Insulating piercing contact with wire retention feature

Abstract

An electrical contact is based on a base section extending from a first end of the contact to a second end of the contact, and a first set of outer walls extending upwards from the base section, with the first set of outer walls located on a first side. The electrical contact also includes a second set of outer walls extending upwards from the base section, with the second set of outer walls located on a second side opposite the first set of outer walls and the first side.The electrical contact also includes a piercing element arranged between the first set of outer walls and the second set of outer walls, the piercing element extending upwards in a direction substantially parallel to at least one wall within the first set of outer walls and the second set of outer walls, the piercing element being configured to pierce an insulated wire.

Description

CROSS-REFERENCE TO RELATED REGISTRATIONS

[0001] The present application claims priority over the preliminary US patent application No. 63 / 401,902 filed on August 29, 2022, the contents of which are incorporated in full into the present application by reference. AREA

[0002] The present disclosure relates generally to the field of electrical connectors and in particular to a type of connector used for forming electrical connections with bundles of wires. STATE OF THE ART

[0003] Various connectors are used to create electrical connections between a wire and any type of electronic or electrical component. These connectors can be sockets, plugs, or sheathed headers, available in a wide variety of sizes, pitches, and coating options. Forming connections with insulated wires is often challenging because it is difficult to pierce or cut the insulation of the wire bundle, or the connector structure is complex. Therefore, it would be advantageous to provide a fast, efficient, and reliable method for forming electrical connections with insulated wire bundles. SUMMARY

[0004] One aspect of the present disclosure relates to an electrical contact. The electrical contact includes a base section extending from a first end of the contact to a second end of the contact. The electrical contact also includes a first set of outer walls extending upward from the base section, the first set of outer walls being arranged on a first side. The contact also includes a second set of outer walls extending upward from the base section, the second set of outer walls being arranged on a second side opposite the first set of outer walls and the first side.The electrical contact further includes a piercing element arranged between the first set of outer walls and the second set of outer walls, the piercing element extending upwards in a direction substantially parallel to at least one wall within the first set of outer walls and the second set of outer walls, and the piercing element being configured to pierce an insulated wire.

[0005] In various embodiments, the electrical contact also includes a side wall arranged between the first group of outer walls and the second group of outer walls, with the piercing element formed within the side wall. In some embodiments, the side wall has a shape complementary to a shape of the insulated wire. In other embodiments, each of the first sets of outer walls and the second set of outer walls encloses two walls, with a first wall of each of the at least one first outer wall and the at least one second outer wall located at the first end and a second wall of each of the at least one first outer wall and the at least one second outer wall located at the second end. In other embodiments, the first set of outer walls, the second set of outer walls, and the at least one side wall form a passage.In various embodiments, the at least one piercing element is a blade. In some embodiments, each wall within the first set of outer walls and the second set of outer walls includes a projection located at an upper termination end. In some embodiments, the first set of outer walls and the second set of outer walls are each formed integrally with the base section.

[0006] Another aspect of the present disclosure relates to an electrical contact assembly. The electrical contact assembly includes an electrical contact. The electrical contact comprises a base section and a first set of outer walls extending upwards from the base section, the first set of outer walls being arranged on a first side.The electrical contact also includes a second set of outer walls extending upwards from the base section, the second set of outer walls being arranged on a second side opposite the first set of outer walls and the first side, and the first set of outer walls and the second set of outer walls forming a passage between them. The electrical contact also includes a piercing element arranged between the first set of outer walls and the second set of outer walls, the piercing element extending in a direction substantially parallel to at least one wall within the first set of outer walls and the second set of outer walls. The electrical contact further includes a plurality of solder lugs extending downwards from the base section.The electrical contact assembly further includes a printed circuit board (PCB), wherein the PCB is configured to receive the electrical contact, and wherein the plurality of solder lugs are structured to be received in corresponding interconnect terminals within the PCB.

[0007] In various embodiments, the plurality of solder lugs includes two pairs of solder lugs, with a first pair of the two pairs of solder lugs arranged at a first end of the electrical contact and a second pair of the two pairs of solder lugs arranged at a second end of the electrical contact. In some embodiments, the electrical contact further includes a support base extending from the base section, the support base being positioned between the first and second pairs of the two pairs of solder lugs. In other embodiments, the base section is structured to rest against the PCB. In further embodiments, the electrical contact further includes a side wall positioned between the first set of outer walls and the second set of outer walls, with the piercing element being formed within the side wall.In various embodiments, each of the first sets of outer walls and the second set of outer walls encloses two walls, wherein a first wall of each of the first sets of outer walls and the second set of outer walls is arranged at a first end of the electrical contact and a second wall of each of the first sets of outer walls and the second set of outer walls is arranged at a second end of the electrical contact.

[0008] Another aspect of the present disclosure relates to a method for forming an electrical connection with an insulated wire. The method includes forming a section of a sheet metal component having a shape corresponding to an electrical contact and soldering the electrical contact to a PCB. The electrical contact comprises a base section and a first set of outer walls extending upward from the base section, the first set of outer walls being arranged on a first side. The electrical contact also includes a second set of outer walls extending upward from the base section, the second set of outer walls being arranged on a second side opposite the first set of outer walls and the first side, with the first set of outer walls and the second set of outer walls forming a passage between them.The electrical contact also includes a piercing element arranged between the first set of outer walls and the second set of outer walls, the piercing element extending in a direction substantially parallel to at least one wall within the first set of outer walls and the second set of outer walls.

[0009] In various implementations, the method also includes cutting the section from the sheet metal. In some implementations, the electrical contact further includes a pair of solder lugs extending downwards from the base section. In other implementations, the method further includes inserting the pair of solder lugs into corresponding connection points on the PCB. In various implementations, the method also includes shaping the section of the sheet metal, which has a shape corresponding to the electrical contact, by bending the sheet metal. In further embodiments, the method also includes providing the insulated wire, aligning the insulated wire with the through-hole, and piercing the insulated wire with the at least one piercing element by pressing the insulated wire into the through-hole.

[0010] This summary is for illustrative purposes only and should not be considered limiting. BRIEF DESCRIPTION OF THE FIGURES

[0011] The revelation will be better understood from the following detailed description in conjunction with the accompanying figures, where identical reference numbers refer to identical elements. They show: Fig. 1 A perspective view of a piercing contact according to an exemplary embodiment. Fig. 2 A perspective view of a contact assembly that includes the piercing contact coupled to a printed circuit board (PCB) Fig. 1 includes, according to an exemplary embodiment. Fig. 3 a perspective view of a wire bundle in a non-locked position relative to the contact assembly of Fig. 2, according to an exemplary embodiment. Fig. 4 a side view of the wire bundle of Fig. 3 in the unengaged position relative to the contact assembly of Fig. 2, according to an exemplary embodiment. Fig. 5 an end view of the wire bundle of Fig. 3 in the unengaged position relative to the contact assembly of Fig. 2, according to an exemplary embodiment. Fig. 6 a perspective view of the wire bundle of Fig. 3 in an engagement position relative to the contact assembly of Fig. 2, according to an exemplary embodiment. Fig. 7 a side view of the wire bundle of Fig. 3 in the engagement position relative to the contact assembly of Fig. 2, according to an exemplary embodiment. Fig. 8 a cross-sectional view along line XX of Fig. 7, which the wire bundle of Fig. 3 in an engagement position relative to the contact assembly of Fig. Figure 2 illustrates an exemplary embodiment. DETAILED DESCRIPTION

[0012] Before considering the figures, which illustrate certain exemplary embodiments in detail, it should be understood that the present disclosure is not limited to the details or methods set forth in the description or illustrated in the figures. It should also be understood that the terminology used herein serves only for descriptive purposes and should not be considered limiting.

[0013] Conventional connectors for forming electrical connections with insulated wire bundles can be cumbersome or ineffective because it is difficult to penetrate or strip the insulation, or because the contact itself requires multiple components. For example, some connector types require secondary housings to position the insulated wire bundles so that a primary component makes the electrical connection with the wire bundle.

[0014] The present disclosure relates to a piercing contact structured to retain the wire bundle within the contact, thereby enabling a secure electrical connection between the contact and the wire bundle. By both facilitating the electrical connection with the wire and retaining the wire, the contact described herein reduces the number of components required to enable secure connections with an insulated wire bundle. Furthermore, the reduction in the number of components necessarily decreases the number of assembly steps required to enable an electrical connection with an insulated wire bundle.

[0015] With reference to Fig. Figure 1 now shows a cloud platform 100 according to an exemplary embodiment. The contact 100 can be structured to allow connection to a printed circuit board (PCB) or other component configured to enable electrical connection. As shown, the contact 100 includes a first set of outer walls 112 set on a first side 101 of the contact 100 and a second set of outer walls 113 set on a second side 102 of the contact 100. In various embodiments, the first set of outer walls 112 and the second set of outer walls 113 are arranged opposite each other, such that the first set of outer walls 112 and the second set of outer walls 113 are mirror images of each other. As shown in Figure 1, the contact 100 is arranged in a way that allows for the connection of the first set of outer walls 112 and the second set of outer walls 113 to be connected ... Fig. As shown in Figure 1, the first set of outer walls 112 can include a first wall 105 and a second wall 106, and the second set of outer walls 113 can include a third wall 110 and a fourth wall 111. As shown, the first set of outer walls 112 and the second set of outer walls 113 are structured such that the second wall 106 and the fourth wall 111 are located at or near a first end 103 of the contact 100, and the first wall 105 and the third wall 110 are located at or near a second end 104 of the contact 110. In various embodiments, each of the first and second sets of outer walls 112, 113 can include two walls, as shown in Figure 1. Fig. Figure 1 shows. In some embodiments, the first and second sets of outer walls 112, 113 can each include any number of walls (e.g., 1, 2, 3, 5, 8, etc.) that may be similar to or equivalent to walls 105, 106, 110, 111. In various embodiments, the first and second walls 105, 106 can be configured as a single wall extending between the first end 103 and the second end 104 of the contact 100. Additionally or alternatively, the third and fourth walls 110, 111 can be configured as a single wall extending between the first end 103 and the second end 104 of the contact.

[0016] The first set of outer walls 112 and the second set of outer walls 113 are arranged in an opposing or mirrored formation, forming a passage 107. The passage 107 can be bounded at both the first end 103 and the second end 104 by a side wall 117, which connects the first set of outer walls 112 and the second set of outer walls 113. The passage 107 can have a shape that is substantially complementary to the shape of a wire bundle. For example, as shown, the passage 107 can have a cylindrical shape to receive a cylindrical wire. In other embodiments, the passage 107 can have a rectangular or oblong shape to receive a rectangular or oblong wire. As shown in Fig. Figure 1 shows embodiments in which each of the first and second sets of outer walls 112, 113 encloses two walls, and in which the second wall 106 and the fourth wall 111 are arranged at the first end 103 and the first wall 105 and the third wall 110 are arranged at the second end 104, the second wall 106 and the fourth wall 111 are connected at the first end 103 by a first side wall 117, and the first wall 105 and the third wall 110 are connected at the second end 104 by a second side wall 117. The first and second side walls 117 can have a shape complementary to the shape of a wire bundle. For example, as shown, the first and second side walls 117 can have a curved shape, so that the passage 107 generally has a cylindrical shape.

[0017] Each side wall 117 encloses at least one piercing element 115 extending upward from the side wall 117 and structured to pierce a wire bundle placed on the contact 100. In various embodiments, the at least one piercing element 115 can extend upward from the side wall 117 in a direction that is substantially parallel to at least one wall of the first or second set of outer walls 112, 113. In various embodiments, the at least one piercing element 115 is a blade. In other embodiments, the at least one piercing element 115 is a needle. In other embodiments, the at least one piercing element 115 is structured to have a substantially rectangular cross-section within a first section and a pointed, substantially triangular second section forming a tip. As in Fig. As shown in Figure 1, the contact 100 can include two piercing elements 115, wherein a first piercing element 115 is arranged inside the side wall 117 at the first end 103 and a second piercing element 115 is arranged inside the side wall 117 at the second end 104.

[0018] As in Fig. As shown in Figure 1, one or more walls (i.e., one or more of the first wall 105, the second wall 106, the third wall 110, and the fourth wall 111) within the first and second sets of exterior walls 112, 113 can include one or more projections 120 located at or near an upper termination end of each wall. For example, as shown in Fig. As shown in Figure 1, each of the first wall 105, the second wall 106, the third wall 110, and the fourth wall 111 includes a rib 120 located near the upper termination end of each wall, such that the width of the passage 107 between the upper termination ends of each wall is smaller compared to the width of the passage 107 closer to a base of each wall. In various embodiments, the one or more projections 120 may be a rib, a knob, a bump, or another similar feature. In some embodiments, each of the first wall 105, the second wall 106, the third wall 110, and the fourth wall 111 may be structured such that the width of each wall increases near the upper termination end of each outer wall, so that each wall forms a projection 120.

[0019] As in Fig. As shown in Figure 1, the first and second walls 105, 106 and the third and fourth walls 110, 111 can be separated by a base section 125 of the contact 110. The base section 125 can be substantially horizontal, such that the first and second sets of outer walls 112, 113 extend substantially vertically upwards from the base section 125. In various embodiments, the base section 125 is formed integrally with each of the first and second sets of walls 112, 113 (i.e., with each of the first wall 105, the second wall 106, the third wall 110, and the fourth wall 111) at each of the first and second ends 103, 104 via connections 127. As shown in Fig. As shown in Figure 1, each of the first and second ends 103, 104 can also include a pair of solder lugs 130 extending downwards from the base section 125 in a substantially perpendicular direction. Each of the solder lugs 130 is configured to be inserted into a corresponding region (e.g., an opening, a terminal, etc.) within a PCB and soldered there. In various embodiments, each pair of solder lugs 130 extends in a direction that is substantially parallel to at least one wall within the first and second sets of outer walls 112, 113. In various embodiments, each pair of solder lugs 130 is separated by a support base 132, which is structured to support the at least one piercing element 115 against a shear force acting on the at least one piercing element 115 when piercing a wire bundle placed on the contact 100.In various embodiments, the contact 100 (and thus the at least one piercing element 115) is made of a material with a large bending radius to prevent cracking during contact 100 formation. Accordingly, the support base 132, located beneath the at least one piercing element 115, is structured to withstand torque and prevent outward deflection of the at least one piercing element 115. In embodiments where the contact 100 can be formed from a material with a smaller bending radius, or in applications where little or no bending moment occurs, the contact 100 can be formed without a support base 132. The support base 132 can be structured to abut a section of a PCB connected to the contact 100.In other embodiments, the support base 132 can be received in a recess or opening within a PCB connected to the contact 100. In other embodiments, the support base 132 is substantially rectangular and extends downwards from the base section 125 in a direction substantially parallel to the solder lugs and perpendicular to the base section 125. In some embodiments, the contact 100 can be shaped to include only the end 103, which has the second and fourth walls 106, 111 (or alternatively only the first and third walls 105, 110), a single side wall 117, a single piercing element 115 arranged within the side wall 115, a single pair of solder lugs 130, and a support base 132. The single-sided contact 100 can also include ribs 120 to hold a wire placed thereon.

[0020] Fig. Figure 2 shows a perspective view of contact 100 coupled to a PCB 140 to form a contact assembly 150, according to an exemplary embodiment. As shown, contact 100 can be arranged on the PCB 140 such that the base section 125 is based on a contact region within the PCB 140. The solder lugs 130 located at the ends 103, 104 of contact 100 are received by the connection terminals 135. As shown, the support base 132 can adjoin a region 137 located between the connection terminals 135.

[0021] To facilitate the electrical connection, the contact assembly 140 is configured to receive a wire 200, as shown in Fig. Figures 3-5 show that the wire 200 can enclose a wire bundle 210, which is insulated by an outer sheath 205 and an insulating layer 215. In various embodiments, the outer sheath 205 is an insulating layer. In other embodiments, the wire 200 can be structured to have a single insulating layer. For example, the wire may have only an outer sheath 205 or only an insulating layer 215. In other embodiments, the wire 200 can have any number of insulating layers (e.g., 3, 5, 7, etc.). In other embodiments, the number of insulating layers of the wire 200 can be based on an application or operating environment of the wire 200 (e.g., a harsh environment).To establish an electrical connection between the contact assembly 140 (and thus the contact 100), the wire 200 can be positioned above the contact 100 such that a lower surface of the outer housing 205 of the wire 200 is aligned with the passage 107, as shown in . Fig. 3 shown. As in Fig. 4 and Fig. As illustrated in Figure 5, the wire 200 can be moved downwards onto the contact 100 before engagement, so that the lower surface of the outer housing 205 is positioned above the at least one piercing element 115. In various embodiments, as shown in Figure 5, the wire 200 can be moved downwards onto the contact 100 before engagement, so that the lower surface of the outer housing 205 is positioned above the at least one piercing element 115. Fig. As shown in Figure 3, the wire 200 can be positioned over two piercing elements 115, so that the wire 200 can be pierced at two points.

[0022] To establish the electrical connection between the contact assembly 140 and the wire 200, the wire 200 can be pressed downwards into the passage 107, as shown in Fig. Figures 6-8 show that the wire 200 is pressed into the passage 107 so that the at least one piercing element 115 (which may include two piercing elements 115) pierces the housing 205, extends through the insulation 215, and engages with the wire bundle 210 to close an electrical connection between the contact 100 and the wire 200. The positioning of the wire 200 is maintained by the first and second sets of outer walls 112, 113. The electrical connection between the wire 200 and the contact 100 is maintained by the projections 120, which can form an interference fit with the wire 200 to prevent the wire from being pushed upwards away from the at least one piercing element 115. For example, the wire 200, as shown in Fig. As shown in Figures 6-8, the contact 100 is positioned such that the first and second walls 105, 106 are located on one side of the wire 200, and the third and fourth walls 110, 111 are located on the opposite side of the wire 200. Accordingly, the wire 200 is held against the contact 100 by the projections 120 of the first wall 105, the second wall 106, the third wall 110, and the fourth wall 111. In this way, the contact 100 can reduce the number of parts required to facilitate both the electrical connection and the retention of the wire 200. Furthermore, the first and second sets of outer walls 112, 113 provide stability to the wire 200 by minimizing the risk of the wire 200 twisting, slipping, or otherwise moving relative to the contact 110.

[0023] In various embodiments, the contact 100 can be manufactured as a single part. In various embodiments, the contact 100 can be manufactured in a manufacturing system comprising one or more components configured for receiving, processing, cutting (or punching), and rolling sheet metal. In some embodiments, the one or more components can include at least one controller. The controller can be configured to include a processor and a non-transitory, computer-readable medium (e.g., a storage device) containing computer-readable instructions that, when executed by the processor, cause the at least one controller to perform one or more operations. In various embodiments, the at least one controller is a computing device (e.g., a microcomputer, microcontroller, or microprocessor).In other embodiments, the at least one controller is configured as part of a data cloud computer system that receives commands from a user control device and / or a remotely controlled computing device. In some implementations, the sheet metal can be cut or punched (i.e., by the one or more components) to have a shape corresponding to contact 100. The cut or punched piece of sheet metal can then be bent, rolled, or otherwise shaped (by the one or more components) to have a structure corresponding to contact 100. For example, a (cut or punched) section of sheet metal can be bent such that the first and second sets of outer walls 112, 113 extend upward from the base section 125, and the solder lugs 130 extend downward from the base section 125.After the contact 100 has been formed, it can be placed on the PCB 140 such that the solder lugs 130 are received in the connection terminals 135 and the support base 132 is adjacent to a region 137 between the connection terminals 135. The solder lugs 130 can then be soldered to the PCB 140 to form the contact assembly 150.

[0024] After the contact assembly 150 has been formed, the wire 200 can be positioned above the contact 100 so that it is aligned with the passage 107 and located above the at least one piercing element 115. The wire 200 can then be pressed onto the at least one piercing element 115, so that the at least one piercing element pierces the housing 205 and the insulation 215 and extends into the wire bundle 210 to form an electrical connection with it. The resulting electrical connection between the contact 100 (and the contact assembly 140) is maintained by the projections 120, which prevent the wire 200 from separating from the at least one piercing element 115 and from moving out of the passage 107.In some embodiments, the lower surface of the housing 205 of the wire 200 abuts or is in contact with the at least one side wall 117 when the wire 200 engages with the contact 100 (i.e. when the at least one piercing element 115 has pierced the wire 200 in such a way that it touches the wire bundle 210).

[0025] Notwithstanding the above with reference to Fig. Various modifications and additions to the embodiments described in 1-8 are conceivable and are taken into account within the scope of this disclosure.

[0026] As used herein with respect to numerical ranges, the terms "about", "approximately", "essentially", and similar terms generally mean + / -10% of the disclosed values, unless otherwise specified. As used herein with respect to structural features (e.g., to describe shape, size, orientation, direction, relative position, etc.), the expressions "about", "approximately", "essentially", and similar terms are intended to cover minor variations in structure that may arise, for example, from the manufacturing or assembly process, and they are intended to have a broad meaning consistent with the usual and accepted usage of people skilled in the art to whom the subject matter of this disclosure belongs.Accordingly, these terms should be interpreted to mean that insignificant or inconsistent modifications or changes to the described and claimed subject matter are to be considered within the scope of disclosure according to the attached claims.

[0027] It should be noted that the term "exemplary" and its variations, as used herein to describe different embodiments, are intended to indicate that these embodiments are possible examples, representations or illustrations of possible embodiments (and that these expressions are not intended to imply that these embodiments are necessarily extraordinary or superlative examples).

[0028] The term "coupled" and its variations, as used herein, signifies the connection of two elements directly or indirectly. Such connections may be stationary (e.g., permanent or fixed) or movable (e.g., removable or detachable). Such a connection may be achieved by directly coupling the two elements, by coupling the two elements using a separate intermediate element and any additional interconnected intermediate elements, or by coupling the two elements using an intermediate element that is integrally formed as a single unitary body with one of the two elements. When "coupled" or variations thereof are modified by an additional term (e.g.,In the case of direct coupling, the general definition of "coupled" provided above is modified by the specific meaning of the additional term (e.g., "directly coupled" means the connection of two elements without a separate intervening element), resulting in a narrower definition than the general definition of "coupled" provided above. Such coupling can be mechanical, electrical, or fluidic.

[0029] The references to the positions of elements contained herein (e.g., "above", "below", "above") are used solely to describe the orientation of the various elements in the FIGURES. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be covered by the present disclosure.

[0030] The hardware and data processing components used to implement the various processes, operations, illustrative logics, logic blocks, modules, and circuits described in connection with the embodiments disclosed herein may be implemented or executed using a general-purpose single-chip or multi-chip processor, a digital signal processor (DSP), an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA) or other programmable logic component, discrete gate or transistor logic, discrete hardware components, or any combination thereof, designed to perform the functions described herein. A general-purpose processor may be a microprocessor or a conventional processor, a controller, a microcontroller, or a state machine.A processor can also be implemented as a combination of computing devices, such as a combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any other such configuration. In some embodiments, certain processes and procedures can be executed by switching logic specific to a particular function. The memory (e.g., storage, storage unit, storage device) can include one or more devices (e.g., RAM, ROM, flash memory, hard disk storage) for storing data and / or computer code to complete or facilitate the various processes, layers, and modules described in this disclosure.The memory can be or include volatile or non-volatile memory and can contain database components, object code components, script components, or any other type of information structure to support the various activities and information structures described herein. In one exemplary embodiment, the memory is communicatively connected to the processor via a processing circuit and includes computer code for executing (e.g., by the processing circuit or the processor) one or more of the processes described herein.

[0031] This disclosure relates to methods, systems, and program products on any machine-readable media for performing various operations. The embodiments of this disclosure can be implemented using existing computer processors, by a special computer processor incorporated into a corresponding system for this or another purpose, or by a hard-wired system. Embodiments within the scope of this disclosure include program products comprising machine-readable media on which machine-executable instructions or data structures are stored or will be stored. Such machine-readable media can be any available media accessible to a general-purpose or specialized computer, or any other machine with a processor.Such machine-readable media can include, for example, RAM, ROM, EPROM, EEPROM, or other optical disk storage devices, magnetic disk storage devices, or other magnetic storage devices, or any other medium that can be used to carry or store the desired program code in the form of machine-executable instructions or data structures, and which can be accessed by a general-purpose or specialized computer, or any other machine with a processor. Combinations of these are also included in the scope of machine-readable media. Machine-executable instructions include, for example, instructions and data that cause a general-purpose computer, a specialized computer, or a specialized processing machine to perform a particular function or group of functions.

[0032] Although the figures and description may illustrate a particular sequence of process steps, the order of these steps may differ from the sequence shown and described, unless otherwise stated above. Furthermore, two or more steps may be performed simultaneously or partially simultaneously, unless otherwise stated above.

[0033] It is important to note that each element disclosed in one embodiment can be combined or used with any other embodiment disclosed herein. Although only one example of an element of one embodiment that can be integrated or used in another embodiment has been described above, it should be considered that other elements of the various embodiments can be integrated or used with any of the other embodiments disclosed herein. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] US 63 / 401,902

[0001]

Claims

[1] Electrical contact comprising: a base portion extending from a first end of the contact to a second end of the contact; a first set of outer walls extending upwardly from the base portion, the first set of outer walls being disposed on a first side; a second set of outer walls extending upwardly from the base portion, the second set of outer walls being disposed on a second side opposite the first set of outer walls and the first side; and a piercing element disposed between the first set of outer walls and the second set of outer walls, the piercing element extending upwardly in a direction substantially parallel to at least one wall within the first set of outer walls and the second set of outer walls, the piercing element configured to pierce an insulated wire. [2] The electrical contact of claim 1, further comprising a sidewall disposed between the first set of outer walls and the second set of outer walls, wherein the piercing element is formed within the sidewall. [3] The electrical contact of claim 2, wherein the sidewall has a shape complementary to a shape of the insulated wire. [4] The electrical contact of claim 2, wherein each of the first set of outer walls and the second set of outer walls includes two walls, a first wall of each of the at least one first outer wall and the at least one second outer wall being disposed at the first end and a second wall of each of the at least one first outer wall and the at least one second outer wall being disposed at the second end. [5] The electrical contact of claim 4, wherein the first set of outer walls, the second set of outer walls, and the at least one side wall form a passageway. [6] The electrical contact of claim 1, wherein the at least one piercing element is a blade. [7] The electrical contact of claim 1, wherein each wall within the first set of outer walls and the second set of outer walls includes a projection disposed at an upper terminal end. [8] The electrical contact of claim 1, wherein each of the first set of outer walls and the second set of outer walls is integrally formed with the base portion. [9] Electrical contact assembly comprising: an electrical contact comprising: a base section; a first set of outer walls extending upwardly from the base portion, the first set of outer walls being disposed on a first side; a second set of outer walls extending upwardly from the base portion, the second set of outer walls being disposed on a second side opposite the first set of outer walls and the first side; wherein the first set of exterior walls and the second set of exterior walls form a passage between them; a piercing element disposed between the first set of exterior walls and the second set of exterior walls, the piercing element extending in a direction substantially parallel to at least one wall within the first set of exterior walls and the second set of exterior walls; and a plurality of solder lugs extending downwardly from the base portion; and a printed circuit board (PCB), the PCB being configured to receive the electrical contact; wherein the plurality of solder tails are structured to be received in corresponding connection terminals within the PCB. [10] The electrical contact assembly of claim 9, wherein the plurality of solder tails comprises two pairs of solder tails, and wherein a first pair of the two pairs of solder tails is disposed at a first end of the electrical contact and a second pair of the two pairs of solder tails is disposed at a second end of the electrical contact. [11] The electrical contact assembly of claim 10, wherein the electrical contact further comprises a support base extending from the base portion, the support base being disposed between each of the first pair and the second pair of the two pairs of solder tails. [12] The electrical contact assembly of claim 11, wherein the base portion is structured to engage the PCB. [13] The electrical contact assembly of claim 9, wherein the electrical contact further comprises a sidewall disposed between the first set of outer walls and the second set of outer walls, the piercing element formed within the sidewall. [14] The electrical contact assembly of claim 9, wherein the first set of outer walls and the second set of outer walls each include two walls, a first wall of the first set of outer walls and the second set of outer walls each being disposed at a first end of the electrical contact and a second wall of the first set of outer walls and the second set of outer walls each being disposed at a second end of the electrical contact. [15] A method of forming an electrical connection with an insulated wire, the method comprising: Shaping a portion of a sheet to have a shape corresponding to an electrical contact; and Soldering the electrical contact on a PCB; wherein the electrical contact comprises: a base section; a first set of outer walls extending upwardly from the base portion, the first set of outer walls being disposed on a first side; a second set of outer walls extending upwardly from the base portion, the second set of outer walls being disposed on a second side opposite the first set of outer walls and the first side; wherein the first set of exterior walls and the second set of exterior walls form a passage between them; and a piercing element set between the first set of outer walls and the second set of outer walls, the piercing element extending in a direction substantially parallel to at least one wall within the first set of outer walls and the second set of outer walls. [16] The method of claim 15, further comprising cutting the section of sheet metal. [17] The method of claim 15, wherein the electrical contact further comprises a pair of solder tails extending downwardly from the base portion. [18] The method of claim 17, further comprising inserting the pair of solder tabs into corresponding connection terminals on the PCB. [19] The method of claim 15, wherein forming the portion of sheet metal having a shape corresponding to the electrical contact comprises bending the sheet metal. [20] The method of claim 15, further comprising: Providing the insulated wire; Aligning the insulated wire with the passage; and Piercing the insulated wire with the at least one piercing element by pressing the insulated wire into the passage.

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