Method for making a screw-on electrical connector

Claim 1

A method of making an electrical connector of the screw-on type which includes a shell of thermoplastic insulating material having a central bore closed at one end by an integral end wall and open at the other end for the reception of the stripped ends of two or more electric wires and a generally tapered wire coil of a size and shape to be disposed in the central bore and arranged to receive and to be turned down on the stripped ends of the wires by rotation of the shell relative to the wires, including the steps of disposing the shell and coil in aligned relation, the small end of the coil toward the open end of the bore of the cap, causing the coil and shell to be brought together with the coil in the bore of the shell, applying sufficient heat to the bore of the shell to soften it and cause it to flow into an adherent relation with outer portions of the coil, and discontinuing the heating step when sufficient interlock has been created between the exterior of the coil and the interior of the shell such that the thus created interlock will be sufficient to withstand the forces applied thereto when the connector is turned down on the stripped ends of a plurality of electric wires.

Claim 2

A method of making an electrical connector of the screw-on type which includes a shell of thermoplastic insulating material having a central bore closed at one end by an integral end wall and open at the other end for the reception of the stripped ends of two or more electric wires and a generally tapered wire coil of a size and shape to be disposed in the central bore and arranged to receive and to be turned down on the stripped ends of the wires by rotation of the shell relative to the wires, including the steps of disposing the shell and coil in aligned relation, the small end of the coil toward the open end of the bore of the cap, causing the coil and shell to be brought together with the coil in the bore of the shell, applying sufficient heat to the bore of the shell to soften it and cause it to flow into an adherent relation with outer portions of the coil, and discontinuing the heating step when sufficient interlock has been created between the exterior of the coil and the interior of the shell such that the thus created interlock will be sufficient to withstand the forces applied thereto when the connector is turned down on the stripped ends of a plurality of electric wires.

Claim 6

A method of making an electrical connector of the screw-on type which includes a shell of insulating thermoplastic material having a central bore closed at one end by an integral end wall and open at the other end with a generally tapered wire coil therein of a size and shape to be disposed in the central bore of the shell and arranged to receive and be turned down on the stripped end of two or more electric wires by rotation of the shell, including the steps of disposing the shell and coil in a generally axially aligned relationship with the small end of the coil disposed toward the open end of the shell, causing the shell and coil to be brought together with the coil and the bore of the shell with the small ends and large ends of each in juxtaposition and a substantial portion of the exterior of the coil in contact with the interior of the shell, applying electromagnetic energy thereto in a frequency range that will cause the coil to heat up sufficiently to soften the plastic of the shell in contact therewith to cause the areas of contact of the plastic to soften and flw into an adherent interlocked relation with portions of the coil and terminating the application of the electromagnetic energy after a period of time sufficient to create an interlock between the coil and shell that will withstand the forces applied thereto when the resultant connector is being turned down on the stripped ends of a plurality of electric wire.

Claim 7

A method of making an electrical connector of the screw-on type which includes a shell of insulating thermoplastic material having a central bore closed at one end by an integral end wall and open at the other end with a generally tapered wire coil therein of a size and shape to be disposed in the central bore of the shell and arranged to receive and be turned down on the stripped end of two or more electric wires by rotation of the shell, including the steps of disposing the shell and coil in a generally axially aligned relationship with the small end of the coil disposed toward the open end of the shell, causing the shell and coil to be brought together with the coil and the bore of the shell with the small ends and large ends of each in juxtaposition and a substantial portion of the exterior of the coil in contact with the interior of the shell, applying electromagnetic energy thereto in a frequency range that will cause the coil to heat up sufficiently to soften the plastic of the shell in contact therewith to cause the areas of contact of the plastic to soften and flw into an adherent interlocked relation with portions of the coil and terminating the application of the electromagnetic energy after a period of time sufficient to create an interlock between the coil and shell that will withstand the forces applied thereto when the resultant connector is being turned down on the stripped ends of a plurality of electric wire.