Amp LLC

The Whitaker Corporation

Daryl Lynn Stoner

Ernest L Beinhaur

William E McClusky

A method for making an electrical connector (10,170) formed by molding a plastic septum (50) transversely across an axially extending connector cavity (22) defined between the axial connector walls about the array of contacts (60) extending axially within the cavity (22) from one connector face to another. The contact sections (62) extending from the connector are initially straight prior to molding and are then subjected to a forming step to define right angles for example, with portions (66) of the contacts (60) embedded with the plastic septum (50) being of irregular cross-section to establish resistance to the stresses of such forming and maintain the sealed nature of the connector (10). The connector may comprise an integrally molded plastic housing (174) or a metal shell (20) with the plastic septum (50) molded therewithin such as about an inner flange (34) for sealing and retention.

Method of making an electrical connector

An article such as an electrical connector (10) formed by molding a plastic septum (50) transversely across an axially extending cavity (22) through a metal shell (20) and about the array of contacts (60) extending axially within the axial shell cavity (22). The metal shell (20) includes a peripheral flange (34) around the inner surface (30) axially at the location (32) of the plastic septum (50), and upon curing and cooling the plastic septum includes portions of solid material axially to each side of the peripheral flange (34). The flange (34) has a dovetail cross-section having undercuts within which solid material of the plastic septum (50) is disposed forming a seal peripherally around the axial cavity (22). The contact sections (62) extending from the connector may then be subjected to a forming step to define right angles for example, with portions (66) of the contacts (60) embedded with the plastic septum (50) being of irregular cross-section to establish resistance to the stresses of such forming and maintain the sealed nature of the connector (10).

Sealed metal shell connector and method of molding a plastic insert

A bushing is placed around a smaller diameter conductor wire rearwardly of an electrical terminal terminated to a conductor end, and is placed within and along a large diameter rearward passageway portion of a connector housing passageway in which the terminal is disposed and removably retained, with the bushing having an outer diameter corresponding to that of the passageway portion. The bushing prevents the rearward end of the terminal from being urged off-center when the conductor is bent at a right angle to extend along the wire exit face of the housing, thus maintaining the conductor concentrically along the entire length of the rearward passageway portion when it otherwise would assume an angle therealong and also urge the rearward terminal end off-center; the bushing thus maintains alignment of the terminal axially along the passageway to minimize potential stubbing during mating of the terminal with a mating terminal. The bushing is adapted to permit slight adjustment movement of the rearward terminal end to allow the terminal to align itself with the mating terminal during connector mating.

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Rexmont, PA, United States of America

Daryl Lynn Stoner