Modular plug for terminating cord having non-planar array of conductors

Abstract

A modular plug especially suited for terminating electrical cords in which the conductors are disposed in a generally non-planar array includes a plastic housing with at least two tiers of conductor-receiving cells and a plurality of terminal-receiving openings associated with the cells. Each opening includes a slot extending parallel to and communicating with the associated cell. The length of each slot is exposed to an exterior surface of the housing. A terminal is inserted partially into each opening with portions of the housing which define the opening being in compressive engagement with edge surfaces of the terminal to support the terminal against unintended movement. An assembler removes a plastic jacket from an end portion of a cord and inserts each insulated conductor into a predetermined one of the cells. Then the assembler actuates a tool to anchor the plug to the cord and to sever excess lengths of the conductors. The terminals that had been partially inserted into the housing are driven into a fully seated position with internal contact portions thereof in engagement with the conductors and with externally exposed edge surfaces presented in a single plane and adapted to be engaged by electrical components of telephone apparatus into which the plug is destined to be inserted.