Method of manufacturing double insulated plugs

Claim 1

A method of manufacturing an electrical plug, the method comprising the steps of: electrically and mechanically attaching a plurality of contacts to a corresponding plurality of conductors to form a plurality of connections; inserting a portion of each of said contacts into a predetermined position in a mating recess in a mold and then placing a preformed insert of insulating material in juxtaposition to and overlying said connections; restraining said insert in juxtaposition to said connections and maintaining said contacts in their predetermined positions in said mating recesses while molding a body of insulating material substantially enclosing said connections and said insert.

Claim 2

A method of manufacturing an electrical plug, the method comprising the steps of: electrically and mechanically attaching a plurality of contacts to a corresponding plurality of conductors to form a plurality of connections; inserting a portion of each of said contacts into a predetermined position in a mating recess in a mold and then placing a preformed insert of insulating material in juxtaposition to and overlying said connections; restraining said insert in juxtaposition to said connections and maintaining said contacts in their predetermined positions in said mating recesses while molding a body of insulating material substantially enclosing said connections and said insert.

Claim 3

A method of manufacturing an electrical plug, the method comprising the steps of: electrically and mechanically attaching a plurality of power contacts and a ground contact respectively to a corresponding plurality of power conductors and a ground conductors to form a plurality of power connections and a ground connection; inserting a portion of each of said contacts into a predetermined position in a mating one of a plurality of spaced apart recesses in a mold and placing a preformed insert of insulating material in juxtaposition to and overlying said connections; holding said insert in juxtaposition to said connections and maintaining saiD contacts in their predetermined positions in said mating recesses while molding a body of insulating material substantially around said connection and said insert, with said body having portions thereof surrounding each of said power connections and with a recess between said body portions.

Claim 4

A method of manufacturing an electrical plug, the method comprising the steps of: electrically and mechanically attaching a plurality of power contacts and a ground contact respectively to a corresponding plurality of power conductors and a ground conductors to form a plurality of power connections and a ground connection; inserting a portion of each of said contacts into a predetermined position in a mating one of a plurality of spaced apart recesses in a mold and placing a preformed insert of insulating material in juxtaposition to and overlying said connections; holding said insert in juxtaposition to said connections and maintaining saiD contacts in their predetermined positions in said mating recesses while molding a body of insulating material substantially around said connection and said insert, with said body having portions thereof surrounding each of said power connections and with a recess between said body portions.

Claim 5

A method of manufacturing an electrical plug, the method comprising the steps of: electrically and mechanically attaching a plurality of power contacts and a ground contact respectively to a corresponding plurality of power conductors and a ground conductor to form a plurality of power connections and a ground connection; inserting a portion of each of said contacts into a predetermined position in a mating one of a plurality of spaced apart recesses in a mold and placing a preformed insert of insulating material in juxtaposition to and overlying said connections, with at least said power connections being received in mating, spaced apart chambers in said insert; restraining said insert in juxtaposition to said connections and restraining said contacts in their predetermined positions in said mating recesses while injection molding a body of insulating material substantially around said connections and said insert, with said body of insulating material substantially filling said chambers about said power connections.

Claim 6

A method of manufacturing an electrical plug, the method comprising the steps of: electrically and mechanically attaching a plurality of power contacts and a ground contact respectively to a corresponding plurality of power conductors and a ground conductor to form a plurality of power connections and a ground connection; inserting a portion of each of said contacts into a predetermined position in a mating one of a plurality of spaced apart recesses in a mold and placing a preformed insert of insulating material in juxtaposition to and overlying said connections, with at least said power connections being received in mating, spaced apart chambers in said insert; restraining said insert in juxtaposition to said connections and restraining said contacts in their predetermined positions in said mating recesses while injection molding a body of insulating material substantially around said connections and said insert, with said body of insulating material substantially filling said chambers about said power connections.