Abstract: An assembly includes a plug at least partially disposed in a cavity of a connector at a front end of the connector. The plug ultrasonically welded to the connector in a configuration. The plug includes an inset portion and a recess formed within the inset portion. The inset portion extends axially into a body of the plug. The recess has a first closed surface forming an outer surface and configured to engage with a tool for aligning the plug with the cavity. The plug encloses the cavity with a second closed surface, such that the cavity is free from receiving a terminal or an electrical wire in the configuration.

Abstract: An assembly includes a plug at least partially disposed in a cavity of a connector at a front end of the connector. The plug ultrasonically welded to the connector in a configuration. The plug includes an inset portion and a recess formed within the inset portion. The inset portion extends axially into a body of the plug. The recess has a first closed surface forming an outer surface and configured to engage with a tool for aligning the plug with the cavity. The plug encloses the cavity with a second closed surface, such that the cavity is free from receiving a terminal or an electrical wire in the configuration.

Abstract: An electrical connector assembly includes a connector defining a front end and an opposing rear end. The connector includes a cavity defined therein, the cavity extending from the front end to the rear end and configured to receive at least one of a terminal or an electrical wire therein. The assembly further includes a plug at least partially disposed in the cavity and ultrasonically welded to the connector.

Abstract: An electrical connector assembly includes a connector defining a front end and an opposing rear end. The connector includes a cavity defined therein, the cavity extending from the front end to the rear end and configured to receive at least one of a terminal or an electrical wire therein. The assembly further includes a plug at least partially disposed in the cavity and ultrasonically welded to the connector.

Abstract: In an FOT connector housing which couples and retains an FOT and an optical fiber with the object of maintaining a desired distance between an FOT interface and the optical fiber, an EMI shield for the FOT comprising an FOT metal casing which maintains the interface side of the FOT in contact with a wall of the casing, the wall of the casing having a thickness designed to achieve and maintain the desired distance between the FOT interface and the optical fiber, the metal casing further including a spring member acting against the FOT cavity to maintain the FOT interface at the desired distance from the optical fiber under spring tension.

Abstract: A spring contact for a female wire harness terminal, the spring contact having a sacrificial ramp which a mating terminal wipes on insertion. The sacrificial ramp includes an aperture below which a failsafe contact connected to a spring portion of the ramp rests until the mating terminal nears full insertion, at which point the spring portion forces the failsafe contact upwardly through the aperture into electrical engagement with the mated terminal. The ramp bears the brunt of the sacrificial wiping; the failsafe contact remains out of wiping contact with the mating terminal until a point at or near the end of terminal insertion, thereby preserving the mating conductive portions of the failsafe leg and the mating terminal from sacrificial wear. This protected, end-of-insertion failsafe connection allows the female spring contact to maintain good electrical connection with the mating terminal over many cycles in high cycle applications.

Abstract: A method of preventing damage to the metal contacts of multiple contact connectors in wiring harnesses during shipment and preinstallation handling. The method comprises the steps of providing essentially identical connector bodies with complemental, multi-point mechanical interconnections so that the connector bodies can be segregated into pairs and releasably attached to one another in such a way that the connector body surfaces relative to which the metal contacts are most exposed are juxtaposed relative to one another. The mated connectors and the associated wiring harnesses are thereafter packaged and shipped to a location where they are assembled into the vehicle. The mated connector pairs are detached from one another so that they may be separately routed in the course of the installation process.

Abstract: An interchangeable modular electrical connector for in-line and bulkhead applications within automobiles. The selection of male and female terminal housings and seals is identical for both the in-line and bulkhead applications, and the female housing is provided with bulkhead securing structure which remains unused and out of the way for in-line connections. Only the male housing cover is specific to each application; however, the in-line and bulkhead male housing covers are interchangeable on the male housing.

Abstract: A socket for operatively holding a wedge-base lamp has terminal guards positioned within a lamp receptacle to protect electrical terminals inside the receptacle from damaging contact by a lamp as it is inserted into the receptacle. The guards comprise a pair of terminal covers located between the terminals and the open end of the receptacle, the covers defining a gap which receives a base portion of the lamp and guides it into a proper position with respect to the terminals. The lamp base has a pair of lead wires which make contact with the terminals, and guide notches formed in the gap-defining edges of the guards engage the wires and draw them into contact with the terminals as the lamp base passes through the gap.

Abstract: A method of preventing damage to the metal contacts of multiple contact connectors in wiring harnesses during shipment and preinstallation handling. The method comprises the steps of providing essentially identical connector bodies with complemental, multi-point mechanical interconnections so that the connector bodies can be segregated into pairs and releasably attached to one another in such a way that the connector body surfaces relative to which the metal contacts are most exposed are juxtaposed relative to one another. The mated connectors and the associated wiring harnesses are thereafter packaged and shipped to a location where they are assembled into the vehicle. The mated connector pairs are detached from one another so that they may be separately routed in the course of the installation process.