Abstract: A structure includes a baseplate, a circuit board parallel and adjacent to the baseplate, and an electronic component. The circuit board has an edge with a scallop formed in the edge, and the scallop is plated with a conductive material. The electronic component includes a power-dissipating surface and a pad for making electrical connection. The electronic component is mounted with the power-dissipating surface in contact with the baseplate and the pad electrically connected to the conductive material.

Abstract: A process for fabricating an electrical connector by the steps of: providing a housing of thermoplastic material having a front surface which will constitute an exterior surface of the connector, a rear surface and an opening extending to the rear surface; installing a conductive contact member so that at least a portion of the conductive contact member is positioned in the opening; and heating a portion of the housing adjacent the rear surface while displacing the portion of the housing to a location to extend across the opening and to contact the conductive contact member, and then allowing the portion of the housing to solidify at that location. The electrical connector may initially have a through opening which extends between the front and rear surfaces and the portion of the housing which is heated will be displaced in a manner to close the opening.

Abstract: A premold insert for securely mounting a light source within the female connector of an extension cord. The premold insert is positioned over the hot blade receiving terminal, the neutral blade receiving terminal, and the ground receiving terminal of the female receptacle. The light source is positioned within said insert such that when the insert is mounted to the terminals, the light source is secure and will not be damaged when the light-permeable plug is molded. By securing the premold insert, and hence the light source in this manner, the light source is more resilient to stress and strains. The insert acts as a shock absorber which limits the damaging effects of mechanical stresses on the light source.

Abstract: An arrangement for establishing electrical contact in joints, and a method of producing the arrangement. The arrangement comprises an electric contact making device which is enclosed in a joint between two metal surfaces between which electrical contact shall be established. The joint and the contact making device are held together and protected by plastic material. The arrangement is produced by applying pressure to the joint so that the surface penetrating devices of the contact making device will spring, and by converting the plastic material from a fluid state to a solid state while maintaining the pressure, so that the resilient biassing effect of the surface penetrating devices against the metal surfaces will be made permanent in the arrangement.

Abstract: A contact assembly formed from an array of insulated resilient solid wires arranged in spaced apart side-by-side relation to each other and retained in assembly by an ultrasonically assembled two-part carrier strip which extends transversely of the wire array. Notches formed in the wires by grinding define exposed conductive surfaces at selected locations. The conductive surfaces are plated with precious metal to define contact surfaces on the wires which are formed to contact configurations.

Abstract: Process for assembly of a connector incorporating an insulator (1) comprising a front part (2) in which working portions (30) of a plurality of contact elements (30, 33, 34) are inserted, these contact elements comprising bent rear portions (32), and distal ends (33) fitted into slots (21) in a rear wing (20) of the insulator (1). The process comprises immobilizing the distal ends (33) by thermoforming in their respective slots (21) without addition of material. The connector thus produced incorporates folds of material (40) solidly attached to the edges (23) of the corresponding slots (21), thereby allowing immobilization and precise position-retention of the contacts (30).

Abstract: An electrical circuit (101) that is disposed on a substrate (103) employs a method and apparatus for providing electromagnetic shielding of the electrical circuit (101). One or more compressible, electrically conductive contacts (107), each of which includes a substantially planar portion (201), are coupled at their respective planar portions (201) to a receptacle area (105) on the substrate (103) that substantially encircles the electrical circuit (101). A shielding enclosure (109) having a top portion (110) and a plurality of side portions (111) is positioned upon the compressible, electrically conductive contacts (107) such that the side portions (111) compress at least some of the compressible, electrically conductive contacts (107) to substantially enclose the electrical circuit (101).

Abstract: A method of terminating a wire comprises the steps of (i) winding the wire around a an end portion of a terminal, (ii) placing a plastic sleeve having a first cavity into a second cavity in an ultrasonic horn, (iii) inserting the portion of the terminal around which the wire is wound into the first cavity of the plastic sleeve while the plastic sleeve is within the second cavity in the ultrasonic horn, (iv) activating the ultrasonic horn causing the plastic sleeve to melt and flow around the terminal and wound wire, (v) deactivating the ultrasonic horn, and (vi) removing the terminal and coil from the horn.

Abstract: The micropin array is comprised of a plurality of micropins having a given diameter and being aligned in parallel to one another at a given pitch, insulating tubular coatings disposed to cover individual micropins, and an adhesive provided to fill spacings among the insulating tubular coatings. This micropin array is produced by the steps of preparing a plurality of coated wire materials composed of a metal core having a given diameter and an insulating tubular coating of a given thickness formed around the metal core, aligning closely and successively the coated wire materials to form a bundle thereof, fixing the bundle of the coated wire materials by means of an adhesive, and cutting the fixed bundle of the coated wire materials by a given length to form a micropin array.

Abstract: In a sliding contact having a base made of an elastic material and a precious metal contact connected to the base, the base extends along a sliding face, and the precious metal contact is connected to the base in the almost vertical direction with respect to the contact position of the precious metal contact and the sliding face by beam welding.

Abstract: The invention relates to a device for the transmission of current between two end points between which there is arranged a ribbon cable (10) having at least two electric conductors. The cable is contained in a housing, serves for electrical connection, and extends in coils. The length of the conductors is substantially greater than the distance between the two end points. At least one of the two end points is moveable relative to the other. For a simple connecting of a further extending line, metal conductors (14), which are insulated from each other, are connected in electrically conductive manner at their two ends to the conductors of the ribbon cable (10). The metal conductors have a course wherein their free ends, developed as contact pins, are accessibly in the completely mounted device from the outside of the housing through a passage opening (16) in a wall (1a) thereof.

Abstract: A biomedical electrode which generally comprises a conductor member partially overlapping a separator construction. The conductor member is preferably a thin flat, flexible member having a pad portion and a tab portion. The tab portion overlaps the separator construction in a manner which centrally positions mechanical and electrical contact of electrode with an electrical lead to electrical instrumentation. Beneath pad portion and all or a substantial portion of separator construction is a conductive adhesive to provide good electrical interface between skin of a subject and the electrical instrumentation. Methods of manufacturing biomedical electrodes from strips of components are also disclosed.

Abstract: A heat-resistant package for electrical components comprises a housing composed of a plurality of independent side walls made of heat resistant ceramic material. Sealed-in leads are provided in one or more of the side walls. After the leads are installed, the ends of the side walls are brazed together to form a closed ring and that ring is brazed to the housing bottom wall. Also, a continuous metal ring may be brazed to the tops of the side walls. The brazings provide hermetic seals between the housing walls and they, along with the seal ring, provide compliance between the walls making the housing resistant to thermal shocks.

Abstract: An electrical connector having first and second coacting parts which include spaced electrical contacts uses a flexible electrical tape having lead ends for connection to a circuit board. Side panels protect the lead ends from damage, during storage and shipment in one position and are releasably connected in a second position to provide support on the leads for bonding. After bonding, the side panels protect the flexible tape from operational damage.

Abstract: A cochlear prosthetic package having a cup-shaped titanium case with a ceramic plate; a plurality of hermetically-sealed feedthroughs are formed in the plate by sintering the plate with hollow metallic tubes located in plate holes and then sealing at least one end of each tube. An electrode cable connector is provided which allows removal and replacement of a case even in the presence of body fluids. A telemetry coil is contained in a metallic tube which extends out of the case; the coil-containing tube has its two ends hermetically-sealed to the case by ceramic insulating bushings.

Abstract: Electrical contacts are fixed in a connector by ultrasonic melting of a portion of the connector body. The contacts are positioned in appropriate apertures having one part formed with a boss which defines a well. A widened section of the contact fits into the well and the boss is melted and forced into the well, thus fixing the contact in position.

Abstract: A screw-on electrical connector is made by a method in which the manufacturing procedure or process is greatly simplified and the resultant connector is of a high quality. method or procedure involves bringing an insulating shell into contact with a coil which is positioned in the bore of the shell and is secured therein in one step by supplying sufficient heat to the bore of the shell to soften it and cause it to flow into an adherent relationship with the outer portions of the coil. At the same time, sufficient axial pressure is applied between the coil and the shell to cause the two to firmly interlock.

Abstract: The present invention relates to a process of forming an electromagnetic shielding gasket by forming a core of elastomeric material, coating the core with bands of an electrically conductive textile material, passing the coating core through a die to calibrate the coated core, heating the coated core to cure the elastomeric material and winding up the cured core.

Abstract: Provided herein are novel layered elastomeric connectors, housings therefor and methods of manufacture for the connectors which includes alternating fused layers of a dielectric elastomer and electrically conductive fibrous mats coextensive with a cross section of the conductor to provide a multiplicity of conductive pathways between two electrically conductive surfaces. In order to promote a more mechanically stable connector, the fibrous mats can be exposed to a coupling agent for enhanced bonding. To enhance the electrical characteristics, the fibrous mats can be electroplated with an electrically conductive metal.

Abstract: A method and machine for making screw-on connectors is disclosed. The connectors have an insulating shell with a bore open at one end and a wire coil in the bore of the shell. The method includes the steps of heating the coils sufficiently so that it in turn heats the bore of the shell in contact with it to soften the interior of the bore, and applying a compressive axial thrust between the shell and coil while the interior of the bore is still soft to force them together to a predetermined axial relation. A suitable machine for accomplishing the steps of this method is also disclosed.

Abstract: This is concerned with a so-called screw-on electrical connector and a method or procedure of making it whereby the manufacturing procedure or process is greatly simplified and the resultant connector is of a quality and efficiency generally at least equal to conventional screw-on connectors.

Abstract: A method of forming a solder joint between a cup shaped high voltage terminal and a secondary lead extending from a secondary coil within a plastic case of an ignition coil. The steps include securing a solder paste to an inwardly extending end of the high voltage terminal, positioning the secondary coil lead relative to the solder paste, and heating the joint without making physical contact therewith to promote melting of the solder to secure and electrically connect the desired components.

Abstract: A terminal pin extends through a first housing portion and has a flange. A hard bead having a high melting temperature is disposed on the flange. At least one layer of insulating material is disposed on the bead and is provided with a lower melting temperature than the bead. A second housing portion is attached to the first housing portion as by welding to define a housing. The layer of insulating material is melted and the terminal pin is pressed in a direction, while the layer is molten, to eliminate any air pockets in the layer and to provide for a hermetic sealing of the layer of insulating material to the bead, the terminal pin and the housing. Instead of a single layer of insulating material, at least a pair of insulating materials may be used. These layers may have melting temperatures less than the bead and the layer closest to the bead may have a higher melting temperature than the layer removed from the bead. The assembly of the connector may be accomplished by the rotation of a turntable.

Abstract: Connectors are made by applying flat cable techniques. A sheet of conductors (1a-1d) is covered on both faces by respective strips of insulating material which are made to adhere to each other and to the conductors. Gaps are left in the strips to leave portions of the conductors bare. The resulting sandwich is cut up to form connector blanks, which blanks are then shaped to obtain connectors which may have various shapes depending on the intended application.

Abstract: Disclosed is a method of fabricating a novel printed circuit structure including a relatively small surface area of flexible material integral with a conventional glass epoxy carrier on which electrical contacts may be formed.

Abstract: A connector assembly for metallic wires comprises a tapered spring coil member made from stiff elastic wire having a distended end at the apex and a thermoplastic member having an elongated shell with a central bore closed at one end by a wall and having on the other end a substantially circular opening. The inside of the bore is substantially tapered such as to be adapted to house the tapered spring coil member. Two recesses are provided in the tapered inside wall of the thermoplastic member running on opposite sides substantially parallel to the central axis of the bore for providing a locking position to the distended end of the inserted spring coil member. A protrusion near the open end of the thermoplastic member retains the tapered spring coil member inside of the thermoplastic member. The thermoplastic member preferably on its outside forms a frustrum of a cone with, in addition, two substantially conical section planes being provided to allow for easy gripping of the connector assembly.

Abstract: A medical electrode for contacting the skin comprises a foam plastic disc (10) which is formed with an aperture (11), and the part of the disc surrounding the aperture is covered by a cover foil (12) on one side thereof. A strip-shaped metal electrode (13) is placed below the foil in the aperture and is connected to the stripped end (14) of a plastic insulated lead (15), whose end portion is covered by the cover foil. The whole assembly is welded together to form a unit in that it is placed between two pressing plates which form a capacitor in a high-frequency circuit, and one of them is of the same size and shape as the cover foil and presses it a distance into the foam plastic disc, which is thus compressed in the area concerned and fixed in the compressed shape because the cell walls partly fuse.

Abstract: The invention provides a novel and improved method for manufacturing an elongated piece of a composite body composed of a rubber or plastic body of an elongated form and a plurality of electroconductive linear bodies embedded in or bonded on the surface of the elongated rubber or plastic body in alignment, each of the linear bodies extending in the transverse direction of the elongated body in substantial parallelism with each other and being in a curved, bent or corrugated form useful as a connector, electromagnetic shielding gasket and the like. Different from conventional known methods, the invention proposes a method in which the linear bodies are first integrated with the sheet of rubber or plastic followed by corrugating the linear bodies together with the sheet and chopping of the thus corrugated composite body into pieces in a plane perpendicular to the longitudinal direction of the linear bodies.

Abstract: The fuse holder comprises a socket member composed of two thermoplastic members joined by ultrasonic welding with formation of a solder-tight welding joint or seam. Contact members disposed within the socket member extend to the exterior and include sealing members or locations which are sealingly enclosed in the welding joint. A lateral contact of these contact members is connected electrically to the connection conductor of a head member made of synthetic material by a bayonet joint and a spring is provided to supply the engagement pressure effective at the fuse.

Abstract: A flexible carrier sheet has an adhesive releasing outer surface and a heat-sealable inner surface, and one or more retaining pads are die-cut from a sheet or strip of breathable foam material attached to the outer surface by pressure-sensitive adhesive. Each retaining pad covers a hole cut within the carrier sheet and supports an electrical contact assembly which projects through the hole to confine an electrical conducting gel. A flexible bottom cover sheet has an air-impervious outer surface and a heat-sealable inner surface, and the edge or border portions of the carrier sheet and bottom cover sheet are heat-sealed together to form an air-tight chamber for the gel. The carrier sheet and bottom cover sheet may also be heat-sealed together in an area extending between adjacent electrodes, and the heat-sealed area may be provided with a line of weakening to provide for convenient separation of single electrode assemblies.

Abstract: A through bulkhead electrical connector (10) is disclosed of the type having interfacial seals (30, 32) on either side of the connector precisely located axially for obtaining an effective interfacial seal. A standard glass bead (20) is fused to the connector shell (12) at one end thereof with carbon fixturing (44) enabling precise location after fusing. The opposite face is defined by a standard resinous insert (38) axially located by engagement with a shoulder (40) machined into the connector shell (12) with the intervening space (52) being filled with a cured mass of epoxy (42) to secure the resinous insert (38) in position.

Abstract: To permit easy attachment, for example, by soldering, of a connecting lead wire to a conductive track on a ceramic plate connected closely adjacent to another plate which may also be ceramic, the first ceramic plate, at least, is bent away from the other ceramic plate at the connecting portion during manufacture; the manufacturing process includes heating the plate to be bent away to be in plastic condition and then applying a bending force to form the bend, permitting the so bent plate to cool, and joining the so-bent plate to the other plate with which it is to form a composite, for example, by glass melt. The bending force may be gravity, by permitting the unsintered plate, upon heating, to fall on a curved surface; or the bending force can be generated by applying a layer of a material having differential shrinkage to the flat, unsintered plate, and heating the composite, so that, upon differential shrinkage, the ceramic plate will be bent away from its originally plane, flat state.

Abstract: To permit direct bonding of a composite electric contact-and-bonding material to a carrier, such as a reed, magnetic strip, or the like, by thermo-electric heating, the side of the contact-and-bonding material is formed with projections, preferably projecting ridges, ribs, or beads, and a bonding or solder material in wire form is adhered, by rolling on to the valley between the projecting ridges, the bonding or soldering material leaving space free between adjacent ridges or ribs and not filling the entire recess, but projecting outwardly at least as far as the projections or ridges, and preferably slightly therebeyond. The soldering or bonding wire may have round or polygonal, preferably triangular cross section with a pointed tip extending outwardly to provide for concentration of heat upon resistance heating the contact material against the carrier strip.

Abstract: A disposable electrode comprising an annulus of foam, a substantially uniform electrode gel in a central region of the annulus, a conductive layer in the electrode gel and making electrical contact with it, and a cap over the conductive layer, electrode gel and annulus of foam. The electrode is made in a plastic tray by placing said annulus in a recess in the tray, placing the conductive layer on the annulus, pouring hot electrode gel into the center region of the annulus, covering the gel with the cap and covering the tray with a sheet which is heat sealed to the tray with the electrode inside.

Abstract: A conduit end is sealed around one or more than one insulated conductor by using a chamber (4) having a peripheral wall, a base with an opening through it communicating with the conduit (2) and an opening opposite the base. The conductor(s) (3) extend through both openings; a pre-formed annular body of a setting resin composition (8) is inserted while in a pasty or viscous condition into the chamber to encircle the conductor or conductors. Axial pressure is then applied to the still pasty or viscous annular body to cause it to flow and form a sealing body in peripherally continuous contact with the chamber and with the, or each, insulated conductor, after which the resin composition sets. A kit for use in the method is also claimed.

Abstract: A piece part, such as a flat metal contact spring (12), is mounted between two plastic details (11 and 25), so that an end portion of the spring 12 projects from the mounting details. One of the details, such as a base member 11, has a cavity 17 within which the spring is placed so that a mounting section (12A) fits within the cavity. The second detail, such as a thermoplastic locking insert 25, includes a finger 25B adapted to fit in the cavity adjacent to the spring section (12A). The insert is provided with pointed energy directors (30 and 31) arranged so that the members can be heated and compressed together, and the directors melt to weld the parts together. The insert and/or the base member is formed with slots (33) so positioned that portions of the molten plastic are forced to flow into the slots during the process so as to encapsulate the mounting section of the spring or other piece part in the plastic.

Abstract: A charge plate for an ink jet printer comprises a rigid support plate provided with a medially extending elongated slot and an electrode support structure cast in place adheringly against the walls of the slot. The electrode support structure is fabricated from a nonconductive casting resin which is cast against a silicone elastomer mold having a series of upstanding pegs coated with a release agent and an overcoating of conductive epoxy. The casting resin flows around the peg structure and bonds itself to the conductive epoxy coating. The conductive epoxy material transfers from the mold surface to the electrode support structure upon mold separation, so that the casting process produces a series of cylindrical charging electrodes cast in place within charging tunnels in the electrode support structure. The resulting product is subjected to a finishing operation, and flexible printed circuit leads are thereafter attached to the charging electrodes.

Abstract: Connection of electrical leads to individual charge electrodes in a charge plate structure is facilitated by the integral formation of such leads during the mold stage of formation of a charge plate. An elastomeric mold is formed from a charge plate master coated with a photoresist material and having base area corresponding to the placement of the electrical leads. The elastomeric mold is coated with an electrically conductive resin, and a charge plate is cast in the mold. Upon separation, the conductive resin transfers to the charge plate structure forming charge electrodes. Lapping or grinding the surface of the structure removes excess resin and leaves the electrical leads intact.