Patent Publication Number: US-7717740-B2

Title: Electrical connector including viewing window assembly and associated methods

Description:
RELATED APPLICATION 
   The present application is a continuation-in-part application of U.S. patent application Ser. No. 11/381,012 filed May 1, 2006, which is a continuation of Ser. No. 11/026,978 filed Dec. 30, 2004 now U.S. Pat. No. 7,094,094 issued Aug. 22, 2006, the entire contents of which are incorporated herein by reference. 

   FIELD OF THE INVENTION 
   The present invention relates to the field of electrical components, and, more particularly, to an electrical connector for connecting together a plurality of cable ends and associated methods. 
   BACKGROUND OF THE INVENTION 
   Underground and submersible junction bus connectors are widely used in electrical power distribution systems. One type of such connector is offered under the designation SWEETHEART® by Homac Mfg. Company of Ormond Beach, Fla., the assignee of the present invention. The SWEETHEART® connector is a cast or welded aluminum connector including a bus, or bar, portion and a series of tubular posts extending outwardly from the bus portion. The posts have an open upper end to receive one or more electrical conductors. A threaded bore is provided in the sidewall of the post, and which receives a fastener to secure the electrical conductor within the upper end of the post. An insulating coating is provided on the lower portion of the posts and bus of the connector. In addition, EPDM insulating sleeves may be used to provide waterproof seals for the posts. U.S. Pat. Nos. 6,347,966; 6,345,438 and 6,262,567 disclose various embodiments of such bus and post connectors. 
   Homac also manufacturers a RAB series of “Flood Seal”® Rubberized Aluminum Bar connectors suitable for direct burial, handhole or pedestal applications. The RAB connector includes a generally rectangular aluminum body having a plurality of spaced apart cable-receiving passageways therein. These cable-receiving passageways are blind holes, that is, they extend inward, but do not extend fully through the connector body. The blind hole is useful to provide sealing at the lower end of the connector body for the later molding of the rubber insulating cover. 
   The connector body also has a fastener-receiving passageway intersecting each cable-receiving opening. A fastener is provided in each fastener receiving passageway. Each fastener comprises a blunt end for bluntly contacting a corresponding insulation-free cable end. In particular, the blunt end may be a ball bottom screw end that helps break up aluminum oxides of the insulation-free cable end to ensure better electrical contact. 
   As the name states, the RAB connector includes a rubber insulating cover over the connector body. The insulating cover includes integrally molded inlets for both the cable-receiving openings and fastener-receiving openings. An insulating boot, such as a cable size adaptor or Rocket may be provided for the cable-receiving inlet, and a sealing cap may be received over the screw in the fastener-receiving inlet. Unfortunately, with less experienced labor crews, it is possible that a cable end may not be fully seated in its blind hole. Thus, even if the fastener initially presses partially against the cable end, this connection may work lose as the RAB connector is subsequently repositioned. 
   U.S. Pat. No. 6,688,921 to Borgstrom et al. discloses a connector similar to the Homac RAB series connector. In place of EPDM, the patent uses a thermoplastic elastomer (TPE) that combines the properties of thermoplastic with the performance characteristics of a thermoset rubber. The use of TPE enables the molding to further form sealing plugs and cable size adaptors attached to the cover with respective tethers. The connector also includes blind cable-receiving passageways, and is thus also susceptible to less reliable connections if the cable ends are not fully seated. 
   Michaud Electrical Equipment of France offered an insulation displacing connector (IDC) including a generally rectangular connector body, and transverse cable-receiving and fastener-receiving passageways. More particularly, the connector body included a backwall having a pattern of sharp ridges thereon to pierce the insulation on the cable end as the end of the fastener engages and presses against the cable end from the opposite side. To be sure the cable end is fully pressed onto the sharp ridges, a plastic viewing window is provided opposite the inlet of the cable-receiving passageway. Accordingly, an installer can view the cable end to be sure the insulation has been pierced. The window is adjacent the rubber cover. Unfortunately, the Michaud IDC device is likely to leak at the window since the seal is only a mechanical seal. In addition, insulation displacement technology may not be suitable for larger cable sizes with thicker insulation coverings. 
   SUMMARY OF THE INVENTION 
   In view of the foregoing background, it is therefore an object of the invention to provide an electrical connector that is craft-friendly for installation, readily manufactured, and that is resistant to leaks in service. 
   This and other objects, features and advantages in accordance with the present invention are provided by an electrical connector including a window assembly comprising an electrically insulating transparent base and a plurality of electrically insulating transparent windows extending outwardly therefrom. More particularly, the connector may include an electrically conducting body having a plurality of spaced apart cable-receiving passageways for receiving respective insulation-free electrical cable ends therein, and with each cable-receiving passageway having a cable inlet opening and a cable end viewing opening opposite the cable inlet opening. The electrically conducting body may also have at least one respective fastener-receiving passageway intersecting each of the cable-receiving passageways. A respective fastener may be provided in each of the fastener-receiving passageways. The individual windows of the window assembly are preferably aligned with respective cable end viewing openings to provide a cover and to permit visual confirmation of proper placement of the insulation-free electrical cable end within a corresponding one of the cable-receiving passageways. The connector may further include an insulating cover on the electrically conductive body and defining a seal with the window assembly. Installers are thus more likely to obtain a good and reliable electrical connection because proper placement of the cable end can be visually inspected. In addition, the electrical connector may be readily manufactured and provide a watertight connector using the window assembly. 
   The window assembly may comprise a plurality of ribs extending outwardly from the base. The base may also have an elongate shape, and each of the ribs may extend transverse to the base between adjacent ones of the electrically insulating transparent windows. 
   The insulating cover may comprise a thermoplastic elastomer (TPE), for example. In addition, the seal between the window assembly and the cover may comprise an integrally molded bond, and the window assembly may comprise polypropylene, for example, as the material to form such a bond with TPE. Other materials may be used in other embodiments. 
   The insulating cover may have an access opening therein for receiving the electrically conductive body therethrough. In accordance with another advantageous feature, the window assembly may close the access opening in the cover. In other words, the access opening permits individual molding of the insulating cover, followed by positioning of the conductive body through the access opening of the cover, and thereafter followed by closing and sealing the access opening using the window assembly. 
   The electrically insulating transparent base and the windows may be integrally formed as a monolithic unit, for example. In addition, the insulating cover may comprise an integrally molded respective tubular cable inlet aligned with each of the cable inlet, and an integrally molded respective tubular fastener inlet aligned with each of the fastener-receiving passageways. The electrically conductive body may have a generally rectangular shape. 
   Another aspect of the invention relates to a method for making an electrical connector. The method may include forming an electrically conductive body to have a plurality of spaced apart cable-receiving passageways for receiving respective insulation-free electrical cable ends therein. Each cable-receiving passageway may have a cable inlet opening, and a cable end viewing opening opposite the cable inlet opening. The conductive body may also be formed to have at least one respective fastener-receiving passageway intersecting each of the cable-receiving passageways. The method may also include forming an insulating cover having an access opening therein and receiving the electrically conductive body therethrough. In addition, the method may include forming a window assembly comprising an electrically insulating transparent base, and a plurality of electrically insulating transparent windows extending outwardly therefrom. The method may further include closing the access opening in the insulating cover with the window assembly so that the electrically insulating transparent windows are aligned with the cable end viewing openings to provide a cover and to permit visual confirmation of proper placement of the cable ends within the cable-receiving passageways. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a rear-bottom perspective view of an embodiment of an electrical connector in accordance with the present invention. 
       FIG. 2  is a side elevational view of the electrical connector as shown in  FIG. 1 . 
       FIG. 3  is a top perspective view of the electrical connector as shown in  FIG. 1 . 
       FIG. 4  is a longitudinal cross-sectional view of the electrical connector as shown in  FIG. 1 . 
       FIG. 5  is an enlarged cross-sectional view of the transparent window used in the electrical connector as shown in  FIG. 1 . 
       FIG. 6  is an enlarged perspective view of the transparent window used in the electrical connector as shown in  FIG. 1 . 
       FIG. 7  is a transverse cross-sectional view of the electrical connector as shown in  FIG. 1 . 
       FIG. 8  is a side elevational view of an insulating boot and integrally formed removable boot closure cap as used in the electrical connector of  FIG. 1 . 
       FIG. 9  is a cross-sectional view of the removable boot closure cap as shown in  FIG. 5 . 
       FIG. 10  is a side elevational view of a tether and an integrally formed removable fastener inlet closure cap as used in the electrical connector of  FIG. 1 . 
       FIG. 11  is a cross-sectional view of the removable fastener inlet closure cap as shown in  FIG. 8 . 
       FIG. 12  is a cross-sectional view of another embodiment of an electrical connector in accordance with the present invention. 
       FIG. 13  is an enlarged cross-sectional view of the cable seating indicator used in the electrical connector as shown in  FIG. 12 . 
       FIG. 14  is an enlarged perspective view of the cable seating indicator used in the electrical connector as shown in  FIG. 12 . 
       FIG. 15  is a transverse cross-sectional view of the electrical connector as shown in  FIG. 12 . 
       FIG. 16  is an exploded view of yet another embodiment of an electrical connector in accordance with the present invention. 
       FIG. 17  is an enlarged cross-sectional view of a portion of the connector shown in  FIG. 16  illustrating the seal between the insulating cover and window assembly. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   The present invention will now be described more fully hereinafter with reference to the accompanying drawings in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the illustrated embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout, and prime notation is used in alternate embodiments to indicate similar elements. 
   Referring now initially to  FIGS. 1-7 , an electrical connector  20  in accordance with the present invention is described. The electrical connector  20  is for a plurality of electrical cables and illustratively comprises an electrically conductive body  21  ( FIG. 4 ), an insulating cover  25 , and a plurality of windows  24  aligned with cable end viewing openings  23  ( FIGS. 4 and 7 ) in the conductive body. The electrically conductive body  21  illustratively has a generally rectangular shape, and may be formed of aluminum, or other conductive material, for example. 
   The electrically conductive body  21  also has a plurality of spaced apart cable-receiving passageways  26  for receiving respective insulation-free electrical cable ends  31  therein.  FIG. 4  illustrates a leftmost cable receiving passageway  26  unused, a center passageway  26  about to receive a cable end  31 , and a rightmost cable receiving passageway having already received therein the cable end  31 . In the illustrated embodiment of the electrical connector  20 , three such passageways  26  are provided, however in other embodiments, two or four or more such passageways may also be provided as will be appreciated by those skilled in the art. 
   Each cable-receiving passageway  26  has a cable inlet opening  27  and the cable end viewing opening  23  opposite the cable inlet opening. The electrically conductive body  21  also illustratively has a respective fastener-receiving passageway  32  intersecting each cable-receiving passageway  26  ( FIG. 7 ). A respective fastener  33  is also provided in each of the fastener-receiving passageways  32  ( FIG. 7 ). The fastener  33  may be a hex head fastener, with a rounded contacting end, for example. In addition, in other embodiments, two or more fasteners may be used for each cable end  31  as will be appreciated by those skilled in the art. 
   Each electrically insulating transparent viewing window  24  may be positioned adjacent a respective cable end viewing opening  23 . The windows  24  thereby provide a cover and permit visual confirmation of proper placement of the insulation-free electrical cable end  31  within a corresponding one of the cable-receiving passageways  26 . By transparent is meant that proper positioning of the cable end  31  is visible therethrough. Accordingly, although the window  24  can be fully transparent, transparent is also meant to include partially transparent or translucent where proper seating of the cable end is still viewable. 
   The insulating cover  25  on the electrically conductive body  21  also has respective window openings  35  therein aligned with the transparent viewing windows  24 . The insulating cover  25  may preferably comprise TPE in some embodiments thereby forming an integrally molded bond with adjacent portions of the transparent viewing windows  24  as will be appreciated by those skilled in the art. 
   With particular reference to  FIGS. 5 and 6 , each of the transparent viewing windows  24  may comprise a mounting flange  37  and a lens  38  extending outwardly therefrom. This configuration of the transparent viewing window  24  and through-holes as contrasted with blind holes permits the cable end  31  to extend further past the fastener  33  to thereby result in a more secure connection as will be appreciated by those skilled in the art. 
   The mounting flange  37  is illustratively overlapped by adjacent portions of the insulating cover as shown perhaps best in  FIGS. 4 and 7 . The mounting flange  37  and the lens  38  may be integrally formed as a monolithic unit, for example, such as by molding. Each transparent viewing window  24  may comprise polypropylene to form a strong bond with the TPE of the insulating cover  25 . Other similar compatible materials may also be used that are moldable and that form a strong bond to the material of the insulating cover  25 . The window  24  may serve to close or seal the cable-receiving passageway  26  during molding of the insulating cover  25 . In addition, the outwardly extending lens  38  and through hole configuration of the cable-receiving passageway  26 , permits the cable end  31  to extend well past the fastener  33  so that a strong and reliable electrical and mechanical connection is produced as will be appreciated by those skilled in the art. 
   The insulating cover  25  also illustratively includes an integrally molded respective tubular cable inlet aligned  41  with each of the cable inlet openings  27 . The electrical connector may further include a respective insulating boot  45  received in each of the tubular cable inlets  41  as will be described in greater detail below. 
   The insulating cover  25  also illustratively comprises an integrally molded respective tubular fastener inlet  51  aligned with each of the fastener-receiving passageways  32  ( FIG. 7 ). A removable fastener inlet closure cap  53  is provided to permit tightening of the fastener  33  and thereafter provide an environmental seal. For an unused cable position, the fastener inlet closure cap  53  may be left in its originally installed position as will be appreciated by those skilled in the art. 
   Referring now additionally to  FIGS. 8 and 9 , additional aspects of the insulating boot  45  of the electrical connector  20  are now described. Each insulating boot  45  may comprise a tubular sidewall  55  having a progressively increasing diameter to an outer open end  56  thereof. The insulating boot  45  also comprises a closed inner end  60  connected to the tubular sidewall  55  opposite the open outer end  56  thereof. In the illustrated embodiment, the diameter of the tubular sidewall  55  is stepped to permit severing along a desired diameter to accommodate a correspondingly sized cable end  31  as will be appreciated by those skilled in the art. In other words, the insulating boot  45  may serve as a cable size adaptor as will be appreciated by those skilled in the art. 
   A respective removable boot closure cap  57  is illustratively included for the open outer end  56  of the insulating boot  45 . The insulating boot  45  also includes an integrally molded tether  58  connecting the removable boot closure cap  57  to the tubular sidewall  55 . Accordingly, the removable boot closure cap  57  is readily available if needed for use, and is readily formed along with the other components of the insulating boot  45  during manufacturing. For example, the insulating boot  45  may be molded from TPE material, although other materials may also be used. 
   The removable boot closure cap  57  includes a flange  62 , and a hollow cylindrical plug  63  having a closed end  64  extending from the flange. Of course, the plug  63  could be solid in other embodiments. The removable boot closure cap  57  also illustratively includes a gripping member or tab  66  extending within the hollow cylindrical plug  63  and beyond the flange  62 . The gripping member  66  facilitates manual grasping or grasping using a suitable tool to permit removal or insertion of the boot closure cap  57 . As will be appreciated by those skilled in the art, the flange  62 , hollow cylindrical plug  63 , and gripping member  66  may be integrally formed as a monolithic unit with the tether  58  and the tubular sidewall  55 . The removable boot closure cap  57  can be inserted for an environmental seal to permit the boot  45  to be used even after it has been cut to receive a cable end  51 , and the cable thereafter removed. 
   Referring now additionally to  FIGS. 10 and 11 , other features of the electrical connector  20  are now described. As noted above, the electrical connector  20  includes a respective removable fastener inlet closure cap  53  for each tubular fastener inlet  51 , and a respective flexible tether  70  having a proximal end  70   a  removably connected adjacent a corresponding tubular fastener inlet  51  and a distal end  70   b  integrally molded with a corresponding removable fastener inlet closure cap  53 . 
   As shown in the illustrated embodiment, the flexible tether  70  may comprise a flexible elongate base with enlarged width distal and proximal ends  70   a ,  70   b  and a reduced width medial portion  70   c  therebetween. The proximal end  70   a  of the flexible elongate base illustratively has a ring shape defining an opening  71  to be removably positioned surrounding a corresponding one of the tubular fastener inlets  51 . Other configurations are also possible; however, the ring shape permits slight elastic expansion to secure the ring around the outside of the fastener inlet as will be appreciated by those skilled in the art. 
   The removable fastener inlet closure cap  53  includes a flange provided by the enlarged width distal end  70   b  of the base, and a hollow cylindrical plug  73  having a closed end  74  extending from the flange. In other embodiments, the plug  73  could be solid, for example. The removable fastener inlet closure cap  53  also illustratively includes a gripping member or tab  76  extending within the hollow cylindrical plug  73  and beyond the enlarged width distal end  70   b . The gripping member  76  facilitates manual grasping or grasping using a suitable tool to permit removal or insertion of the fastener inlet closure cap  53 . The cylindrical plug  73  also includes an integrally molded peripheral friction rib  78  in the illustrated embodiment. As will be appreciated by those skilled in the art, the cylindrical plug  73 , and gripping member  76  may be integrally formed as a monolithic unit with the tether  70 . As will be appreciated by those skilled in the art, because of its relative large size and ruggedness, the tether  70  itself may be grasped and used to manipulate the fastener inlet closure cap  53 . 
   The flexible tether  70  and removable fastener inlet closure cap  53  may be molded separately and thereafter installed on the fastener inlet  51  of the cover, in contrast to the similar tether and cap disclosed in U.S. Pat. No. 6,688,921 to Borgstrom et al. as discussed in the Background of the Invention section. In the Borgstrom et al. patent, the tether, its associated cap and an insulating boot are all molded simultaneously with the insulation cover. This may make molding more difficult and complicated as compared to the separate tether and cap, and separate insulating boot described herein. The separate tether and cap, and separate insulating boot may permit different materials and/or properties to be provided for these components as will also be appreciated by those skilled in the art. 
   Referring now to  FIGS. 12-15  another embodiment of an electrical connector  20 ′ is now described. In this embodiment, the transparent windows described above are replaced with moveable cable seating indicators  100 . The moveable cable seating indicators  100  also provide a cover and permit visual confirmation of proper placement of the insulation-free electrical cable end  31 ′ within a corresponding one of the cable-receiving passageways  26 ′. Also in this embodiment, the cable end viewing openings of the conductive body  21 ′ may be considered as seating indicator openings  23 ′ therein aligned with the moveable cable seating indicators  100 . In addition, the insulating cover  25 ′ may comprise the TPE forming an integrally molded bond with adjacent portions of the moveable cable seating indicators  100 . 
   Each moveable cable seating indicator  100  illustratively includes a mounting flange  101  and a pop-out indicator  103  extending outwardly therefrom, with the mounting flange being overlapped by adjacent portions of the insulating cover  25 ′. The mounting flange  101  and the pop-out indicator  103  may be integrally formed as a monolithic unit, for example. The pop-out indicator  103  illustratively includes a pleated cylindrical sidewall  104  and a closed end cap  105  connected to the sidewall ( FIGS. 13 and 14 ). The pop-out indicator  103  also facilitates placement of the cable end  31 ′ well-past the fastener  33 ′ to provide a more reliable and secure connection. 
   As will be appreciated by those skilled in the art, in this embodiment of the connector  20 ′ the moveable cable seating indicator  100  need not be formed of a transparent material. For example, each moveable cable seating indicator  100  may comprise TPE, or other material, to form a strong bond with the TPE of the insulating cover  25 ′. The cable seating indicators  100  may also comprise polypropylene, or other similar materials as will be readily appreciated by those skilled in the art. The moveable cable seating indicator  100  may include carbon black or other materials to provide UV protection as will also be appreciated by those skilled in the art. Those other elements of the connector  20 ′ not specifically mentioned are similar to elements described above with reference to the embodiment  20  shown in  FIGS. 1-11 . These other elements are indicated with prime notation and need no further discussion herein. 
   Now referring additionally to  FIGS. 16 and 17 , yet another embodiment of an electrical connector  110  is described. In this embodiment, the electrical connector  110  includes a window assembly  111 . The window assembly  111  illustratively includes an electrically insulating transparent base  112  and a plurality of electrically insulating windows  113  extending outwardly therefrom. The connector  110  also includes an electrically conducting body  114  having a plurality of spaced apart cable-receiving passageways  115  for receiving respective insulation free electrical cable ends, not shown. Each cable receiving passageway  115  may also have a cable inlet opening and a cable viewing opening  117  opposite the cable inlet opening. In the perspective of the exploded view of  FIG. 16  provided for clarity of explanation, the cable inlet opening is not visible, but its position will be readily appreciated by those skilled in the art especially in view of drawings and associated description for the previous embodiments of the connectors  20 ,  20 ′. 
   The electrically conducting body  114  also has a pair of respective fastener-receiving passageways  121  intersecting each of the cable receiving passageways  115 . Of course in other embodiments, only a single fastener-receiving passageway  121  or more than two such passageways may be provided. A respective fastener, not shown, may be provided in each of the fastener-receiving passageways  121 . The electrically conductive body  114  illustratively has a generally rectangular shape and may be made of a lightweight conductive material, such as aluminum, for example. 
   The individual windows  113  of the window assembly  111  are aligned with respective cable end viewing openings  117  upon assembly of the connector  110  to provide a cover and to permit visual confirmation of proper placement of the insulation-free electrical cable ends within corresponding ones of the cable receiving passageways  115 . The electrically insulating transparent base  112  and the windows  113  may be integrally formed as a monolithic unit. 
   In the illustrated embodiment, the window assembly  111  comprises a plurality of ribs  123  extending outwardly from the base  112 . The base  112  also has an elongate shape, and each of the ribs  123  extends transverse to the base between adjacent ones of the electrically insulating transparent windows  113  as shown in the illustrated embodiment. Those skilled in the art will appreciate that the ribs may provide additional reinforcement and/or aesthetic features, that these ribs are optional, and that other locations on the base  112  are also possible. 
   The electrical connector  110  also further includes an insulating cover  122  on the electrically conductive body  114  and defining a seal  124  ( FIG. 17 ) with the window assembly  111  when the connector is assembled as will be appreciated by those skilled in the art. The insulating cover  122  may comprise a thermoplastic elastomer (TPE), for example. In addition, the seal  124  between the window assembly  111  and the cover  122  may comprise an integrally molded bond. In particular, the window assembly  111  may comprise polypropylene, for example, as the material to form such a bond with TPE. In other embodiments, the seal  124  may be provided by a suitable adhesive as will be appreciated by those skilled in the art. Of course, the insulating cover  122  and window assembly  111  may comprise other electrically insulating materials as will be appreciated by those skilled in the art. 
   The insulating cover  122  also illustratively has an access opening  125  for receiving the electrically conductive body  114  therethrough. The window assembly  111  closes the access opening  125  in the cover  122 . Accordingly, the access opening  125  advantageously permits individual molding of the insulating cover  122 , followed by positioning of the conductive body  114  through the access opening of the cover, and thereafter followed by closing and sealing the opening using the window assembly  111 . This may simplify the molding operation for the cover as compared to the approach of properly positioning the individual windows prior to molding the cover as disclosed elsewhere herein and in U.S. Pat. No. 7,144,279. 
   The insulating cover  122  illustratively includes an integrally molded respective tubular cable inlet  126  aligned with each cable inlet  116 . The tubular cable inlet  116  may house a cable seal, not shown, and an optional cap, not shown, may also be optionally provided. The insulating cover  122  also illustratively comprises a pair of integrally molded respective tubular fastener inlets  127  aligned with each pair of fastener-receiving passageways  121 . Closure caps, not shown, may also be provided for the fastener-receiving passageways as will be appreciated by those skilled in the art. 
   Returning again to  FIGS. 1-7 , one method aspect is for making an electrical connector  20  for a plurality of electrical cables. The method may include forming an electrically conductive body  21  to have a plurality of spaced apart cable-receiving passageways  26  for receiving respective insulation-free electrical cable ends  31  therein. Each cable-receiving passageway  26  may have a cable inlet opening  27  and a cable end viewing opening  23  opposite the cable inlet opening. The conductive body  21  may also be formed to have at least one respective fastener-receiving passageway  32  intersecting each of the cable-receiving passageways  26 . 
   The method may further include aligning a respective electrically insulating transparent viewing window  24  adjacent each of the cable end viewing openings  23  to provide a cover and to permit visual confirmation of proper placement of the insulation-free electrical cable end  31  within a corresponding one of the cable-receiving passageways  26 . In addition, the method may include overmolding an insulating cover  25  on the electrically conductive body  21  and having a respective window opening  35  therein aligned with each of the transparent viewing windows  24 . The insulating cover  25  may comprise TPE forming an integrally molded bond with adjacent portions of the electrically insulating transparent viewing windows  24 . 
   Returning again additionally to  FIGS. 8 and 9 , another method aspect is also for making an electrical connector  20  for a plurality of electrical cables. The method may include forming an electrically conductive body  21  to have a plurality of spaced apart cable-receiving passageways  26  for receiving respective electrical cable ends  31  therein, with each cable-receiving passageway having a cable inlet opening  27 . The electrically conductive body  21  may be formed to have at least one respective fastener-receiving passageway  32  intersecting each of the cable-receiving passageways  26 . 
   The method may also include forming an insulating cover  25  on the electrically conductive body  21  and comprising an integrally molded respective tubular cable inlet  41  aligned with each of the cable inlet openings  27 . The method may also comprise positioning a respective insulating boot  45  in each of the tubular cable inlets  41 . Moreover, each of the insulating boots  45  may comprise a tubular sidewall  55  having a progressively increasing diameter to an open outer end  56  thereof, a removable boot closure cap  57  for removable positioning in the open outer end of the tubular sidewall, and an integrally molded tether  58  connecting the removable boot closure cap to the tubular sidewall. 
   Another aspect of the invention relates to a method for making an electrical connector for a plurality of electrical cables as explained with reference again to  FIGS. 17 ,  10  and  11 . The method may include forming an electrically conductive body  21  to have a plurality of spaced apart cable-receiving passageways  26  for receiving respective electrical cable ends  31  therein. Each cable-receiving passageway  26  may have a cable inlet opening  27 . The conductive body  21  may also be formed to have at least one respective fastener-receiving passageway  32  intersecting each of the cable-receiving passageways  26 . 
   The method may further comprise forming an insulating cover  25  on the electrically conductive body  21 , and comprising a respective integrally molded tubular fastener inlet  51  aligned with each of the fastener-receiving openings  32 . The method may also include forming a respective flexible tether and cap assembly with the tether  70  having a proximal end  70   a  to be removably connected adjacent a corresponding tubular fastener inlet  51 , and a distal end  70   b  integrally molded with a corresponding removable fastener inlet closure cap  53 . The method may also include removably connecting each proximal end  70   a  on a respective tubular fastener inlet  51 , and positioning each removable fastener inlet closure cap  53  in a respective tubular fastener inlet. 
   Returning again to  FIGS. 12-15 , another method aspect is for making an electrical connector  20 ′ for a plurality of electrical cables. The method may include forming an electrically conductive body  21 ′ to have a plurality of spaced apart cable-receiving passageways  26 ′ for receiving respective electrical cable ends  31 ′ therein. Each cable-receiving passageway  26 ′ may have a cable inlet opening  27 ′ and a cable seating indicator opening  23 ′ opposite the cable inlet opening. The conductive body  21 ′ may also be formed to have at least one respective fastener-receiving passageway  32 ′ intersecting each of the cable-receiving passageways  26 ′. 
   The method may further include aligning a respective moveable cable seating indicator window  100  adjacent each of the seating indicator openings  23 ′ to provide a cover and to permit visual confirmation of proper placement of the insulation-free electrical cable end  31 ′ within a corresponding one of the cable-receiving passageways  26 ′. In addition, the method may include overmolding an insulating cover  25 ′ on the electrically conductive body  21 ′ and having a respective opening  35 ′ therein aligned with each of the moveable seating indicators  100 . The insulating cover  25 ′ may comprise TPE forming an integrally molded bond with adjacent portions of the moveable, electrically insulating, cable seating indicators  100 . 
   Now referring again to  FIGS. 16 and 17 , yet another method is for making an electrical connector  110 . The method includes forming an electrically conducting body  114  having a plurality of spaced apart cable-receiving passageways  115  for receiving respective insulation free electrical cable ends. Each cable receiving passageway  115  may also have a cable inlet opening and a cable viewing opening  117  opposite the cable inlet opening. The method may also include forming an insulating cover  122  having an access opening  125 . As in the illustrated embodiment, the insulating cover  122  receives the electrically conductive body  114  through the access opening  125 . The method also includes making a window assembly  111  including an electrically insulating transparent base  112  and a plurality of electrically insulating windows  113  extending outwardly therefrom. The method may further include closing the access opening  125  in the insulating cover  122  with the window assembly  111  so that the electrically insulating transparent windows  113  are aligned with the cable end viewing openings  117 . In the closed and aligned position, the insulating cover  122  and the window assembly  111  provide a cover and permit visual confirmation of proper placement of the insulation-free electrical cable ends within the corresponding cable-receiving passageways  115 . 
   Many modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Accordingly, it is understood that the invention is not to be limited to the illustrated embodiments disclosed, and that other modifications and embodiments are intended to be included within the spirit and scope of the appended claims.