Abstract: Two-piece socket contact assemblies and methods for manufacturing these assemblies are provided. The manufacturing process includes providing a blank strip of indefinite length, piercing the strip to provide a plurality of apertures, profiling a contact body shape along at least an edge portion of the blank to form precursors of a contact body, forming the precursors into a predetermined configuration, plating these precursors, and thereafter assembling them with a coaxially disposed sleeve.

Abstract: A filter insert (40) includes filters (43) having electrodes (48, 60) and contacts (54, 64) axially, mechanically engaging contact post members (28) of a connector (20) to provide filtering extending between signal and ground conductors in the form of connector contacts to filter unwanted signal frequencies. An alternative insert (68) includes filters (69) having slotted beam elements (78) that engage post members (28) from a side thereof with a common ground bus (90) tying the filters to ground. A further alternative insert (108) provides contact elements (116) connecting filters (103) to signal and ground conductors in the form of the wires (104) of a cable (102). The contact elements (54, 64, 78, 116) of the inserts (40, 68, 108) bite into the signal and ground conductors or contacts of a connector or a cable to provide a solderless interconnection of the insert. Filters, including dielectric elements (56, 86, 126,) and inductive elements (44) are contemplated to provide C, LC and pi-filters.

Abstract: A shorting contact for an electrical system has a first circuit body having at least one shorting spring and a second circuit body having at least one shorting spring. The circuit bodies are mounted adjacent and opposite one another internally in a plug housing so that the shorting springs may contact one another to form an electrical connection. The respective circuit bodies are each in electrical connection with respective socket contacts. A header to be mated to the plug housing has a rib formed thereon. When the header is mated to the plug housing the rib extends through a slot in a spacer between the header and the plug housing and the rib contacts the shorting springs and separates the shorting springs to open the electrical circuit.

Abstract: A system for attaching a wire shield and a cover cap to the rear of an electrical plug. The plug is provided with four U-shaped members extending outwardly from the periphery of the plug casing, two on each of the opposite sides of the casing, near its corners. Four latching prongs extend forwardly from the shield, in alignment with the U-shaped members, each of which when advanced into a U-shaped member engages a detent shoulder on the inside of the top of the U-shaped member, to accomplish the desired latching. The cap, if used, has four forwardly-extending latching prongs each positioned to slide into a U-shaped member, just below the shield-latching prongs, until it engages a detent shoulder on the casing below the shield prong. Support structure integral with the U-shaped member preferably provides support to hold the shield latches in place even if the cap prongs are not present, as when a cap is not used.

Abstract: A receptacle contact is provided in which small, noble-metal contacts are provide on the distal end portions of one or more cantilevered resilient beams located within a receptacle shell, by forming openings in the shell wall adjacent to the distal end portions of the beams and depositing the noble-metal on the thus-exposed distal end portions of the beams. The receptacle is made by providing a flat starting blank with a projection for each beam; the projections are folded inwardly, over the blank, and the main body of the blank then folded up to form the shell which surrounds the bent-up beams. The openings are formed in the blank at positions on the blank such that, after the bending operation is completed, they confront the distal end portions of the beams, as desired. Only then is the noble-metal deposit formed on the thus-exposed distal end portions of the beams.

Abstract: Seals (20, 102) for an electrical connector (130) comprising a receptacle (10) and a pin header (122) has been disclosed. The first seal (20) includes grooves (50) in a body portion (30) which cooperate with ribs (b 52) on an end cap (22) to provide proper assembly orientation. A rim portion (106) on a second seal (102) includes an outwardly facing mating surface (114) for compression sealing and an inwardly facing surface (116) for peripheral sealing.

Abstract: A connector (10) having a terminal position assurance member (12) for insuring the proper positioning of terminals (18) in the connector housing (14) is disclosed. The assurance member (12) in cooperation with cantilever beams (30) located in the terminal cavities (24) cannot be fully seated in the housing (14) if improperly positioned terminals (18) are holding the beams (30) in a blocking position relative to the assurance member (12). The assurance member (12) further includes latching arms (60) which must be depressed before the assurance member (12) can be fully seated.

Abstract: A method of making electrical contacts (10) for either tin or gold-plating without changing the overall dimensional shape of the contact (10) has been disclosed. The method includes the step of providing a given spring rate for a pair of cantilever beams (26) by cutting the beam (26) to a predetermined width without changing the length thereof.

Abstract: A blind mate shielded input/output connector assembly is disclosed for use in the robotic assembly of an electrical component, such as a radio, to electrical conductors, such as electrical wires in a harness in an automobile. The connector assembly includes a header which can be fixedly mounted to the electrical component and which includes an alignment post protruding beyond printed circuit board pins located in the header. A receptacle module includes cavities for receiving multi-contact electrical connectors and an alignment cavity into which the alignment post can be inserted. The receptacle module is mounted to a carrier panel beyond which conductors in the harness extend so that the receptacle module can move in any direction within the plane of the panel, thus permitting alignment during straight line movement of the header toward the panel. The receptacle module can also be used to provide EMI shielding and a filter can be mounted in the header.

Abstract: A blind mating connector for simultaneously providing electrical and mechanical connection of an electrical component to an instrument panel is disclosed such that a robotic installation of the electrical device is possible. A floating receptacle in the panel is located at a theoretical center at which the device-end connector is expected to arrive by means of resilient O-rings contained in grooves on flanges extending from the floating receptacle. The floating receptacle is movable in any direction in the plane of the panel and is rotatable about any axis. Thus, errors in alignment and in the insertion direction of the electrical device are tolerated while ensuring a proper electrical and mechanical connection between the device and the floating receptacle.

Abstract: An electrical connector assembly of terminals terminated to conductors of cables assures the retention of the terminals in the passageways of the housing by an insert member inserted into a transverse cavity at the cable-receiving face along one side of the cables of a row after the terminated terminals are fully inserted. The insert member has forwardly facing stop surfaces which engage rearwardly facing stop surfaces of annuli of the terminals at rearward ends thereof spaced away from the cable insulation. The terminals are preferably primarily retained in the passageways by conventional means so that the insert is a secondary retention means. The insert is secured such as by a pair of latch arms at ends thereof which latch to the housing when the insert's stop surfaces engage those of the terminals of the row.

Abstract: A floating electrical connector for rack and panel connector systems capable of being inserted into and reliably retained within an opening in a panel without tools and without separate fastening elements. The connector includes a connector housing having first and second transverse slots on opposed first and second sides of the housing within which portions of the opening defining edge of the panel extend when the connector is mounted to the panel for longitudinally retaining the connector on the panel while permitting limited longitudinal movement of the connector relative to the panel. The connector also includes first and second retention means for laterally retaining the first and second sides of the connector in the opening while permitting limited lateral movement of the connector relative to the panel. The connector is mountable within a limited space on a panel and can withstand substantial forces encountered while being mated with or disconnected from a complementary connector.