Amp LLC

The Whitaker Corporation

Ernest L Beinhaur

William E McClusky

Daryl Lynn Stoner

Daniel T Casey

Earl R Kreinberg

Joseph M Pawlikowski

John K Daly

Homer E Henschen

Michael J McKee

Michael Patrick Green

Paul S Vinson

Joseph G Porter

Marshall S Mountz

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

A board stiffener (50) of rigid construction of high heat resistance material having recesses (62) to be secured to a large circuit board (10) over a plurality of electrical articles having contacts (24) soldered to the board, such as electrical connectors (20). The board stiffener (50) is mounted firmly to the board at locations near each recess (62) in abutment with top surfaces (34) of connectors (20) and provides resistance against warping by the board (10) during high temperature soldering operations. The board stiffener (50) can have channels (68,70) along the bottom surface (52) and the recess surfaces (72,74) to enable flow of solvent during flux cleaning following soldering operations.

Circuit board stiffener

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 strap comprised of a layer of magnetic material on a layer of nonmagnetic conductive metal comprises a self-regulating heater, which is wrapped around a length of heat recoverable tubing disposed around a terminal being terminated to a conductor wire, or a pair of wires being spliced. When energized, the strap generates thermal energy melting solder of a preform within the tubing, terminating the terminal to the wire, or the two wires together, and sealing the termination simultaneously. A plurality of terminals in a connector housing include solder tails extending rearwardly from the housing so that respective wire ends may be placed therealong within solder preforms within heat recoverable tubing therearound. A strap comprising a self-regulating temperature source is wrapped around the array of solder tails and wire ends and is energized to solder the array and seal the terminations. A high frequency alternating current induced in or transmitted to the magnetic layer of the strap causes the strap to generate thermal energy sufficient to melt the solder and shrink the tubing. The strap may have several layers and may be shapable to conform to the outer surfaces of the heat recoverable tubing lengths. A strap may seal an open end of a length of heat recoverable tubing having a sealant preform therewithin, when wrapped therearound and energized.

Methods of terminating and sealing electrical conductor means

A housing for a hermetically sealed bulkhead connector is machined of an integral metal member to have a precisely planar bulkhead-engaging surface of a mounting section extending peripherally around a contact support section disposed within a hood section extending through a cutout of the bulkhead. The housing also is machined to have precisely planar surfaces of a contact support section to facilitate assembly of contacts precisely concentrically disposed in passageways through the support section and securing therein by glass seals to comprise a parallel contact array. The housing is free of joints between the several sections which could provide sites for breaching the hermetic nature of the housing. No steps are performed which involve impacting or striking the housing which could disturb the precise planarity of the several precisely machined surfaces. The contact positions may be identified by laser etched indicia.

Hermetically sealed electrical bulkhead connector

A power distribution system utilizes flat power cable in combination with a plurality of adapter members for the distribution of power within electronics systems. The adapter members allow flat power cable to be interconnected to conventional crimpable contacts and thereafter routed through conventional electrical connectors. The adapters also allow interconnection between flat cable and power busses or between flat cables and printed circuit boards. The adapters can also allow the interconnection of tabs and receptacles to flat power cable. The adapters are crimpable to the flat cable by means of hand tools which provides for a versatile means of distributing power.

Flat cable power distribution system

A powdered metal insert (2) is disclosed for use with a fiber optic cable (16) or a wire (60). The insert (2) is positioned in a connector with the cable positioned along the longitudinal axis of the insert. Termination of the insert to the cable occurs as a force is applied to the insert in a direction which is parallel to the longitudinal axis of the insert. This longitudinal force results in an evenly distributed transverse force being applied to the cable and the connector. This even distribution of forces along the cable can be easily and accurately controlled so that the powdered metal insert (2) can be used effectively to provide the mechanical connection required for the fiber optic cable (16) as well as to effectively provide the mechanical and electrical connection of the stranded wire.

Powdered metal connector

An electrical connector for electrically connecting cables together. More particularly, the connector includes a body member being U-shaped to provide a central opening and having cable receiving grooves on each side of the opening. Further included is a cap member having a section which slides into the central opening and laterally extending arms which overlap the body member and have grooves facing and cooperating with the grooves in the body member to confine cables therebetween. The body and cap members can be assembled, disassembled, and reused.

Electrical connector

Wire connector comprises a terminal of wound spring wire which is received in a cavity in a plastic base and contained therein by a plastic cover. The terminal comprises a first conical helix wound from a wire receiving end to a constricted end then back upon itself to form a shorter second helix ending at a shoulder. Conductors are twisted into the terminal causing it to expand and grip the conductors resiliently while a finger of spring metal prevents rotation relative to the housing. The first helix is nested in U-shaped recesses in partitions in the cavity so that the shoulder bears against a partition when the wires are pulled.

Wire connector

A toolless splice sealant device is taught. Briefly stated, a splice enclosure suitable for enclosing a splice or connection is utilized. Disposed in the splice enclosure is a sealant material. The splice enclosure has one or more compression buttons such that upon application of the splice enclosure to the splice, compression of the compressable buttons causes the sealant, through hydraulic pressure, to completely fill all voids which may exist, forcing the sealant around and along connector and wire. This thereby environmentally seals the splice and prohibits the contamination of the splice which may affect the electrical integrity thereof.

Toolless splice sealant device

A device for conduit sealing and repair is taught. Briefly stated, a cable or conduit is passed through an opening in a foundation or bulk head enclosure. A substantially cylindrical collar which is longitudinally split into two portions is placed onto the conduit with the conduit and collars then placed into the enclosure opening. An expandable foam is injected into an opening in the collar which, when expanded forces apart the two portions thereby snuggly fitting the collar into the opening. The foam is also allowed to exit through openings in the collar and thereby fills any voids between the exterior of the collar and the interior portion of the opening and which thereby forms a water tight as well as gas tight seal. Reentry into the opening for removal and/or replacement of the conduit is accomplished by pulling on stainless steel strap which are positioned in openings and around portions of the collar. Therefore the removal of the collar as well as the foam which is inside and outside of the collar is easily accomplished.

Device for conduit seal and repair

A resilient boot 10 used to cover the axial juncture between a cable 40 and an anode 30 is supported in a rolled and stretched condition on a hollow support member 20 which has a flange 28 to removably retain the tubular section 16 of the boot 10 in roll form 18 and a flange 23 to removably retain the sleeve section 12 of the boot 10 in roll form 14. The support member 20 is assembled over the juncture and roll 18 is unrolled so that tubular section 16 conforms snugly to the cable 40 and roll 14 is unrolled so that sleeve section 12 conforms snugly to the anode 30. The tubular section 27 of the support member 20 removed stresses at the juncture which results from lateral movement of the cable.

Anode cover assembly having internal support member

A device to form an effective environmental tight seal on a free end of cables, conduits and the like is disclosed. The subject device is formed by a unitary member of resilient material, such as rubber, which has a cylindrical configuration with one permanently closed end. The closed end has a substantially greater thickness than the sidewalls of the device. The other end is preferably temporarily closed. The device is applied by forcing the permanently closed end against the free end of the cable so that the closed end passes through the cylindrical portion until the device is reversed upon itself and is in sealing gripping engagement on the cable or the like. When one end of the device is temporarily closed by a sealing member, the device will be slightly inflated as it is pushed against the cable end thereby easing application of the device. The temporary seal will be removed by penetration or when internal pressure increases beyond a limit.

Growing community of inventors

Harrisburg, PA, United States of America

Ernest L Beinhaur