Patent ID: 7351369

Claim:
A method of making a twist-on wire connector comprising: forming a mold cavity in a first mold having an internal mold part with the internal mold part having a mold surface in the shape of a female spiral thread; injecting a liquid metal into the mold cavity to form an electrically conducting spiral core; removing the electrically conducting spiral core from the mold cavity by removing the internal mold part with the electrically conducting spiral core retained thereon; placing the electrically conducting spiral core retained on the internal mold part in a second mold cavity; injecting an electrically insulating polymer plastic into a second mold cavity to cover an exterior surface of the electrically conducting spiral core; removing the internal mold part from the second mold while retaining the electrically conducting spiral core on the internal mold part to provide an injection molded twist-on wire connector with an electrically conducting spiral core and an external insulated housing; wherein the liquid metal injected comprises a liquid metallic amorphous alloy.