Pre-loaded electrical connectors, assembly apparatus and method

Claim 1

A method of connecting predetermined conductors to predetermined terminals in each of two mateable electrical connectors said connectors having a row of contact terminals therein, each terminal occupying a distinct position in said row in one connector and corresponding to the terminal in the same position in the other connector, each contact terminal having a contact portion and a conductor-receiving portion which is adapted to receive a conductor upon movement of said conductor laterally of its axis towards said conductor receiving portion, said method comprising the steps of: positioning said connectors adjacent to each other with said row of terminals in each connector extending substantially parallel to the row of terminals in the other connector, and with the said contact portion of each row proximate to the contact portion of the said terminals in the other row and the said wire-receiving portions remote from each other, locating intermediate portions of said conductors across said rows with the axes of each conductor in alignment with the said conductor-receiving portions of two corresponding terminals in each of said rows, said connectors being positioned so that each pair of corresponding terminals is in alignment, moving said conductors laterally of their axes towards said terminals and securing each conduCtor to the conductorreceiving portions of two opposed corresponding terminals, and cutting out the portion of each conductor which extends between each pair of corresponding terminals.

Claim 2

A method of connecting predetermined conductors to predetermined terminals in each of two mateable electrical connectors said connectors having a row of contact terminals therein, each terminal occupying a distinct position in said row in one connector and corresponding to the terminal in the same position in the other connector, each contact terminal having a contact portion and a conductor-receiving portion which is adapted to receive a conductor upon movement of said conductor laterally of its axis towards said conductor receiving portion, said method comprising the steps of: positioning said connectors adjacent to each other with said row of terminals in each connector extending substantially parallel to the row of terminals in the other connector, and with the said contact portion of each row proximate to the contact portion of the said terminals in the other row and the said wire-receiving portions remote from each other, locating intermediate portions of said conductors across said rows with the axes of each conductor in alignment with the said conductor-receiving portions of two corresponding terminals in each of said rows, said connectors being positioned so that each pair of corresponding terminals is in alignment, moving said conductors laterally of their axes towards said terminals and securing each conduCtor to the conductorreceiving portions of two opposed corresponding terminals, and cutting out the portion of each conductor which extends between each pair of corresponding terminals.

Claim 4

A method of connecting predetermined conductors to terminals in each of two multi-contact electrical connectors or the like, said connectors being of the type comprising an insulating housing having said contact terminals therein, each of said terminals having a conductor receiving portion which is adapted to receive a conductor upon movement of said conductor laterally of its axis and into said conductor receiving portion, said conductor receiving portions in each of said connectors being arranged in side-by-side relationship in a row, said method comprising the steps of: positioning said two connectors in side-by-side relationship with said rows of conductor receiving portions extending parallel to each other and with corresponding conductor-receiving portions in said two rows in alignment, locating said conductors in parallel side-by-side relationship with the axes of said conductors extending normally, and across, said rows and with the spacing between adjacent conductors being equal to the spacing between adjacent conductor-receiving portions in said rows, severing said conductors along at least one severing line which extends between said rows, and moving said conductors laterally of their axes and into said conductor-receiving portions.

Claim 5

A method of connecting predetermined conductors to terminals in each of two multi-contact electrical connectors or the like, said connectors being of the type comprising an insulating housing having said contact terminals therein, each of said terminals having a conductor receiving portion which is adapted to receive a conductor upon movement of said conductor laterally of its axis and into said conductor receiving portion, said conductor receiving portions in each of said connectors being arranged in side-by-side relationship in a row, said method comprising the steps of: positioning said two connectors in side-by-side relationship with said rows of conductor receiving portions extending parallel to each other and with corresponding conductor-receiving portions in said two rows in alignment, locating said conductors in parallel side-by-side relationship with the axes of said conductors extending normally, and across, said rows and with the spacing between adjacent conductors being equal to the spacing between adjacent conductor-receiving portions in said rows, severing said conductors along at least one severing line which extends between said rows, and moving said conductors laterally of their axes and into said conductor-receiving portions.

Claim 6

The method set forth in claims 3, said rows being spaced apart by a predetermined distance, said severing step being carried out by severing said conductors along two parallel severing lines, each of said severing lines being between said rows and being adjacent to one of said rows.