Abstract: A wire harness assembly and a method of forming such a wire harness assembly is presented. The wire harness assembly includes a plurality of wire cables and a wire support defining elongate slots having open and closed ends. The cables are disposed within the slots. Retaining teeth are defined by side walls of the slots and are configured to separate one wire cable from another wire cable in the same slot. The wire harness assembly also includes a slug formed of a moldable material that encases the wire support. The slug also encases a portion of each of the wire cables. The wire harness assembly further includes a grommet encircling the slug. The slug may be formed by disposing the cables within the slots of the wire support, arranging the wire support and the cables in a mold, injecting a moldable material into the mold, and curing the moldable material.

Abstract: An electrical connection system and method includes a first connector housing matable to a second connector housing along a mating axis. The first connector housing contains a mating assist lever (MAL) that rotationally pivots between an INOPERATIVE position and a CLOSED position and includes a locking means. When the MAL is positionally rotatable to the CLOSED position the first connector housing and the second connector housing are mated together such that the locking means is disposed adjacent an external surface of the second connector housing. A sufficiently applied force against the locking means actuates the locking means so that the locking means latchingly secures the first connector housing to the second connector housing. A CPA member, also disposed on the MAL, slidingly communicates with the latched locking means transverse to the mating axis and ensures the latched locking means does not become unlatched so that electrical connection system remains mated.

Abstract: An electrical connection system and method includes a first connector housing matable to a second connector housing along a mating axis. The first connector housing contains a mating assist lever (MAL) that rotationally pivots between an INOPERATIVE position and a CLOSED position and includes a locking means. When the MAL is positionally rotatable to the CLOSED position the first connector housing and the second connector housing are mated together such that the locking means is disposed adjacent an external surface of the second connector housing. A sufficiently applied force against the locking means actuates the locking means so that the locking means latchingly secures the first connector housing to the second connector housing. A CPA member, also disposed on the MAL, slidingly communicates with the latched locking means transverse to the mating axis and ensures the latched locking means does not become unlatched so that electrical connection system remains mated.

Abstract: A mat seal device for preventing water from entering an electrical connector through an opening provided for cables to be inserted into the connector. The device includes an elastic mat that plugs an opening in the connector. A peripheral edge seal of the mat seals between the mat and an inner surface of the connector housing. Cable insertion holes receive cables into the connector and prevent moisture from passing through the holes around the cables received in those holes. Each cable insertion hole includes annular sealing ribs that elastically enlarge when receiving a cable and seal against an outer surface of the cable. Recesses formed in front and back surfaces of the mat adjacent the cable insertion holes relieve expansion of the sealing ribs.

Abstract: A stagable electrical connector and method of assembly has a housing and a shuttle that moves with respect to the housing from a staged position to an assembled position. An electrically conductive terminal snap fits to the shuttle when in the staged position and generally does not move with respect to the shuttle as the shuttle is then moved from the staged position to the assembled position that further secures the terminal to the shuttle. Preferably, a one-way coupler is carried between the shuttle and the housing to strongly resist withdrawal of the shuttle from the housing as the terminal is snap fitted to the shuttle. During snap fitting of the terminal, a flex beam of the shuttle is free to move giving way to the terminal and resiliently flexing back when the terminal is fitted to the shuttle.

Abstract: A stagable electrical connector and method of assembly has a housing and a shuttle that moves with respect to the housing from a staged position to an assembled position. An electrically conductive terminal snap fits to the shuttle when in the staged position and generally does not move with respect to the shuttle as the shuttle is then moved from the staged position to the assembled position that further secures the terminal to the shuttle. Preferably, a one-way coupler is carried between the shuttle and the housing to strongly resist withdrawal of the shuttle from the housing as the terminal is snap fitted to the shuttle. During snap fitting of the terminal, a flex beam of the shuttle is free to move giving way to the terminal and resiliently flexing back when the terminal is fitted to the shuttle.

Abstract: A host electronics device has slot for receiving an IC card. An IC protection or dummy card is provided for insertion into the slot. The card is a one-piece, substantially planar molded body. One end of the body receives a portion of the connector of the device in a manner such that a surface of the body exerts a frictional force on the connector. Portions of the body provide reinforcement for the slot.

Abstract: An IC card adapter includes a printed circuit board attached on a first edge to solder tails extending from a first connector and on an opposing second edge to solder tails extending from a second connector. The printed circuit board, first connector and second connector form a subassembly. The subassembly is provided with a first keyed interlock surface which mates with a second keyed interlock surface on a lower molded housing adapted to receive the subassembly. The first and second keyed interlock surfaces orient the subassembly and lower housing. The lower molded housing also includes a first latching member which snap-fits with a second latching member on an upper molded housing. When the lower and upper housings are engaged, they define a cavity which encloses the printed circuit board.