Patent ID: 7370413

Claim:
A method making an electrical connector having a hard base part forming at least one rearwardly and forwardly open seat and formed with a transverse passage extending across the seat generally at the rear seat end; a respective contact in the seat having a front end and a rear end; a respective wire projecting forwardly into the seat and connected in the seat to the rear contact end; and a soft jacket encapsulating a rear end of the base part and a front end of the wire and extending, at least partially into the rear seat end, the method comprising the steps of sequentially: fitting the contact to the seat and connecting the wire to the rear contact end; fitting a flow-blocking bar through the passage into a position blocking forward flow in the seat to the front contact end; enclosing the rear end of the base part and the flow-blocking bar in a cavity of a mold; and filling the cavity with a hardenable resin such that the resin surrounds and encapsulates the rear end of the base part and flows into the seat only rearward of the flow-blocking bar.