Abstract: An electrical connector assembly for first and second pivotally mounted circuit members includes a dielectric housing portion for each member, each portion having a plurality of terminal receiving cavities formed therein, with first and second sets of terminals mounted therein. The housing portions are joined together for pivoting about an axis of rotation. Each terminal of each housing portion has a mating contact surface centrally located with respect to the axis of rotation. A compressive bias force is applied between mating terminal pairs which extends along the axis of rotation.

Abstract: Disclosed is a board mounted electrical connector for terminating the free end of a flat round conductor cable to post terminals mounted on the board. The connector includes a housing having a cable receiving end and opposed mating end, with a bottom wall having a board engaging surface extending therebetween. Extending parallel to the board engaging surface, between the conductor receiving and mating end is a plurality of wire and terminal receiving cavities which have an open top, communicating with a top surface of the connector housing. Terminals received in the cavities have a wire engaging portion with insulation piercing barbs, and an opposed pin engaging portion with an integrally formed cantilever spring finger. When loaded into the housing, the wire engaging portion of the terminal terminates wire conductors received at one end of the cavity while the pin engaging portion is positioned adjacent pin receiving passageways located adjacent the mating end of the housing.

Abstract: A multicircuit electrical connector for mass terminating a plurality of insulation-clad wires includes a dielectric housing with a plurality of terminal-receiving cavities formed therein and a wall adjoining the cavities. Wire-receiving regions are formed in the wall, each for receiving a wire moved laterally of its axis into a respective cavity. Improved strain relief means are formed in the housing wall, one adjacent each wire-receiving region. Each strain relief means includes first and second resilient fingers offset from each other along a wire axis and constricting a wire-receiving entrance to a region. The first fingers are mounted to the wall for independent movement relative to their generally opposing second finger, and are independently moveable with respect thereto, as wires are simultaneously introduced into said wire-receiving regions during mass termination in said connector.

Abstract: Electrical connectors are slidably received in side-by-side serial array in elongated, hollow tubular cassettes. The cassettes are shaped to receive the connectors only in a single orientation, and protect terminals which partly extend from the connector housings in an intermediate assembly stage. Cassettes are vertically stacked in a feed system, and when the bottom cassette is emptied of connectors, it is released from the stack and replaced with a full cassette.

Abstract: A method and apparatus for manufacturing a plurality of electrical harnesses in a single machine cycle. A push bar device spaces a plurality of connectors in a predetermined, spaced relation one to another at a first station. The plurality of connectors are moved in longitudinal alignment from a first station to a second station where the connectors are each terminated to wires, for example ribbon cables. The terminated connectors then are moved back toward the first station pulling the cables with the connectors and then the cables are cut at the second station at a predetermined length. A second plurality of connectors can be loaded in predetermined spaced relation at the second station and terminated to the cut cable ends to manufacture a plurality of double-ended harnesses in a single machine cycle.

Abstract: Disclosed is an apparatus for voiding selected terminals from a connector assembly wherein an array of terminals, joined to a common carrier member, are partially preloaded in a connector housing. The apparatus includes a punch having a first projection which engages and deforms the terminal. The punch further includes a second projection following the first projection, for severing the terminal from the carrier strip. The selected terminals are disengaged and extracted from the connector housing and severed from the carrier member, at the voiding station.

Abstract: Disclosed is a method and apparatus for extracting an electrical terminal having a canted locking lance from a first housing, and preparing the locking lance of the terminal for insertion in the same or a second similar housing. The connector housing includes an outer wall having a window formed therein for receiving a free end of the locking lance. The lance free end engages an edge of the window when the terminal is fully inserted in the connector housing, thereby preventing withdrawal of the terminal from the housing. A tool is provided with first and second lance engaging portions, the first lance engaging portion including a projection of predetermined dimensions receivable in the window to depress and deform the locking lance, allowing extraction of the terminal from the connector housing. Deformation of the lance is limited to a repairable amount. The second lance engaging portion of the tool includes a hook-like lance reforming member insertable beneath the lance and a floor of the terminal.

Abstract: Several embodiments of a method and apparatus for accurately positioning solid components for a robotic pickup mechanism having a floating gripper head, are described. In a first arrangement, connectors are transported along a guide track, with linear arrays of solid projections depending from each connector received in slots formed in the track. Conveyance of the connector is completed when a leading projection contacts an accurately positioned stop wall located in one of the projection receiving slots. An alignment bar, generally coextensive with the linear array of solid projections, presses the projections against a track wall communicating with the slot. In a second arrangement, a gauge block is elevated to receive the solid projections of the connector, and is thereafter translated to a final loading position adjacent a robotic pickup mechanism. In a third embodiment, a shuttle mechanism for use with a gauge block is disclosed.

Abstract: Disclosed is a connector arrangement for electrically interconnecting adjacent, parallel, spaced-apart printed circuit boards. The connector includes a housing having a mounting surface and passageway for receiving a pin-like male commoning element. The connector further includes a stamped, integral terminal mounted in the housing, which has a resilient female contact disposed in the pin-receiving passageway, and a board engaging portion which is secured to a first printed circuit board. A connector is provided on each printed circuit board to be electrically interconnected, and the pin-receiving passageways are aligned in registry. After installation of the connectors and printed circuit boards, the pin-like male commoning element is inserted through the passageways and apertures provided in each printed circuit board adjacent each passageway, so as to engage each female contact element of each connector to be interconnected.

Abstract: Disclosed is a shielded receptacle assembly mateable with a plug connector having an external metallic shield. The connector assembly includes an insulating receptacle housing having a mating edge with a plug-receiving cavity extending into the housing from the mating edge. An end wall opposes the mating edge and a plurality of sidewalls are joined with the end wall to define plug receiving cavity. Housing terminals are mounted in the receptacle housing for mating with corresponding plug terminals.An integral stamped metallic conductive shield is mounted on the outside of the receptacle housing, and includes reversely bent shield engaging cantilever fingers for mating with the external plug shield. The housing includes outwardly projecting shield mounting studs electrically formed on two opposing sidewalls. Slots formed in corresponding shield sidewalls slidingly receive and engage the studs during assembly of the shield and housing members.

Abstract: Disclosed is a flexible substrate assembly including an elongated flexible substrate having a plurality of spaced apart component receiving regions, with a solid component disposed on each of said regions. A plurality of flexible strap members are disposed adjacent each component receiving region on one side thereof, and are joined to the other side of the region such that the strap overlies the region to form a tube-like passageway for receiving and containing a solid component. Several embodiments of the invention include different configurations of strap members are punched out from the flexible substrate so as to form a flap-like member having a free end, which is joined to the substrate so as to form a tube-like passageway. Also disclosed are methods for fabricating the substrate assembly and dispensing solid components contained in the substrate assemblies. Also, packaging arrangements and apparatus to produce packaging arrangements including the flexible substrate assemblies are also disclosed.

Abstract: An electrical terminal having improved retention in a connector housing is disclosed. The terminal is slidingly received in a housing cavity through a rearward end of the housing. When fully inserted in the cavity, the terminal engages a stop wall adjacent the mating end of the housing. A canted locking lance extends at a given angle from the terminal body. The lance cooperates with a window formed in the housing wall when the terminal is fully inserted in the housing cavity. When the terminal is fully inserted, the housing edge adjacent the window is engaged by the lance to prevent withdrawal of the terminal from the housing cavity. First and second lance portions are defined by a branch or fork in the free end of the lance, with the first lance portion extending at a steeper angle than the second lance portion. The corner formed at the housing wall adjacent the window is thereby received between the two lance portions to prevent withdrawal of the terminal from the housing cavity.

Abstract: An improved two-piece modular phone jack assembly and method of making the same. The jack assembly includes a connector housing and a carrier subassembly mounted in the housing. The carrier subassembly has a support member which mounts a plurality of stamped metallic elongated conductors. The support member includes a body portion, a generally horizontal base portion extending rearwardly of the body portion and a generally horizontal cantilevered top portion extending forwardly of the body portion. The conductors are positioned and stacked onto the upper surface of the top portion of the support member so that simultaneous forming of said conductors can occur during the manufacturing process.

Abstract: A method of packaging solid members having rigid projections, e.g., electrical connectors, on a flexible foam substrate assembly. The method generally includes disposing a portion of the substrate at a workstation and causing the solid member to move toward the substrate so that the projections penetrate the substrate to removably mount said solid member therein. This procedure is repeated as different portions of the substrate are presented to the workstation until a desired number of solid members have been mounted on the substrate. The substrate can then be reeled or arranged in such a manner to be mounted within a suitable container for future removal of the solid members from the substrate.

Abstract: Disclosed is an apparatus for severing connector sticks into separate connector modules. A stick is formed by arranging individual connector housings in a serial row, and joining the connectors by a pair of L-shaped carriers. The carriers are arranged to overlie an outside corner of each housing, with one leg of the L-overlying a sidewall, and the other leg of the L-overlying the bottom wall. A tool bit is provided with first and second cutting surfaces, which sever respective legs of the carrier. The tool bit is configured to be received between individual connector housings, to provide alignment with the legs of the carrier member. The tool bit is arranged to sever a substantial portion of one carrier leg, and to thereafter sever both carrier leg portions.A method for severing the connector stick is also disclosed. According to the method, a substantial portion of the first carrier member is severed first, and the first and second carrier legs are thereafter simultaneously severed.

Abstract: A robotic tool for mounting an edge connector on a mother board, and mounting a daughter board to the edge connector. The mother and daughter boards are of the printed circuit board type, with the edge connector including a plurality of terminals mounted in a socket for receiving an edge of the daughter board at a first angle, and for electrically mating with the edge of the daughter board when the daughter board is rotated to a second angle. The tool includes a programmable robotic arm selectively moveable to a predetermined position on the mother board, and having a free end with a pair of end portions moveable toward and away from each other. A pair of jaws are mounted to the end portions, for movement therewith. The jaws have first outwardly extending connector engaging portions and second inwardly opening daughter board-receiving recesses. The same jaws are used to mount the edge connector to the mother board, and to insert and rotate the daughter board for mating and locking with the edge connector.

Abstract: Disclosed is an improved for dispensing solid members, such as electrical connectors, having extended rigid projections inserted in a penetrable flexible substrate sheet material. The apparatus for dispensing the solid members includes a rotatable drum having a solid surface. The sheet material containing the solid members is pulled across the drum surface by a frictional drive roller, thereby pulling the sheet material radially inwardly past the solid projections, creating a gap between the solid members and the sheet material. Wedge-like finger members are inserted in the gap, to complete removal of solid projections from the sheet material, thereby releasing the solid members for slideable movement along the finger members to a remote work station.

Abstract: In an electrical commoning arrangement including a printed circuit board with at least two parallel rows of conductive pins mounted therein, a removeable shunt connector for electrically commoning two pins is disclosed. The shunt connector includes a terminal defining at least three colinear pin receiving portions whereby the shunt connector can be selectively mated with two adjacent pins of the same row, or with two corresponding pins of different rows.

Abstract: Disclosed is a plug and receptacle connector arrangement for interconnecting a printed circuit board with a multi-conductor flat cable. The receptacle assembly includes terminals of the tuning fork type, and a housing which is mounted to an edge of a printed circuit board. The plug assembly includes a plurality of U-shaped channels having two parallel spaced-apart cable engaging walls joined by a common bight portion. One end of the bight portion comprises a plug terminal contact surface which is received by the tuning fork receptacle terminals. At the opposing end of the terminal, each wall cable engaging includes an insulation displacement termination portion for interconnection to the flat cable. Right angle and straight (in-line) embodiment of the invention are disclosed. The connector arrangement is particularly advantageous when used in a vibrating environment of an automobile or other moving vehicle.

Abstract: An electrical harness fabrication machine which produces harnesses which comprise ribbon cable having a connector at each end. Each connector has a housing with terminals loaded therein. Prior to termination to the cable, the terminals are partially preloaded into their respective housings so that conductor engaging ends thereof are presented to a termination station for mass termination. A conductor engaging end of the terminals are free standing sections which form an insulation displacement slot therebetween. The termination assembly has a portion adjacent conductor stuffing blades for laterally supporting the conductor engaging ends of the terminals during the termination operation. In addition, pilot members are provided to cooperate with a connector nest having a preloaded connector received therein and the conductors for accurately aligning the conductors, conductor engaging ends of the terminals and the termination assembly with respect to one another.