The Whitaker Corporation

Amp LLC

William E McClusky

Gregory Gordon Griffith

William F Foley

Ernest L Beinhaur

David H Gutter

Daryl Lynn Stoner

Steve Robbins

Bruce W Shoemaker

David Francis Fleming

Trevor Dale Alexander

Scott Von Snyder

Barbara Ann Adams

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

This invention relates to the field of high density connectors for connecting circuit board edges to other connectors. A modular design is provided which has modules that fit into a frame to form the connector. Each module consists of a housing having a base and a cover which receives the circuit card edge. The cover is designed to insulate between adjacent contacts and to maintain contact tail spacing. This cover also eliminates the need for additional potting material between contact tails and reduces the overall height of the connector.

Electrical connector module for a high density electrical connector

An electrical terminal (10) including a contact section (14) extending from a body section (12), and a pin section (16) extending from the body section to be inserted into a circuit board through hole (20). The pin section (16) is defined by a pair of spaced apart opposing legs (30) each having a compliant portion (42) defined by a pair of arcuate beams (48) spaced apart by a slot (50), the arcuate beam pair at outer edges (54) being larger in dimension than the through hole diameter. Insertion compresses the arcuate beams (48) of each pair together generating force in a first direction, and compresses the legs toward each other generating force in an orthogonal direction.

Method of making an electrical terminal

Electrical terminal with compliant pin section

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

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Harrisburg, PA, United States of America

William E McClusky