Method of fabricating a connector using a pre-molded connector structure

Claim 1

A method of fabricating a connector, comprising the steps of: providing a pre-molded connector structure including at least one terminal connected to and projecting from a core; providing a mold device including at least two mold members with each mold member having a cavity formed therein; enveloping the pre-molded connector structure within the respective cavities of the at least two mold members whereby the core of the pre-molded connector structure and the at least two mold members contact each other to form a molding cavity about a molding portion of the core and a receiving cavity sized to receive a non-molding portion of the core and the at least one terminal without the at least one terminal contacting the at least two mold members; and causing a molten molding material to enter into and occupy the molding cavity without the molten molding material migrating into the receiving cavity.

Claim 2

A method of fabricating a connector, comprising the steps of: providing a pre-molded connector structure including at least one terminal connected to and projecting from a core; providing a mold device including at least two mold members with each mold member having a cavity formed therein; enveloping the pre-molded connector structure within the respective cavities of the at least two mold members whereby the core of the pre-molded connector structure and the at least two mold members contact each other to form a molding cavity about a molding portion of the core and a receiving cavity sized to receive a non-molding portion of the core and the at least one terminal without the at least one terminal contacting the at least two mold members; and causing a molten molding material to enter into and occupy the molding cavity without the molten molding material migrating into the receiving cavity.

Claim 3

A method of fabricating a connector, comprising the steps of: providing a pre-molded terminal structure including a core and at least one terminal connected to and extending through the core, the terminal having a first terminal end section projecting from one surface of the core and a second terminal end section projecting from another surface of the core; providing a mold device including a first mold member, a second mold member and a third mold member, each of the first, second and third mold members having a cavity formed therein; enveloping the pre-molded terminal structure within the respective cavities of the first, second and third mold members whereby respective ones of two of the first, second and third mold members contact the core of the pre-molded connector structure and form respective receiving cavities about the first and second terminal end sections of the terminal without the first and second terminal end sections contacting the respective ones of the two of the first, second and third mold members and a remaining one of the first, second and third mold members contacting respective ones of the two of the first, second and third mold members to form a molding cavity about the core; and causing a molten molding material to enter into and occupy the molding cavity whereby the receiving cavities are isolated from the molding cavity in a manner to prevent migration of the molten molding material into either one of the receiving cavities.

Claim 4

A method of fabricating a connector, comprising the steps of: providing a pre-molded terminal structure including a core and at least one terminal connected to and extending through the core, the terminal having a first terminal end section projecting from one surface of the core and a second terminal end section projecting from another surface of the core; providing a mold device including a first mold member, a second mold member and a third mold member, each of the first, second and third mold members having a cavity formed therein; enveloping the pre-molded terminal structure within the respective cavities of the first, second and third mold members whereby respective ones of two of the first, second and third mold members contact the core of the pre-molded connector structure and form respective receiving cavities about the first and second terminal end sections of the terminal without the first and second terminal end sections contacting the respective ones of the two of the first, second and third mold members and a remaining one of the first, second and third mold members contacting respective ones of the two of the first, second and third mold members to form a molding cavity about the core; and causing a molten molding material to enter into and occupy the molding cavity whereby the receiving cavities are isolated from the molding cavity in a manner to prevent migration of the molten molding material into either one of the receiving cavities.