Electrical contact terminal

An electrical terminal stamped and formed from a single thickness of metal stock, comprising:

• a hollow body portion having opposed first and second major side sections and opposed first and second minor side sections;
• at least one contact member extending forwardly from each of said first and second major side sections;
• first and second transition portions extending rearwardly from respective said first and second major side sections;
• and
• a barrel portion including first and second barrel sections extending rearwardly from respective ones of said first and second transition portions, each of said first and second barrel sections having a seam extending axially therealong, said first barrel section being nested within said second barrel section such that said seam of said first barrel section is essentially diametrically opposite the seam of said second barrel section, said barrel portion thereby having two thickness of metal;
• whereby
• upon crimping said barrel portion to a wire member, said barrel portion acts as if it were a continuous annular body and said first and second transition portions provide for improved transmission of current from said wire and through said terminal without excessive heating.

A method for making an electrical terminal from a single thickness of metal stock comprising the steps of:

• selecting a metal stock having the desired properties;
• stamping a terminal blank from said stock, said blank having a forward portion adapted to be formed into at least one contact section, a first intermediate section extending from said forward section and adapted to be formed into a hollow body portion, a second intermediate portion adapted to be formed into first and second transition portions extending rearwardly of said first intermediate section, and first and second rearward portions adapted to be formed into first and second barrel sections extending rearwardly from respective said first and second transition portions;
• forming said first rearward portion into said first barrel section;
• partially forming said second rearward portion into a U-shaped member;
• forming said first intermediate portion into said hollow body portion of said terminal such that said formed first barrel section is nested within the U-shaped member;
• and
• forming said U-shaped member into an outer barrel section such that a seam of said first barrel is essentially diametrically opposed from a seam of said second barrel section and a continuous portion of said second barrel section overlies said seam of said first barrel section.