Method for insert molding a contact module

Abstract

A method for manufacturing an electrical connector having at least two rows of high density contacts, comprises steps of stamping and forming, depositing, insert molding, severing, and assembling. Each contact carrier strip has a number of contacts, a first carrier and a second carrier forming positioning structures thereon. Each contact includes a soldering section, a connecting section, a securing section and a contacting section jointed together end to end. The connecting sections of the contacts of different contact carrier strips are perpendicular to both the soldering sections and the securing sections. The contact carrier strips are deposited in a mold. A contact base is insert molded around the contacts for enclosing appropriate sections of the contacts thereby forming a contact module after properly depositing the contact carrier strips in the mold. The soldering sections of the contacts of different contact carrier strips are alternately aligned and remain in the same plane. The connecting sections of the contacts of different contact carrier strips separate the securing sections from the contacting sections due to different lengths thereof. The first and second carriers are cut away from the contact carrier strips to form a contact module which is assembled to other components.