No-crimp electrical connectors and method of manufacture

A no-crimp electrical connector for electrically connecting first and second electrical wires to each other comprising:

• a non-conductive housing member having at least first and second connection chambers separated by an insulated wall, each said connection chamber having a threaded interior wall,
• a conductive metal insert member securely mounted in said insulated wall, said insert member having first and second ends, each said first and second ends being in said first and second connection chambers, respectively, said first end having a wire passage having a diameter D1 for receiving said first wire, a crossbore in said first end, a ball seated in said crossbore, said ball having a diameter D2 which is larger than said diameter D1, and a first threaded male member adapted to be threadedly engaged with the threads in said first connection chamber and adapted to engage said ball and cam said ball inwardly in said crossbore to engage and clamp said first wire received in said first wire passage,
• said second end of said insert member having a wire-engaging clamp means for pressing said second wire against a surface on said second end of said insert member and a second hollow threaded male member adapted to engage the threads in said second connection chamber and clamp said second wire to said insert member.