Abstract: A process for heading of a blank (30) formed from a length of wire stock to form a brush contact (10) having a different diameter ends, (12,14) and an intermediate shoulder (16) with a relatively great reduction in the length of the blank (30) occurring during successive heading steps, including clamping the blank in one of a plurality of holders (166), each having a counter bore (46) opening onto an end face against which a respective one of a series of coning dies (32,50,56,64) are brought into abutment. Each coning die is formed with an opening (38,50,58,66) of successively larger diameters receiving a protruding end of the blank. Respective punches (40,52,60,68) are axially advanced in a respective coning die against the blank and during forming of the blanks, simultaneously forcing the blank material against the interior of the coning die opening and outward into the counterbore.

Abstract: Conductive terminals (40) are plastically deformed whereby to connect electrically and mechanically to one or another of a pair of tubular electrical conductors (10,20) of a triaxial connector. Each terminal has an annular groove (41) therein received within a respective notch (13) in a lip extending from one of the respective tubular conductors (20, 30) and the terminal is struck to deform the walls of the groove around the lip. The other end of each terminal (40) is connected to the connector housing (1) by a plastic potting compound (50).

Abstract: A spiral band (400) having a lock arm (420) for resisting rotation of a coupling nut (300) relative to a plug shell (100), coupling nut (300) including a radial flange (322) having a plurality of detents (340) disposed equiangularly therearound and spiral band (400) being tightly spiraled to interference fit an annular groove (110) of plug connector shell (100) and dome shaped to axially bias the plug shell (100) oppositely of the coupling nut (300), radial expansion of the spring band (400) relative to the plug shell by lock arm (420) allowing uncoupling rotation and radial contraction of spring band (400) followed by lateral deflection of the lock arm from engagement with the detent (340) allowing uncoupling rotation.

Abstract: A continuous 360.degree. electrically conductive seal between a back shell (30) and an electrically conductive cable braid (46) is provided by a pair of coaxial sleeves (68, 74), a ferrule (56), and an annular shoulder (80), the conductive seal resulting from interference fitting between the sleeves, ferrule and back shell and the shoulder plastically deforming. Outer sleeve (68) is interference fit in ferrule (56). Inner sleeve (74) has its outer periphery interference fit within the outer sleeve and within the back shell. The annular shoulder extends outwardly from the inner sleeve to define forward and rearward facing V-shaped teeth and is comprised of a malleable material adapted to plastically deform within respective teeth extending rearwardly and forwardly from the outer sleeve and the back shell.

Abstract: The invention is a three-piece contact assembly for an electrical connector. The contact assembly is characterized by an inner sleeve (10) captivated between a forward outer sleeve (20) and a rear outer sleeve (30) to eliminate deformation and relative movement between the sleeves of a contact assembly.

Abstract: A make-before-break switch arrangement and a circuit element are disposed in a connector shell, the shell having an electrically conductive connector contact and being adapted to couple to a coaxial cable having a shield conductor and a center conductor whereby when disconnected from a compatible connector, an electrical signal passes through a first circuit path comprising the shield conductor, the circuit element, the connector contact and the center conductor, but when connected to the compatible connector, the electrical circuit path does not include the circuit element but passes through the center conductor, the connector contact and a contact in the compatible connector with EMI shielding being maintained through the shield conductor, the shell and the barrel of the compatible connector.

Abstract: The invention is a three-piece contact assembly for an electrical connector. The contact assembly is characterized by an inner sleeve (10) captivated between a forward outer sleeve (20) and a rear outer sleeve (30) to eliminate deformation and relative movement between the sleeves of a contact assembly.

Abstract: The invention is a three-piece contact assembly for an electrical connector. The contact assembly is characterized by an inner sleeve (10) captivated between a forward outer sleeve (20) and a rear outer sleeve (30) to eliminate deformation and relative movement between the sleeves of a contact assembly.

Abstract: A terminal (20; 20') comprised of a tubular metal sleeve (23; 33') includes four insulation slicing-conductor penetrating fins (26; 42) and a coaxially disposed conductor penetrating conical spike (32, 40) to provide a redundant electromechanical connection with a center conductor (16) of a wire (10), the fins extending longitudinally along and radially inward from the interior wall (24A) of the sleeve (23; 33') to terminate in a penetrating point (26p; 44) and the conical spike (32, 40) terminating in a point (32A; 45A) for impaling itself into the center conductor (16), the fins longitudinally slicing through the wire insulation (12) to expose the conductor (16) and the conical spike (32; 40) simultaneously impaling itself into the center of the conductor to expand the conductor and the sliced insulation radially outward, inward radial crimping of the sleeve driving the fins into the conductor and press-fitting the insulation segments against the sleeve to form a mechanical fitment therewith.

Abstract: A circuit breaker connector (100) for joining the ends of a pair of cables (10, 20) and passing an electrical signal therethrough, including a contact arrangement comprising an input contact (38) and an output contact (44) electrically connected to an internal switch contact (70) with the contacts cooperating to define a first electrical circuit path, and make-before-break switch means (72, 60) allowing insertion of an external circuit element (90) without interrupting the first circuit path for completing a second electrical circuit path including the circuit element (90) before breaking the first electrical circuit path.

Abstract: A spring member (40) is integrally molded to a radial flange (36) of a coupling nut (30), the spring member including a detent tooth (42) and having one end thereof being formed into the flange and the other end free to flex radially inward and outward to engage successive ratchet teeth (14) around the outer periphery of a plug shell (12) to which the coupling nut is rotatably mounted.

Abstract: A spring member (40) comprising a plate (42) and a U-shaped leaf portion (44) is carried on the inner wall of a coupling nut (30), the leaf portion including a deflectable leaf portion (45) including a detent (46) and a foot portion (43), the wall having a helical groove (36) for captivating a pin (18) extending from a receptacle shell (12) and an annular rib (60) for seating the spring member adjacent the terminus (35) of the groove, the receptacle being drawn into metal-to-metal contact with a plug shell (20) by coupling rotation of the coupling nut whereupon the detent captivates the pin and locks the coupling nut from uncoupling rotation relative to the plug shell.

Abstract: An annular, radially expansible/contractible, spiral spring (50) includes a cantilever arm (51) provided with a distal locking tab (60), the spring being interference fit in an annular groove (26) of a plug shell (20) to both mount a coupling nut (30) thereon and provide means for resisting rotation of the coupling nut in both directions, the tab (60) being adapted to engage a contiguous succession of ratchet teeth (40) disposed annularly around a cylindrical hub (36) extending coaxially from the coupling nut, external coupling torque tending to expand the spring whereby the spring slides about the groove and external uncoupling torque tending to contract the spring and tighten the spring fitment around the plug shell, increased torque driving tab (62) and arm (60) radially outward from the ratchet tooth to allow coupling nut rotation.

Abstract: A two-part electrical connector assembly (10, 20) includes a coupling member (30) rotatably carried by one connector part for engaging the other connector part and is characterized by a cylindrical cup-shaped detent sleeve (44) carried by the one part (10) and coupled to said coupling member, normally inoperative ratchet means (56, 70) engageable between the one part and the detent sleeve for resisting rotation of the coupling member, the ratchet means being adapted to become operable only when the two parts approach a fully mated condition by rotation of the coupling member in a mating direction, and indicating means (60, 40) including an indicator member (64) associated with the ratchet means for indicating the position of the connector parts, the indicating means initially providing a tactile and audible indication that the parts are approaching the mated condition and the indicator member providing a visual indication that the fully mated condition has finally been achieved.

Abstract: A continuous 360.degree. electrically conductive seal about the back shell (30) of an electrically conductive connector shell (20) having teeth extending aftwardly from its end face (34) and around the braid shield (46) of a coaxial-type cable (40) connected to the back shell by an accessory boot (50) protects signal carrying conductors from EMI entry and the surrounding area from EMI leakage. A frusto-conical wall including an electrically conductive annular wall portion, such as provided by the inner wall (100) of an accessory ferrule (56), or of an electrically conductive annular cap (68, 78, 86) mounted in the ferrule is interference fit about the toothed end face of the connector shell so as to overlap and completely encircle the back shell at a point inwardly of the valleys (36) of the teeth.

Abstract: A bayonet-type lock arrangement in an electrical assembly for resisting unwanted rotation of a coupling member when a pair of connector members (10, 20) are in metal-to-metal contact, the lock arrangement including a one piece lock ring (56) having three cams (58) with each cam being disposed in the terminus of one of the helical grooves and each including a cam surface (58c) and an abutment shoulder (58d), a locator key (60) on the lock ring being received in an axial keyway (62) of the coupling member to maintain each cam in its respective terminus (53), and a waved washer (52) biasing the lock ring forwardly, each of the bayonet pins (18) passing over the respective cam surfaces being captivated and prevented by the respective abutment shoulders from uncoupling rotation.

Abstract: An interfacial seal for electrical connector assembly characterized by sealing towers (21) on a first insert (10) that are axially compressed and radially expanded by the forward end (43) of respective socket contacts in a second insert (20) so that the walls of each tower (21) are in pressure tight contact with the wall (32) of respective passages (33) in the second insert (30).

Abstract: A spiral band (400) having a lock arm (420) for resisting rotation of a coupling nut (300) relative to a plug shell (100), coupling nut (300) including a radial flange (322) having a plurality of detents (340) disposed equiangularly therearound and spiral band (400) being tightly spiraled to interference fit an annular groove (110) of plug connector shell (100) and dome shaped to axially bias the plug shell (100) oppositely of the coupling nut (300), radial expansion of the spring band (400) relative to the plug shell by lock arm (420) allowing uncoupling rotation and radial contraction of spring band (400) followed by lateral deflection of the lock arm from engagement with the detent (340) allowing uncoupling rotation.

Abstract: A frangible pin (15) extends radially between interfitted first and second shell portions (21, 26) comprising an electrical connector assembly, the pin having a cross-sectional area sized to shear upon application of an external force so that the shells can break-away from one another.

Abstract: The invention is an anti-decoupling mechanism for a connector assembly characterized by an axially extending portion (42) at the free end of a spring (40) which engages an axially extending shoulder (12) at the start of a thread (11) on one of the housings (10) during a portion of the final coupling rotation of the coupling ring (30) around the first housing (10). During the final portion of coupling rotation of the coupling ring (30) the projection (41) is moved inwardly to increase the pressure between the projection (41) and the teeth (21) thereby resisting decoupling of the housings (10, 20) when the coupled connector assembly is subjected to vibration.