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: A grounding strap (4) is secured to a connector shell (2) by a sleeve (5) which connects opposite ends of the strap together without the need for welding. The strap (4) reduces electromagnetic radiation passing through the shell and includes a plurality of very thin slits (43) that enable the grounding strap to be compressed radially inward when the connector shell (2) is mated to another connector shell.

Abstract: An igniter plug that has the forward insulator 80 connected to the outer electrode 24 by a metal ring 60 which is brazed at 62 to the insulator 80 and welded at 61 to the outer electrode 24.

Abstract: The invention is a method of making a pressure tight seal for a glow plug characterized by applying a high current to heat a groove (31) in the outer shell (3) of a glow plug while simultaneously pressing together the sealing elements adjacent the groove i.e. an insulator (2), a gasket (1), the flared end (42) of a protective tube (4) and a shoulder (32) within the shell (3). The grooves (31) concentrates the heat and allows the shell to be compressed around the elements of the seal.

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: An igniter plug that includes a metal sleeve 10 to retain a central electrode 30 within a ceramic insulator 40 to prevent vibration of the electrode tip 35 during operation.

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: This invention provides a single core pin for use with a mold that may be rearranged to provide a plurality of molded configurations. The core pin is characterized by a plurality of arcuate segments 11 arranged to make up a cylindrical core pin 10. On at least one of the arcuate segments 11 there is along the outer surface thereof at least one radial projection 12 extending a predetermined axial distance along the surface.

Abstract: A temperature compensated resistive oxygen sensor and a method of manufacturing the same. On the surface of the sensor there are disposed in spaced relation three electrodes. One electrode and a portion of a second electrode is completely covered by a layer of a resistive material which is sensitive to changes in temperature. Another layer of resistive material which is sensitive to both changes in temperature and changes in the partial pressure of oxygen in the gas to which it is exposed covers the first resistive layer as well as the third electrode and the remaining portion of the second electrode. It is also a feature of the present invention that these layers are applied by shielding part of the surface of the sensor and applying the first layer by a hot thin-layer technique and by removing the shield and applying the second layer also by a hot thin-layer technique.

Abstract: An activated solid electrolyte oxygen gas sensing element with increased voltage output, shortened switching time and reduced internal resistance, the sensing element having inner and outer conductive catalyst electrodes thereon, is produced by subjecting the outer surface with the outer electrode to a nonoxidizing atmosphere and applying a direct current to the element while the same is at an elevated temperature, the current being applied with the outer electrode as an anode.

Abstract: The invention is a spring return type aircraft ignition switch characterized by retainer plate (10) that includes a tab (12) that extends between a portion of the coil spring (20) and the wall (65) of the rotor body (60) to prevent the windings from the coil (20) from wedging from between the retainer plate (10) and the rotor body (60).

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.

Abstract: A releasable electrical connector consisting of a connector plug mating with a corresponding connector receptacle which may be disconnected by a separating force applied to a surrounding operating sleeve and the connectorl receptacle. The operating sleeve is shifted axially by the separating force against the bias of compression springs to a release position. The springs are received within grooves formed along the exterior of a segmented spring retaining housing, the segments forming an anchoring flange disposed within a recess formed about the connector plug. A plurality of arcuate threaded coupling segments assembled within the operating sleeve provide a threaded coupling, which segments in the nonreleasing position of the operating sleeve are positioned radially inward to mate with a corresponding thread on the receptacle and serve to create a mating force between the receptacle and plug upon rotation of the operating sleeve and to retain the connector and plug in the connected position.

Abstract: A socket contact is disclosed for miniature electrical connectors of the plug and receptacle type. The socket contact (10) comprises a contact sleeve (12) with two contact fingers (66) each extending as a cantilever beam from its root in the sleeve. A reenforcing ridge (68) in each finger extends from a point spaced from the free end of the contact finger to a point past the root of the finger to increase the stiffness of the finger. The radius of each finger and the location of the ridge thereon is such that the ridge is not engaged by a mating contact pin upon insertion into the socket.

Abstract: An electrical contact (10) of the hermaphrodite type is disclosed for use in a mateable electrical connector. The contact (10) comprises a tubular body (12) having a mating end (16), a wire receiving end (14) and locking means (18) adapted to secure the contact in the connector. The mating end (16) includes plural contact fingers (30) with each contact finger having a radially extending blade (38) terminating in bevelled edges (40,42). The blades (38) are spaced so that the mating end of one such contact (10) may be axially inserted into the mating end of another such contact (10') with each blade of one contact being wedgingly engaged between the adjacent blades of the other contact. The locking means (18) comprises plural shoulders (44), each shoulder of which constituting a U-shaped leaf spring being formed in the wall (20) of the tubular body (12) and each being substantially compressible in the axial direction.

Abstract: A filter connector is disclosed having a compound filter with two filter elements (20,22) connected in cascade in the filter contact (14). Separate ground plates (40,50) are provided for each of the filter elements (20,22). Each filter element, such as a pi section filter, is provided with an electrode arrangement which facilitates connection of filter elements in cascade and minimizes susceptibility to flash-over between electrodes. The filter element comprises a center conductor (74) with a dielectric sleeve (100) coaxially thereof. A ground electrode (80) is disposed on the external surface of the sleeve, one active electrode (78) extends from the internal surface to the external surface of the sleeve over one end surface thereof and another active electrode (82) extends from the internal surface to the external surface of the sleeve over the other end surface thereof.

Abstract: An electrical contact, for use in pin and socket type connectors, is fabricated as a unitary, composite body of metal and plastic. The contact (10) comprises a tubular body (12) having a wire receiving end (16) and a mating end (14). The composite tubular body (12) includes a sleeve (18) of wire cloth which is impregnated to form multiple islands (32) of plastic between the wires (34) on the internal surface and a plastic jacket (24) on the external surface. The contact fingers (22) are surrounded by a plastic hood (40) which provides a closed entry (42) for guiding a mating pin contact (44). The socket contact (10) is fabricated by stamping wire cloth to form a sleeve blank (18') and rolling the blank to form the sleeve (18). The sleeve (18) is fitted with core members (60) and (62) and placed in a mold cavity for injection molding of the plastic.