US3664018A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of manufacturing a mating electrical connector
Assignee: Individual
•
Filing: 1970-05-06
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Granted: 1972-05-23
•
Expires: 1990-05-06
Abstract
Abstract The disclosure describes a method of manufacturing in situs a mating electrical connector for a pre-existing installed connector. This is accomplished by installing wired mating connector contacts into engagement with corresponding connector contacts of the pre-existing connector. A strip of material, suitably Mylar, is then wrapped about the face of the preexisting connector to form a reservoir which contains the installed connector contacts. The reservoir is subsequently filled with heated softened flowable thermoplastic material, suitably low density polyethylene, and the thermoplastic material is then allowed to harden which leaves remaining in the reservoir a hardened body of thermoplastic material in which the installed mating connector contacts are firmly anchored and the body is easily separated from the face of the pre-existing connector. The Mylar strip is then removed and the formed connector may be left in location or removed and reinserted as otherwise desired in the same manner as any other electrical connector.
Inventors
- 👤 John Peter Mcgregor
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-05 09:10
CPC Classifications
H; H01; H01R; H01R43/00; B; B29; B29C; B29C45/00; B29C45/03; B29C45/036; Y; Y10; Y10T; Y10T29/00; Y10T29/49; Y10T29/49002; Y10T29/49117; Y10T29/49204; Y10T29/49208; Y10T29/4921; Y10T29/4922; Y10T29/4998
Claims Analysis
Total Claims: 24
Claim 1
Independent Claim
213 words
The method of producing a mating electrical connector for a pre-existing electrical connector; said pre-existing connector having a plurality of connector contacts comprising the steps of: selecting a desired corresponding plurality of mating connector contacts from a supply of such contacts, with each of said contacts including an anchorable portion thereon; attaching said selected connector contacts to corresponding wires as desired; installing each one of said selected connector contacts into engagement with a corresponding one of the plurality of connector contacts in said pre-existing connector and wrapping a wide strip of Mylar material about the face of said pre-existing connector to form therewith a reservoir, said reservoir surrounding and at least partially containing said installed selected mating connector contacts; applying an adhesive tape to said strip to maintain said formed reservoir; filling said reservoir to a predetermined depth above the anchorable portion of said installed mating contacts with heated low density polyethylene in the flowable state; cooling said low density polyethylene at room temperature to the solid state by which said polyethylene hardens to the solid state to define a connector body having said installed mating connector contacts anchored therewithin; and removing said strip of Mylar material; whereby said formed connector remains in mating engagement with said pre-existing connector and is detachable therefrom.
Claim 2
Independent Claim
213 words
The method of producing a mating electrical connector for a pre-existing electrical connector; said pre-existing connector having a plurality of connector contacts comprising the steps of: selecting a desired corresponding plurality of mating connector contacts from a supply of such contacts, with each of said contacts including an anchorable portion thereon; attaching said selected connector contacts to corresponding wires as desired; installing each one of said selected connector contacts into engagement with a corresponding one of the plurality of connector contacts in said pre-existing connector and wrapping a wide strip of Mylar material about the face of said pre-existing connector to form therewith a reservoir, said reservoir surrounding and at least partially containing said installed selected mating connector contacts; applying an adhesive tape to said strip to maintain said formed reservoir; filling said reservoir to a predetermined depth above the anchorable portion of said installed mating contacts with heated low density polyethylene in the flowable state; cooling said low density polyethylene at room temperature to the solid state by which said polyethylene hardens to the solid state to define a connector body having said installed mating connector contacts anchored therewithin; and removing said strip of Mylar material; whereby said formed connector remains in mating engagement with said pre-existing connector and is detachable therefrom.
Claim 3
Dependent Claim
52 words
The invention as defined in claim 1 wherein the step of filling said reservoir includes the steps of heating a cartRidge of thermoplastic low density polyethylene to place said polyethylene in the flowable state, forcing said heated flowable polyethylene through a nozzle and directing the output from said nozzle into said reservoir.
Claim 4
Dependent Claim
24 words
The method as defined in claim 1 which includes the step, prior to filling said reservoir, of heating said installed selected mating connector contacts.
Claim 5
Independent Claim
186 words
The method of producing a mating electrical connector for a pre-existing electrical connector, said pre-existing connector having a plurality of connector contacts, comprising the steps of: selecting a desired corresponding plurality of mating connector contacts from a supply of such contacts, each of which includes an anchorable portion thereon; attaching said selected connector contacts to corresponding wires as desired; installing each one of said selected connector contact into engagement with a corresponding one of the plurality of connector contacts of said pre-existing connector; wrapping a strip of Mylar material about the face of said pre-existing connector to form therewith a reservoir, said reservoir surrounding and at least partially containing said installed selected mating connector contacts; filling said reservoir to a predetermined depth with thermoplastic material in the flowable state; cooling said thermoplastic material at room temperature to the solid state by which said thermoplastic material hardens to the solid state to define a connector body having said installed mating connector contacts anchored therewithin; and removing said strip of Mylar material, whereby said formed connector remains in mating engagement with said pre-existing connector and is detachable therefrom.
Claim 6
Independent Claim
186 words
The method of producing a mating electrical connector for a pre-existing electrical connector, said pre-existing connector having a plurality of connector contacts, comprising the steps of: selecting a desired corresponding plurality of mating connector contacts from a supply of such contacts, each of which includes an anchorable portion thereon; attaching said selected connector contacts to corresponding wires as desired; installing each one of said selected connector contact into engagement with a corresponding one of the plurality of connector contacts of said pre-existing connector; wrapping a strip of Mylar material about the face of said pre-existing connector to form therewith a reservoir, said reservoir surrounding and at least partially containing said installed selected mating connector contacts; filling said reservoir to a predetermined depth with thermoplastic material in the flowable state; cooling said thermoplastic material at room temperature to the solid state by which said thermoplastic material hardens to the solid state to define a connector body having said installed mating connector contacts anchored therewithin; and removing said strip of Mylar material, whereby said formed connector remains in mating engagement with said pre-existing connector and is detachable therefrom.
Claim 7
Independent Claim
165 words
The method of forming a mating electrical connector for a pre-existing connector which comprises the steps of: installing desired selected mating connector contacts in engagement with corresponding connector contacts of a pre-existing connector, at least some of said selected connector contacts having attached thereto a predetermined length of electrical wire and each of said selected contacts having an anchorable portion, and wrapping a strip of flexible nonporous heat resistant material about the face of said pre-existing connector to form a reservoir about the face of said pre-existing connector; said reservoir surrounding and including therein at least portions of said installed selected connector contacts; filling said formed reservoir to a predetermined depth above the anchorable portion of said contacts with a thermoplastic material in the flowable state; cooling said thermoplastic material to form a solid mass, whereby said thermoplastic material forms a solid connector body which is detachable from said face of said pre-existing connector and which anchors therein each of said installed selected connector contacts.
Claim 8
Independent Claim
165 words
The method of forming a mating electrical connector for a pre-existing connector which comprises the steps of: installing desired selected mating connector contacts in engagement with corresponding connector contacts of a pre-existing connector, at least some of said selected connector contacts having attached thereto a predetermined length of electrical wire and each of said selected contacts having an anchorable portion, and wrapping a strip of flexible nonporous heat resistant material about the face of said pre-existing connector to form a reservoir about the face of said pre-existing connector; said reservoir surrounding and including therein at least portions of said installed selected connector contacts; filling said formed reservoir to a predetermined depth above the anchorable portion of said contacts with a thermoplastic material in the flowable state; cooling said thermoplastic material to form a solid mass, whereby said thermoplastic material forms a solid connector body which is detachable from said face of said pre-existing connector and which anchors therein each of said installed selected connector contacts.
Claim 9
Dependent Claim
54 words
The method defined in claim 5 wherein the step of wrapping said strip includes the step of abutting a portion of the width of said strip with the sides of said connector which surrounds said face of said pre-existing connector with the remaining width portion of said strip extending out from said connector face.
Claim 10
Dependent Claim
48 words
The method as defined in claim 6 wherein said step of filling said reservoir includes the steps of heating a thermoplastic cartridge from the solid state to the flowable state, forcing said heated flowable thermoplastic through a nozzle and directing the output from said nozzle into said reservoir.
Claim 11
Dependent Claim
47 words
The method as defined in claim 5 wherein said step of filling said reservoir includes the steps of heating a thermoplastic cartridge from the solid state to the flowable state, forcing said flowable thermoplastic through a nozzle and directing the output from said nozzle into said reservoir.
Claim 12
Independent Claim
157 words
The method of forming a mating electrical connector for a pre-existing connector which comprises the steps of: wrapping a strip of flexible material about the face of said pre-existing connector to form a reservoir about the face of the pre-existing connector, said reservoir having said connector face as a bottom and extending outwardly therefrom a predetermined distance and installing selected mating connector contacts in engagement with corresponding connector contacts of said pre-existing connector, at least some of said selected connector contacts having attached thereto a predetermined length of electrical wire and all of said selected connector contacts having anchorable portions; filling said formed reservoir to a predetermined depth with a thermoplastic material in flowable form; hardening said thermoplastic material to the solid state to form a solid mass whereby said thermoplastic material forms a solid connector body which is detachable from said face of said pre-existing connector and which holds each of said installed selected connector terminals.
Claim 13
Independent Claim
157 words
The method of forming a mating electrical connector for a pre-existing connector which comprises the steps of: wrapping a strip of flexible material about the face of said pre-existing connector to form a reservoir about the face of the pre-existing connector, said reservoir having said connector face as a bottom and extending outwardly therefrom a predetermined distance and installing selected mating connector contacts in engagement with corresponding connector contacts of said pre-existing connector, at least some of said selected connector contacts having attached thereto a predetermined length of electrical wire and all of said selected connector contacts having anchorable portions; filling said formed reservoir to a predetermined depth with a thermoplastic material in flowable form; hardening said thermoplastic material to the solid state to form a solid mass whereby said thermoplastic material forms a solid connector body which is detachable from said face of said pre-existing connector and which holds each of said installed selected connector terminals.
Claim 14
Independent Claim
131 words
The method of forming a mating electrical connector for a pre-existing connector which comprises the steps of: installing selected mating connector terminals in engagement with corresponding connector terminals of a pre-existing installed connector and wrapping a strip of flexible material about the face of said pre-existing connector to form a reservoir about the face of said pre-existing connector, said reservoir surrounding and including therein at least portions of said installed selected connector terminals; filling said formed reservoir to a predetermined depth with a hardenable material in the flowable state; hardening said material to the solid state to form a solid mass, whereby said hardenable material forms a solid connected body which is detachable from said face of said pre-existing connector and which holds therein each of said installed selected connector terminals.
Claim 15
Independent Claim
131 words
The method of forming a mating electrical connector for a pre-existing connector which comprises the steps of: installing selected mating connector terminals in engagement with corresponding connector terminals of a pre-existing installed connector and wrapping a strip of flexible material about the face of said pre-existing connector to form a reservoir about the face of said pre-existing connector, said reservoir surrounding and including therein at least portions of said installed selected connector terminals; filling said formed reservoir to a predetermined depth with a hardenable material in the flowable state; hardening said material to the solid state to form a solid mass, whereby said hardenable material forms a solid connected body which is detachable from said face of said pre-existing connector and which holds therein each of said installed selected connector terminals.
Claim 16
Dependent Claim
57 words
The method as defined in claim 10 wherein said step of wrapping said strip includes the step of abutting a portion of the width of said strip with the sides of said connector which surrounds said face of said pre-existing connector with the remaining substantial portion of the width of said strip extending outwardly from said face.
Claim 17
Dependent Claim
49 words
The method as defined in claim 11 wherein said hardenable material comprises a thermoplastic material and the steps of filling said reservoir include heating said thermoplastic material to the flowable plastic state, forcing said flowable material through a nozzle and directing the output from said nozzle into said reservoir.
Claim 18
Dependent Claim
16 words
The method as defined in claim 6 including the step, after cooling, of removing said strip.
Claim 19
Dependent Claim
16 words
The method as defined in claim 11 including the step, after hardening, of removing said strip.
Claim 20
Dependent Claim
16 words
The method as defined in claim 12 including the step, after hardening, of removing said strip.
Claim 21
Dependent Claim
16 words
The method as defined in claim 8 including the step, after cooling, of removing said strip.
Claim 22
Dependent Claim
13 words
The method as defined in claim 10 wherein said wide strip comprises: Mylar.
Claim 23
Dependent Claim
15 words
The method as defined in claim 5 wherein said thermoplastic material comprises low density polyethylene.
Claim 24
Dependent Claim
21 words
The method as defined in claim 2 which includes the step, prior to filling, of heating said selected mating connector contacts.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1975-05-23 | 1975-11-22 | 1976-05-23 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1979-05-23 | 1979-11-22 | 1980-05-23 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1983-05-23 | 1983-11-22 | 1984-05-23 | $7700.00 | Window Closed / Lapsed |