Method and apparatus for flat conductor cable termination

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, said engagement means comprising:
• a remote engagement portion of said penetrating means;
• abutment means for providing a reaction surface against which said conductor portion of said flexible flat conductor means is supported when said engagement 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;
• and
• said abutment means comprising a pair of spring arms carried by said contact apparatus, each of said spring arms comprising a reaction surface operable to support said flexible flat conductor means against a penetrating force of said remote engagement portion of said penetrating means.

A method of terminating a 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 in a position in general alignment with the prongs and the adjacent flat conductor means portion, said die including a nose section initially positioned in alignment with the space between the prongs;
• 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 surface means of the die bending surface, generally away from one another and into orientation with a direction of extent generally opposite said direction of extent,
• engagement of the bent prongs with a conductor of the flat conductor means sandwiched between the prongs and the cooperable abutment surfaces of the contact that include reaction surfaces supporting the conductor, and
• crimping against the prongs of a flat conductor portion located between the penetrating prongs, the engagement of the bent prongs with the conductor of the flat conductor means crimped between the prongs and the cooperable abutment surfaces of the contact being enforced against spring biasing force provided by the abutment surfaces.

A method of terminating a 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 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 surface means of the die bending surface, generally away from one another and into orientation with a direction of extent generally opposite said direction of extent, and
• engagement of the bent prongs with a conductor of the flat conductor means sandwiched between the prongs and the cooperable abutment surfaces of the contact that include reaction surfaces supporting the conductor;
• the engagement of the bent prongs with the conductor of the flat conductor means crimped between the prongs and the cooperable abutment surfaces of the contacts being enforced against spring biasing force provided by the abutment surfaces.