Manufacture of low profile clip connector

A method of manufacturing an electrical clip-like connector including an electrical cable having plural insulated conductors, a pair of connector bodies molded to respective longitudinally spaced apart portions of the cable and each including therein plural contacts having contacting portions for engaging respective leads of an electrical device and coupling portions electrically connected to respective conductors of the cable, and at least one resilient connecting member which connects the bodies for relative pivotal-like movement to permit clip-like attachment of the connector to the electrical device, comprising the steps of:

• (a) simultaneously urging the coupling portions of the contacts for each body into mechanical and electrical engagement with respective conductors of the cable to form electrical junctions therebetween which are longitudinally spaced along the cable from the electrical junctions formed between conductors and the contacts for the other body;
• (b) using a pair of premolded inserts of non-conductive material placed within respective body forming cavities of a mold in supporting engagement with the mold to support the contacts for respective bodies in proper position with respect to the body forming cavities;
• (c) positioning the resilient connecting member in the mold with opposite ends thereof extending into respective body forming cavities;
• and
• (d) after closing the mold, flowing plastic material into each cavity to mold a balance forming part of the respective body about at least a part of each of the respective contacts, cable, insert and connecting member to form an integral structure with each insert forming a part of the respective connector body.

A method of manufacturing an electrical connector including an electrical cable having plural insulated electrical conductors, and at least one connector body including therein plural electrical contacts having contacting portions for engaging respective leads of an electrical device and coupling portions electrically connected to respective conductors of the cable, said method comprising the steps of:

• (a) simultaneously urging the coupling portions of the contacts into mechanical and electrical engagement with respective conductors of the cable to form electrical junctions therebetween;
• (b) using a premolded insert of electrically non-conductive material placed within a cavity of a mold in supporting engagement with the mold to support the contacts in proper position in relation to such mold cavity, and
• (c) after having closed the mold, flowing molten plastic material into the mold cavity to mold a balance forming part of the connector body about at least a part of each of the contacts, cable, and insert to form an integral structure with the insert forming a part of the connector body;
• and including the steps of:
• (1) aligning a gap in the insulation of the cable with openings in the contacts which in turn are aligned with holes in the insert, and
• (2) flowing plastic material into such aligned gap, openings and holes to lock mechanically the cable and contacts in the connector body.