Electrical connector housing having cut blade and method of making the same

Abstract

An electrical connector housing for an electrical connector includes a slot disposed within the housing and located between a plurality of contact tabs and the front surface of the housing. The slot extends vertically from the upper surface of the housing to communicate with a plurality of channels within the housing for receiving insulated wires. A cutting disc is received and fixed in the slot for cutting portions of the insulated wires that extend beyond the slot or the cutting disc along the length of the connector housing. The housing prevents short circuits, sparks, and other electrical hazards arising from exposed or open wire ends on the connector.

Description

Technical Field

[0001] The present disclosure relates to an electrical connector housing and a method of using the same, and more particularly to an electrical connector housing having a cutting piece therein and a method of using the same for manufacturing an electrical connector. Prior Art

[0002] As electrical components for high-speed data transmission become more complex and specialized, corresponding wires are given more specifications and subject to stricter requirements. While improving the application and performance of these connectors, it is necessary to establish strict standards for their performance. The Federal Communications Commission (FCC) rules and other industry standards, such as Power over Ethernet (POE) and the Institute of Electrical and Electronics Engineers (IEEE) 802.3 standard (also known as Alternative B mode), require precise configurations and dimensions. The housing of an electrical connector must be made of a moldable material such as plastic that can be fully molded and deformed to capture and retain wires inside while insulating the internal current and maintaining precise dimensions. At the same time, the housing must have sufficient rigidity to reliably support the wires and their associated contact pieces in precise positions to ensure their correct engagement with the associated system components. In addition, the moldable material for making the housing needs to ensure that the wires can be cut and terminated fully and effectively, and the insulation layer of each wire must isolate the individual conductors, and the connector must ensure that there is no short circuit between one wire and another or electrical connection to adjacent hardware. Furthermore, each conductor needs to maintain insulation and isolation from adjacent conductors and continuous external paths. The insulation and isolation should be sufficient to prevent any current from flowing between conductors or to the external path. In addition, the insulation layer should be durable enough to resist abrasion for a long time. For example, there is a product called Simply45 Cap isolation cover (see US 10,811,831), which is an isolation cap / barrier strip that can be attached to the connector and cover the exposed wires after termination to prevent short circuits, sparks, and other electrical risks caused by the exposed or open wire ends on the connector.

[0003] Therefore, the construction, electrical, and electronics industries all expect to provide an electrical connector housing that insulates wires and reduces the need for additional caps or auxiliary protection measures (such as the electrical connector housing of US 10,811,831), which can eliminate sparks or electromigration on parallel, coaxial, close, or adjacent conductive materials and at the same time comply with FCC regulations and POE standards. Summary of the Invention

[0004] To overcome the foregoing problems, the inventor of the present application, Robert W Sullivan, has improved the inventions in his U.S. Patents Nos. 5,996,224, 6,017,237, 6,105,229, 9,543,729, 10,116,082, 10,573,990, and 11,146,014 in this disclosure. For more than 20 years, the eight-wire connector systems disclosed in the above U.S. patents have been sold in the market under the registered trademark EZ-RJ45 and have been applied to Ethernet cable systems throughout the industry. This disclosure aims to improve the EZ-RJ45 connector to achieve reliable electrical connection under relatively harsh or extreme environmental conditions.

[0005] In one embodiment of this disclosure, a housing of an electrical connector is provided, which has a front end wall with holes or openings formed horizontally therein. The housing has a cutting piece therein for cutting off the excess connecting wire portion, and the cutting piece is positioned separated from the front end of the connector. The housing of the electrical connector provides sufficient space and guiding paths to accommodate and guide the cutting piece, and the cutting piece and the electrical connector are integrated. The wires are supported in a small space of the connector, and the excess wires are cut off inside the connector. After being cut off, the excess wires are removed from the front end of the connector, thereby insulating the cut ends of the wires to avoid short circuits, generating sparks or rubbing against each other, exposing copper or contacting the corresponding wires. The conductors in the wires are cut off or internally positioned in the housing of the electrical connector away from the front of the housing of the electrical connector. Thereby, after the wires are cut and terminated, the conductors can be insulated without using additional hardware or using a cap / bar system for auxiliary operations. Thus, the distal end (the cut end) of the bare wire maintains a safe distance from the front end of the connector. The housing of the electrical connector is correctly mated in the designated space of its associated terminal board to meet the requirements of FCC regulations and POE, and there is no need to worry about the problems caused by the protrusion of the excess wire ends.

[0006] In one embodiment of this disclosure, the contact plate / pin / slice is bonded, embossed or manufactured together with the cutting piece to form an integral body. They are crimped, and the wires are simultaneously cut off by the cutting piece of the connector. In another embodiment, the contact plate / pin / slice is separated from the cutting piece, and the cutting piece cuts the insulated wires in series. In yet another embodiment, a separate external slice is provided to cut the insulated wires through a slot in the housing of the electrical connector. All embodiments are good at cutting off the excess insulated wires while the housing of the electrical connector is crimped, and insulating and protecting the exposed cut wire ends. During the crimping process, the contact slices are forced to conductively engage with the associated wires.

[0007] Since the cutting piece is disposed inside the electrical connector housing, the user can reduce the need for a cutting tool, which requires expensive cutting pieces or costly replacements when the cutting pieces become dull. In addition, the internal cutting piece is configured to cut all protruding wire ends simultaneously or sequentially during a crimping operation without the need for expensive external cutting pieces or modifications to the cutting / crimping tool, and reduces the need for auxiliary operations.

[0008] In yet another embodiment, a guiding path is provided vertically inside the electrical connector housing, which allows two horizontal or flat rows of wires to be inserted through and pass through the front wall of the housing. In operation, a tool fixedly contacts a plate / pin / slice inside the housing to crimp the insulated wires, and then, by an auxiliary step, the cutting piece is driven to cut the excess wires passing through the guiding path. Alternatively, the tool drives the plate / pin / slice downward together with the cutting piece, so that the contact slice and the wires are crimped and the excess portions of the wires are cut. These improvements are intended to provide a connector suitable for use with CAT6A Ethernet cables and POE-compliant CAT6 type transmissions, and reduce the adverse effects of short circuits, sparks, and cross-conduction to other non-ideal contacts.

[0009] In summary, the advantages brought by the present disclosure include: (1) the way the wires are arranged inside the connector can minimize the interference or crosstalk between each wire and the data stream being transmitted; (2) the speed of data transmission can be increased while reducing the energy required; and the wires are also insulated to prevent electrical short circuits and avoid corrosion. In addition, in the above embodiments, the color-coded wires inserted into the connector can protrude outward from their front ends so that a technician can view the color-coded wires to confirm their correct relative positions before cutting them. The driving engagement of the metal contact plate / pin / slice with the wires and the cutting of the wires can be performed simultaneously or in series. This makes the process of connecting and cutting the wires faster and more efficient. In addition, it eliminates the need for a separate cutting tool and makes the connection more secure. Brief Description of the Drawings

[0010] Reading the following embodiments in conjunction with the accompanying drawings can best understand various aspects of the present disclosure. It should be noted that, according to standard practices in the industry, various features are not drawn to scale. In fact, for the clarity of discussion, the dimensions of various features can be arbitrarily enlarged or reduced.

[0011] FIG. 1 is a schematic diagram showing a first embodiment of the present disclosure.

[0012] FIG. 2 is a schematic diagram showing a part of an insulating wire being cut using a tool in the first embodiment of the present disclosure.

[0013] FIG. 3 is a schematic diagram showing an insulating wire being cut and crimped using a tool in the second embodiment of the present disclosure.

[0014] FIG. 4 is a schematic diagram showing that the contact piece is first pressed downward to crimp the insulating wire, and then a tool is used to cut a part of the insulating wire in the second embodiment of the present disclosure.

[0015] FIG. 5 is a schematic diagram showing a part of the insulating wire being cut in the second embodiment of the present disclosure.

[0016] FIG. 6 is a front schematic diagram of the first embodiment shown in FIG. 1.

[0017] FIG. 7 is a front schematic diagram of the second embodiment shown in FIG. 3.

[0018] FIG. 8 is a front schematic diagram of the third embodiment of the present disclosure.

[0019] FIG. 9A is a schematic diagram showing a cutting piece in contact with a contact piece in an embodiment of the present disclosure.

[0020] FIG. 9B is a partial enlarged view of part A in FIG. 3. Embodiments

[0021] The following disclosure provides many different embodiments or examples for implementing different features of the provided invention subject matter. Specific examples of components and configurations are set forth below to simplify the present disclosure. Of course, these are only examples and are not intended to be limiting. For example, the form in which the first feature is over or on the second feature in the following description may include embodiments in which the first and second features are in direct contact, and may also include embodiments in which additional features may be formed between the first and second features, such that the first and second features may not be in direct contact. In certain embodiments, the present disclosure may repeat element symbols / or letters in various examples. This repetition is for the purpose of simplicity and clarity and does not itself determine the relationship between the various embodiments and / or configurations discussed.

[0022] In addition, for ease of description, spatial relative terms such as "below", "beneath", "lower", "above", "upper", and the like may be used herein to describe the relationship between one element or feature and another element(s) or feature(s) shown in the figures. Spatial relative terms are intended to encompass the orientation of the device during use or operation, which in some embodiments is different from the orientation depicted in the figures. The device may be oriented in other directions (rotated 90 degrees or otherwise), and the spatial relative terms used herein may be interpreted accordingly.

[0023] As shown in FIGS. 1 and 6, in the first embodiment of the present disclosure currently disclosed, an electrical connector housing 100 is provided. The electrical connector housing 100 has an upper surface 130 and includes a plurality of contact pieces 110, each of which is received in a groove 120. A plurality of channels 140 are formed inside the electrical connector housing 100 and are positioned below the plurality of contact pieces 110. Each channel 140 communicates with a rear opening 150 and extends through a front surface 160 of the electrical connector housing 100. In the electrical connector housing 100, a slot 170 is formed between the plurality of contact pieces 110 and the front surface 160 of the electrical connector housing 100 in the length direction of the electrical connector housing 100. The slot 170 extends vertically from the upper surface 130 of the electrical connector housing 100 to communicate with each of the plurality of channels 140.

[0024] Please refer to FIG. 2. The slot 170 is configured to receive a cutting piece 210 of a cutting tool 200, wherein a position where a tip 211 of the cutting piece 210 is not located in the plurality of channels 140 is defined as a first position and a position where the tip 211 of the cutting piece 210 is located in the plurality of channels 140 is defined as a second position. As shown in FIG. 2, the slot 170 is spaced apart from the plurality of contact pieces 110 in the length direction of the electrical connector housing 100. In this configuration, the contact pieces 110 can be pressed downward by a tool (not shown). First, as shown in FIG. 2, a user needs to push the cutting tool 200 with the cutting piece 210 from the first position downward to the second position, so that the cutting piece 210 cuts the insulating wires 500 in the channels 140, and the tip 211 of the cutting tool 200 is located in the plurality of channels 140. As shown in FIG. 2, a crimping portion 220 is used to crimp a rear portion 190 of the electrical connector housing 100, so that the rear portion of the electrical connector housing 100 tightly clamps the insulating wires 500. In some embodiments of the present disclosure, a left side 111 of the contact pieces 110 is substantially flush with one side of the slot 170, and the left side of the contact pieces 110 contacts that side of the slot 170.

[0025] As shown in FIGS. 3 and 7, in the second embodiment of the present disclosure, an electrical connector housing 100a is provided. The electrical connector housing 100a has a structure similar to that of the electrical connector housing 100a shown in FIG. 1, and further includes a cutting piece 180 accommodated and held in a slot 170, wherein the cutting piece 180 is movable between a first position in which a tip 181 of the cutting piece 180 is not located in a plurality of channels 140 and a second position in which the tip 181 of the cutting piece 180 is located in one of the plurality of channels 140. In some embodiments of the present disclosure, at the same position as the position of the cutting piece 180 shown in FIG. 3, the cutting piece 180 is directly pre-embedded in the electrical connector housing 100a. As shown in FIG. 3, the cutting piece 180 is spaced apart from the plurality of contact pieces 110 in the longitudinal direction of the electrical connector housing 100a. FIG. 9B shows a partially enlarged portion A in FIG. 3. The shape of the contact pieces 110 in FIG. 9B reflects the actual shape of the physical contact pieces, while the shape shown in FIG. 3 is for illustrative purposes only. In some embodiments of the present disclosure, the cutting piece 180 contacts the plurality of contact pieces 110 in the longitudinal direction of the electrical connector housing 100a. Referring to FIG. 9A, it shows the details of this configuration. In some embodiments of the present disclosure, the cutting piece 180 is a single cutting piece and is made of a hard plastic or ceramic hard enough to cut the insulated electric wire 500. The single cutting piece 180 can also be made of any other non-conductive material hard enough to cut the insulated electric wire 500. In some embodiments of the present disclosure, the cutting piece 180 and the contact piece 110 are integrally formed, wherein the cutting piece 180 is hard enough to cut the insulated electric wire 500 and wherein the contact piece 110 is strong enough to crimp the electric wire 500. In some embodiments of the present disclosure, only a single cutting piece tip 181 in the single cutting piece 180 is made of a non-conductive material or coating hard enough to cut the insulated electric wire 500 and insulate the end of the electric wire.

[0026] Figure 3 shows a way to operate the electrical connector housing 100a: Provide a crimping tool 300; the crimping tool 300 includes a first part 310, a second part 320, and a third part 330 attached to the body of the crimping tool 300. When a user pushes the crimping tool 300 downward, the first part 310 abuts against the upper part of the cutting piece 180, and at the same time the second part 320 abuts against the contact pieces 110. As a result, as shown in Figure 5, the contact pieces 110 move downward and pierce the insulation layer of the insulated wires to establish an electrical connection between the contact pieces 110 and the insulated wires, and the cutting piece 180 moves downward to cut off the portions of the insulated wires 500 that protrude beyond the slot 170 or the cutting piece 180. The cut-off portions are removed from the front of the electrical connector housing 100a, thereby insulating the cut ends of the wires 500 to avoid short circuits, sparks, or mutual friction, resulting in exposed copper or contact with the corresponding wires. Then, the third part 330 crimps a rear part 190 of the electrical connector housing 100a and tightly clamps the insulated wires 500.

[0027] In another operation of the electrical connector housing 100a as shown in Figure 4: Provide a crimping tool 300a; the crimping tool 300a includes a first part 310a and a second part 330a attached to the body of the crimping tool 300a. In this operation, the contact pieces 110 can be pressed downward by a tool (not shown) to first pierce the insulation layer of the insulated wires, and then establish an electrical connection between the contact pieces 110 and the insulation layer of the insulated wires 500 as shown in Figure 4, and then the crimping tool 300a continues to be pushed downward. As a result, the cutting piece 180 moves downward to cut off the portions of the insulated wires 500 that protrude beyond the slot 170 or the cutting piece 180 (see Figure 5). The second part 330a crimps a rear part 190 of the electrical connector housing 100a, thereby tightly clamping the insulated wires 500 by the rear part 190 of the electrical connector housing 100a.

[0028] In the third embodiment of the present disclosure as shown in FIG. 8, an electrical connector housing 100b is provided. The channels 140 of the electrical connector housing 100b are configured in two rows and a part of the two rows of channels 140 communicate with each other. The plurality of cutting pieces 180b in the embodiment of the present disclosure are made of metal, such as steel. The electrical connector housing 100b has a structure similar to that of the electrical connector housing 100a shown in FIGS. 2 and 7. The difference between the electrical connector housing 100b and the electrical connector housing 100a is that the latter has a single cutting piece 180 while the former has a plurality of cutting pieces 180b received in a plurality of thin and narrow slots 170b, and each of the cutting pieces 180b is positioned and aligned with one of the corresponding channels 140, wherein the cutting pieces 180b are spaced apart from each other in the lateral direction in FIG. 8 and are movable between a first position in which the tips 181b of the cutting pieces 180b are not located in one of the plurality of channels 140 and a second position in which the tips 181b of the cutting pieces 180b are located in one of the plurality of channels 140. In some embodiments of the present disclosure, the cutting pieces 180b are spaced apart from the plurality of contact pieces 110 in the length direction of the electrical connector housing 100b. In some other embodiments, the cutting pieces 180b respectively contact the plurality of contact pieces 110 in the length direction of the electrical connector housing 100b.

[0029] In an embodiment of the present disclosure, a method of manufacturing an electrical connector is provided. The method includes the following steps: (a) providing the electrical connector housing 100 of the first embodiment above (see FIG. 1); (b) providing a tool 200 having a cutting piece 210; (c) sequentially inserting each of the plurality of insulated wires 500 from the rear opening 150 of the electrical connector housing 100 and passing the plurality of insulated wires 500 through the corresponding channels 140 so that their front ends protrude beyond the slots 170; (d) pressing the contact pieces 110 of the electrical connector housing 100 by a crimping tool (not shown), thereby moving the contact pieces 110 of the electrical connector housing 100 downward and piercing the insulation layers of the insulated wires to establish an electrical connection between the contact pieces 110 and the insulated wires 500; and (e) pressing the cutting piece 210 of the tool 200 into the slot 170 of the electrical connector housing 100, thereby moving the cutting piece 210 downward to cut off the portion of the insulated wire 500 that protrudes beyond the slot 170 in the length direction of the electrical connector housing 100. In step (e), the crimping portion 220 of the tool 200 moves downward simultaneously to crimp a rear portion 190 of the electrical connector housing 100, thereby tightly clamping the insulated wires 500 by the rear portion 190 of the electrical connector housing 100.

[0030] Another method for manufacturing an electrical connector disclosed herein includes the following steps: (a) providing the electrical connector housing 100a of the second embodiment described above (see FIG. 3); (b) inserting each of a plurality of insulated wires 500 through the rear opening 150 of the electrical connector housing 100a, and passing each of the plurality of insulated wires 500 through the corresponding channel 140 such that its front end projects beyond the slot 170 or the cutting piece 180; and (c) simultaneously pressing the contact pieces 110 and the cutting piece 180 of the electrical connector housing 100a as shown in FIGS. 3 and 5, thereby moving the contact pieces 110 downward to pierce the insulation layers of the insulated wires 500 to establish an electrical connection between the contact pieces 110 and the insulated wires 500, and moving the cutting piece 180 downward to cut off the portions of the insulated wires 500 that project beyond the slot 170 or the cutting piece 180. The cutting piece may or may not be made as part of a contact piece or as an independent subset of a unit, or may be external to the electrical connector housing 100a.

[0031] Another method for manufacturing an electrical connector disclosed herein includes the following steps: (a) providing the electrical connector housing 100b of the third embodiment described above (see FIG. 8); (b) inserting each of a plurality of insulated wires 500 through the rear opening 150 of the electrical connector housing 100b, and passing each of the plurality of insulated wires 500 through the corresponding channel 140 to project beyond the thin slots 170b or the cutting pieces 180b; and (c) simultaneously pressing the contact pieces 110 and the cutting pieces 180b of the electrical connector housing 100a, thereby moving the contact pieces 110 downward to pierce the insulation layers of the insulated wires 500 to establish an electrical connection between the contact pieces 110 and the insulated wires 500, and moving the cutting pieces 180b downward to correspondingly cut off the portions of the insulated wires 500 that project beyond the thin slots 170b or the cutting pieces 180b. The cut-off portions are removed from the front of the electrical connector housing 100b, thereby insulating the cut ends of the insulated wires 500 to avoid short circuits, sparks, or mutual friction, copper exposure, or contact with corresponding wires.

[0032] Although the numerical ranges and parameters set forth in this disclosure are approximations within a broad scope, the numerical values set forth in specific examples are as precise as possible. However, any numerical value inherently contains certain errors which are bound to be caused by the standard deviation found in their respective test measurements. In addition, the terms "substantially", "approximately" or "about" as used herein generally refer to within the numerical value or range that can be considered by those of ordinary skill in the art. Alternatively, the terms "substantially", "approximately" or "about" refer to within the range of the average standard error that can be accepted by those of ordinary skill in the art. Those of ordinary skill in the art can understand that the acceptable standard error may vary depending on different technologies. Except for the operating / work examples, or unless otherwise explicitly stated, all numerical ranges, quantities, numerical values and percentages disclosed herein, such as material quantities, durations, temperatures, operating conditions, quantity ratios or others similar, should be understood to be modified by the terms "substantially", "approximately" or "about" in all cases. Therefore, unless stated to the contrary, the numerical parameters set forth in this disclosure and the appended claims are approximations, which can vary according to requirements. At a minimum, each numerical parameter should be interpreted in light of the number of significant digits presented and by applying ordinary rounding methods. The ranges herein can be expressed from one endpoint value to the other endpoint value or the range between the two endpoint values. Unless otherwise stated, all ranges disclosed herein include the endpoint values.

[0033] The features of several embodiments are outlined above so that those skilled in the art can better understand various aspects of this disclosure. Those skilled in the art should understand that they can easily design or modify other operations and structures based on this disclosure to achieve the same purpose and / or achieve the same advantages as the embodiments introduced herein. Those skilled in the art should also understand that such equivalent structures do not depart from the spirit and scope of this disclosure, and they can make various modifications, substitutions or alterations to this disclosure without departing from the spirit and scope thereof.

[0034] In addition, the scope of this application is not limited to the specific embodiments of the processes, machines, manufactures, compositions, means, methods and steps described in the specification. As can be easily understood by those of ordinary skill in the art from the disclosure of the present invention, processes, machines, manufactures, compositions, means, methods or steps that can perform substantially the same functions or achieve substantially the same results as the corresponding embodiments described herein can be used according to the present invention, either existing or to be developed later. Therefore, the appended claims are intended to embrace such processes, machines, manufactures, compositions, means, methods and steps within their scope.

[0035] 100, 100a, 100b: Electrical connector housing 110: Contact piece 111: Left side of the contact piece 120: Groove 130: Upper surface 140: Channel 150: Rear opening 160: Front surface 170: Slot 170b: Thin slot 180, 180b: Cutting piece 181, 181b: Tip 190: Rear part 200: Tool 210: Cutting piece 211: Tip 220: Crimping part 300, 300a: Crimping tool 310, 310a: First part 320, 330a: Second part 330: Third part 500: Insulated wire / wire

Claims

1. An electrical connector housing, comprising: a plurality of contact tabs, each of the plurality of contact tabs being received in a groove formed in an upper surface of the electrical connector housing; a plurality of channels formed inside the electrical connector housing and positioned below the plurality of contact tabs; each of the plurality of channels communicating with a rear opening and extending through a front surface of the electrical connector housing; and a slot formed between the plurality of contact tabs and the front surface of the electrical connector housing, the slot extending vertically from the upper surface of the electrical connector housing to connect with each of the plurality of channels.

2. The electrical connector housing as claimed in claim 1, wherein the slot is configured to receive a cutting blade of a cutting tool, wherein the position of a tip of the cutting blade not located in the plurality of channels is defined as a first position, and wherein the position of the tip of the cutting blade in the plurality of channels is defined as a second position.

3. The electrical connector housing as claimed in claim 2, wherein the slot is spaced apart from the plurality of contact pieces along a length direction of one of the electrical connector housings.

4. The electrical connector housing as claimed in claim 2, wherein the side of the contact piece facing the front surface is substantially flush with and contacts the corresponding side of the slot.

5. The electrical connector housing as claimed in claim 1, further comprising a cutting tab received in the slot, wherein the cutting tab is movable in a first position where a tip of the cutting tab is not located in one of the plurality of channels and in a second position where the tip of the cutting tab is located in one of the plurality of channels.

6. The electrical connector housing as claimed in claim 5, wherein the cut tab is spaced apart from the plurality of contact tabs along the length of the electrical connector housing.

7. The electrical connector housing as claimed in claim 5, wherein the cutting disc contacts the plurality of contact tabs along one of the length directions of the electrical connector housing.

8. The electrical connector housing as claimed in claim 5 or 6, wherein the cutting disc is a single cutting disc and is made of metal, hard plastic or ceramic that is hard enough to cut insulated wires.

9. The electrical connector housing as claimed in claim 1, wherein the channels are arranged in a lower and a upper column and alternately in the two columns, and the slot includes a plurality of thin slots, the electrical connector housing further including a plurality of slits received in the thin slots, each of the plurality of slits being positioned with respect to one of the corresponding channels, wherein the slits are spaced apart from each other in a lateral direction and movable in a first position where a plurality of tips of the slits are not located in one of the plurality of channels and in a second position where the tips of the slits are located in one of the plurality of channels.

10. The electrical connector housing as claimed in claim 9, wherein the cut tabs are spaced apart from the plurality of contact tabs along a length direction of one of the electrical connector housings.

11. The electrical connector housing as claimed in claim 9, wherein the cut tabs respectively contact the plurality of contact tabs along a length direction of one of the electrical connector housings.

12. The electrical connector housing as claimed in claim 9, wherein the following channels and the above channels in the two columns are partially connected together.

13. The electrical connector housing as claimed in claim 9, wherein the plurality of cut tabs are made of metal.

14. The electrical connector housing as claimed in claim 9, wherein the plurality of cut tabs and the contact tabs are integrally formed.

15. An electrical connector housing as claimed in claim 13 or 14, wherein a plurality of cut discs made of the metal are coated with an insulating material.

16. A method of manufacturing an electrical connector, comprising: (a) providing an electrical connector housing as described in claim 1; (b) providing a tool having a cutting blade and a crimping portion; (c) inserting each of a plurality of insulated wires through a rear opening of the electrical connector housing and passing each wire through a corresponding channel such that the front ends of the plurality of insulated wires protrude beyond the slot; and (d) simultaneously pressing the contacts of the electrical connector housing through the crimping portion of the tool and pressing the cutting blade of the tool into the slot of the electrical connector housing, thereby causing the contacts of the electrical connector housing to move downward and pierce the insulation layer of the insulated wires to establish an electrical connection between the contacts and the insulated wires, and the cutting blade moving downward to cut off the portions of the insulated wires protruding beyond the slot.

17. A method of manufacturing an electrical connector, comprising: (a) providing an electrical connector housing as described in claim 5; (b) inserting each of a plurality of insulated wires through a rear opening in the electrical connector housing, and passing each wire through a corresponding channel to protrude beyond the slot; and (c) simultaneously pressing the contact tabs and the cutting tab of the electrical connector housing such that the contact tabs move downward and pierce the insulation layer of the insulated wires to establish an electrical connection between the contact tabs and the insulated wires, and the cutting tab moves downward to cut off the portion of the insulated wires protruding beyond the slot.

18. A method of manufacturing an electrical connector, comprising: (a) providing an electrical connector housing as described in claim 9; (b) inserting each of a plurality of insulated wires through a rear opening in the electrical connector housing, and passing each wire through a corresponding channel to protrude beyond the slots; and (c) simultaneously pressing the contacts and the plurality of cutting tabs of the electrical connector housing, such that the contacts move downward and pierce the insulation layer of the insulated wires to establish an electrical connection between the contacts and the insulated wires, and the plurality of cutting tabs move downward to correspondingly cut off portions of the insulated wires protruding beyond the slots.

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