Method of making an electrical connector

• US 7,114,247 B2
• Filed: 10/27/2004
• Issued: 10/03/2006
• Est. Priority Date: 10/27/2004
• Status: Expired due to Fees

• Current Assignee: Carrec International, Ltd.
• Original Assignee: OSRAM Sylvania Inc. (Ams-Osram AG)
• Inventors: Brown, Shane, Seymour, Douglas G., Swantner, Michael J.
• Primary Examiner(s): Tugbang, A. Dexter
• Assistant Examiner(s): NGUYEN, TAI V
• Application Number:
  US10/974,345
• Publication Number:
  US 20060085977A1
• Time in Patent Office: 706 Days
• Field of Search: 297/47, 298/84, 298/37, 298/57, 298/58, 439/374, 439/246, 439/401, 439/624, 439/66
• US Class Current: 29/747
• CPC Class Codes: H01R 13/504 different pieces being moulded, cemented, welded, e.g. ultrasonic, or swaged together
• CPC Class Codes: H01R 43/24 Assembling by moulding on contact members
• CPC Class Codes: Y10T 29/49139 by inserting component lead or terminal into base aperture
• CPC Class Codes: Y10T 29/49174 Assembling terminal to elongated conductor
• CPC Class Codes: Y10T 29/49176 with molding of electrically insulating material
• CPC Class Codes: Y10T 29/49222 forming array of contacts or terminals
• CPC Class Codes: Y10T 29/53209 Terminal or connector

Abstract

A method of making an electrical connector comprises the steps of: forming an electrically conductive member having a body including an interface, the body having a longitudinal chamber therein; forming an electrically conductive pin; overmolding the interface with a first electrically insulating material; overmolding at least a part of the electrically conductive pin with a second electrically insulating material to form an overmolded electrically conductive pin; and inserting the overmolded electrically conductive pin into the longitudinal chamber.

Claims

1. A method of making an electrical connector comprising the steps of:

forming an electrically conductive member having a body including an interface, said body having a longitudinal chamber therein;

said interface comprising a first circumferential flange, a second circumferential flange spaced therefrom, and an anti-rotation lug extending between the first and second circumferential flanges;

forming an electrically conductive pin;

overmolding said interface with a first electrically insulating material;

overmolding at least a part of said electrically conductive pin with a second electrically insulating material to form an overmolded electrically conductive pin; and

inserting said overmolded electrically conductive pin into said longitudinal chamber.

2. The method of claim 1 wherein said electrically conductive member is formed with a second chamber at a right angle to said longitudinal chamber and connected thereto.

3. The method of claim 2 wherein said electrically conductive pin is formed with two termini connected by an intermediate portion and said intermediate portion only is overmolded with said second electrically insulating material.

4. The method of claim 3 wherein said electrically conductive pin is formed with two legs at a right angle to each other and said second chamber includes locking means for engaging a part of said electrically insulating material formed about one of said legs.

5. The method of claim 1 wherein said electrically conductive member is die-cast zinc.

6. The method of claim 1 wherein said electrically conductive pin is brass.

7. The method of claim 1 wherein said first insulating material is 33% glass-filled nylon.

8. The method of claim 7 wherein said second insulating material is unfilled nylon.