Method for producing contact shorting bar insert for modular jack assembly

Abstract

The disclosure is directed to a method of manufacturing a shorting bar insert for placement in a modular jack assembly to provide for the selective shorting of predetermined contacts during periods of nonelectrical engagement, with a modular plug, such as for an 8 position miniature modular jack in accordance with USOC STYLE RJ48X, for example. The method comprises the steps of preparing a strip of stamped contacts from a planar sheet metal blank joined together by a removable carrier strip having a front face and a back face, where the contacts are formed in pairs in parallel relationship and joined together at their ends remote from the carrier strip, the carrier strip including registration means, such as holes, offset from the centerline of each respective pair of contacts. Thereafter, placing a pair of contact containing carrier strips in back-to-back relationship with the registration means aligned, whereby the contacts are realigned in overlapping relationship, and insert molding a dielectric material about the joined ends of the overlapping sets of contacts. Finally, removal of the carrier strips will reveal a modular jack assembly insert having projecting parallel contacts matching the modular jack contact slot spacing.

Dependencies are inferred from the claim text.