprising: die means movable relative to said contact and including bending surface means cooperable with said prongs; said bending surface means comprising arcuate surfaces positioned adjacent one another to define a die nose receivable between said prongs and having an extent greater than the distance between said spaced prongs; said arcuate surfaces, upon relative movement of said die means toward said contact prongs with a flat conductor means between the prongs and the arcuate surfaces, being operable to controllably enforce penetration of the prongs through a conductor portion of the flat conductor means and bending of the prongs into engagement with the conductor; and said die nose including swaging means, operable upon such relative movement, to form projections on inner adjacent lower portions of said prongs crimping a portion of the conductor between the prongs.