Modular plug coupler

Claim 2

An electrical coupler for electrically coupling at least two similar electrical connectors, the coupler comprising: an insulative housing means having at least two mating faces for access of the two electrical connectors, where the two mating faces are transversely directed relative to each other; and a terminal subassembly disposed within the housing means, the subassembly including a plurality of solid wires spaced apart in a common plane, the wires including intermediate portions having a first and a second leg at first and second ends of the intermediate portion, and two spring contact portions extending from ends of the first and second legs, a portion of the length of the intermediate portions being integrally molded within an insulative web of material which transversely spans the wires, the intermediate portions including a deformed portion within the integral web, and the first and second legs being formed relative to the intermediate portion to dispose the spring contact portions adjacent to the mating faces of the housing means.

Claim 3

The coupler of claim 1 wherein each wire which is molded within the insulative web has an irregular cross section located within the insulative web and relative to the remainder of the contact member length.

Claim 4

The coupler of claim 1 wherein the wire comprise solid conductors having a generally round cross section.

Claim 5

The coupler of claim 3 wherein the conductors are coined at positions where the contact members are located within the insulative web.

Claim 6

The coupler of claim 1 wherein the housing means comprises two housing members with end faces which abut to form a unitary housing.

Claim 7

The electrical coupler of claim 1 wherein the two mating faces are diametrically opposed from each other.

Claim 8

An electrical coupler for electrically interconnecting two electrical plug members, the coupler comprising: an insulative housing means comprising two mating faces having openings therein for reception of the electrical plug members, a terminal member comprising a commoning section intermediate two resilient contact portions, each resilient contact portion comprising a free end of the terminal member reversely bent about a leg portion, the terminal member being disposed within the housing means with the resilient contact portions disposed adjacent to the mating faces of the coupler, the resilient contact portions being resiliently movable towards a base wall within the housing means upon reception of a plug member, and further comprising plate portions, with each plate portion being disposed adjacent to the resilient contact portions and parallel with the respective mating face, the plate portions having elongate apertures therein for receiving the free ends of the terminals and retaining them in lateral alignment, the plate portions further including at an edge thereof channels formed transversely of the plates which overlie the terminals to position said terminals against respective base walls in a laterally spaced arrangement.

Claim 9

An electrical coupler for electrically interconnecting two electrical plug members, the coupler comprising: an insulative housing means comprising two mating faces having openings therein for reception of the electrical plug members, a terminal member comprising a commoning section intermediate two resilient contact portions, each resilient contact portion comprising a free end of the terminal member reversely bent about a leg portion, the terminal member being disposed within the housing means with the resilient contact portions disposed adjacent to the mating faces of the coupler, the resilient contact portions being resiliently movable towards a base wall within the housing means upon reception of a plug member, and further comprising plate portions, with each plate portion being disposed adjacent to the resilient contact portions and parallel with the respective mating face, the plate portions having elongate apertures therein for receiving the free ends of the terminals and retaining them in lateral alignment, the plate portions further including at an edge thereof channels formed transversely of the plates which overlie the terminals to position said terminals against respective base walls in a laterally spaced arrangement.

Claim 10

The coupler of claim 7 wherein inner walls which form the mating faces, include upstanding channels for receiving the reversely bent portions of the terminals.

Claim 11

The coupler of claim 7 wherein the mating faces are parallel to each other.

Claim 12

The coupler of claim 7 wherein the mating faces are perpendicular to each other.

Claim 13

The coupler of claim 7 wherein the terminals include a molded web spanning the commoning portion which encapsulates the terminals.

Claim 14

An electrical coupler for interconnecting two like electrical plugs, the coupler comprising: a housing means including at least two mating faces along a common axial centerline, the at least two mating faces being adjacent to two base walls, the two mating faces having plug receiving openings therein extending inwardly to an interior portion of the housing means, the housing means further comprising two plate members which are parallel to each other, which define an inner endwall to said openings and which are within said housing means in a transverse relation to said common axial centerline, the plates further including at an edge thereof channels formed transversely of the plates, electrical terminal means including intermediate portions and spring contact portions extending from the intermediate portions and towards the mating faces, thereafter reversely bent towards the respective plate members, the electrical terminal means being defined by a plurality of side by side conductors retained in position by an integral web which spans the conductors, the electrical terminal means being disposed within the housing means with the spring contact portions adjacent to the mating faces and the web being intermediate the plate members, and with the intermediate portions extending diagonally within the housing means to dispose base portions of the terminals in an abutting relationship with the base walls with the channels of the plates overlying the terminals to position said terminals against respective base walls in a laterally spaced arrangement.

Claim 15

An electrical coupler for interconnecting two like electrical plugs, the coupler comprising: a housing means including at least two mating faces along a common axial centerline, the at least two mating faces being adjacent to two base walls, the two mating faces having plug receiving openings therein extending inwardly to an interior portion of the housing means, the housing means further comprising two plate members which are parallel to each other, which define an inner endwall to said openings and which are within said housing means in a transverse relation to said common axial centerline, the plates further including at an edge thereof channels formed transversely of the plates, electrical terminal means including intermediate portions and spring contact portions extending from the intermediate portions and towards the mating faces, thereafter reversely bent towards the respective plate members, the electrical terminal means being defined by a plurality of side by side conductors retained in position by an integral web which spans the conductors, the electrical terminal means being disposed within the housing means with the spring contact portions adjacent to the mating faces and the web being intermediate the plate members, and with the intermediate portions extending diagonally within the housing means to dispose base portions of the terminals in an abutting relationship with the base walls with the channels of the plates overlying the terminals to position said terminals against respective base walls in a laterally spaced arrangement.

Claim 16

The coupler of claim 12 wherein the mating faces are defined along a common axial centerline.

Claim 17

The coupler of claim 13 wherein the plate members are parallel to each other thereby defing a cavity therebetween for the reception of the web portion.

Claim 18

The coupler of claim 12 wherein the mating faces are defined at a right angle with respect to each other.

Claim 19

The coupler of claim 15 wherein the housing means includes two base walls which are perpendicular to each other, and the terminal means includes base portions disposed against the base walls with the spring contact portions being reversely bent towards the base walls.

Claim 20

The coupler of claim 12 wherein the mating faces include channels interior thereof for aligning the spring contact portions of the terminal means.