Modular plug coupler

Claim 2

An electrical coupler which can electrically interconnect two identical electrical plugs, the coupler comprising: a first insulative housing member comprising a front mating face having a plug receiving opening therein, and a rear face having a pocket recessed from the rear face, the housing further comprising laterally aligned vertical grooves in the rear face which are in transition with channels which extend from the grooves to a position proximate the front mating face; a second housing member comprising a front mating face having a second plug receiving opening therein, the second housing member having a mounting face which abuts the rear face of the first housing member, and a second plurality of laterally aligned grooves; and a terminal subassembly which includes a plurality of electrically conductive contact elements integrally insert molded and encapsulated within a web of insulative material intermediate the ends of the contact elements, the subassembly being formed with the web profiled slightly smaller than the pocket for receipt within the recessed pocket, with the web and intermediate portions of the contact elements extending parallel to the front mating face, with first sections of the intermediate portions extending from one side edge of the web and disposed within the laterally aligned grooves and thereafter formed to extend forward towards the front mating face, and thereafter reversely bent to extend diagonally inwardly, thereby forming a first plurality of contact members; the terminal subassembly further comprising second sections of the intermediate portions extending from an opposite side of the web as the first said sections, the second sections forming a second plurality of contact members.

Claim 3

The coupler of claim 1 wherein the front mating face of the two housing members are parallel and profiled for receipt of the matable plugs with the plugs oriented in a facing relationship and rotated 180° relative to each other.

Claim 4

The coupler of claim 2 wherein the mounting face of the second housing member is a rear face.

Claim 5

The coupler of claim 1 wherein the front mating faces of the two housing members are perpendicular and profiled for receipt of the matable plugs when the plugs are at a right angle relative to each other.

Claim 6

The coupler of claim 4 wherein the mounting face is a bottom face.

Claim 7

The coupler of claim 1 wherein the channels in the first housing member are within a top wall which defines the upper extent of the plug receiving opening.

Claim 8

The coupler of claim 6 wherein the conductive contact elements are formed from round wire.

Claim 9

An electrical coupler which can electrically interconnect two identical electrical plugs, the coupler comprising: a first insulative housing member comprising a front mating face having a plug receiving opening therein, and a rear face having a recessed pocket therein, the housing further comprising laterally aligned grooves in the rear face which are in transition with channels which extend from the grooves to a position proximate the front mating face, the housing further comprising at least two apertures extending through the rear face, straddling the said grooves, with access to forwardly facing latch surfaces which are accessible through the plug receiving opening; a second housing member comprising a front mating face having a second plug receiving opening therein, the second housing member having a second plurality of laterally aligned grooves, the second housing member further comprising a mounting face which abuts the rear face of the first housing member, the mounting face including at least two latching arms extending therefrom, which are insertable through the apertures of the first housing member, the latching arms having latching surfaces which are cooperable with the latch surfaces of the first housing member to retain the first and second housing members together; and a plurality of electrically conductive contact elements, wherein the plurality of conductive contact elements are formed into a terminal subassembly with an integral web insert molded over the contact elements spanning the lateral extent of the contact elements intermediate their ends, with first sections of the contact elements disposed within the laterally aligned grooves, extending forward towards the front mating face, and then reversely bent to extend diagonally inwardly, thereby forming a first plurality of contact members; the contact elements further comprising second sections extending in an opposite direction from the first said sections, the second sections including second reversely bent portions disposed within the second plurality of laterally aligned grooves thereby forming the second plurality of contact members, whereby the web is profiled similar to the pocket for receipt therein of the web and the first and second housing members are latchable one to the other to latch the housings together with the web retentively trapped therebetween.

Claim 10

An electrical coupler which can electrically interconnect two identical electrical plugs, the coupler comprising: a first insulative housing member comprising a front mating face having a plug receiving opening therein, and a rear face having a recessed pocket therein, the housing further comprising laterally aligned grooves in the rear face which are in transition with channels which extend from the grooves to a position proximate the front mating face, the housing further comprising at least two apertures extending through the rear face, straddling the said grooves, with access to forwardly facing latch surfaces which are accessible through the plug receiving opening; a second housing member comprising a front mating face having a second plug receiving opening therein, the second housing member having a second plurality of laterally aligned grooves, the second housing member further comprising a mounting face which abuts the rear face of the first housing member, the mounting face including at least two latching arms extending therefrom, which are insertable through the apertures of the first housing member, the latching arms having latching surfaces which are cooperable with the latch surfaces of the first housing member to retain the first and second housing members together; and a plurality of electrically conductive contact elements, wherein the plurality of conductive contact elements are formed into a terminal subassembly with an integral web insert molded over the contact elements spanning the lateral extent of the contact elements intermediate their ends, with first sections of the contact elements disposed within the laterally aligned grooves, extending forward towards the front mating face, and then reversely bent to extend diagonally inwardly, thereby forming a first plurality of contact members; the contact elements further comprising second sections extending in an opposite direction from the first said sections, the second sections including second reversely bent portions disposed within the second plurality of laterally aligned grooves thereby forming the second plurality of contact members, whereby the web is profiled similar to the pocket for receipt therein of the web and the first and second housing members are latchable one to the other to latch the housings together with the web retentively trapped therebetween.

Claim 11

The coupler of claim 8 wherein the front mating faces of the two housing members are parallel and profiled for receipt of the matable plugs with the plugs oriented in a facing relationship and rotated 180° relative to each other.

Claim 12

The coupler of claim 9 wherein the mounting face of the second housing member is a rear face.

Claim 13

The coupler of claim 8 wherein the front mating faces of the two housing members are perpendicular and profiled for receipt of the matable plugs when the plugs are at a right angle relative to each other.

Claim 14

The coupler of claim 11 wherein the mounting face is a bottom face.

Claim 15

The coupler of claim 8 wherein the channels in the first housing member are within a top wall which defines the upper extent of the plug receiving opening.