Angled electrical header connectors

A right-angle electrical header connector comprising:

• a housing comprising a first electrical terminal port and a second electrical terminal port, wherein the first electrical terminal port is positioned approximately 90 degrees from the second electrical terminal port;
• a first electrical terminal and a first electrical insulator assembly disposed within the first electrical terminal port, wherein the first electrical insulator is separate from the housing and formed from an electrically nonconductive material and comprises a wall section and an end section, wherein the wall section is interposed between the first electrical terminal and the first electrical terminal port and extends axially inwardly adjacent an open end of the first electrical terminal port, wherein the wall section forms a first open annular space and a second open annular space, wherein the first open annular space extends radially between opposed surfaces of the first electrical terminal port and the wall section adjacent the open end, wherein the second open annular space extends radially between opposed surfaces of the first electrical terminal and the wall section adjacent the open end;
• and
• a second electrical terminal and a second electrical insulator assembly disposed within the second electrical terminal port, wherein the second electrical insulator is interposed between the second electrical terminal and the second electrical terminal port;
• wherein the first electrical terminal includes an attachment feature that extends into the second electrical terminal port, wherein the second terminal includes an attachment feature, and wherein the first electrical terminal attachment feature and the second electrical terminal attachment feature are mechanically attached and electrically connected with one other in situ within the housing to form a fixed electrical-mechanical connection therebetween.

A method for making a right-angle header comprising:

• forming a first electrical terminal and a first electrical insulator assembly by surrounding at least a portion of an outside surface of the first electrical terminal with a first electrical insulator, wherein the first electrical insulator comprises a wall structure extending axially therefrom along a length of the first electrical terminal, wherein an open annular space extends radially between the wall structure and the first electrical terminal, the first electrical insulator comprising an end section that is in direct contact with the first electrical terminal;
• forming a second electrical terminal and a second electrical insulator assembly by surrounding at least a portion of an outside surface of the second electrical terminal with a second electrical insulator;
• inserting the first electrical terminal and the first electrical insulator assembly into a first electrical terminal port of a housing, and inserting the second electrical terminal and the second electrical insulator assembly into a second electrical terminal port of the housing, wherein the first electrical terminal port and the second electrical terminal port are oriented within the housing approximately 90 degrees from one another, wherein the open annular space extends inwardly from adjacent an open end of the first electrical terminal port, and wherein a portion of the first electrical insulator adjacent the end section is interposed between the first electrical terminal and housing to electrically insulate the first electrical terminal from the housing;
• and
• moving one of the first electrical terminal or the second electrical terminal within its respective first electrical terminal port or second electrical terminal port to form a fixed electrical-mechanical connection in the housing with the other of the first electrical terminal or the second electrical terminal.