Abstract: An improved electrical connector assembly (10) is disclosed. The assembly is especially adapted for engagement with a printed circuit board (76) having electrical circuits formed on both sides thereof. The assembly includes a body (12) of molded dielectric material having four spaced rows of passages (24) extending therethrough from a front face (26) to a rear face (28) of the body. The assembly also includes brush wire electrical contacts (14) each received in its respective passage. Each of the contacts has a cylindrical body portion (62) and an elongated tail (64) attached to one end of its body portion. The ends (72) of the termination portions extend beyond the rear face and form two spaced straight line rows adapted to receive the printed circuit board therebetween. The ends (63) of the body portions opposite their respective termination portions comprise four spaced apart, straight line rows of body portion ends.

Abstract: An apparatus (10) is provided which both untwists and shears a forward end of twisted conductive strands of a multi-stranded wire (40). A pair of strand receiving members (20, 30) having acutely angled front surfaces (24, 34) are slidably disposed and in spaced relationship by a support (12). To untwist the strands the twisted strands are inserted into and passed through a wire passage (26) and into guide bores (27) of the first strand receiving member (20). To shear the strands, the strands are then passed from the first strand receiving member (20) and into guide bores (37) of the second strand receiving member (30). Strand receiver (30) is then displaced with respect to strand receiver (20) with the strands extending between the front surfaces being sheared apart and provided with an acutely angled end defining an elliptical surface. The strand shearing is preferably across the minor axis of the ellipse.

Abstract: A dielectric insert 10 for securing a plurality of electrical connector retention clips 29. The insert 10 includes passages 15 having therein retention clip shoulder housings 17 and an abutment 21 which define a cavity 23 within which a retention clip 29 can be removably mounted. The insert 10 is an integral body molded of a dielectric material. A means for molding the insert 10 through the use of a core pin 53 and a bushing 61 is also disclosed. This insert 10 and the means for molding it are adapted to either the pin contact 33 or the socket contact 43 used in electrical connectors 77 and 77'.

Abstract: A method of making a hermaphroditic electric contact including steps of forming a tubular body with fingers having offset blade portions extending longitudinally from one end portion of the body, bending the blade portions to face radially inwardly of the body, cutting openings in the body to form medial wall portions, forcing the opposite ends of the tube together and allowing the wall portions to bend outwardly and form U-shaped locking shoulders, the locking shoulders being axially compressible during twisting fitment of the contact into a retention shoulder formed in a connector passage.

Abstract: An electrical contact includes means for piercing the insulation of an insulated conductor wire, the piercing means including inner and outer coaxially interfitted sleeves slidably disposed for movement between first and second axial positions which define an electrically unconnected and an electrically terminated position with respect to the wire. One embodiment includes the outer sleeve having diametrically disposed openings, the inner sleeve having a pair of axial slots disposed in register with the openings, a deflectable arm extending radially outwardly from an axial end of each slot and through a respective opening with each arm including a pointed end for piercing the insulation of the wire. Means for locking the sleeves in the terminated position include a resilient lance being adapted to spring outwardly from the inner sleeve to abut an end of the outer sleeve. In operation, a wire is inserted into the wire receiving end of the inner sleeve in the first position.

Abstract: An apparatus (100) and method for sorting a batch (200) of electrical contact pieces (11, 11') into two groups. The apparatus is characterized by a tiltable frame (72) concentrically mounting an assembly of a rotatable circular table (74) in spaced relation to a platform (80) having a radial wall (82) of less diameter than the table (74) to define an opening (86) therebetween. The circular table (74) includes an annulus sized to receive contacts. A guide arrangement (46) including a pair of guide members (50, 52) allows the contacts to pass to the rotating annulus, the good contacts rolling between the opening and through central holes in the table and the bad contacts rotating around and being scraped from the annulus.

Abstract: A method of making a releasable electrical connector assembly having a brush-type contact including the steps of: positioning an elongated electrical conductor having an axial passage extending therethrough; sliding over the conductor an elongated body having a flanged end portion extending radially outwardly; inserting several straight wires of electrically conductive material into one end of the conductor; securing together the wires, the conductor and the elongated body, the wires forming a brush for releasably mating with a like bunch of wires; inserting an exposed electrically conducting end portion of a cable into the opposite end of the conductor and into engagement with the ends of the wires; securing the end portion of the cable and the conductor together, thereby establishing an electrical circuit relationship between the cable, the straight wires and the conductor and thereby providing the brush-type contact.

Abstract: A one-piece molded protection cap 200 having a bayonet-type coupling arrangement and a resilient member 260 for fitting about a pair of contacts terminated to a cable 50 in a connector 100 of the type including a pair of locking lugs 150. The coupling arrangement includes a pair of separated annular walls 220 with a rigid latch 280 between each with each latch having a V-shaped ridge 250 having a peak 257 for bearing against a lip 154 extending from the lug of the connector, a keyway 254 initially allowing axial approach and retreat of the locking lugs while preventing rotation, the V-shaped ridge then allowing rotation while preventing substantial axial retreat or approach, the resilient member (260) biasing the cap from the connector and locking the lug in a locking recess 258 in the final rotated position.

Abstract: An improved electrical connector assembly (10) is disclosed. The assembly is especially adapted for engagement with a printed circuit board (76) having electrical circuits formed on both sides thereof. The assembly includes a body (12) of molded dielectric material having four spaced rows of passages (24) extending therethrough from a front face (26) to a rear face (28) of the body. The assembly also includes brush wire electrical contacts (14) each received in its respective passage. Each of the contacts has a cylindrical body portion (62) and an elongated tail (64) attached to one end of its body portion. The ends (72) of the termination portions extend beyond the rear face and form two spaced straight line rows adapted to receive the printed circuit board therebetween. The ends (63) of the body portions opposite their respective termination portions comprise four spaced apart, straight line rows of body portion ends.

Abstract: Strain relief apparatus for a plurality of discrete side-by-side cables (60) terminating in a matable electrical connector (10) housing (11) disposing a like plurality of contacts in a generally linear array or parallel side-by-side relation with each terminated wire extending axially rearwardly therefrom. The strain relief apparatus includes a pair of U-shaped channels (30, 40) having confrontable medial bight portions for clasping plates (36, 46) provided with aligned sets of apertures (37, 47) and coated with a deformable plastic material (55), the medial bight portions when brought into confronting relation and compressed together about the rearwardly extending wires passing therebetween rigidly secures an axial portion of each of the wires and prevents forces from deflecting the wires. A pair of stand-off support brackets (20) securingly spaces each of the channels axially rearward from the connector entry face (14).

Abstract: A one piece insert (10) for retaining a plurality of electrical contacts (20) in an electrical connector. The insert (10) includes a plurality of bores or passageways (15) having integral with the insert means for retaining a contact within each of the insert passages. The integral means for retaining a contact (20) includes a plurality of radially deflectable contact retaining fingers (11) adjacent a plurality of ribs (16). Shoulders (17) on the ribs (16) and the free ends (12) of the retention fingers (11) engage forwardly and rearwardly facing shoulders (21, 22) on a contact, thereby captivating a portion (25) of the contact within the insert. The radially deflectable fingers (11) in the insert allow a contact to be inserted and removed from one end of an electrical connector.

Abstract: An apparatus for automatically inserting electrical contacts into an electrical connector, the apparatus including a vibrating bowl (12, 112) which orients the contacts by vibrating and releases the oriented contacts one at a time to a contact loading position and guide device extending from the contact loading position to a contact unloading position adjacent the connector for guiding the contact in a forward direction to a cavity of the connector. The guide device includes a slide member (160) having a slide rod (162) slidably supported in a housing (142) for axially reciprocating each successive contact from the contact loading position to the contact loading position. At the contact loading position the contacts are propelled by an air pressure and guided to the unloading position adjacent the connector and into the connector.

Abstract: An electrical connector assembly (10) and method of making wherein the connector does not require a separate contact but comprises end strands (52) of a multistranded electrical conductor (wire 50). The strands (52) are formed into a loop (56) having overlapping portions (57) and the overlapping portions are secured together by a weld. The forward portion of the strands (52) are straightened into axial alignment and the ends (53) of each strand cut and provided with angled end surfaces (54). The conductor (wire) so prepared is inserted into a molded housing (20) having two mating halves (30, 40), at least one of which is provided with a channel (33) including a loop cavity (62) and a projection (60). The loop (56) of the conductor is mounted over the projection and the two connector halves secured together to complete the connector assembly.

Abstract: Two embodiments of apparatus and method for automatically inserting electrical contacts into an electrical connector (31) are disclosed. Each electrical contact (14) is of the type having a retaining shoulder (21) and the electrical connector is of the type adapted to retain the contacts in cavities (62) formed in the connector. The apparatus includes a vibrating bowl (12, 112) which orients the contacts by vibrating and releases the oriented contacts one at a time. In the first embodiment, a rotary indexer (26), having a plurality of contact receiving passages (40) formed about its outer periphery, receives the oriented contacts, rotates about its axis (27) and releases the reoriented contacts into a plastic transfer tube (52). A slide unit (28) allows the contacts one at a time into a lower part (55) of the tube and into an air chamber (29) at a loading position.

Abstract: A pin terminal (12) and a socket terminal (62) for coupling the free ends of a pair of optical fibers is disclosed. The terminals (12,62) are adapted for mounting in respective connector members (10,18) of the multiple terminal type. The pin terminal (12) has an optical fiber cable (14) secured at the rearward end with the fiber (50) extending partially through a channel (32). The socket terminal (62) has a cable (16) secured at its rearward end with the free end of the fiber (52) extending partially through the socket terminal. When the pin terminal is telescopically inserted into the socket terminal, the fiber (52) enters the channel (32) which includes self-aligning means for the fibers.

Abstract: A pin terminal (12) and a socket terminal (62) with self-alignment means (32, 54) in the pin is disclosed for coupling free ends of a pair of optical fibers (50, 52). The pin and socket terminal (12, 62) are adapted for mounting in respective connector members (10, 18) of the multiple terminal type. The self-alignment means for the fibers includes an alignment channel (32) in the pin and a spring wire (54) disposed in the channel. A bottom wall of the channel is a V-groove and the spring wire urges the free ends of the fibers into the V-groove when the fibers are inserted from opposite ends of the channel.

Abstract: An integral electrical contact (10, 110, 210) and a method for making the electrical contact is disclosed. The contact includes an elongated electrical conducting base portion (19, 119, 219) which has an axial passage (29, 129, 229) extending therethrough and also includes several axially aligned electrical wires (20, 120, 220) integrally formed with the base portion. The wires are axially aligned with the passage of the base portion and extend beyond a first end (18, 118, 218) of the base portion. Each of the wires which extends beyond the first end of the base portion includes an end portion (24, 124, 224) that terminates in an acutely angled surface. The electrical contact is made by coining an electrically conductive flat sheet of material (12) to form a plurality of elongated raised design portions (14, 16, 114, 116, 214, 216) which are axially aligned and extend inwardly from one end surface (13) of the sheet.

Abstract: An electrical connector is disclosed with means for producing a tactile signal when the connector members (10,12) are in a fully mated condition. An indicator (60) is movably mounted on the coupling nut (14) and is engageable by the opposed connector member (10) when the members are in a fully mated condition. An indicator element (60) is disposed in a passage (64) in the wall of the coupling nut (14) and a cam shaped surface (66) on the indicator element engages the starting end (72) of the thread (26) of the opposed member which causes it to move abruptly, i.e. "pop out" to a signal position when the full mate condition is reached.

Abstract: An electrical connector assembly having a strain relief grommet (30) spaced apart from a moisture sealing grommet (20) to prevent radial forces applied to a wire (40) entering the moisture sealing grommet from deflecting a passage (22) in the moisture sealing grommet and allowing moisture to enter the passage (22).

Abstract: An electrical contact for a coaxial cable (3) includes a tubular shell (17, 35) forming an outer contact element (19, 37) and an inner socket (13) or pin (31) type contact element having a pair of laterally spaced resilient fingers (49, 63) housed in a tubular insulator (15, 33). As the tubular insulator (15, 33) is inserted into the tubular shell (17, 35), wedge blocks (85, 107) extending laterally through slots (95, 113) in the walls of the insulator, compress the resilient fingers of the contact element against the center conductor of the cable. The cable shielding (7) is splayed back over a resilient sleeve (115) at one end of a bushing (21) which slides onto the end of the cable. This sleeve is split longitudinally and is resilient such that it may be compressed radially to insert it into the tubular shell (17, 35) where it expands to press the splayed back cable shielding into contact with the tubular shell.