Abstract: One half-connector terminates leads in the ballast, carrying electricity to and from the ballast coils. Another half-connector terminates leads outside the ballast, connected e. g. to carry power to lamp sockets. A hook extended from a first of the half-connectors engages a catch formed in a second. A retaining surface, preferably associated with the second half-connector, keeps the hook engaged with the catch. Preferably the space between the retaining surface and the catch is smaller than the unstressed dimension of the hook barb--but during the act of engagement the barb deforms to pass between the catch and surface; then the barb springs back into shape and is held behind the catch. In this process also preferably the retaining surface cooperates with the first half-connector to support the shaft or beam of the hook at both ends--as in a classical double-ended beam spring structure, contrasted with a cantilevered spring in a conventional hook and catch.

Abstract: One half-connector terminates a set of leads in the ballast, for carrying electrical power to and from the ballast coils. Another half-connector terminates another set of leads outside the ballast, connected e.g. to carry power to lamp sockets. Male contacts, preferably formed very inexpensively as bared ends of one set of leads, are held in a first of the half-connectors; female contacts, connected to the other set of leads, are held in a second of the two half-connectors. Through-holes in the second half-connector each hold one female contact; each hole has a necked-down section, forward from the contact, and some device (preferably an ultrasonically displaced slug) to retain the contact. In one aspect of the invention, each hole also has a bore whose transverse preformed dimension is biggest immediately rearward from the necked-down forward section.

Abstract: An assembly tool helps connect an electrical external half-connector to an internal half-connector at an aperture in a ballast case. The tool includes a fulcrum for stabilizing the tool against the case, and tongue for pushing the external half-connector into engagement while clearing the connector wires, to avoid damage. A handle of the tool is used to rotate the tool about the fulcrum. If the connector has a latch to deter pull-out, the tool also preactuates or depresses the latch to eliminate frictional resistance to inserting the latch--and so reduce the required engagement force. Latch depression is simultaneous with the point in the insertion process where the latch hook passes its mating engagement member. The tool dimensions provide a high mechanical advantage to help push the two connector halves together against friction. The tool converts the connector-engaging task from wrist action to a stress-free upper-body movement.

Abstract: This inexpensive, small half connector includes at least one electrical terminal (usually a female contact). The half-connector body defines a hole to receive each terminal. Each terminal has at least one retaining element for engaging the half connector (e.g., a springy tang that snaps into behind an internal flange) to retain the terminal in the half connector. Each hole has a segment of relatively large transverse dimension to receive its terminal, generally with transverse clearance about the circumference of the terminal. Each hole also has a segment of reduced transverse dimension to receive the terminal and engage the retaining element(s) of that terminal to retain the terminal. Each hole has some integral feature--in other words, some structural element(s) integral with the half-connector body--for centering the terminal in the large-dimension segment of the hole.

Abstract: A half-connector body has lateral ears that fit in small notches in the ends of the side walls of a ballast can, preferably at the top. An end wall, if present, traps the ears longitudinally in the notches; resilience of that wall, and of its attachment to the can bottom, enhance tight longitudinal fit. The half connector (a receptacle) presses against, and partly protrudes through an orifice in, the end wall (if present). Outside the ballast, in a new fixture, a jack slides freely in the receptacle to make wiring-harness connections. The jack has a ratchet-like manually operable hook to secure the jack until manually released. Each contact or lead in either half connector is preferably provided with individual strain relief by permanent deformation (as for example using a die punch, without heating or plastic flow) of the connector wall inward, to displace material irreversibly around the wires.

Abstract: A half-connector body has lateral ears that fit in small notches in the ends of the side walls of a ballast can, preferably at the top. An end wall, if present, traps the ears longitudinally in the notches; resilience of that wall, and of its attachment to the can bottom, enhance tight longitudinal fit. The half connector (a receptacle) presses against, and partly protrudes through an orifice in, the end wall (if present). Outside the ballast, in a new fixture, a jack slides freely in the receptacle to make wiring-harness connections. The jack has a ratchet-like manually operable hook to secure the jack until manually released. Each contact or lead in either half connector is preferably provided with individual strain relief by permanent deformation (as for example using a die punch, without heating or plastic flow) of the connector wall inward, to displace material irreversibly around the wires.

Abstract: An integral terminal made from a non-stranded, electrically conductive wire has a portion of the wire which is distorted and flattened from its normal shape in first and second dimensions relative to the axis of the wire into a substantially flat piece. This flat piece has substantially increased surface area and reduced thickness relative to the original cross-sectional area of the wire and which can be bent. The flat piece has an integral part formed therefrom extending in a third dimension different from the first and second dimensions for making mechanical engaging contact with an external post or pin where the third dimension is in a direction above or below the flat piece.

Abstract: A fluorescent lamp ballast is provided which is uniquely suited to automated manufacture and assembly. The versatile ballast construction includes primary and lag coil bobbins each having substantially planar flanges at their respective ends, with a magnetic core having portions disposed inside and on opposite sides of the bobbins. A primary coil is wound on the primary coil bobbin, and a lag coil is wound on the lag coil bobbin, the coils having starts, taps and finishes. Each bobbin flange has a plurality of holes extending inwardly from an outer flange edge, with conductive pins partially inserted into a number of the flange end holes, each of the pins being electrically coupled to one of the coil starts, taps and finishes. A planar elongated printed circuit board whose length and width dimensions are approximately the same as that of the bobbins positioned end-to-end, is part of the ballast assembly.