4,968,263
`[11] Patent Number:
`[19]
`Umted States Patent
`
`Silbernagel et al.
`[45] Date of Patent:
`Nov. 6, 1990
`
`684703 12/1952 United Kingdom ................ 439/252
`OTHER PUBLICATIONS
`IBM Technical Disclosure Bulletin, “Controlled Direc-
`tion Buckling Beam”, vol. 17, No. 5, Oct. 1974.
`Pri
`Ex
`‘ e —G
`F. Paum
`Att’:rlrz1)ey)z, A;e’::,no: Fin:l:Louis A.eIn{echt; Stephen 2.
`Weiss; Charles S. Cohen
`
`ABSTRACT
`[57]
`A muhi-Phi electrical e°n_neet_°r is adapted for Surface
`§n°;“:mS ‘[3111as Pflntfid Circuit board.
`'fhedicionnfect_or
`mc 11 es a e
`er or ousmg av_mg a p ur‘
`y o pm-
`r°°={Vm8 fhmush h°1eS- A Pluflhty 0‘ ‘°1’m_'m1 Pm? are
`geiceizgeidfm 1:1; holes offthe hCa.dCl','tV:lth port1(t)l111s
`8.
`01' S
`ace 11101111 mg 011 Clfclll
`l'2.C€S On
`6
`prinpted circuit board. The terminal pins have spaced
`enlargements located on opposite sides of the header to
`:31“ :11::p1.nss";t‘1j1i:t1;‘;1::‘Egjtzflffiffiffgtfhfiiigfg
`the hgeaderlzlxalout the holesgwhereb the ins can float in
`V
`P.
`.
`the holes to accommodate any non-uniform spacing
`between the header and the Printed elremt b°3_fd and
`ensure contact of the terminal pm portions with the
`circuit traces on the printed circuit board.
`
`[751
`
`[54] MULTI-PIN ELECTRICAL CONNECTOR
`FLOATING TE
`AL PINS
`““'°“‘°’5‘ R'Y"'°'“‘ 5- 5“"°"“'8°‘~ N?P°“’i“'=9
`gffi“ 5- Fm 5'» D“ ”‘““‘°5v "°‘h
`.
`‘
`.
`[731 A“‘8“°°’ M°‘°‘ "‘°°"P°"“°“v L151‘? 111-
`[21] App}, No; 500,359
`
`Mau'.28,1990
`[22] Filed:
`[51]
`Int. c1.s ........................................... HOIR 13/629
`[52] US. Cl. ...................................... 439/246; 439/83; '
`439/741
`[58] Field of Search ........................ 439/246, 247-252,
`439/74, 34’ 741, 83, 692
`Refefeflm Cmd
`U_s. PATENT DOCUMENTS
`2,864,068 12/1953 Roth .................................... 439/252
`2’878’587 3/1959 Jubcnvmc
`439/84
`3,017,597
`1/1962 Nava et al. ..
`439/243
`3,132,912 5/1964 Friedman
`439/252
`3,904,934 9/1975 Martin .....
`..... 439/74
`4,854,882
`8/1989 Corridon ............................ 439/246
`FOREIGN PATENT DOCUMENTS
`
`
`
`[55]
`
`3005634
`
`8/1981 Fed. Rep. of Germany ........ 439/74
`
`19 Claims, 2 Drawing Sheets
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`2 2
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`2
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`NU MARK Ex.1029 p.1
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`U.S. Patent
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`Nov. 6, 1990
`
`Sheet 1 of2
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`4,968,263
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`I2
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`F|G.3
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`NU MARK Ex.1029 p.2
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`U.S. Patent
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`Nov. 6, 1990
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`Sheet 2 of 2
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`4,968,263
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`20
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`%IIIII'IIIA
`28
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`22 IL
`//111111
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`NU MARK Ex.1029 p.3
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`

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`1
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`4,968,263
`
`MULTI-PIN ELECTRICAL CONNECTOR WITH
`FLOATING TERMINAL PINS
`
`FIELD OF THE INVENTION
`
`This invention generally relates to electrical connec-
`tors and, particularly, to a multi-pin electrical connec-
`tor adapted for mounting on a printed circuit board,
`with floating terminal pins to accommodate any non-
`uniform spacing between the connector and the printed
`circuit board.
`
`BACKGROUND OF THE INVENTION
`
`Multi-pin electrical connectors are widely used for
`connecting circuit traces on printed circuit boards with
`other printed circuit boards or with a complementary
`connector. For instance, the multi-pin connector may
`be a male plug having terminal pins mounted to or on
`the printed circuit board for conductively engaging
`circuit traces on the board, the pins of the male plug, in
`turn, being mateable with terminal contacts in a comple-
`mentary female receptacle connectable with the male
`plug.
`In some such arrangements, the terminal pins of the
`multi-pin connector have solder tails which are inserted
`through holes in the printed circuit board and soldered
`to surrounding circuit traces on the board for establish-
`ing electrical conductivity therewith. In other such
`arrangements, commonly termed surface mount tech-
`nology, the solder pins are soldered to the circuit traces
`on the printed circuit board by surface engagement
`rather than extending through holes in the board.
`One of the problems with multi-pin connectors of the
`character described, particularly those in which the
`solder tails of the pins are surface mounted to the board,
`is encountered when there is non-uniform spacing be-
`tween the connector header or housing and the printed
`circuit board. In other words, the terminal pins are
`fabricated uniformly or identical to each other, with
`identical dimensions, including the length of the solder
`tails which project from the connector header or hous-
`ing. Should the printed circuit board be warped, bent or
`have other irregularities resulting in non-uniform spac-
`ing between the connector header and the surface of the
`printed circuit board, some of the solder tails of the
`terminal pins end up being spaced from the circuit
`traces on the board, resulting in inferior solder connec-
`tions or no connections at all. This is equally true if the
`circuit board, itself, is precisely planar, but the header
`or housing of the connector is not flat and has a bend
`therein or other irregular surface problems, again result-
`ing in non-uniform spacing between the header and the
`board.
`This invention is directed to solving these problems
`by providing a multi-pin electrical connector wherein
`the terminal pins are mounted on the header or housing
`of the connector in a manner to float (i.e., have limited
`movement in relation to the header or housing) to ac-
`commodate any non-uniform spacing between the
`header or housing and the printed circuit board.
`SUMMARY OF THE INVENTION
`
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`An object, therefore, of the invention is to provide a
`new and improved multi-pin electrical connector
`adapted for surface mounting on a printed circuit board.
`In the exemplary embodiment of the invention, the
`connector includes a header or housing having a plural-
`ity of pin-receiving through holes. A plurality of termi-
`
`65
`
`2
`nal pins are received in the holes of the header. The
`terminal pins have spaced enlargement means located
`thereon on opposite sides of the header to retain the pins
`in the holes. The enlargement means being are along the
`pins a distance greater than the thickness of the header
`about the holes, whereby the pins can float in the holes
`to accommodate any non-uniform spacing between the
`header and the printed circuit board.
`In the preferred embodiment of the invention, the
`holes in the header have cross-sectional dimensions
`greater than the dimensions of the pins within the holes -
`thereby allowing the pins to float by moving trans-
`versely, longitudinally and angularly pivoting in rela-
`tion to the holes.
`Other objects, features and advantages of the inven-
`tion will be apparent from the following detailed de-
`scription taken in connection with the accompanying
`drawings.
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`The features of this invention which are believed to
`be novel are set forth with particularity in the appended
`claims. The invention, together with its objects and the
`following description taken in conjunction with the
`accompanying drawings,
`in which like reference nu-
`merals identify like elements in the figures and in which:
`FIG. 1 is a fragmented elevational view of a multi-pin
`electrical connector having a header and a plurality of
`floating pins according to the invention, and illustrating
`the connector in conjunction with a printed circuit
`board which has a bow therein;
`FIG. 2 is a vertical section through the header to
`illustrate one of the pin-receiving holes therein, with a
`terminal pin mounted in the hole;
`FIG. 3 is a perspective view of one of the terminal
`pins according to the invention;
`FIG. 4 is a fragmented horizontal section through
`another embodiment of a connector employing a con-
`-nector housing with floating terminal pins according to
`the concepts of the invention;
`FIG. 5 is a vertical section taken generally along line
`5-5 of FIG. 6; and
`FIG. 6 is an elevational View of the embodiment of
`FIGS. 4 and 5, in conjunction with a printed circuit
`board with an uneven upper surface.
`DETAILED DESCRIPTION OF THE
`PREFERRED EMBODIMENT
`
`Referring to the drawings in greater detail, generally,
`FIGS. 1-3 show an electrical connector having termi-
`nal pins mounted in a header, and FIGS. 4-6 show an
`electrical connector having the terminal pins mounted
`in a housing, both embodiments being shown for estab-
`lishing an electrical connection between the terminal
`pins and a printed circuit board.
`to FIGS. 1-3, a
`More particularly, referring first
`multi-pin electrical connector, generally designated 10,
`is adapted for surface mounting on a printed circuit
`board 12 (FIG. 1). The connector includes a header 14
`having a plurality of pin-receiving through holes 16
`(FIG. 3).
`A plurality of terminal pins, generally designated 18,
`are received in holes 16 of header 14 as best illustrated
`in FIG. 3. Each pin terminal 18 has a terminal portion
`20 projecting upwardly (as viewed in the drawings)
`from header 14 and a solder tail portion 22 extending at
`a right-angle to terminal portion 20 and disposed below
`
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`NU MARK Ex.1029 p.4
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`

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`3
`header 14. Solder tail portion 22 has a bottom surface 24
`for surface engagement with and soldering to a printed
`circuit trace 26 on board 12.
`Up to this point, it might be said that the construction
`of terminal pins 18 and their mounting in holes 16 of
`header 14 generally are conventional. However, hereto-
`fore such terminal pins predominantly have been press-
`fit into the holes in the header. This construction or
`assembly of the connector presents a number of prob-
`lems, including the creation of stresses in the insulating
`material of which header 14 is fabricated. Such headers
`normally are molded and have built-in stresses due to
`the molding operation. Press-fitting terminal pins into
`the header compounds the stress problem. In addition,
`close tolerances had to be maintained between the di-
`mensions of the pins and the dimensions of the holes in
`the header. Significantly, the tight press-fit mounting of
`the pins left no accommodation for irregularities in
`either the printed circuit board or the header which
`might cause non-uniform spacing between the header
`and the printed circuit board, which would result in the
`solder tail portions of some of the terminal pins being
`spaced from the circuit traces on the printed circuit
`board. Such spacing results in inferior solder connec-
`tions or no connections at all.
`FIG. 1 illustrates a common defect wherein it can be
`seen that printed circuit board 12 is bowed downwardly
`to create non-uniform spacing between the board and
`header 14. Conversely, the printed circuit board may be
`flat or planar and the header be bowed for one reason or
`another. Surface irregularities can cause non-uniform
`spacing between the header and the board. Heretofore,
`in order to combat such spacing problems, in order to
`ensure pin contact with the circuit traces on the printed
`circuit board, the pins were made to extremely close
`tolerances or were made of a thin material so that the
`pins could bend, either situation being undesirable.
`The invention contemplates solving these problems
`by mounting terminal pins 18 in header 14 so that the
`pins can float in the holes to accommodate any non~
`uniform spacing between the header and the printed
`circuit board. More particularly, spaced enlargements
`28 are located on terminal portion 20 of each terminal
`pin 18 to be located on opposite sides of header 14 to
`retain the pins in the holes but allow for floating action
`of the pins in the holes relative to the header, axially of
`the holes. This is accomplished, as seen in FIGS. 1 and
`3, by spacing enlargements 28 a distance greater than
`the thickness of header 14, at least in the area of the
`header about the holes.
`With a bowed or warped printed circuit board as
`shown in FIG. 1, it can be seen that the end-most termi-
`nal pins 18 are moved upwardly in their respective
`holes 16 (FIG. 3) with its lower enlargement in engage-
`ment with the bottom header 14. The center terminal
`pin is moved downwardly under gravity, whereby its
`upper enlargement 28 substantially rests on top of
`header 14 while the bottom surface 24 of solder tail
`portion 22 of that pin establishes surface contact with its
`respective circuit trace 26 located at the most extreme
`lower extent of the bow in the printed circuit board.
`The intermediate terminal pins, i.e., between the end-
`most pins and the center pin, float in their holes in the
`header as their bottom surfaces 24 establish surface
`engagement with their respective circuit traces 26 for
`subsequent soldering. The differential between the spac-
`ing between the enlargements on the terminal pins and
`the thickness of the header can be determined through
`
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`4,968,263
`
`4
`manufacturing experience where bowing, warping or
`other irregularities are encountered during a mass pro-
`duction environment.
`In manufacture, enlargements 28 can be provided in a
`variety of processes, one of which would be to coin or
`punch the enlargements of the pin blank whereby the
`enlargements are integral with the pin, as shown partic-
`ularly in FIG. 2. In other words, there may be indenta-
`tions 30 (FIG. 2) in opposite sides of the pin to cause
`material to bulge outwardly on the other two sides to
`form enlargements 28.
`In assembly, only one of the enlargements, such as the
`bottom enlargement of each pin in FIGS. 1-3, would be
`punched or stamped into the pin blank. A plurality of
`such pre-punched pins then can be assembled to header
`14, in a jig for instance, by inserting terminal portions 20
`of the pins upwardly through holes 16 in the header.
`Once so assembled, the upper enlargement 28 can be
`stamped out of the blank while in the jig at a predeter-
`mined distance from the lower enlargements. The
`spaced enlargements thereby retain the pins in the holes
`of the header yet provide a floating action to accommo-
`date any non-uniform spacing between the header and
`the printed circuit board to which the terminal pins are
`to be soldered.
`FIG. 3 shows hole 16 having a cross-sectional dimen-
`sion greater than the cross-dimensions of the pin within
`the hole. This is somewhat exaggerated in the figure to
`exemplify the fact that no stresses whatsoever are cre-
`ated by forcing pins through the insulating material of
`the header. On the other hand, the holes may be inten-
`tionally enlarged to provide floating action by allowing
`the pins to move transversely, longitudinally, and angu-
`larly pivoting in relation to the holes, as described
`below in relation to FIGS. 4-6.
`More particularly, FIGS. 4-6 show terminal pins 18
`mounted in holes 16a in the base 32 of a multi-pin con-
`nector housing, generally designated 34. Like numerals
`are applied to the portions of pins 18 corresponding to
`like portions described above in relation to FIGS. 1-3.
`In the embodiment of FIGS. 4-6, connector housing
`34 has sockets 36 and into which the terminal portions
`20 of terminal pins 18 extend. Because the housing sur-
`rounding sockets 36 prevents access to the terminal
`portions of the pins for stamping purposes, the right-
`hand (as viewed in FIGS. 4 and 5) enlargements 28 of
`the terminal pins are pre-forrned before the pins are
`inserted through holes 16a in base 32 of housing 34. To
`this end, the angled solder tail portion 22 of each pin
`originally may be collinear with terminal portion 20,
`prior to assembly in the housing, and then the solder tail
`portion can be bent while in the jig just as the left-hand
`enlargement is formed after insertion of the pin through
`the respective hole in the housing.
`In the embodiment of FIGS. 4-6, it can be seen that
`the electrical connector is adapted for surface mounting
`and soldering of tips or distal ends 40 of the solder tails
`to circuit traces 26 on printed circuit board 12 (FIG. 6).
`Therefore, within the concepts of the invention,
`the
`terminal pins are provided with a floating action, gener-
`ally in the direction of double-headed arrow A, by
`means of enlarging holes 16a in the housing in order
`that the terminal pins can sort of “teeter” or float within
`the holes to accommodate any non-uniform spacing
`between the housing and the printed circuit board.
`Still further, the terminal pins in the embodiment of
`FIGS. 4-6 should be designed so that there is a greater
`pin mass outside the housing than inside the housing,
`
`
`NU MARK Ex.1029 p.5
`
`

`
`4,968,263
`
`5
`i.e., on one side of the hole (the left side in FIGS. 4 and
`5) versus the other side, whereby the greater mass can
`be utilized to ensure contact of the pin tips 40, by grav-
`ity, with the printed circuit traces on board 12. This can
`be accomplished simply by making the bent solder tail
`portion 22 longer than terminal portion 20. Sockets 36
`form receptacles for receiving complementary connec-
`tors having terminal contacts for establishing electrical
`connection with terminal portions 20 of terminal pins
`18.
`It will be understood that the invention may be em-
`bodied in other specific forms without departing from
`the spirit or central characteristics thereof. The present
`examples and embodiments, therefore, are to be consid-
`ered in all respects as illustrative and not restrictive, and
`the invention is not to be limited to the details given
`herein.
`We claim:
`
`1. A multi-pin electrical connector adapted for sur-
`face mounting on a printed circuit board, comprising:
`a header having a plurality of pin-receiving through
`holes;
`a plurality of male terminal pins of substanially con-
`stant cross section along the length thereof, the
`terminal pins being received in the holes of the
`header, with portions projecting therefrom for
`surface engagement with circuit
`traces on the
`printed circuit board; and
`spaced enlargement means on the terminal pins lo-
`cated on opposite sides of the header to retain the
`pins in the holes,
`the enlargement means being
`spaced along the pins a distance greater than the
`thickness of the header about the holes whereby
`the pins can float in the holes to accommodate any
`non-uniforrn spacing between the header and the
`printed circuit board and ensure contact between
`said portions of the terminal pins with the circuit
`traces.
`
`2. The multi-pin electrical connector of claim 1
`wherein said enlargement means are formed integral
`with the terminal pins.
`3. The multi-pin electrical connector of claim 2
`wherein said enlargement means are coined portions of
`the terminal pins.
`4. The multi-pin electrical connector of claim 1
`wherein said holes in the header have cross-sectional
`dimensions greater than the dimensions of the pins
`within the holes to provide for floating of the pins in a
`direction transverselyof the holes.
`5. The multi-pin electrical connector of claim 1
`wherein said holes in the header have cross-sectional
`dimensions greater than the dimensions of the pins
`within the holes to provide for floating of the pins in a
`direction longitudinally of the holes.
`6. A multi-pin electrical connector of claim 1 wherein
`said holes in the header have cross-sectional dimensions
`greater than the dimensions of the pins within the holes
`to provide for floating of the pins in an angular pivoting
`direction in the holes.
`7. The multi-pin electrical connector of claim 1
`wherein said terminal pins have greater masses on one
`side of said holes than the other side of the holes
`whereby the greater masses can be utilized to insure
`contact of the pins, by gravity, with the printed circuit
`board when the header is appropriately oriented.
`8. A multi-pin electrical connector adapted for sur-
`face mounting on a printed circuit board, comprising;
`
`6
`a header having a plurality of pin-receiving through
`holes;
`a plurality of male terminal pins of substantially con-
`stant cross section along the length thereof, the
`terminal pins being received in the holes of the
`header, with portions projecting therefrom for
`surface engagement with circuit
`traces on the
`printed circuit board, the terminal pins having inte-
`gral enlarged portions located on opposite sides of
`the header to retain the pins in the holes, the en-
`larged portions being spaced a distance greater
`than the thickness of the header about the holes
`whereby the pins can float axially in the holes; and
`said holes in the header having cross-sectional dimen-
`sions greater than the dimensions of the pins within
`the holes to provide for floating of the pins.
`9. The multi-pin electrical connector of claim 8
`wherein said floating of said pins is in a direction trans-
`versely of the holes.
`10. The multi-pin electrical connector of claim 8
`wherein said floating of said pins is in a direction longi-
`tudinally of the holes.
`11. The multi-pin electrical connector of claim 8
`wherein said floating of said pins allows for the angular
`pivoting of the pins within the holes.
`12. The multi-pin electrical connector of claim 8
`wherein said enlargement means are coined portions of
`the terminal pins.
`13. The multi-pin electrical connector of claim 8
`wherein said terminal pins have greater masses on one
`side of said holes than the other side of the holes
`whereby the greater masses can be utilized to insure
`contact of the pins, by gravity, with the printed circuit
`board when the header is appropriately oriented.
`14. A multi-pin electrical connector adapted for sur-
`face mounting on a printed circuit board, comprising:
`a housing having a plurality of horizontal pin-receiv-
`ing through holes;
`a plurality of male terminal pins of substantially con-
`stant cross section along the length thereof,
`the
`terminal pins being received in the holes in the
`header;
`the holes in the header having cross-sectional dimen-
`sions greater than the dimensions of the pins within
`the holes to provide for floating of the pins in the
`holes in a vertical direction; and
`wherein said terminal pins have enlarged portions
`located on opposite sides of the housing to retain
`the pins in the holes.
`15. The multi-pin electrical connector of claim 14
`wherein said terminal pins have greater masses on one
`side of said holes than the other side of the holes
`whereby the greater masses can be utilized to insure
`Contact of the pins, by gravity, with the printed circuit
`board when the housing is appropriately oriented.
`16. The multi-pin electrical connector of claim 14
`wherein said enlarged portions on the pins are spaced a
`greater distance than the thickness of the housing about
`the holes.
`17. The multi-pin electrical connector of claim 14
`wherein each said terminal pin includes a terminal por-
`tion projecting into the housing and a solder tail portion
`projecting outside the housing, the solder tail portion
`being bent at an angle to the terminal portion for surface
`mounting of a distal end of the solder tail portion to a
`circuit trace on the printed circuit board.
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`NU MARK Ex.1029 p.6
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`

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`8
`hole to retain the pin in the hole, and a solder tail
`portion below the header and bent at an angle to
`the terminal portion for surface engagement with a
`circuit trace on the printed circuit board, the en-
`larged portions on the pin being spaced a distance
`greater than the thickness of the header about the
`hole whereby the pin can float vertically in the
`hole to accommodate any non-uniform spacing
`between the header and the printed circuit board
`and ensure engagement of the solder tail portion
`with the circuit trace on the printed circuit board.
`II
`It
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`4,968,263
`
`7
`18. The multi-pin electrical connector of claim 17
`wherein solder tail portion has a greater mass than the
`terminal portion.
`19. A multi-pin electrical connector adapted for sur-
`face mounting on a printed circuit board, comprising:
`a header having a plurality of generally vertical pin-
`receiving through holes;
`a plurality of terminal pins received in the holes of the
`header, each terminal pin having a vertical terminal
`portion projecting upwardly of the header, a pair
`of spaced enlarged portions along the terminal
`portion on opposite sides of the header and of
`greater dimensions than the cross-dimensions of the
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`NU MARK Ex.1029 p.7