Miniature connector and method of making

Claim 2

An electrical connector capable of miniature construction for use with a mating plug having a plurality of closely adjacent extending terminals, said connector comprising: a. first insulation body means having a cavity forming end cap means having an inner surface with a plurality of parallel juxtaposition bores disposed in at least one row and extending longitudinally between said inner surface and the end face of said end cap means; b. a plurality of pin terminal means each having a forward pin portion recessed within substantially the entire length of said plurality of bores disposed in said end cap means and having a rearward portion adapted to be connected to electrical conductor means with a depending tail segment formed at the rear portion of each of said plurality of pin terminals, said tail segment engaging said first insulation body means in a manner preventing displacement through the end face of said cap means and with a tubular sleeve member formed intermediate said forward pin portion and said rearward portion, and communicating with the inner surface of said first insulation body; c. at least one other insulation body means having an end portion constructed and arranged to lie within said cavity of said end cap means and engage the rear portion of each of said plurality of pin terminal means; d. and bonding means bonding said other insulation body means between the inner faces of said end cap means thereby bonding said insulation body means into an integral unit.

Claim 3

An electrical connector capable of miniature construction for use with a mating plug having a plurality of closely adjacent extending terminals, said connector comprising: a. a first insulation body having a cavity forming an end cap with a plurality of parallel juxtaposition bores disposed in multiple rows and extending longitudinally through the end face of said end cap; b. a plurality of pin terminals each having a forward pin portion recessed within said plurality of bores disposed in said end cap and having a rearward portion adapted to be connected to an electrical conductor; c. a plurality of second insulation bodies equal in number to the number forming said multiple rows, each having an end portion of reduced cross sectional area constructed and arranged to lie within said cavity of said end cap and having a plurality of grooves formed in a surface face of each of said second insulation bodies including said end portion, said plurality of grooves communicating with certain of said plurality of bores formed in said first insulation body, said plurality of pin terminals having said rearward portions of each disposed in said plurality of grooves; d. and bonding material bonding said plurality of second insulation bodies between said plurality of pin terminals, and bonding the end portions of said second insulation bodies and the inner communicating surfaces of said end cap thereby bonding said insulation bodies into an integral member.

Claim 4

An electrical connector capable of miniature construction for use with a mating plug having a plurality of closely adjacent extending terminals, said connector comprising: a. a first insulation body having a cavity forming an end cap with a plurality of parallel juxtaposition bores disposed in multiple rows and extending longitudinally through the end face of said end cap; b. a plurality of pin terminals each having a forward pin portion recessed within said plurality of bores disposed in said end cap and having a rearward portion adapted to be connected to an electrical conductor; c. a plurality of second insulation bodies equal in number to the number forming said multiple rows, each having an end portion of reduced cross sectional area constructed and arranged to lie within said cavity of said end cap and having a plurality of grooves formed in a surface face of each of said second insulation bodies including said end portion, said plurality of grooves communicating with certain of said plurality of bores formed in said first insulation body, said plurality of pin terminals having said rearward portions of each disposed in said plurality of grooves; d. and bonding material bonding said plurality of second insulation bodies between said plurality of pin terminals, and bonding the end portions of said second insulation bodies and the inner communicating surfaces of said end cap thereby bonding said insulation bodies into an integral member.

Claim 5

The structure as set forth in claim 2 including: e. a plurality of recesses communicating transversely with the rearward portions of said plurality of grooves formed in said surface face of each of said second insulation bodies; f. a plurality of depending tail segments formed at the rear portion of each of said plurality of pin terminals, said tail segments constructed and arranged for cooperatively engaging said plurality of recesses and being anchored thereby.

Claim 6

The plurality of pin terminals set forth in claim 2 including: a tubular sleeve member formed intermediate said forward pin portion and said rearward portion, said sleeve member disposed in communication with the edge of said plurality of second insulation bodies and within said bores of said first insulation body.

Claim 7

The plurality of pin terminals set forth in claim 2 including: at least a pair of leaf spring contact members constructed and arranged in opposed relationship and in convergingly and resiliently deformable relationship for engaging the extending terminals of the mating plug within said bores of said first insulation body.

Claim 8

An electrical connector capable of miniature construction for use with a mating plug having a plurality of closely adjacent socket terminals, said connector comprising: a. a first insulation body having a cavity forming an end cap with a plurality of bores disposed in parallel juxtaposition and extending longitudinally through the end face of said end cap; b. a second insulation body having an end portion of reduced cross sectional area constructed and arranged to lie within said cavity of said end cap; c. a first plurality of grooves formed in a side face of said second insulation body including said end portion, said first plurality of grooves communicating with certain of said plurality of bores formed in said first insulation body; d. a third insulation body having an end portion of reduced cross sectional area constructed and arranged to lie adjacent said end portion of said second insulation body and within said cavity of said end cap; e. a second plurality of grooves formed in a side face of said third insulation body including said end portion, said second plurality of grooves communicating with the remainder of said plurality of bores distinct from those communicating with said first plurality of grooves; f. a first plurality of pin terminals disposed in said first plurality of grooves, said pin terminals having a forward pin portion receSsed within certain of said plurality of bores communicating with said first plurality of grooves, and having a rearward portion adapted to be connected to electrical conductors; g. a second plurality of pin terminals disposed in said second plurality of grooves, said pin terminals having a forward pin portion recessed within the remainder of said plurality of bores distinct from those communicating with said first plurality of grooves, and having a rearward portion adapted to be connected to electrical conductors; h. bonding material disposed between said second and third insulation bodies, and the end portion of said second and third insulation bodies and the inner communicating faces of said end cap thereby bonding said insulation bodies into an integral body.

Claim 9

An electrical connector capable of miniature construction for use with a mating plug having a plurality of closely adjacent socket terminals, said connector comprising: a. a first insulation body having a cavity forming an end cap with a plurality of bores disposed in parallel juxtaposition and extending longitudinally through the end face of said end cap; b. a second insulation body having an end portion of reduced cross sectional area constructed and arranged to lie within said cavity of said end cap; c. a first plurality of grooves formed in a side face of said second insulation body including said end portion, said first plurality of grooves communicating with certain of said plurality of bores formed in said first insulation body; d. a third insulation body having an end portion of reduced cross sectional area constructed and arranged to lie adjacent said end portion of said second insulation body and within said cavity of said end cap; e. a second plurality of grooves formed in a side face of said third insulation body including said end portion, said second plurality of grooves communicating with the remainder of said plurality of bores distinct from those communicating with said first plurality of grooves; f. a first plurality of pin terminals disposed in said first plurality of grooves, said pin terminals having a forward pin portion receSsed within certain of said plurality of bores communicating with said first plurality of grooves, and having a rearward portion adapted to be connected to electrical conductors; g. a second plurality of pin terminals disposed in said second plurality of grooves, said pin terminals having a forward pin portion recessed within the remainder of said plurality of bores distinct from those communicating with said first plurality of grooves, and having a rearward portion adapted to be connected to electrical conductors; h. bonding material disposed between said second and third insulation bodies, and the end portion of said second and third insulation bodies and the inner communicating faces of said end cap thereby bonding said insulation bodies into an integral body.

Claim 10

The structure as set forth in claim 6 including: i. an indentation formed in one side of said second insulation body, said third insulation body disposed in said second insulation body and filling said indentation.

Claim 11

The structure set forth in claim 7 including: forming said first plurality of grooves in the bottom and edge portion of said indentation opposite said end portion of reduced cross sectional area, said second plurality of grooves being disposed in said third insulation body on the same side as said first plurality of grooves whereby said rearward portions of said first and second plurality of pin terminals are disposed on the same side of said integral body.

Claim 12

The invention as set forth in claim 6 including: a tubular sleeve member formed integral and intermediate said forward and rearward portions of each of said first and second plurality of pin terminals, said tubular sleeve member and said pin portion formed from single piece flat stock material.

Claim 13

In the method of manufacturing an electrical connector of miniature construction having a first insulation body with an end cap including a plurality of parallel bores disposed in multiple rows formed therein and a cavity adapted to receive a plurality of second insulation bodies equal in number to the number of said multiple rows in which a plurality of elongated pin terminals having solder pads are disposed, the steps which include: a. securing the plurality of pin terminals to the plurality of second insulation bodies, the ends of said pin terminals extending beyond the edge of said plurality of second insulation bodies; b. bonding said plurality of second insulation bodies to each other to form a subassembly; c. pressing said subassembly into the cavity of the first insulation body and said pin terminals into the bores of said first insulation body; d. bonding said subassembly to said first insulation body forming an electrical connector; e. pressing said subassembly into said cavity of said first insulation body but stopping short of the full penetration of said cavity to expose a portion of said subassembly; f. and applying adhesive to said exposed portion of said subassembly and pressing said subassembly into said cavity for full penetration thereof.

Claim 14

In the method of manufacturing an electrical connector of miniature construction having a first insulation body with an end cap including a plurality of parallel bores disposed in multiple rows formed therein and a cavity adapted to receive a plurality of second insulation bodies equal in number to the number of said multiple rows in which a plurality of elongated pin terminals having solder pads are disposed, the steps which include: a. securing the plurality of pin terminals to the plurality of second insulation bodies, the ends of said pin terminals extending beyond the edge of said plurality of second insulation bodies; b. bonding said plurality of second insulation bodies to each other to form a subassembly; c. pressing said subassembly into the cavity of the first insulation body and said pin terminals into the bores of said first insulation body; d. bonding said subassembly to said first insulation body forming an electrical connector; e. pressing said subassembly into said cavity of said first insulation body but stopping short of the full penetration of said cavity to expose a portion of said subassembly; f. and applying adhesive to said exposed portion of said subassembly and pressing said subassembly into said cavity for full penetration thereof.

Claim 15

The method of manufacture as set forth in claim 10 including the steps of: g. curing the adhesive for a predetermined period of time.

Claim 16

The method of manufacturing an electrical connector as set forth in claim 10 including the steps of: orienting said plurality of second insulation bodies so that the solder pads are on the same side of said second insulation bodies, and tinning said solder pads with a coating of solder.

Claim 17

In the method of manufacturing an electrical connector of miniature construction having a first insulation body with an end cap including a plurality of parallel bores formed therein and a cavity adapted to receive at least a second and third insulation body in which a plurality of elongated pin terminals having solder pads are disposed, the steps which include: a. securing certain of the plurality of pin terminals to the second insulation body, the ends of said pin terminals extenDing beyond the edge of said second insulation body; b. securing certain of the plurality of pin terminals to the third insulation body, the ends of said pin terminals extending beyond the edge of said third insulation body; c. bonding said second and third insulation bodies to each other to form a subassembly; d. pressing said subassembly into the cavity of the first insulation body and said pin terminals into the bores of said first insulation body; e. and bonding said subassembly to said first insulation body forming an electrical connector.

Claim 18

In the method of manufacturing an electrical connector of miniature construction having a first insulation body with an end cap including a plurality of parallel bores formed therein and a cavity adapted to receive at least a second and third insulation body in which a plurality of elongated pin terminals having solder pads are disposed, the steps which include: a. securing certain of the plurality of pin terminals to the second insulation body, the ends of said pin terminals extenDing beyond the edge of said second insulation body; b. securing certain of the plurality of pin terminals to the third insulation body, the ends of said pin terminals extending beyond the edge of said third insulation body; c. bonding said second and third insulation bodies to each other to form a subassembly; d. pressing said subassembly into the cavity of the first insulation body and said pin terminals into the bores of said first insulation body; e. and bonding said subassembly to said first insulation body forming an electrical connector.

Claim 19

The method of manufacture as set forth in claim 13 including the steps of: f. pressing said subassembly into said cavity of said first insulation body but stopping short of the full penetration of said cavity to expose a portion of said subassembly; g. applying adhesive to said exposed portion of said subassembly and pressing said subassembly into said cavity for full penetration thereof.

Claim 20

The method of manufacture as set forth in claim 14 including the steps of: h. curing the adhesive for a predetermined period of time.

Claim 21

The method of manufacturing an electrical connector as set forth in claim 13 including the steps of: orienting said plurality of second and third insulation bodies so that the solder pads are on the same side of said second and third insulation bodies, and tinning said solder pads with a coating of solder.