Abstract: A stepped electrical connector having a printed circuit board mounted in an electrically insulating housing. The board has a first collection of electrical contacts extending in a given direction and a second collection of contacts extending in the opposite direction. The number of contacts in the second collection is less than the first collection and the circuitry on the board accommodates the difference.

Abstract: A channel outlet comprising a housing of insulative material has means for mounting the outlet in an opening in a channel-shaped cover of a channel housing and includes a terminal-receiving member and a cover member. Power terminals and a ground terminal are secured in cavities in the terminal-receiving member. The terminals have a first section adapted to terminate a respective electrical conductor thereto. The power terminals have wrap-around receptacle sections adapted to receive blade terminals of a conventional electrical plug therein. The ground terminal includes a contact member for sliding electrical contact with a ground pin of the electrical plug and a ground tab extending exteriorly of the cover member for ground connection to a channel-shaped base of the channel housing.

Abstract: A bulb socket for a wedged-base bulb which can be manufactured at a low cost and yet which is capable of maintaining good resilience of its contact portions over a long period of time. The socket includes a molded-resin body and a plurality of terminals partially embedded in the body as the latter is being molded. Bulb contact parts of the terminals are formed with a wall having an approximately U shape so as to surround the contact portions which pinch the wedged parts of the bulb. The wall preferably extends above the contact portions.

Abstract: A muliconductor electrical cable termination assembly and method of making the same having an integral structural combination of a multiconductor electrical cable, a plurality of electrical contacts, and a housing part that is molded about at least a portion of each of the contacts and a portion of the cable. Each contact forms a junction with a respective conductor of the cable, and the integral housing part is molded with the assistance of a mold core under elevated temperature and pressure conditions so that each of the junctions is fully encapsulated by the molded body part to create a hermetically sealed junction zone which is free of air, moisture, oxygen, and other like deleterious contaminants, and which helps to prevent the contamination of the junction when the cable termination assembly is utilized in a hostile environment.

Abstract: Closely spaced electrical contacts are increasingly difficult to place in the manufacture of connectors and a strip molded onto stamped contact elements provide locating and alignment of the contact elements to make the same easily located in molded housing or tooling for molding. Wire support surfaces molded as part of the strip insure placement of conductors for connection with the contact elements.

Abstract: Method and apparatus for making an electrical device including a contact supported in a housing having a space within which at least part of such contact may move, wherein the contact is placed with respect to a mold core that resiliently deforms the moving part of the contact to a condition it ordinarily would be expected to take during use in connection with another contact and cooperates with at least such moving part of the contact to form a composite core that is placed in a mold cavity to mold a housing about part of the contact and to at least part of the contact while the composite core defines the space within which the moving part of the contact can deform during use. An electrical connecting device is made by the aforementioned process.

Abstract: The present invention is directed to an electrical wire and cable assembly prepared using a thermosetting type chloropolyethylene (CPE) insulation or jacket compound for cord construction and a thermoplastic type CPE compound for the plug, connector or strain relief assembly. This wire and cable assembly requires no adhesive for bonding the thermosetting CPE insulation to the injection molded thermoplastic CPE compounds used for the plug, connector or strain relief assemblies. The bonding occurs between the two types of CPE compounds, providing a superior degree of bonding than previously used materials.

Abstract: A coaxial right-angle plug connector includes a "clean" right-angle inner contact member having a continuous insulative cover molded therearound including the bend to be self-retaining thereon and to have consistently concentric coaxial outer surfaces, with larger diameter cover portions around the portion within the conductive housing. The front horizontal contact portion and the outer contact therearound mate with contact means of conventional receptacle connectors, while the vertical portion of the inner contact descends from the housing near the front thereof reducing the length of the signal path and lessening reflection.

Abstract: A male shielded electrical connector comprises a metal frame member (3, 30, 300) and a dielectric housing member (6, 60, 600) molded to the metal frame member forming a unitary housing with metal section (5, 50, 500) and a section of housing member (6, 60, 600) forming a male connecting section (4, 40, 400) having a smooth continous exterior surface (4", 40", 400") part of which is metal and the other part is dielectric material.

Abstract: An intermediate electrical component for application of a molded jacket to form an electrical connector. This component includes a first conductor having a first core formed of strands of metallic wire surrounded by an insulating jacket with a first metallic terminal element mechanically attached to the core at its stripped first end. The component similarly includes a second conductor attached to a second metallic terminal element. The component further includes an electrically insulative body of a thermoplastic material molded about the conductors and terminals with the body having a first end and a second end. The body maintains the terminal elements in spaced relationship with the conductors extending beyond the body second end and the terminal elements being accessible adjacent the body first end. The body has a window extending substantially therethrough and separating the first and second terminal elements adjacent their locations of attachment to the cores of their corresponding conductors.

Abstract: A composite unit including metal and resin wherein a metal member and a resin member are formed integrally. A seal film made of resin or rubber having high affinity to metal and characterized by flexibility is interposed between contact surfaces of the metal member and the resin member. The seal film is formed of a dispersion having as its main component a copolymer of alkyl methacrylate-alkyl acrylate. The metal member is formed of an Fe group material and the resin member is formed of polyamide resin. The seal film, after being coated on the outer surface of the metal member as a liquid material is embedded in the resin member by insert-molding resin. The metal member is formed to provide a bracket of a starter motor and the resin member to provide a brush holder. A seal member made of rubber is baked onto the contact surfaces between the bracket and the brush holder, and the seal member is embedded in the brush holder made of resin.

Abstract: In a contact device for making an electrically conductive connection between a conductor and a contact stud of an ECG electrode, a spring element serves as a contact part and has an apertured plate with an aperture therethrough. The apertured plate with the aperture is arranged in front of contact zones of the spring element. The diameter of the aperture is selected such that only a contact stud with a head which does not exceed a permissible maximum diameter is insertable into the contact device through the apertured plate.

Abstract: A connector housing assembly having a ring-like packing formed integrally with a resin housing member to provide an improved sealing function at a reduced manufacturing cost. The housing is formed by resin molding using male and female molds. In one embodiment of the invention, the first male mold is removed and replaced with another male mole shaped so as to form a hollow portion corresponding to the desired shape of the packing. Rubber material is poured into the hollow portion through lead-in paths in at least one of the female mold or the second male mold. In another embodiment, the two molds used to form the housing are both removed, and the first male mold is replaced with a second male mold defining the hollow portion used to form the packing.

Abstract: The invention relates to a captive nut terminal for an electronic module power connector (4,4'), of the type comprising a lug (4b) projecting above the resin embedding the circuits of the module, bent at right angles above the upper face of the module and having a hole (6) for the subsequent passage of a screw for connection to an external terminal and a nut disposed under said lug in line with the hole, said terminal being characterized in that the nut is held captive in a housing (8) of a size and shape allowing the nut a slight multidirectional play but preventing rotation thereof, said housing being formed in the upper face of a piece (7,7') fixed to and positioned on the connector (4,4'), under the lug (4b), and having, on at least one of its sides, a hollow (13) for anchoring said piece in said resin.

Abstract: An hermetically sealed terminal construction having a terminal pin assembly wherein inner and outer pin parts are interconnected by a fuse link surrounded by a protective capsule defining an expansion cavity, the terminal pin assemblies extending through and being hermetically sealed to sleeves forming part of the supporting base, including a dielectric sealing member which covers the protective capsules and contiguous portions of the adjoining pin parts, the sealing member being adapted to fracture upon rupture of the protective capsules caused by disintegration of the fuse links, thereby causing the adjoining pin parts and contiguous areas of the sealing member to separate from the remainder of the terminal, thereby cutting off the flow of current through the terminal.

Abstract: A cable termination assembly (200) includes a flat ribbon multiconductor cable (204), able to be slit to separate the conductors into respective pairs of adjacent conductor that are able to be rotated or twisted, a strain relief body (210) directly molded to the cable (204) to form an integral structure therewith, plural electrical contacts (212) that are placed in IDC relation to form IDC junctions with respective conductors (208) of the cable, and a separate cover (214) that can be slid over at least part of the contacts and strain relief body for fastening with respect thereto. The conductor pairs are twisted during the molding step, and as a result of the twist the outboard conductors are brought adequately inboard of the ends of the assembly to facilitate the desired IDC connections while maintaining side and end stackability. A method and apparatus for making the cable termination assembly.

Abstract: An electrical coupler for interconnecting two modular telephone plugs includes a housing having two mating faces with openings for receiving the two modular telephone plugs. The terminals within the coupler comprise wire which is formed to include two resilient portions disposed adjacent to the modular plug openings. A terminal subassembly is disclosed wherein a plurality of solid conductors are aligned side-by-side and a web is molded over the span of wires such that when the wires are cut to the desired length, the integrally molded web forms a terminal subassembly for ease of installation of the terminals within the housing.

Abstract: An effective seal is provided for an electrical connector (10) by means of a substantially-rigid molded plastic insert (13) received in the housing (11) for the electrical connector (10). A potting compound (19) is injected, preferably through an opening in the base portion (14) of the insert (13), and into the space between the base portion (14) of the insert and the bottom wall of a casing (24) which supports a plurality of spaced-apart terminals (12) encapsulated by the potting compound (19). An interfacial seal (20) comprising an elastomeric sealing member is disposed flush against the base portion (14) of the insert (13), opposite to the potting compound (19).

Abstract: The invention is directed to a power plug which has a high physical strength against traction forces tending to pull the blades out of the plug body. The power plug of the invention realizes the above characteristics by comprising a pair of blades, each of the blades having one end connected to a cord, and a blade retaining member. The blade retaining member is made of an electrically insulating material, and has retaining portions which retain the blades so that they are not displaced relative to the blade retaining member. A resin molded plug body embeds the blade retaining member, proximal end portions of the pair of blades at which the blades are connected to the cord, and an end portion of the cord to which the blades are connected.

Abstract: A telephone modular jack includes a base for receiving thereon a contact block carrying an array of spring contacts, the corresponding number of terminal units, and a cover, all mounted downwardly upon the base to be capable of being assembled by an automated technique. Each of the terminal units has a lug which is press-fitted to each one of lead tabs extended from the spring contacts when the contact block is mounted on the base. Each spring contact has a first end portion, a middle portion, and a second end portion, the portions being bent with respect to the others. The contact block includes a upright support and a horizontal support in parallel with the base. The middle portion of each spring contact is molded in the upright support in such a manner as to project the first end portion from the top of the upright support diagonally downward to the base, while the second end portion extends through the horizontal support and projects therefrom to define the lead tab at its end.

Abstract: A low profile modular telephone receptacle (15) is shown. A unitary housing (16) having a pair of transverse support members (35, 36) is provided. A top plate (17) having the necessary plurality of conductors (20) embedded therein is also provided. During assembly, the ends (22, 25) of the conductor are bent to predetermined angles (62, 65) and the top plate is joined to the bottom plate by ultrasonic welding. The resultant receptacle is one in which a minimum height dimension (h) above the necessary height dimension of the opening (18) to accept a standard modular plug is provided. In the preferred method of construction, the top plates (17) are injection molded onto continuous strands of filaments to form the conductors (20). A plurality of slots (55, 56) are provided at one end of the top plate to guide the conductors corresponding openings (46) in the bottom plate when the ends of the conductors forming a terminal set for connecting the receptacle to a utilization circuit are fabricated.

Abstract: A molded electrical lamp socket includes threaded, insulating portions on the inner wall of the socket to engage the lamp. The side electrode providing electrical contact for the lamp is desirably set deeply within the socket, to reduce the danger of accidental finger contact with an electrically conducting lamp. Where the side electrode is of the edge-on type, the insulating threads center the lamp in the socket and reduce the incidence of shaving and jamming of the lamp.

Abstract: A wire entrance fitting for eliminating leakage through a side wall of a tank has a tubular member which is externally threaded at opposed ends. Plural, threaded members are received in the tubular member and extend through an encapsulating, generally inert material. A first end of the threaded members receives an exposed wire from a cathodic protection system positioned in the tank for inhibiting corrosion, is crimped thereto, and sealingly encapsulated by a resinous material. A second end of the threaded members extends outwardly from the tank for connection to an external power supply. A flange is disposed along the tubular member and extends outwardly therefrom. The flange facilitates receipt of a junction box in one arrangement and positions an elastomeric seal member along an inner face of the tank side wall in a second arrangement.

Abstract: An electrical connector having inner and outer conductors along with a sleeve. The outer conductor has an inwardly directed annular ridge adapted to interlock with the sleeve. The sleeve is preferably of teflon. In order to maintain contact between the sleeve and the annular ridge of the outer conductor with changes in temperature, the length of the ridge is related to the diameter of the sleeve at each point along the slope of the end slope of the ridge by the equation L=D tan .theta.. The angle related in the equation is the end bevel angle on the ridge and when this angle is on the order of 45.degree., then the relationship reduces to one in which the length of the ridge is comparable to the diameter of the sleeve in order to maintain contact over a temperature change range.

Abstract: A method of assembling an electrical pin connector utilizing a molded carrier element to support and hermetically seal a number of preoriented and spacially disposed electrical pin connectors prior to inserting the carrier into a correspondingly shaped aperture of a shell housing and bonding the carrier to the shell housing to provide a hermetic seal thereto.

Abstract: A reinforced protective housing that may be utilized for protection of electrical contacts; such housing is reinforced with cured resin-coated open mesh glass cloth. Electrical contacts are incorporated into the glass cloth reinforced plastic body to form a unitary electrical connector component. A method of manufacturing cured resin-coated open mesh glass cloth reinforced molded plastic electrical connectors.

Abstract: An electrical connector system for a pressure sensor which can be sealed to a pressure source and sealed from the environment. The connector system comprises an electrical lead assembly molded into a unitary housing which has integral seals for sealed mating with a cooperative connector housing and for sealed coupling to a positive or negative pressure source.

Abstract: A cable termination assembly, and a mold and method of molding the same, includes an electrical cable including at least one conductor, at least one electrical contact, a support body for at least preliminarily supporting the electrical contact, the electrical contact having an insulation displacement connection portion, a contacting portion, and an offset between said portions, and the support body having a land for cooperating with the offset to support the electrical contact during insulation displacement connection connecting of the insulation displacement connection portion to such conductor. Part of the electrical contact and the support body cooperate during the mentioned molding to effect a shut off function blocking flow of molding material of the strain relief into an area of the support body where the contacting portion is located.

Abstract: Electrical connection pin for surface-mountable electrical coils which has one end embedded in a coil member web and has its other free end attached to a circuit board. The connection pin is fashioned with flat end faces, particularly flanges, and is fashioned symmetrical in reference to a plane perpendicular to a longitudinal axis of the connection pin and passing through the longitudinal center of the connection pin.

Abstract: The terminal assembly includes a terminal element made of yieldable material and a tubular post made of soft, flowable material. One end portion of the terminal element is defined by a slotted tube-like member adapted to telescope into the post. When the post and the tube-like member are squeezed axially together during assembly, the tube-like member collapses axially and expands radially to cause the soft material of the post to flow into and interlock with the slots and thereby establish a positive electrical and mechanical connection between the terminal element and the post.

Abstract: The invention proposes an electrical contact terminal arrangement for cycle fenders constructed from a molded multi-layer laminate of plastic with at least one metal foil layer embedded therein. The arrangement includes a metal head having a substantially flat underside which is pressed against an outer surface of the fender. A shaft-like projection is formed onto the underside of the head, extending at right angles to the underside and when mounted penetrating the fender. An attachment means anchored on this projection secures the contact terminal arrangement in the cycle fender.In order to attain long service life of the contact location between the metal foil and the contact arrangement projection, and to attain low transitional resistance, only one shaft-like projection is provided, disposed concentrically with the head. A large number of contact protrusions is embodied on the outer circumference of the shaft-like projection, extending in the longitudinal direction thereof.

Abstract: A current leadthrough particularly for a refrigerator comprises an insulator with a plurality of electrically conductive spaced apart pins extending through the insulator. The insulator includes a disc-shaped base portion with a plurality of nub portions corresponding to the member of pins, the pins extending through the nub portions. The nub portions extending upwardly from the base portion and the base portion comprise a material having temperature stability which is insensitive to chemicals and has some elasticity.

Abstract: A connector assembly for an anti-skid hydraulic braking system comprises a bulkhead connector extending through an aperture in a sidewall of the brake fluid reservoir, a connector harness mounted along the inside of the reservoir sidewalls extending from the bulkhead connector to three solenoid assemblies mounted on the reservoir floor, and a solenoid connector on each solenoid assembly in engagement with the connector harness. The solenoids extend through floor apertures into the master cylinder to respective hydraulic lines extending to brake cylinders in the wheels, one of the solenoids handling both rear wheels. The bulkhead connector mates with a connector outside the reserovir which is terminated to a wire harness connected to the on-board microprocessor to relay current to the solenoids when data from individual wheel speed sensors is processed to determine that a particular wheel is about to skid.

Abstract: Wellhead electrical connection apparatus for feeding electricity into a well under fluid pressure, includes a mandrel sleeve having an internal sleeve shoulder formed to face high pressure end of sleeve. A performed rigid high mechanical strength dielectric insulator support having an external insulator shoulder is installed within the sleeve with the insulator shoulder in abutment with the internal shoulder of sleeve. Insulator support means is mounted and sealed in physically bonded relation within the interior of the sleeve by means of dielectric potting material disposed as an insulator film or sleeve in surface areas between insulator support and sleeve. Insulator support has a plurality of holes extending in parallel and laterally spaced apart relation through the insulator with each hole having an internal hole shoulder formed to face high pressure end of sleeve.

Abstract: A method and apparatus for sealing electrical conductors through a pressure barrier provides high pressure sealing. The apparatus includes a tubular housing with conductor rods which are inserted in the housing, which is then filled with epoxy and allowed to harden. The conductor rods are also insulated. A grommet is press fitted on each end of the housing, by pushing the grommet over installation pins which insert over the conductor rods. A mandrel is used to drive the grommet into compressive contact with the bore of the housing. Once in place, the installation pins are pulled and the mandrel is removed.

Abstract: A method for manufacturing a switch includes the steps of forming integrally a clip for clamping a movable contact out of a flat terminal member configured in hoop material by bending uprightly a projected portion of the terminal member, and then insert-molding the thus bent terminal member at the bottom of a box body made of insulating material to hold the integrally formed clip inside the box body.

Abstract: An overmolded electrical connector in which a flexible spring finger contact is encased in a rigid plastic material in such a manner that the spring finger is not restrained from flexing by the rigid plastic material. The connector comprises an assembly that includes a terminal block, a cover and a terminal that has the flexible spring finger. The terminal is assembled to the terminal block such that the spring finger is located in a cavity in the block. The cover is now attached to the block and the assembly is overmolded by injection molding apparatus. The cover and block have a cooperating tongue and groove to prevent molding material from entering the cavity that contains the spring finger. The cover has crush ribs that engage a tab portion of the terminal that extends from the cavity to a point exterior of the assembly.

Abstract: Manufacture of low profile clip connectors characterized by a cap in the form of a planar strip of plastic material provided with plural tapered holes spaced along its length. The cap is loaded into a test clip mold along with a cable/contact sub-assembly with the cap in juxtaposition with the side of the cable opposite the contacts which are soldered to respective conductors of the cable. After the mold is closed, molten plastic material is introduced into the mold cavity to form the balance of a clip body, the molten material flowing up through an insulation removed area of the cable around the soldered junctions and into the tapered holes in the cap which locks the cap to the thusly molded balance forming portion of the clip body.

Abstract: To reliably prevent ingress of moisture to a connection between an electrical connecting cable or line to an electrical apparatus within a housing, the conductors of the cable or line are externally surrounded by an insulating layer which is of such a material that it joins, by melting or chemical reaction with the material of a surrounding bushing or sleeve, which bushing or sleeve then can be secured in a wall of the apparatus, for example by a removable rubber ring (FIG. 2) or can be molded into the housing of an electrical apparatus, for example a sensor; preferably, the materials of the housing and of the plug or sleeve also join, either by melting together or by chemical reaction. For a melt connection, a thermoplastic such as polyamide is suitable; for reactive connection, a reactive thermosetting plastic, for example polyester imide, or epoxy may be used.