Note: Descriptions are shown in the official language in which they were submitted.
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DESCRIPTION
MODULAR ELECTRICAL CONNECTOR AND
SYSTEM FOR MOLDING CONTACT SUPPORTING MODULES
BACKGROUND OF THE INVENTION
This invention relates in general to modular
electrical telephone connectors. Specifically, it is
directed to a family or set of such connectors having
identical mating ends but different terminating ends
depending upon the particular application.
Connectors for multi-conductor telephone cables
are well known. The mating ends of these connectors
generally include a plurality of flat-blade type contacts,
with male and female versions designed to cooperatively
intermate to form highly reliable, though relatively low
cost, electrical connections. Over the yearsr different
terminating ends have been provided on these connectors
such asO solder terminations; wire-wrap terminations;
insulation displacement terminations, including both com-
posite and flat cables; printed circuit terminations, etc.
Generally, a manufacturer will produce a line of such con-
nectors having a basic body style, common mating ends and
different termination ends. Examples of such connectors
are those manufactured and sold by the Amphenol North
; America Divi~ion of Bunker Ramo Corporation under the
series tradenames "57" and 9157'l.
Recently, connectors with all plastic bodies have
come into use in the telephone industryO These connec-
tors, while incorporating the same type of electrical con-
tacts as their metal-with-plastic-insert forebears~ are
capable of being molded in one piece. Understandably, the
~ ~2~
molds tend to be complex and expensive. Individual flat-
blade contacts are inserted in the connector bodies which
include cooperating means for retaining the contacts in
position. Additionally, suitable protective covers or
hoods, strain relief clamps and mounting brackets are pro-
vided, and the connector is ready for installation.
It will be appreciated that the tooling costs for
the molds to produce such connector bodies can be quite
high, especially when the molds include a lot of side
pulls, core pins and the like. A further important cost
factor is the number of mold cavities which, of course,
determines the number of parts that can be produced by the
mold in a single shot. This output capability may be
referred to as the mold throughput. Simple economics dic-
tate that large production requirements generally enableuse of high-speed efficient molding techniques, whereas
low volume molding can be quite expensive. Herein lies
the problem solved by the present invention.
Telephone connectors of the above types are
acceptable for use in many foreign countries. The par-
ticular type of termination end used may~ however, differ
from the popular domestic connector in the family. Indeed,
it is more probable that the termination ends desired are
not the same as those used in ~he domestic market.
For example, in some countries a large market
exists for telephone connectors of "standard" front end
(mating end) design but having termination ends suitable
only for printed circuits. In others, flat cable ter-
mination connectors are in demand. In yet othersl the
wire-wrap terminations are required. Unfortunately for a
manufacturer, the fact that the market for any particu-
lar connector termination configuration in any given
remote location is usually not sufficiently large to
justify the tooling costs involved. Such markets are
usually serviced by importing connectors where there is a
domestic counterpartO However, even here~ rnany oreign
countries, in a laudable effort to build up their domestic
industrial base, are encouraging home-manufacture or
assembly and consequently, discouraging importation. All
of the above points to the need for a cost-efficient way
to service these limited and remotely situated markets.
The present invention answers the problems in a
number of waysO It envisions a modularized all plastic
body connector having a maximum degree of acceptability in
the world markets with the complex common mating parts
being molded where demand will insure efficiencies and the
simpler, yet different, termination parts being molded at
the remote location~ The connector body is formed by
joining the two parts at the remote location.
While there have been two-piece telephone-type
connector bodies in the prior art, it is believed to have
been due to the difficulty of producing the connector in
one piece and not to any desire for interchangeability.
For example, one connector manufactured by DDK of Japan
includes a two-piece plastic body with one piece defining
essentially the mating part of the connector and an insert
supporting a plurality of molded-in-place contacts which
cooperate with the mating part when the insert is joined
to the finished connector. The molded-in-place contacts
apparently precluded a one-piece construction, which is
not believed feasible, if indeed possible.
Modular components of telephone-type connectors
also are in the prior art, as evidenced by United States
Letters Patents Nos. 3~760,336, 4,239,317 and 4,239,320,
all of which are assigned to the assignee of the present
invention. However, the modular concepts of these patents
are limited to providing standardized telephone plugs or
adapters, standardi~ed telephone jack connec~ors, modular
bloc~s for different sized pin and socket contacts in a
standard connector shell~ or the like. Another U.S.
Patent No. 3,885~849 discloses a ~ircular connector which
has dif~erent types of molded male and female inserts so
that different connector combinations can be obtainedO
However, no known prior art has been directed to modulari-
~ation of the connector itself for use with a wide variety
of termination systems at remote locations.
SUMMARY OF THE INVENTI ON
It is therefore an object of the present invention
to provide a new and impro~ed modular electrical telephone
connector of a standardized design for mating with a
complementary standardized connector having a plurality of
contact elements but with different terminating ends
depending on the particular application.
Another object of the present invention is to
provide a novel method and system for molding all plastic
- 10 contact-supporting connector bodies or modules of a modu-
lar electrical connector of the character described.
In accordance with these and other objects and
advantages of the invention which will become apparent
upon reading the following detailed description, the pre-
sent invention is realized in a modular electricaltelephone connector which includes molded plastic common
housing means defining a mating portion of the connector
and including a generally open-ended cavity. Molded
plastic insert means are provided including a set or
family of contact-supporting modules definir,g different
termination configurations of the connector. Each of the
modules are constructed and arranged for interchangeably
nesting in and substantially filling at least one end of
the cavity of the housing means. The contact-supporting
modules of the set thereof each supports a plurality of
contact elements different from the contact elements of
other of the modules. Of course, any number of each par-
ticular type of contact-supporting module is contemplated
Mounting means are provided for releasably securing any
one of the modules within the cavity of the housing means.
Each of the plurality of contact elements includes an
identical mating portion at one end of the cavity for
mating with a contact element of the complementary stan-
dardized connector, and a termination portion at the other
end of the cavity forming a termination configuration
defined by the selected module. Thus, the modular electri-
cal connector can be adapted for mating with the comple-
mentary connectcr and tenninating with different
1 ~8~54:~
arrangements and types of conductors by interchanging the
modulesO
The invention contemplates contact-supporting
modules of different configurations for supporting a
plurality of contact elements to effect different types of
termination. For instance, one disclosed contact-
supporting module supports a plurality of contact elements
each of which includes a termination portion for piercing
the insula~ion and establishing electrical connection with
the conductor of a single insulated wire conductor, nor-
mally comprising a strand of a multi-conductor cable.
Another disclosed contact-supporting module supports a
plurality of contact elements each of which includes a
termination portion for piercing the insulation and
lS establishing electrical connection with a conductor of a
multi-conductor flat cable. A further disclosed contact-
supporting module supports a plurality of contact elements
each of which includes a termination portion for
establishing electrical connection with a conductor of a
printed circuit board. Of course, other types of contact-
supporting modules are contemplated for different types of
termination systems, with the modules being releasably
mountable in the molded plastic common housing means.
The invention also contemplates a system or
method for molding all plastic contact~supporting modules
or bodies of an electrical connectorO More particularly~
the system includes providing at a firs~ loca~ion mold
means for molding common, standardized housings for mating
with complementary standardized electrical connectors
havin~ a plurality of contact elementsO The system
provides at each of a plurality of different locations
mold means for molding different contact-supporting modu-
les which are similarly constructed in-part for disposi-
tion within the common housings but which are diffe~rently
3~ constructed in part for supporting a plurality of contact
elements having different termination means~ With this
system the modular electrical connector can be adapted at
the different locations for terminating with different
~ ~$2~
--6--
selected conductors by utilizing the common housings
molded at the first location and interchanging the contact-
supporting modules at the respective different locations,
such as various countries throughout the world.
Accordingly, a method of efficiently producing,
at different locations, limited quantities of all plastic
connector bodies in a set of connector bodies having iden-
tical mating ends and differen~ termination ends is pro-
vided. The method comprises the steps of molding the
mating ends of the connector bodies at a first location in
high throughput molds; molding the termination ends of the
connector bodies at remote locations in low throughput
molds, each low throughput mold producing termination ends
complementary to and cooperable with any mating end from
said high throughput mold such that when joined together a
connector body in said set is produced; and joining ary of
the terrnination ends to any of the mating ends to form a
connector body.
The molding system or method as described above
is also readily adaptable for providiny mold means for
molding one piece all plastic contact-supporting modules
or bodies of an electrical connector, as well as in two
pieces. The system includes providing a first mold por-
tion for molding a common mating portion of the module and
a complementary second mold portion for molding a ter-
mination portion of the module integral with the mating
portion. A third mold portion is provided complementary
to and cooperable with the first mold portion for selec-
tively moldiny only the mating portion of the module,
corresponding to the aforesaid molded plastic housing
means of the modular connectorO A fourth mold portion is
provided complementary to and cooperable with the second
mold portion for selectively molding only ~he terrninatiOn
portion of the module, corresponding to the aforesaid
molded plastic insert means of the modular connector~
Thus, only four mold portions or cavities are required to
mold either a one-piece modular connector or a modular
connector comprising separate housing means and
interchangeable insert means in the form of contact sup-
porting modules.
Accordingly, a method of fabricating all plastic
contact-supporting connector bodies having a mating part
and a terminating part in one piece or in two pieces is
provided. The method comprises the steps of fabricating
the one-piece connector body in a two-piece mold having a
first portion for molding the mating part and a comple-
mentary second portion for molding the termination part
integral with the mating part; fabricating the mating part
of the two-piece connector in a mold consisting of the
first portion and a third portion complementary to and
cooperable with the first portion; fabricating the ter-
mination part of the two-piece connector body in a mold
consisting of the second portion and a fourth portion
complementary to and cooperable with the second portion;
and affixing parts fabricated by the last two steps,
respectively, to each other. It is contemplated that a
plurality of different second portions and a like plura-
lity of different fourth portions complementary to andcooperable with said second portions, respectively, are
provided for molding a plurality of different termination
parts for cooperahle engagement with the mating part of
the two-piece connector body.
BRIEE` DESCRIPTION OF THE DRAWINGS
The features of this invention, which are believed
to be novel and unobvious, are se~ forth with particularity
in the appended claim~. The invention, together with its
objects and advan~ages, may be best understood by
reference to the follo~ing description taken in conjunc-
tion with the accompanying drawings in which like
reference numerals identify like elements in the several
figures and in which:
FIGURE 1 is a perspective view of a modular
electrical cornector in accordance with the present inven-
tion, including a contact-supporting module for ter-
minating individual insulated wire conductors of a
multi-conductor cable, in con~unction with ~wo different
~ ~2~
types of hood means and a cable clamp means;
FIGURE 2 is an exploded perspective view of a
modular electrical connector in accordance with the pre-
sent invention, including a contact supporting module for
terminating the individual conductors of a multi-
conductor flat cable in conjunction with a cable hold-
~ down member and a pair of end clips for holding acomplementary connector;
FIGURE 3 is an exploded perspective view of a
modular electrical connector in accordance with the pre-
sent invention, including a contact-supporting module for
terminatiny the conductors of a printed circuit board
which would be disposed generally transversely of the con-
nector in conjunction with a pair of end hold-down clips
as shown in Figure 2;
FIGURE 4 is an exploded perspective view of a
modular electrical connector in accordance with the pre-
sent invention, including a contact supporting module for
terminating the conductors of a printed circuit board-
which would ~e disposed generally parallel with the axisof the connector in conjunction with mounting means for
the printed circuit board and a pair of end hold-down
clips as shown in Figure 2;
FIGURE 5 is a sectional view, on an enlarged
scale t taken generally along line 5-5 of Figure l;
FIGURE 6 is a sectional view through a pair of
opposed mold cavities for molding the common housing means
of the present invention, as particularly shown in Figure S;
FIGURE 7 is a sectional view through a pair of
opposed mold cavities for molding the contact-supporting
module shown in Figure 5;
FIG~RE 8 is a perspective view through a pair of
opposed mold cavities, including the lower cavity of
Figure 6 and the upper cavity of ~igure 7, for molding a
one-piece plastic electrical connector of the type shown
in Figure 5; and
FIGURE 9 is a somewhat schematic view
illustrating the modular electrical connector concept of
~ ~825~
the present invention, illustrating the common molded
plastic housing means in conjunction with a set of dif-
ferent contact-supporting modules.
DESCRIPTION OF TH~ PREFERRED EMBODIMENT
Referring to the drawings in greater detail, and
first to Figures 1 and 5, the invention contemplates a
modular electrical telephone connector, generally
designated 10, for mating with a complementary connector
(not shown) having a plurality of contact elements. The
connectors are of a general, standardized type, such as the
connector of Bunker Ramo Corporation sold under the trade-
names "57" and "157" Series. Connector 10 includes molded
plastic housing means 12 which has a configuration
elongated generally transversely of open-ended cavity
means 14. Molded plastic insert means is provided in the
form of a contact-supporting module 16 which is
constructed and arranged for interchangeably nesting in
and substantially filling one end of the cavity means.
Referring to Figure 5, the open-ended cavity means includes
an upper or "rear" end 14a for receiving contact-
supporting module 16, and a lower or "front'; end 14b for
mating with the complementary connector. Passages 18 com-
municate between cavity ends 14a, 14b and through which
insulation-piercing contact elements generally designated
20, extend. Each contact element includes a mating portion
20a exposed within cavity end 14b for mating with a con-
tact element of the complementary connector and a ter-
mination portion 20b extending through cavity end 14a and
accessible through tbe sides of module 16 for terminating
with individual conductors. Termination portion 20b of
each contact has a known channel configuration for
piercing the insulation of a single insulated wire conduc-
tor of a multi-conductor cable~ The individual insulated
wire conductors are terminated to the contacts through
slots 22 molded into opposite sides of an upwardly-
protruding portion 24 of contact supporting module 16.
Mating portions 20a of contacts 20 are aligned with slots
26 molded in opposite sides of an internal rib 28 f
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--10--
housing 12 which defines the mating portion of the connec
tor.
As shown in Figure 1, housing 10 has a pair of
end flanges 30 and side ribs 32. End flanges 30 have
through holes 34. The invention contemplates providing
modular components such as hoods 36 and 38 and a cable
clamp 40 for use in conjunction with the termination
system provide~ by contact-supporting module 160 More
particularly, hood 36 has interior grooves (not shown) for
sliding along ribs 32 to mount the hood onto the connector
from either end thereof. Hood 36 has an end aperture 42
for alignment with the through holes 34 of either end
flange 30 to secure the hood in place by appropriate
means. Likewise, cable clamp 40 has a bracket portion 44
for sliding onto either end flange 30 and the end extremi-
ties of ribs 32, with a slot 46 for alignment with through
holes 34 to secure the cable clamp in place by appropriate
means. Hood 36 and cable clamp ~0 are designed for faci-
litating termination of a multi-conductor cable extending
end wise away frGm the connector.
Hood 38 has a pair of apertures 48 for alignment
with through holes 34 of end flanges 30 for securing the
hood to the connector. Hood 38 has an enlarged opening 50
to facilitate terminating a multi-conductor cable with the
cable extending through opening 50 generally perpen-
dicularly away from the rear of the connectorO
At this point, it should be noted that side ribs
32 for facilitating mounting hood 36 and cable clarnp 40 to
the connector are not shown in Figure 5. This has been
done to facilitate a description of the molding system of
the present invention which ~ill be described hereinafter.
Referring to Figure 2, the modular electrical
telephone connector of the present invention is sho~n to
include common housing 12 as described in relation to
Figures 1 and 5. Other reference numerals to certain por-
tions of the housing have been omitted so as not to
clutter the drawins. In this embodiment of the modular
connector, a molded plastic contact supporting module 52
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1 1~2~
is shown or terminating the conductors of a common multi-
conductor flat cable Inot shown). The module has a
generally elongated, rectangular configuration for
interchangeably nesting in cavity end 14a of housing 12.
Bosses 54 are molded onto the sides of the module for snap
fit within recesses 56 molded into the sides of cavity end
14a. This provides mounting means for releasably securing
the module within the housing. It should be noted that
similar mounting means are provided, although not shown,
on contact-supporting module 16 described hereinbefore.
Module 52 supports a plurality of contact ele-
ments which include mating portions 58, similar to the
mating portions 20a of contacts 20, for mating with the
contact elements of the complementary connector. The
contacts are assembled through slots 59 molded into oppo-
site sides of the module. The contacts have slotted
insulation-piercing termination portions ~0 for piercing
the insulation and establishing electrical connection with
the conductors of a multi-conductor flat cable. An
elongated hold-down member 62 has end brackets 64 for
snapping over side ribs 32 of housing 12 to hold ~he flat
cable in termination with insulation-piercing portions
60 of the supported contacts. A pair of end clips 66 are
shown for sliding over end flanges 30 and the extremities
of side ribs 32 of housing 12. These clips have wire
clamps 68 pivotally mounted on the underside thereof for
holding the complementary connector in mating engagement
with housing 12 of the modular connector7
Referring to Figure 3, a common housing 12 again
is shown identical to the housings described in conjunc~
tion with Figures l and 2. In this embodiment of the
modular electrical telephone connector, a contact-
supporting module 70 is sho~n for termination with a
printed circuit boardO Like module 52~ module 70 is
elongated and generally rectangularly shaped for
interchangeably nesting in cavity end 14a of housing 12.
Again, bosses 72, like bosses 54 of module 52, are pro-
vided for releasably snapping the modul~ into the housing
I ~$2~
-12
with the bosses snapped into recesses 56 of the housing~
Module 70 supports a plurality of contact elements which
include rnating portions 74 similar to mating portions 20a
of contacts 20. Similarly, the contacts are assembled
through slots 75 molded into opposite sides of the module.
~owever, the contact elements of module 70 have ter-
mination portions 76 for establishing electrical connec-
tion with the conductors of a printed circuit board, in
known fashion In this embodiment, termination portions
76 of the contact elements extend generally axially of the
open-ended cavity means of housing 12 for termination with
a printed circuit board disposed generally transversely of
the cavity means. This embodiment again shows end clips
66 for holding a complementary connector in mating engage-
ment with housing 1~ of the modular connector.
Referring to Figure ~, an embodiment of the modu-
lar electrical telephone connector of the present inven-
tion again is shown to include common housing 12. In this
embodiment, a contact-supporting module 78 is shown simi-
lar to module 70 for termination with a printed circuitboard and supporting contact elements which include mating
portions 80 similar to the mating portions 20a of contacts
20J Similarly, the contacts are assembled through slots
81 molded into opposite sides of the module. However, the
sontact elements supported by module 78 have termination
portions 82 which are generally L-shaped for termination
with a printed circuit board (not shown~ which would be
disposed generally parallel to the axis of the cavity
means of housing 12. ~therwise, module 78 is molded in
accordance with the present inYentiDn SO as to be
releasably mountable within cavity end 14a of housing 12
similar to interchangeable mo~ules 16, 52 and 70 pre-
viously described~
Figure 4 shows a panel 84 having flanges 86 with
through holes 88 for alignment with through holes ~4 of
end flanges 30 of housing 12 in order to mount ~he panel
to the housing by appropriate means. The panel has a
plurality of apertures 90 for receiving termination por-
5 ~ ~
tions 82 of the contact elements supported by module 78.The apertures properly space and align the contact ter-
mination portions for termination with the conductors of
the printed circuit board. ~ protective hood 92 is shown
with depending bosses 94 for positioning within slots 96
of module 78 so that the hood covers the contact ter-
_ mination portions to protect the same~ End clips 66 againare shown for holding a complementary connector in mating
engagement with housing 12 of the modular connector.
Thus, Figures 1-5 illustrate the modular electri-
cal telephone connector concept of the present invention
wherein molded plastic housing means in the form of a
single, co~non housing 12 is provided defininy a mating
portion of the modular electrical connector for receiving
molded plastic insert means in the form of a set of
contact-supporting modules 16, 52, 70 and 78 defining dif-
ferent terrnination configurations of the modular connec-
tor. The termination portions are designed for
selectively piercing the insulation and establishing
electrical connection with individual insulated conductors
of a multi-conductor cable ~module 16); for piercing the
insulation and establishing electrical connection with the
conductors of a multi-conductor flat cable (module 52);
for establishing electrical connection with the conductors
of a printed circuit board disposed generally transversely
of the connector (module 70); and for establishing
electrical connection with the conductors of a printed
circuit board disposed generally parallel to the axis of
the connector (module 78)o Of course, other types of
modules for providing different termination configurations
for different termination systems are conternplated by the
present invention, such as wire wrap termination sys~ems,
or the like. With this invention, the common housings can
be molded at a first location in considerable numb~rs and
shipped to other locationsy such as countries throughout
the world, where the contact-supporting rnodules can be
molded as modular cornponents for use with the ~lousings in
accordance with the particular desired termination system
~ ~2~
-14-
at that location~
With such a modular electrical telephone connec-
tor system as described above, the invention contemplates
a system and method for molding the connector bodies,
including the common housings, as well as the contact-
supporting modules, with minimum molding equipment and the
minimum of molding dies or cavities for supplying
telephone connectors of different configurations to dif-
ferent remote locations, such as different countries
-- 10 throughout the world. Considerable expense thus is
avoided in tooling the mold cavities for the modular
electrical telephone connectors of the present invention.
More particularly, referring to Figures 5-~,
Figure 5 has already been described in detail as
disclosing contact-supporting module 16 in conjunction
with common housing 12. It should be pointed out at the
outset that the following described molding system and
method are equally applicable for contact-supporting
modules other than module 16.
Figure 6 illustrates simple mold means which
includes a first mold portion or die 100 and a secondr
opposed mold portion or die 102 which cooperate to define
a mold cavity, generally designated 104. The mold dies
separate along a parting line 106. Mold cavity 104 con-
forms to the shape of housing 12, as is readily apparen~ by
comparison with Figure 5O Of course, retractable core
pins, side pu115 or slides will be required on mold die
100 in order to form slots 2~ in the housing, as indicated
by dotted line 108, and in mold die 102 for forming aper-
30 tures 18, as indicated by dotted lines 110~ In addition,
retractable side pulls or slides would also be provided at
the sides of mold die 100 to form the side ribs 32 of the
housing. These retractable core pins, side pulls and sli-
des are common molding techniques and are not shown in the
figures to avoid cluttering the drawing.
Referring to Figure 7, a lower mold die 112 and
an upper, opposed mold die 114 are shown with a parting
line 116. The dies cooperate to define a mold cavity,
1 ~825~
-15-
generally designated 11~, conforming to the configuration
of contact supporting module 16 (Figure 5). Again,
retractable core pins or slides would be incorporated in
mold die 114 to form side notches or grooves 22 (Figure 5)
of the contact-supporting module, as indicated by the
dotted lines 120.
The uniqueness of the modular electrical
telephone connector systern of the present invention is
further exemplified with reference to Figure 8 wherein
mold means is sho~n for molding the entire modular
electrical connector, including the mating portion defined
by housing 12 and the contact-supporting portion defined
by module 16, in a one-piece integral construction. This
is desirable when a sufficient volume of electrical con-
nectors of a particular termination system is required ata single location, such as a single country. This com-
bination of mold means can also be used at the domestic
location where the common housings are fabricated. More
particularly, it can be seen from Figure 8 that by simply
using the lower mold die 100 shown in Figure 6, for molding
housing 12, and by using the upper mold die 114, shown in
Figure 7, for molding contact-supporting module 16, a mold
cavity, generally designated 122, is formed for molding
the entire electrical connector body as a single~ unitary
construction. Tooling mold dies is one of the major
expenses in fabricating molded plastic electrical connec-
tors, and it i5 readily apparent that considerable savings
are afforded while permitting versatility in fabrication
when volume manufact~ring is involved.
The unique mold and molding system described
above affords methods of fabricating all plastic contact-
supporting connector bodies not heretofore available. In
particular, a method is provided for efficiently pro-
ducing, at different locations, limited quantities of all
plastic connector bodies in a set or family of connector
bodies having identical mating ends and different termina-
tion ends. The method comprises the steps of molding the
mating ends (i.ec housings 12) of the connector bodies at
~ ~2~4 ~
-16-
a first location in high throughput molds; molding the
termination ends (i.e. modules 16, 52, 70 and 78) of the
connector bodies at remote locations in low throughput
molds, each low throughput mold producing termination ends
complementary to and cooperable with any mating end irom
the high throughput mold such that when joined together a
connector body in the set is produced; and joining any of
the termination ends to any of the mating ends to form a
connector body.
In addition, a method is provided for fabricating
all plastic contact supporting connector bodies having a
mating part and a terminating part in one piece or in two
pieces as described in relation to Figures 5-8. The
method comprises the steps of fabricating the one-piece
connector body in a two-piece mold having a first portion
(i.e. die 100) or molding the mating part, and a comple-
mentary second portion (i.e. die 114) for molding the ter-
mination part integral with the mating part; fabricating
the mating part of the two-piece connector in a mold con-
sisting of the first portion and a third portion (i.e. die102) complementary to and cooperable with the first
portion; fabricating the termination part of the two--piece
connector body in a mold consisting of the second portion
and a fourth portion (i.e. die 11~) complementary to and
cooperable with the seccnd portion; and affixing parts
fabricated by the last two steps, respectively, to each
other. This method contemplates providing a plurality of
different second die portions and a like plurali~y of dif-
ferent fourth die portions complementary to and cooperable
with the second portions, respectively, for molding a
plurality of different termination parts for cooperable
engagement with the mating part of the two~piece connector
body.
Referring to Figure 9, the modular electri~al
connector system of the present invention is shown
some~Yhat schematically in order to illustrate the inter-
relationship and interchangeability between the molded
plastic housing means and the family or set of contact-
1 1825~ ~
-17-
supporting modules. ~ modular electrical connector
assembly is shown at the bottom of the figure with a com-
mon housing 12 assembled to one of the set of contact-
supporting modules, namely, module 16. Above these
assemblies, a single common housing 12a is shown in align-
ment for receiving and mounting any one of the other con-
tact supporting modules in the set thereof, namely, modules
52, 70 and 780 Each of modules 52, 70 and 78 is shown
schematically supporting contact elements having identical
mating portions 58, 74 and 80, respectively, but with dif-
ferent termination portions 60, 76 and 82, respectively,
as described hereinbefore. In addition, other modular
components are illustrated, such as hood 36, cable clamp
~o and flat cable hold-down member 62, all of which may be
fabricated at the same location as common housing 12 and
shipped therewith to other locations for selective
assembly with the different contact-supporting modules 16,
52, 70 and 78 to provide telephone connectors of different
termination configurations. An important advantage of
such a system is that all of the components, except for
the contact-supporting modules, can be fabricated in con-
siderable volume and shipped at considerably less expense
than with completely assembled connectors. ~his is impor-
tant where different termination systems are used at dif-
ferent locations, such as different countries throughoutthe world.
It will be understood that the invention may be
embodied in other specific orms without departing from
the spirit or central characteristics thereof. The pre-
sent examples and embodiments, therefore, are to be con-
sidered in all respects as illustrative and not
restrictive, and the invention is not to be limited to the
details given herein~
