A method of manufacturing an electrical connector coupled to a counterpart connector is disclosed. The method includes: (a) disposing a plurality of signal terminals; (b) forming a first mold part to support the signal terminals through primary insert molding, the first mold part being formed to have a protrusion at one end thereof in a longitudinal direction of the electrical connector and a first groove at the other end thereof in the longitudinal direction of the electrical connector; (c) placing a fitting beside the first mold part; and (d) forming a second mold part to support the first mold part and the fitting through secondary insert molding, the second mold part being formed to surround the protrusion of the first mold part while filling the first groove.

A method of manufacturing an electrical connector coupled to a counterpart connector is disclosed. The method includes: (a) disposing a plurality of signal terminals; (b) forming a first mold part to support the signal terminals through primary insert molding, the first mold part being formed to have a protrusion at one end thereof in a longitudinal direction of the electrical connector and a first groove at the other end thereof in the longitudinal direction of the electrical connector; (c) placing a fitting beside the first mold part; and (d) forming a second mold part to support the first mold part and the fitting through secondary insert molding, the second mold part being formed to surround the protrusion of the first mold part while filling the first groove.

The invention relates to a multi-way connector (4) for electrically contacting electrical assemblies (2, 3). The multi-way connector (4) comprises a connector body (5) having a first connection surface (6) and having a second connection surface (7). The multi-way connector (1) also comprises a plurality of electrical contact elements (8), which extend through the connector body (5) at least from the first connection surface (6) to the second connection surface (7). The contact elements (8) form contact sections (9) in the region of the connection surfaces (6, 7) for electrically contacting corresponding counter contact elements (10) of the respective associated assembly (2, 3). The contact sections (9) on at least one of the connection surfaces (6, 7) can be mechanically secured to the respective associated counter contact elements (10). According to the invention, the connector body (5) has multiple foil elements (11) that are stacked on one another and connected to one another. A respective two of the foil elements (11) form a foil pair (12). At least one of the contact elements (8) runs between the two stacked foil elements (11) of at least one of the foil pairs (12).

The invention relates to a multi-way connector (4) for electrically contacting electrical assemblies (2, 3). The multi-way connector (4) comprises a connector body (5) having a first connection surface (6) and having a second connection surface (7). The multi-way connector (1) also comprises a plurality of electrical contact elements (8), which extend through the connector body (5) at least from the first connection surface (6) to the second connection surface (7). The contact elements (8) form contact sections (9) in the region of the connection surfaces (6, 7) for electrically contacting corresponding counter contact elements (10) of the respective associated assembly (2, 3). The contact sections (9) on at least one of the connection surfaces (6, 7) can be mechanically secured to the respective associated counter contact elements (10). According to the invention, the connector body (5) has multiple foil elements (11) that are stacked on one another and connected to one another. A respective two of the foil elements (11) form a foil pair (12). At least one of the contact elements (8) runs between the two stacked foil elements (11) of at least one of the foil pairs (12).

A vehicle USB Type-C connector, comprising a cable end member and a board end member engaged together; the CPA is inserted into the engagement groove; the PCB attached male head has an end protruding from a cavity opening on one end of the cable end plastic shell cavity; the encapsulated outer mold is inserted into a cavity opening on another end of the cable end plastic shell cavity; the encapsulated outer mold has an engagement side on two sides thereof and inserted into the lateral engagement groove; the upper lock plate is engaged above the engagement groove, the lower lock plate is inserted into the engagement groove, and the CPA is fastened with the cable end member. The present invention reduces the on-board height and strengthens the liability after engagement.

A vehicle USB Type-C connector, comprising a cable end member and a board end member engaged together; the CPA is inserted into the engagement groove; the PCB attached male head has an end protruding from a cavity opening on one end of the cable end plastic shell cavity; the encapsulated outer mold is inserted into a cavity opening on another end of the cable end plastic shell cavity; the encapsulated outer mold has an engagement side on two sides thereof and inserted into the lateral engagement groove; the upper lock plate is engaged above the engagement groove, the lower lock plate is inserted into the engagement groove, and the CPA is fastened with the cable end member. The present invention reduces the on-board height and strengthens the liability after engagement.

An electrical connector with thin interior walls is made by extruding a polymer or polymer composite into a sheet of approximately 0.25 mm to 0.5 mm thickness. The sheet is then calendered to a thickness of about 0.05 mm to 0.3 mm. The calendered sheet is cut into notched sections. The notched sections are assembled and placed into an injection molded housing of a connector. The sections are secured in place by using an adhesive, force fit, snap fit, or welding process to form the thin interior walls of the connector.

An electrical connector with thin interior walls is made by extruding a polymer or polymer composite into a sheet of approximately 0.25 mm to 0.5 mm thickness. The sheet is then calendered to a thickness of about 0.05 mm to 0.3 mm. The calendered sheet is cut into notched sections. The notched sections are assembled and placed into an injection molded housing of a connector. The sections are secured in place by using an adhesive, force fit, snap fit, or welding process to form the thin interior walls of the connector.

A splice connector assembly configured to conduct more than 1 kilowatt of electricity includes a terminal having a connection portion configured to interconnect with a corresponding mating terminal. The terminal also has an attachment portion. The attachment portion has a planar shape. The attachment portion is attached to a first wire electrical cable and is also attached to a second wire electrical cable. The first cable has a different cross-sectional area than the second cable. The splice connector assembly also includes a dielectric housing defining a cavity in which the terminal is disposed.

A splice connector assembly configured to conduct more than 1 kilowatt of electricity includes a terminal having a connection portion configured to interconnect with a corresponding mating terminal. The terminal also has an attachment portion. The attachment portion has a planar shape. The attachment portion is attached to a first wire electrical cable and is also attached to a second wire electrical cable. The first cable has a different cross-sectional area than the second cable. The splice connector assembly also includes a dielectric housing defining a cavity in which the terminal is disposed.