Method of mounting electrical contacts within a connector body

Claim 1

A method of manufacturing an electrical connector component comprising the steps of: providing a thermoplastic insulator having a flat forward face and a flat rear face; forming a bore in the insulator having a passage opening at the forward face and a second smaller passage opening at the rear face defining at the junction of the two passages a forward facing radial shoulder; inserting into the passage in the insulator an electrical contact having a forward portion and a rear portion separated by a collar thereon that has a rearward facing shoulder that engages the forward facing shoulder of the insert; inserting a ring-shaped piece of thermoplastic material over the forward portion of said contact until it engages the forward facing shoulder thereon; and applying sufficient heat and pressure against the ring-shaped piece of thermoplastic material so as to cause the thermoplastic material of the ring and the insulator to bond together in a manner such that the forward face remains substantially flat, whereby the material when cooled provides an annular abutment against the contact collar that prevents the contact from being withdrawn from the bore in the insulator.

Claim 2

A method of manufacturing an electrical connector component comprising the steps of: providing a thermoplastic insulator having a flat forward face and a flat rear face; forming a bore in the insulator having a passage opening at the forward face and a second smaller passage opening at the rear face defining at the junction of the two passages a forward facing radial shoulder; inserting into the passage in the insulator an electrical contact having a forward portion and a rear portion separated by a collar thereon that has a rearward facing shoulder that engages the forward facing shoulder of the insert; inserting a ring-shaped piece of thermoplastic material over the forward portion of said contact until it engages the forward facing shoulder thereon; and applying sufficient heat and pressure against the ring-shaped piece of thermoplastic material so as to cause the thermoplastic material of the ring and the insulator to bond together in a manner such that the forward face remains substantially flat, whereby the material when cooled provides an annular abutment against the contact collar that prevents the contact from being withdrawn from the bore in the insulator.

Claim 3

A method of mounting electrical contacts which comprises the steps of: forming a body of thermoplastic material having a flat face on one side and a face on the opposite side that includes a plurality of truncated cones, each of said cones having a bore therethrough that extends to the opposite face of the body, each of said bores having an enlarged bore portion on the side of the body having the truncated cones thereon, the enlarged portion of the bore forming a shoulder at the interface with the remaining smaller portion of the bore; inserting into the bore in the thermoplastic body from the side having the cones an electrical contact having a forward portion and a rear portion separated by a collar thereon that engages the shoulder of the thermoplastic body; and applying sufficient heat to the truncated cone portion of the thermoplastic insert to cause the thermoplastic material to move radially inwardly and abut the other shoulder of said collar, whereby the material when cool provides an annular abutment against the contact collar that prevents the contact from being withdrawn from the bore in the insulator.

Claim 4

A method of mounting electrical contacts which comprises the steps of: forming a body of thermoplastic material having a flat face on one side and a face on the opposite side that includes a plurality of truncated cones, each of said cones having a bore therethrough that extends to the opposite face of the body, each of said bores having an enlarged bore portion on the side of the body having the truncated cones thereon, the enlarged portion of the bore forming a shoulder at the interface with the remaining smaller portion of the bore; inserting into the bore in the thermoplastic body from the side having the cones an electrical contact having a forward portion and a rear portion separated by a collar thereon that engages the shoulder of the thermoplastic body; and applying sufficient heat to the truncated cone portion of the thermoplastic insert to cause the thermoplastic material to move radially inwardly and abut the other shoulder of said collar, whereby the material when cool provides an annular abutment against the contact collar that prevents the contact from being withdrawn from the bore in the insulator.

Claim 5

A method of mounting electrical contacts which comprises the steps of: forming a body of thermoplastic material having a flat face on one side and a face on the opposite side that includes a plurality of truncated cones, each of said cones having a bore therethrough that extends to the opposite face of the body, each of said bores having a larger cross-sectional area on the side of the body having the truncated cones thereon, the enlarged portion of the passage forming a shoulder at the interface with the smaller passage; inserting into the passage in the thermoplastic body an electrical contact having a forward portion and a rear portion separated by a collaR thereon that engages the shoulder of the thermoplastic body; and applying sufficient heat and pressure against the truncated cone portion of the thermoplastic insulator surrounding the contact as to cause the thermoplastic material to abut the collar on the contact whereby when the thermoplastic material cools, the contact is prevented from being withdrawn from the bore by the deformed thermoplastic material.

Claim 6

A method of mounting electrical contacts which comprises the steps of: forming a body of thermoplastic material having a flat face on one side and a face on the opposite side that includes a plurality of truncated cones, each of said cones having a bore therethrough that extends to the opposite face of the body, each of said bores having a larger cross-sectional area on the side of the body having the truncated cones thereon, the enlarged portion of the passage forming a shoulder at the interface with the smaller passage; inserting into the passage in the thermoplastic body an electrical contact having a forward portion and a rear portion separated by a collaR thereon that engages the shoulder of the thermoplastic body; and applying sufficient heat and pressure against the truncated cone portion of the thermoplastic insulator surrounding the contact as to cause the thermoplastic material to abut the collar on the contact whereby when the thermoplastic material cools, the contact is prevented from being withdrawn from the bore by the deformed thermoplastic material.

Claim 7

A method of manufacturing an electrical connector component comprising the steps of: providing a thermoplastic insulator having a first flat face and a second face; forming a bore in the insulator having a first passage opening at the first face and a second smaller passage opening at the second face defining at the junction of the two passages a radial shoulder; inserting into the passage in the insulator an electrical contact having a forward portion and a rear portion separated by a collar thereon that has two shoulders facing in opposite directions, one of which engages the shoulder of the insert; inserting a ring-shaped piece of thermoplastic material over the contact until it engages the other shoulder of said collar; and applying sufficient heat and pressure against the ring-shaped piece of thermoplastic material so as to cause the thermoplastic material of the ring and the insulator to bond together in a manner such that the forward face remains substantially flat, whereby the material, when cooled, provides an annular abutment against the contact collar that prevents the contact from being withdrawn from the bore in the insulator.

Claim 8

A method of manufacturing an electrical connector component comprising the steps of: providing a thermoplastic insulator having a first flat face and a second face; forming a bore in the insulator having a first passage opening at the first face and a second smaller passage opening at the second face defining at the junction of the two passages a radial shoulder; inserting into the passage in the insulator an electrical contact having a forward portion and a rear portion separated by a collar thereon that has two shoulders facing in opposite directions, one of which engages the shoulder of the insert; inserting a ring-shaped piece of thermoplastic material over the contact until it engages the other shoulder of said collar; and applying sufficient heat and pressure against the ring-shaped piece of thermoplastic material so as to cause the thermoplastic material of the ring and the insulator to bond together in a manner such that the forward face remains substantially flat, whereby the material, when cooled, provides an annular abutment against the contact collar that prevents the contact from being withdrawn from the bore in the insulator.

Claim 9

A method of mounting electrical contacts which comprises the steps of: forming a body of thermoplastic material having a first face of one side that includes a plurality of projections, each of said projections having a bore therethrough that extends to an opposite second face of the body, each of said bores having a first section and a second smaller section coaxial therewith that terminates on the other side of said thermoplastic body, the enlarged section of the bore forming a shoulder at the interface with the smaller section of the bore; inserting into the passage in the thermoplastic body from the first face side an electrical contact having a forward portion and a rear portion separated by a collar thereon having a first and second shoulder, one of which engages the shoulder of the thermoplastic body; and applying sufficient heat and pressure to the projecting portion of the thermoplastic insert to cause the thermoplastic material to abut said other shoulder of said contact collar, whereby the material when cool provides an annular abutment against the contact collar that prevents the contact from being withdrawn from the bore in the insulator.

Claim 10

A method of mounting electrical contacts which comprises the steps of: forming a body of thermoplastic material having a first face of one side that includes a plurality of projections, each of said projections having a bore therethrough that extends to an opposite second face of the body, each of said bores having a first section and a second smaller section coaxial therewith that terminates on the other side of said thermoplastic body, the enlarged section of the bore forming a shoulder at the interface with the smaller section of the bore; inserting into the passage in the thermoplastic body from the first face side an electrical contact having a forward portion and a rear portion separated by a collar thereon having a first and second shoulder, one of which engages the shoulder of the thermoplastic body; and applying sufficient heat and pressure to the projecting portion of the thermoplastic insert to cause the thermoplastic material to abut said other shoulder of said contact collar, whereby the material when cool provides an annular abutment against the contact collar that prevents the contact from being withdrawn from the bore in the insulator.

Claim 11

A method of mounting electrical contacts which comprises the steps of: forming a body of thermoplastic material having a first face on one side and a second face on the opposite side that includes a plurality of projections, each of said projections having a bore therethrough that extends from the first face to the opposite second face of the body, each of said bores having an enlarged section and a coaxial smaller section, the enlarged section of the bore forming a shoulder at the interface with the smaller section; inserting into the passage in the thermoplastic body an electrical contact having a forward portion and a rear portion separated by a collar thereon that engages the shoulder of the thermoplastic body; and applying sufficient heat and pressure to the projections to cause the thermoplastic material to move radially inwardly and abut the collar on the contact on both sides thereof, whereby when the thermoplastic material cools, the contact is prevented from being withdrawn from the bore in the insulator.

Claim 12

A method of mounting electrical contacts which comprises the steps of: forming a body of thermoplastic material having a first face on one side and a second face on the opposite side that includes a plurality of projections, each of said projections having a bore therethrough that extends from the first face to the opposite second face of the body, each of said bores having an enlarged section and a coaxial smaller section, the enlarged section of the bore forming a shoulder at the interface with the smaller section; inserting into the passage in the thermoplastic body an electrical contact having a forward portion and a rear portion separated by a collar thereon that engages the shoulder of the thermoplastic body; and applying sufficient heat and pressure to the projections to cause the thermoplastic material to move radially inwardly and abut the collar on the contact on both sides thereof, whereby when the thermoplastic material cools, the contact is prevented from being withdrawn from the bore in the insulator.