Universal hybrid electrical/fiber optic insert cap and hybrid connector and methods

A hybrid connector insert cap comprising:

• a first side;
• a second side;
• and
• a body, the body comprising a plurality of portions, wherein each portion has initially a universal structure operable for receiving an electrical terminal when a first predetermined amount of material is subsequently removed from the portion and to receive a fiber optic terminal when a second predetermined amount of material is subsequently removed from the portion.

A connector comprising:

• a connector housing;
• and
• an insert cap positioned within the connector housing, the insert cap comprising,
• a plurality of terminal sections,
• a first terminal positioned within a first one of the plurality of terminal sections, wherein the first terminal is coupled to a first conductor,
• a second terminal positioned within a second one of the plurality of terminal sections, wherein the second terminal is coupled to a second conductor, and
• wherein a third one of the plurality of terminal sections is configured as a universal terminal section and does not include a terminal therein.

A method of forming a custom hybrid insert cap from a blank or universal insert cap for use in a connector, the method comprising:

• providing a blank insert cap having a plurality of terminal sections;
• determining a connector configuration for the custom hybrid insert cap;
• removing material from one or more selected first terminal sections to form one or more electrical terminal receptacles operable for receiving one or more electrical terminals based on the determined connector configuration;
• and
• removing material from one or more selected second terminal sections to form one or more fiber optic terminal receptacles operable for receiving fiber optic terminals based on the determined connector configuration.