Modular plug having superior dielectric strength for terminating cords

Abstract

A modular plug for terminating a multiconductor cord and adapted to be inserted into a jack to establish electrical connections between cord conductors and contact wires in the jack possesses superior dielectric strength. The plug includes a plastic housing having conductor-receiving cells extending between a closed end of the plug and a chamber common to all the conductors with the spacing of the cells differing from that of the jack wires. Terminal-receiving slots extend between the chamber and an exterior surface of the housing with the length of each slot being parallel to the associated cell and communicating with an exterior surface of the housing through an opening defined by at least one camming surface. The openings are spaced the same as the jack wires and the same as terminals being fed by automatic machinery for insertion. As the terminals are inserted into the openings, they engage the camming surfaces, and are caused to shift laterally as they are seated in the slots so that internal contact portions of the terminals engage electrically the conductors in the chamber while exposed edge surfaces are supported for engagement with the jack wires. Only those portions of the terminals which have been coated with a corrosion-resistant material are exposed while substantial lengths of opposed side edge surfaces of the terminals are in an interference fit with walls of the slots to prevent unintended movement.