EP0070392A2

EP0070392A2 - Modular electrical connector and system for molding contact supporting modules

Info

Publication number: EP0070392A2
Application number: EP82105330A
Authority: EP
Inventors: Dennis J. Krob
Original assignee: Allied Corp
Current assignee: Allied Corp
Priority date: 1981-07-21
Filing date: 1982-06-18
Publication date: 1983-01-26
Also published as: CA1182541A; EP0070392A3; ZA825217B

Abstract

A modular electrical telephone connector for mating with a complementary connector having a plurality of contact elements. The connector includes a molded plastic common housing and a set of contact-supporting modules. Each module defines a different termination configuration for the connector and is interchangeably nestable in the housing. The modules of the set thereof each supports a plurality of contact elements different from the contact elements of other modules of the set. The contact elements each includes an identical mating portion at one end of the housing when the respective module is nested therein for mating with a contact element of the complementary connector, and a termination portion at the other end of the housing forming a termination configuration defined by the selected module. A system and method of molding all plastic contact-supporting modules or connector bodies is provided and includes providing at a first location mold means for molding common housings, and providing at each of a plurality of different locations mold means for molding different contact-supporting modules. A system and method is provided for fabricating connector bodies having a mating part and a terminating part in one piece or in two pieces.

Description

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 years, different terminating ends have been provided on these connectors such as: solder terminations; wire-wrap terminations; insulation displacement terminations, including both composite and flat cables; printed circuit terminations, etc. Generally, a manufacturer will produce a line of such connectors 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 Division of Bunker Ramo Corporation under the series tradenames "57" and "157".
Recently, connectors with all plastic bodies have come into use in the telephone industry. These connectors, while incorporating the same type of electrical contacts as their metal-with-plastic-insert forebears, are capable of being molded in one piece. Understandably, the 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 provided, 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 dictate that large production requirements generally enable use 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 particular 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 the 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 termination connectors are in demand. In yet others, the wire-wrap terminations are required. Unfortunately for a manufacturer, the fact that the market for any particular 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 counterpart. However, even here, many foreign 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 ways. 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, standardized telephone jack connectors, modular blocks 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 circular connector which has different types of molded male and female inserts so that different connector combinations can be obtained. However, no known prior art has been directed to modulari- zation of the connector itself for use with a wide variety of termination systems at remote locations.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide a new and improved 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 contact-supporting connector bodies or modules of a modular 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 present invention is realized in a modular electrical telephone 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 defining 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 particular 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 standardized connector, and a termination portion at the other end of the cavity forming a termination configuration defined by the selected module. Thus, the modular electrical connector can be adapted for mating with the complementary connector and terminating with different arrangements and types of conductors by interchanging the modules.
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 insulation and establishing electrical connection with the conductor of a single insulated wire conductor, normally 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 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 connector. More particularly, the system includes providing at a first location mold means for molding common, standardized housings for mating with complementary standardized electrical connectors having a plurality of contact elements. The system provides at each of a plurality of different locations mold means for molding different contact-supporting modules which are similarly constructed in-part for disposition within the common housings but which are differently 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 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 identical mating ends and different termination ends is provided. 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 any of the termination 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 providing 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 portion for molding a common mating portion of the module and a complementary second mold portion for molding a termination 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 selectively molding only the mating portion of the module, corresponding to the aforesaid molded plastic housing means of the modular connector. A fourth mold portion is provided complementary to and cooperable with the second mold portion for selectively molding only the termination 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 supporting 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 complementary 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 termination 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 plurality of different fourth portions complementary to and cooperable with said second portions, respectively, are provided for molding a plurality of different termination parts for cooperable engagement with the mating part of the two-piece connector body.

BRIEF DESCRIPTION OF THE DRAWINGS

The features of this invention, which are believed to be novel and unobvious, are set forth with particularity in the appended claims. The invention, together with its objects and advantages, may be best understood by reference to the following description taken in conjunction 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 connector in accordance with the present invention, including a contact-supporting module for terminating individual insulated wire conductors of a multi-conductor cable, in conjunction with two different 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 present 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 a complementary connector;
FIGURE 3 is an exploded perspective view of a modular electrical connector in accordance with the present invention, including a contact-supporting module for terminating the conductors of a printed circuit board which would be disposed generally transversely of the connector 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 present invention, including a contact supporting module for terminating the conductors of a printed circuit board which would be disposed generally parallel with the axis of 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, taken generally along line 5-5 of Figure 1;
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 5;
FIGURE 7 is a sectional view through a pair of opposed mold cavities for molding the contact-supporting module shown in Figure 5;
FIGURE 8 is a perspective view through a pair of opposed mold cavities, including the lower cavity of Figure 6 and the upper cavity of Figure 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 the present invention, illustrating the common molded plastic housing means in conjunction with a set of different contact-supporting modules.

DESCRIPTION OF THE 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 tradenames "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 communicate 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 contact element of the complementary connector and a termination portion 20b extending through cavity end 14a and accessible through the 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 conductor 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 of housing 12 which defines the mating portion of the connector.
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 provided by contact-supporting module 16. 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 extremities 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 40 are designed for facilitating termination of a multi-conductor cable extending end wise away from 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 perpendicularly away from the rear of the connector.
At this point, it should be noted that side ribs 32 for facilitating mounting hood 36 and cable clamp 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 will be described hereinafter.
Referring to Figure 2, the modular electrical telephone connector of the present invention is shown to include common housing 1₂ as described in relation to Figures 1 and 5. Other reference numerals to certain portions of the housing have been omitted so as not to clutter the drawing. In this embodiment of the modular connector, a molded plastic contact supporting module 52 is shown for terminating the conductors of a common multi-conductor flat cable (not 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 elements 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 opposite sides of the module. The contacts have slotted insulation-piercing termination portions 60 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 the 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 connector.
Referring to Figure 3, a common housing 12 again is shown identical to the housings described in conjunction with Figures 1 and 2. In this embodiment of the modular electrical telephone connector, a contact-supporting module 70 is shown for termination with a printed circuit board. 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 provided for releasably snapping the module into the housing with the bosses snapped into recesses 56 of the housing. Module 70 supports a plurality of contact elements which include mating 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. However, the contact elements of module 70 have termination portions ₇₆ for establishing electrical connection 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 engagement with housing 12 of the modular connector.
Referring to Figure 4, an embodiment of the modular electrical telephone connector of the present invention again is shown to include common housing 12. In this embodiment, a contact-supporting module 78 is shown similar to module 70 for termination with a printed circuit board and supporting contact elements which include mating portions 80 similar to the mating portions 20a of contacts 20. Similarly, the contacts are assembled through slots 81 molded into opposite sides of the module. However, the contact 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. Otherwise, module 78 is molded in accordance with the present invention so as to be releasably mountable within cavity end 14a of housing 12 similar to interchangeable modules 16, 52 and 70 previously described.
Figure 4 shows a panel 8₄ having flanges 86 with through holes 88 for alignment with through holes 34 of end flanges 30 of housing 12 in order to mount the panel to the housing by appropriate means. The panel has a plurality of apertures 90 for receiving termination portions 82 of the contact elements supported by module 78. The apertures properly space and align the contact termination portions for termination with the conductors of the printed circuit board. A protective hood 92 is shown with depending bosses 94 for positioning within slots 96 of module 78 so that the hood covers the contact termination portions to protect the same. End clips 66 again are shown for holding a complementary connector in mating engagement with housing 12 of the modular connector.
Thus, Figures 1-5 illustrate the modular electrical telephone connector concept of the present invention wherein molded plastic housing means in the form of a single, common housing 12 is provided defining 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 different termination configurations of the modular connector. 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). Of course, other types of modules for providing different termination configurations for different termination systems are contemplated by the present invention, such as wire wrap termination systems, or the like. With this invention, the common housings can be molded at a first location in considerable numbers and shipped to other locations, such as countries throughout the world, where the contact-supporting modules can be molded as modular components for use with the housings in accordance with the particular desired termination system at that location.
With such a modular electrical telephone connector 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 different remote locations, such as different countries 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 5-8, 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 second, 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 conforms to the shape of housing 12, as is readily apparent by comparison with Figure 5. Of course, retractable core pins, side pulls or slides will be required on mold die 100 in order to form slots 26 in the housing, as indicated by dotted line 108, and in mold die 102 for forming apertures 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 slides are common molding techniques and are not shown in the figures to avoid cluttering the drawing.
Referring to Figure 7, a lower mold die l12 and an upper, opposed mold die 114 are shown with a parting line 116. The dies cooperate to define a mold cavity, generally designated 118, 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 system of the present invention is further exemplified with reference to Figure 8 wherein mold means is shown 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 connectors of a particular termination system is required at a single location, such as a single country. This combination 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 connectors, and it is readily apparent that considerable savings are afforded while permitting versatility in fabrication when volume manufacturing 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 producing, at different locations, limited quantities of all plastic connector bodies in a set or family of connector bodies having identical mating ends and different termination ends. The method comprises the steps of molding the mating ends (i.e. housings 12) of the connector bodies at 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 from 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) for molding the mating part, and a complementary second portion (i.e. die 114) 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 (i.e. die 102) 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 114) complementary to and cooperable with the second 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 plurality of different 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 electrical connector system of the present invention is shown somewhat schematically in order to illustrate the interrelationship and interchangeability between the molded plastic housing means and the family or set of contact-supporting modules. A modular electrical connector assembly is shown at the bottom of the figure with a common 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 alignment for receiving and mounting any one of the other contact supporting modules in the set thereof, namely, modules 52, 70 and 78. Each of modules 52, 70 and 78 is shown schematically supporting contact elements having identical mating portions 58, 74 and 80, respectively, but with different termination portions 60, 76 and 82, respectively, as described hereinbefore. In addition, other modular components are illustrated, such as hood 36, cable clamp 40 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 considerable volume and shipped at considerably less expense than with completely assembled connectors. This is important where different termination systems are used at different locations, such as different countries throughout the world.
It will be understood that the invention may be embodied in other specific forms without departing from the spirit or central characteristics thereof. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details given herein.

Claims

1. A modular telephone connector, for mating with a complementary connector, having a plurality of contact elements, comprising:

molded plastic common housing means defining a mating portion of said modular electrical connector and including a generally open-ended cavity;

molded plastic insert means including a set of contact-supporting modules, each of said modules supporting a plurality of said contact elements and defining a different termination configuration of said modular electrical connector and being interchangeably nestable in said cavity of said housing means;

mounting means for mounting said modules in said cavity; and

said plurality of contact elements having identical mating portions at one end of said cavity when the respective module is nested in said cavity and termination portions at the other end of said cavity forming a termination configuration defined by the selected module, whereby the modular electrical connector is adapted for mating with said complementary connector and terminating with different arrangements and types of conductors by interchanging said modules.

2. The modular electrical connector of claim 1 wherein one of said set of contact-supporting modules supports a plurality of contact elements each of which includes a termination portion for piercing the insulation and establishing electrical connection with a conductor of a single insulated wire conductor of a multi-conductor cable.

3. The modular electrical connector of claim 1 wherein one of said set of contact-supporting modules supports a plurality of contact elements each of which includes a termination portion for piercing the insulation and establishing electrical connection with a conductor of a multi-conductor flat cable.

4. The modular electrical connector of claim 1 wherein one of said set of contact-supporting modules 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.

5. The modular electrical connector of claim 1 wherein one of said set of contact-supporting modules supports a plurality of contact elements each of which includes a termination portion for piercing the insulation and establishing electrical connection with the conductor of a single insulated wire conductor; a second of said set of contact-supporting modules supports a plurality of contact elements each of which includes a termination portion for piercing the insulation and establishing electrical connection with a conductor of a multi-conductor flat cable; and a third of said set of contact-supporting modules 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.

6. The modular electrical connector of claim 1, including molded plastic hood means for covering said other end of said cavity and protecting the termination portions of said contact elements and the conductors terminated thereto, and complementarily engageable mounting means on said hood means and said housing means for mounting the hood means on the housing means from any one of a plurality of different directions.

7. The modular electrical connector of claim 6 wherein said housing means has a configuration elongated generally transversely of said cavity means defining two opposite housing ends, and the complementary mounting means on said housing means is disposed at said opposite housing ends for mounting said hood means onto either end of said housing means.

8. The modular electrical connector of claim 1 wherein said contact elements are adapted for terminating individual conductors of a multi-conductor cable, and including cable clamp means and complementarily engageable mounting means on said cable clamp means and said housing means for mounting the cable clamp means on the housing means from any one of a plurality of different directions.

9. A system of molding all plastic contact-supporting bodies of an electrical connector, comprising:

providing mold means for molding a one-piece contact-supporting body, including a first mold portion for molding a common mating portion of said body and a complementary second mold portion for molding a termination portion of said body integral with said mating portion;

providing a third mold portion which is complementary to and cooperable with said first mold portion for selectively molding only said mating portion of said body; and

providing a fourth mold portion which is complementary to and cooperable with said second mold portion for selectively molding only said termination portion of said body.

10. 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 comprising the steps of:

fabricating the one-piece body in a two-piece mold having a first portion for molding said mating part and a complementary second portion for molding said termination part integral with said mating part;

fabricating the mating part of said two-piece connector in a mold consisting of said first portion and a third portion complementary to and cooperable with said first portion;

fabricating the termination part of said two-piece connector body in a mold consisting of said second portion and a fourth portion complementary to and cooperable with said second portion; and

affixing parts fabricated by said last two steps, respectively, to each other.

11. A system for molding all plastic contact-supporting modules of a modular electrical connector, comprising:

providing at a first location mold means for molding common housings for mating with complementary electrical connectors having a plurality of contact elements;

providing at each of a plurality of different locations mold means for molding different contact-supporting modules which are similarly configured in part for interchangeable nesting within said common housings but which are differently configured in part for supporting a plurality of contact elements having different termination configurations, whereby the modular electrical connector can be adapted at said different locations for terminating with different selected conductors by utilizing said common housings molded at said first location and interchanging said contact supporting modules at said respective different locations.

12. A method of efficiently producing, at different locations, limited quantities of all plastic connector bodies in a set of connector bodies having identical mating ends and different termination ends, comprising the steps of:

molding the mating ends of said connector bodies at a first location in high throughput molds;

molding the termination ends of said connector bodies at remote locations in low throughput molds;

each said 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 any of said termination ends to any of said mating ends to form a connector body.