Method and process for manufacturing a terminal block

1. A method of manufacturing a terminal block for a telecommunication cable comprising:

providing a preformed substrate member comprising:

an elongated podium member having a distal end, a proximal end, a front side, a back side, a plurality of wire receiving slots on an outer edge of the podium member and a plurality of electrical connector slots positioned within the podium member, wherein the plurality of wire receiving slots are arranged in groups of three comprised of a first and a second wire receiving slot, which are configured to receive one wire each of a pair of insulated electrical wires, which are each attached to an electrical contact, and a third wire receiving slot configured to receive the pair of insulated electrical wires from the first and second wire receiving slots and guide the pair of insulated electrical wires towards the proximal end of the podium member;

an electrical connector positioned within each of the plurality of electrical connector slots, and wherein each electrical connector has a pair of electrical contacts extending therefrom; and

at least one insulated electrical wire attached to each of the electrical contacts;

placing the preformed substrate member in a mold; and

injecting a dielectric material into the mold containing the podium member to form an overmolded terminal block, wherein the dielectric material covers the at least one insulated electrical wire and a portion of the electrical contact positioned within the electrical connector.

2. The method of claim 1 , further comprising attaching a bond clamp to the at least one insulated electrical wire.

3. The method of claim 2 , further comprising attaching the bond clamp to the podium member.

4. The method of claim 1 , wherein the mold includes a cavity configured to receive a portion of the electrical connector, which does not receive overmolding.

5. The method of claim 1 , wherein the electrical connector is a multi-use connector.

6. The method of claim 1 , wherein each of the plurality of electrical connectors has a first end and a second end and which are adapted to receive the pair of insulated electrical wires at the first end on the back side of the substrate member and to receive electrical conductors on the front side of the substrate member.

7. The method of claim 6 , wherein the first end of the electrical connector comprises an insulation displacement contact terminal.

8. The method of claim 6 , wherein the second end of the electrical connector comprises an insulation displacement contact terminal.

9. The method of claim 1 , further comprising gathering a plurality of insulated electrical wires in a bundle to form a cable, wherein the insulated electrical wire comprises an electrical wire surrounded by an insulated outer jacket and cutting the insulated electrical wire at a second end to form a bundle of wires.

10. The method of claim 9 , further comprising multiple pairs of electrical wires extending from the cable, wherein the electrical wires are connected to the electrical connectors on the back side of the substrate member.

11. The method of claim 1 , wherein the dielectric material is selected from the group comprising acrylonitrile butadiene styrene (ABS), polyolefin, polyurethanes, polyvinyl chloride, polystyrene, polycarbonates, polyesters, suitable plastics and desirable blends of the foregoing or other suitable materials.

12. The method of claim 1 , wherein the dielectric material is injected by applying a force to the dielectric material of greater than 1 g.

13. The method of claim 1 , wherein the insulated electrical wires are comprised of a plurality of color-coded outer jackets adapted to identify pairs of electrical wires.

14. The method of claim 1 , further comprising removing an outer jacket of insulation from the insulated electrical wires to expose an individual wire contained therein before connecting the insulated electrical wires to the electrical connectors, and wherein the step of removing the outer jacket of insulation to expose the individual wire contained therein is performed by an insulation displacement contact terminal.

15. The method of claim 1 , wherein the insulated electrical wires comprise soft copper wires having a gauge of about 19 AWG to about 26 AWG, and wherein the insulated electrical wires are color-coded and have an outer jacket of polyvinyl chloride.

16. The method of claim 1 , wherein each of the electrical connectors comprise a pair of wire receiving passages movable between a first position in which a pair of wires are held apart from electrical contact and a second position in which the pair of wires are inserted into the electrical contact, wherein the connector is capable of removing the pair of wires from the electrical contact and reinserting the pair of wires into the electrical contact.

17. The method of claim 1 , wherein the wiring of the podium member starts at the distal end and works towards the proximal end of the podium member.

18. The method of claim 17 , further comprising a plurality of pairs of insulated electrical wires, which form a cable.