Abstract: A low profile electrical connector assembly has terminals attached to insulated electric cables that are disposed in topless slots of a connector base. Each terminal has two longitudinally spaced retention slots. The connector base has two transverse grooves that extend through sidewalls of the topless slots to provide terminal retainers that engage the forward retention slots to retain the terminals in a longitudinal direction. The connector base has a third transverse groove that extends through the sidewalls of the topless slots with selected sidewalls having undercuts for retaining a bottomless connector cover. The connector cover has a face plate that has a plurality of apertures that align with the topless slots, a lower ledge, and a depending lock bar. The lock bar is disposed in the third transverse groove and extends through the rearward retention slots to further retain the terminals in the longitudinal direction.

Abstract: The present invention is an automated wire harness machine (40) capable of manufacturing a wire harness (42) unique in-part due to the automation process. The novel wire harness is generally a plurality of bundled, preferably un-stripped, insulated wires (46). Each un-stripped end portion (180, 182) of each wire is preferably terminated to one of a series of electrical connectors (44) of the wire harness. Each connector has at least one wafer (52) which houses a plurality of terminals (54) preferably crimped and electrically terminated to the ends of the wires. The wire harness machine preferably utilizes a pallet (56) which holds all of the wafers of one wire harness. A conveyor (58) transports the pallet and wafers through a series of stations which perform automated manufacturing steps. The first station is a terminal inserter (64) which inserts and locks the terminals within pre-assigned cavities (114) of the wafers.

Abstract: The present invention is an automated wire harness machine capable of manufacturing a wire harness unique in-part due to the automation process. The novel wire harness is generally a plurality of bundled, preferably un-stripped, insulated wires 46. Each un-stripped end portion of each wire is preferably terminated to one of a series of electrical connectors of the wire harness. Each connector has at least one wafer which houses a plurality of terminals preferably crimped and electrically terminated to the ends of the wires. The wire harness machine preferably utilizes a pallet which holds all of the wafers of one wire harness. A conveyor transports the pallet and wafers through a series of stations which perform automated manufacturing steps. The first station is a terminal inserter which inserts and locks the terminals within pre-assigned cavities of the wafers.

Abstract: This invention provides a female terminal of one-piece construction for a printed circuit board in which the rectangular receptacle has an interlock arrangement that reduces the length of the open seam at the fourth corner of the rectangular receptacle. The interlock arrangement is accomplished by fabricating one side wall of interlocking segments that are integrally attached to opposite end walls of the rectangular receptacle so that the open seam does not run the entire length of the receptacle. The interlocking side wall segments are preferably shaped to minimize the size of the sheet metal blank to save material and reduce manufacturing costs. The contact tongues of the female terminal are also preferably shaped to provide one or more of the following features—an open and controlled contact gap to lower terminal engage force while maintaining a stable contact force; over stress projection; and double sided mating capability.

Abstract: The invention includes first and second electrical connectors and a connector position assurance member that is lockable in a pre-staged position. A first connector includes a pivotally connected pump handle lock arm positioned to lock on to a nub on the second connector. A connector position assurance member (CPA) is constructed for slidable movement on the first connector and includes two forward reaching arms each having a stop on a lower edge that engage a shoulder positioned on the first connector when the CPA is in a pre-staged position. In this pre-staged position, a lock arm of the CPA grabs into the pump handle on the first connector. The stop, shoulder and lock arm prevent forward or backward slidable movement of the CPA from this locked pre-staged position.

Abstract: A fusible electrical connector assembly comprises a sheet metal terminal of one-piece construction having an intermediate fuse portion and a housing having a fuse chamber in which the intermediate fuse portion of the terminal is disposed. The fuse chamber is defined in part by spaced slotted walls. The terminal has conformations which cooperate with the respective slotted walls to retain the terminal parts in assembly with the housing when the intermediate fuse portion has "blown" and to maintain a spacing between the ends of the fuse portion remnants.

Abstract: A unitized manual actuator assembly is attached to a printed circuit board for operating poppet switches mounted thereon. The actuator assembly comprises a two-piece housing having a pair of integral tube guides disposed in the housing. A pin is slideably disposed in each tube guide with one end protruding out of the housing for operating the switches. The internal end of each pin has an integral hollow cap covering and protecting the upper open end of its associated tube guide. A coil spring surrounds each tube guide and engages the integral hollow cap of the pin to bias it against a rocker member pivotally mounted in the housing. The rocker member has an operator portion extending through an opening in the housing and a pair of oppositely extending arms engaged by the hollow caps so that the pins translate in opposite directions when the rocker member is pivoted.

Abstract: A connector (10) for mating a flexible printed circuit (48) to a printed circuit board (50) comprises a housing (12) and a spring (14) which is translatably disposed in a cavity (16) of the housing. The cavity (16) has an outer entrance portion (18) in which the spring (14) is temporarily retained while it receives the flexible printed circuit (48) and the printed circuit board (50). The spring (14), the flexible printed circuit (48) and the printed circuit board (50) are then moved into a reduced inner portion (20) of the cavity (16) to increase the spring forces acting on the flexible printed circuit (48) and the printed circuit board (50).