Abstract: A conductive terminal for a flat flexible cable comprises a first contact surface, and a second contact surface opposing the first contact surface. The first and second contact surfaces define a space therebetween for receiving a flat flexible cable along a longitudinal direction of the terminal. A dimpled structure is defined on the first contact surface and includes a plurality of dimples extending from the first contact surface in a direction of the second contact surface. The dimpled structure includes at least one dimple having a first height, and at least one dimple having a second height, distinct from the first height.

Abstract: A method of detecting temperature of an electrical terminal. The method includes: applying a material patch to a surface of the electrical terminal, the thermal mass of the material patch is less than 25 percent of the thermal mass of the electrical terminal, whereby the material patch does not appreciably increase the electrical resistance or thermal capacitance of the electrical terminal; and remotely sensing a change in the material patch with an electrically isolated circuit which is external to the electrical terminal to determine if the electrical terminal is operating at a safe temperature to optimize current flow across the electrical terminal.

Abstract: A method of detecting temperature of an electrical terminal. The method includes: applying a material patch to a surface of the electrical terminal, the material patch containing a polymer matrix with a polymeric positive temperature coefficient material which contains a mixture of electrically conductive magnetic particles, whereby the material patch does not appreciably increase the electrical resistance or thermal capacitance of the electrical terminal; and remotely sensing a change in the material patch with an electrically isolated circuit which is external to the electrical terminal to determine if the electrical terminal is operating at a safe temperature to optimize current flow across the electrical terminal.

Abstract: A self-lubricating connector with a housing having a contact receiving cavity with a contact provided therein. A lubricating device is positioned in the housing proximate the contact. The lubricating device extends into the contact receiving cavity and has lubricant provided therein. The lubricant from the lubricating device is deposited or on the outside surface of the contact as the contact is moved between the first position and the second position, reducing wear on the contacts as the contacts are moved between the first position and the second position.

Abstract: A self-lubricating connector with a housing having a contact receiving cavity with a contact provided therein. A lubricating device is positioned in the housing proximate the contact. The lubricating device extends into the contact receiving cavity and has lubricant provided therein. The lubricant from the lubricating device is deposited or on the outside surface of the contact as the contact is moved between the first position and the second position, reducing wear on the contacts as the contacts are moved between the first position and the second position.

Abstract: A low insertion force contact includes a main body and a spring beam extending from the main body at a mating end of the low insertion force contact. The spring beam has a mating interface configured for mating electrical connection to a mating contact. The spring beam includes a conductive base layer extending to the mating interface. A silver coating layer is provided on the conductive base layer. The silver coating layer is provided at the mating interface. A silver sulfide surface layer forms a solid lubricant directly on the silver coating layer. The silver sulfide surface layer forms a film having a controlled thickness at the mating interface.

Abstract: A self-lubricating connector with a housing having a contact receiving cavity with a contact provided therein. A lubricating device is positioned in the housing proximate the contact. The lubricating device extends into the contact receiving cavity and has lubricant provided therein. The lubricant from the lubricating device is deposited or on the outside surface of the contact as the contact is moved between the first position and the second position, reducing wear on the contacts as the contacts are moved between the first position and the second position.

Abstract: A low insertion force contact includes a conductive base layer extending to a mating end including a mating interface configured for mating electrical connection to a mating contact. A silver coating layer is provided on the conductive base layer. The silver coating layer is provided at the mating end. A silver sulfide surface layer forms a solid lubricant directly on the silver coating layer. The silver sulfide surface layer forms a film defining a surface of the low insertion force contact having a controlled thickness at the mating interface.

Abstract: A low insertion force contact includes a conductive base layer extending to a mating end including a mating interface configured for mating electrical connection to a mating contact. A silver coating layer is provided on the conductive base layer. The silver coating layer is provided at the mating end. A silver sulfide surface layer forms a solid lubricant directly on the silver coating layer. The silver sulfide surface layer forms a film defining a surface of the low insertion force contact having a controlled thickness at the mating interface.

Abstract: A low insertion force contact includes a main body and a spring beam extending from the main body at a mating end of the low insertion force contact. The spring beam has a mating interface configured for mating electrical connection to a mating contact. The spring beam includes a conductive base layer extending to the mating interface. A silver coating layer is provided on the conductive base layer. The silver coating layer is provided at the mating interface. A silver sulfide surface layer forms a solid lubricant directly on the silver coating layer. The silver sulfide surface layer forms a film having a controlled thickness at the mating interface.

Abstract: A method of detecting temperature of an electrical terminal. The method includes: applying a material patch to a surface of the electrical terminal, the thermal mass of the material patch is less than 25 percent of the thermal mass of the electrical terminal, whereby the material patch does not appreciably increase the electrical resistance or thermal capacitance of the electrical terminal; and remotely sensing a change in the material patch with an electrically isolated circuit which is external to the electrical terminal to determine if the electrical terminal is operating at a safe temperature to optimize current flow across the electrical terminal.

Abstract: A crimping device includes an anvil and a crimp tooling member. The anvil is configured to receive a terminal on a top surface thereof. The crimp tooling member has a forming profile recessed from a bottom side of the crimp tooling member. The forming profile is configured to engage a crimp barrel of the terminal as the crimp tooling member moves towards the anvil during a crimping operation to crimp the crimp barrel into mechanical and electrical engagement with an electrical wire disposed within the crimp barrel. The forming profile defines at least one pocket along a top-forming surface of the forming profile that extends between two side walls of the forming profile. Each pocket is configured to form a corresponding protrusion in the crimp barrel of the terminal during the crimping operation.

Abstract: A method is provided for crimping an electrical terminal to an electrical wire having electrical conductors. The method includes positioning the electrical wire and the electrical terminal between opposing crimp tooling members of a crimp tool. The method also includes pressing a crimp barrel of the electrical terminal against the electrical conductors of the electrical wire using the crimp tooling members such that the electrical conductors are mechanically and electrically connected to the crimp barrel. The crimp barrel is pressed against the electrical conductors such that at least some contact portions of metallic surfaces of at least some of the electrical conductors melt and form hot weld bonds with one or more contact portions of the metallic surface of one or more adjacent electrical conductors.

Abstract: A crimping device includes an anvil and a crimp tooling member. The anvil is configured to receive a terminal on a top surface thereof. The crimp tooling member has a forming profile recessed from a bottom side of the crimp tooling member. The forming profile is configured to engage a crimp barrel of the terminal as the crimp tooling member moves towards the anvil during a crimping operation to crimp the crimp barrel into mechanical and electrical engagement with an electrical wire disposed within the crimp barrel. The forming profile defines at least one pocket along a top-forming surface of the forming profile that extends between two side walls of the forming profile. Each pocket is configured to form a corresponding protrusion in the crimp barrel of the terminal during the crimping operation.

Abstract: A method is provided for crimping an electrical terminal to an electrical wire having electrical conductors. The method includes positioning the electrical wire and the electrical terminal between opposing crimp tooling members of a crimp tool. The method also includes pressing a crimp barrel of the electrical terminal against the electrical conductors of the electrical wire using the crimp tooling members such that the electrical conductors are mechanically and electrically connected to the crimp barrel. The crimp barrel is pressed against the electrical conductors such that at least some contact portions of metallic surfaces of at least some of the electrical conductors melt and form hot weld bonds with one or more contact portions of the metallic surface of one or more adjacent electrical conductors.

Abstract: A method of manufacturing a circuit board includes providing a metal substrate and applying a dielectric layer to the metal substrate and sacrificial bumps on the dielectric layer. The method also includes printing a conductive seed layer on the dielectric layer and the sacrificial bumps and plating a conductive circuit layer onto the conductive seed layer.

Abstract: A circuit board includes a dielectric layer and sacrificial bumps on the dielectric layer in predetermined circuit common areas. A conductive seed layer is printed on the dielectric layer and the sacrificial bumps. A conductive circuit layer is plated onto the conductive seed layer. Sections of the conductive circuit layer and the conductive seed layer in the circuit common areas are removed. Optionally, the circuit board may include a metal substrate, with the dielectric layer applied on the metal substrate.

Abstract: A conductive structure and method of manufacturing therefor includes a plurality of stacked metal laminates secured to one another via an intermetallic bond made from a metallic bonding agent.

Abstract: A signal connector assembly with a plug contact within a plug having a high resistive portion. When the plug of the assembly first makes contact with the electrical receptacles within a mating receptacle, the high resistive portion prevents a current surge. As the plug is further inserted into the receptacle, the energy passing from the plug to the receptacle is gradually increased. Eventually, the receptacle contacts within the receptacle pass the high resistive portion and make contact with the conductive portion of the plug contact, thereby permitting transmission of valid signals without the generation of spurious errors.

Abstract: A signal connector assembly with a plug contact within a plug having a high resistive portion. When the plug of the assembly first makes contact with the electrical receptacles within a mating receptacle, the high resistive portion prevents a voltage surge. As the plug is further inserted into the receptacle, the energy passing from the plug to the receptacle is gradually increased. Eventually, the receptacle contacts within the receptacle pass the high resistive portion and make contact with the conductive portion of the plug contact, thereby permitting transmission of valid signals without the generation of spurious errors.