Abstract: A cable includes a plurality of elongated sections each composed of a tubular electric conductor, electric insulation surrounding the electric conductor, and an outer cable jacket surrounding the electric insulation. An inner tubular member of titanium or alloyed stainless steel is accommodated in the electric conductor and defines a channel for a cooling medium such as water. The inner tubular members of each two consecutive cable sections have flanges that are welded or soldered to one another, and a bridging element is interposed between the electric conductors of the two consecutive electric conductors and welded or soldered thereto. The electric conductor preferably is a circumferentially complete one-piece tubular element extruded onto the inner tubular member.

Abstract: The present invention consists of a connector suitable for joining, to pass electrical current therethrough, ends respectively of wires, cables or the like, of different metals, such as copper and aluminum, the connector of the present invention involving a housing containing an electrically conductive fluid medium, such as mercury, that, at least partially, covers in any attitude the connector is placed in longitudinal electrical contacts, the contacts formed respectively from the same metal as the respective wire or cable ends that the contacts are electrically connected to, which contacts are arranged parallel to one another, at least parts of opposite conductive surfaces thereof covered by the fluid medium no matter what attitude the connector is placed in to pass current therethrough, with, in one embodiment, said wire or cable ends inserted in sealing arrangement in the housing themselves becoming the contacts.

Abstract: This disclosure depicts a ductile metallic electrical and mechanical connector for attachment to one or more electrical cables and formable by a compressible process. The connector comprises at least one bifurcated body member having first and second leg portions initially connected by a reduced cross-sectional thickness portion of the body member to provide a plastically flowable hinge connection. The first and second leg portions define an initial predetermined angle such that the body member can laterally engage an uninsulated section of an electrical cable. The first leg has on the end opposite the reduced thickness portion an axially extending rib member and axially extending inner and outer ridges disposed on either side of the rib member. The second leg has on the end opposite the reduced thickness portion axially extending inner and outer fingers.

Abstract: A current carrying member embedded in a brick-like member and having a wrapping comprising a flexible graphitic covering providing intimate contact with respect to the brick, also allowing the current carrying member and the brick to expand at different rates under conditions of heat while still retaining a very intimate electric contact.

Abstract: An electrical conductor connection between at least two aluminum conductors which includes a weld nugget having a substantially cylindrical cross-sectional configuration perpendicular to the major surfaces of the aluminum conductors. The ends of the weld nugget are convexly cupped and extend outwardly past the major surfaces of the aluminum conductors to provide visual verification of joint integrity. The electrical conductor connection is formed by a method which includes providing an aperture in one of the conductors to be joined and providing a recessed backup against the other conductor, aligned with the aperture. Timed, multiple sequence MIG arc spot welding provides a weld nugget having the desired shape and diameter at the interface or throat between the two conductors. The method also enables the welding operation to be performed out of position, without sag or run of the molten pool of aluminum.

Abstract: A tin plated brass lead terminal for a button diode is disclosed. The lead terminal comprises a flat plate portion which generally defines a horizontal plane, a first upward projection centrally connected to the flat plate portion and a plurality of second projections downwardly extending from the flat plate portion. The flat plate portion comprises a major surface which is substantially rectangular in its horizontal peripheral shape and which is intended to be soldered to a cylindrical raised contact electrode of a button diode. The first upward projection has a notch therein around which a wire lead can be wrapped and the second downward projections aid in locating the major surface of said flat plate portion with respect to the raised cylindrical contact of the button diode.

Abstract: A solder connection between an aluminum and copper conductor includes cladding a strand of aluminum wire with a copper coating, severing the cladded aluminum wire to a suitable length and soldering the severed end to the strand of copper wire with a lead-tin solder forming a hermetical seal about the soldered joint including any portion of the aluminum exposed to the ambient at the joint prior to soldering.

Abstract: Described herein are coupling means for joining substrates, for example, tubular articles, which include an inner member, having disposed thereon a fusible agent for binding the substrates together, and an outer member. The substrates to be joined are inserted between the fusible agent and outer member and the resulting assembly is heated. The application of heat is maintained until it permeates the assembly and raises the temperature of the fusible agent enough that it melts and flows through and/or about the substrates to be joined. The inner and outer members act to confine the melted fusible agent by defining boundaries between which it can flow. Longitudinal flow of the agent can be controlled by limiting the area heated, by the configuration of the coupling members or substrates, or by providing the coupling with additional members that "dam" longitudinal flow. When the heating is discontinued, the fusible agent hardens to bind the substrates together.

Abstract: An electrically conductive adhesive comprises electrically conductive particles mixed in a non-conductive base at such a mixing ratio that the conductive particles are not in contact with one another. When this adhesive is disposed between facing electrodes, it provides electric conductivity between the facing electrodes but maintains electric insulation in the lateral direction.

Abstract: An oxygen sensor comprises an electrolyte which is shaped into a conical tube having a closed end of small diameter and an open end of large diameter. The wall thickness of the electrolyte is gradually decreased toward the closed end from the open end and that of the closed end is 0.3 to 1.0 mm so as to provide a high sensitivity.

Abstract: A soldered joint between a thin flat conductive lead and a flat conductive pad in which the lead is "rippled," that is, formed with undulations each of which engages the surface of the pad so that during soldering, the molten solder fills the spaces between the pad and the lead and then solidifies forming the soldered joint.

Abstract: A device for use in joining wires such as electrical conductors is disclosed. The device comprises a ferrule, the exterior surface of which is covered with a coat or layer comprising an explosive composition. The method of joining includes coaxially aligning the end portions of two wires within the ferrule and then detonating the explosive composition to produce a metallurgical bond between the ferrule and each wire end. Apparatus for forming the novel splice is also disclosed.

Abstract: An improved aluminum electrode hanger contact and method of making the same, which includes a longitudinal hole drilled in the end of the hanger. In one embodiment, a slot or slots are cut in such bar into the hole. Tin-coated copper inserts are inserted in the slot or slots with the inner ends thereof projecting into the hole and the outer ends closely underlying or projecting from the end of the hanger. In other embodiments, circular passages are provided transversely of the drilled hole and inserts in the form of tin-coated copper rod or rods are inserted in the passages. Superheated molten metal is permitted to flow into the hole filling the same, such molten metal preferably being obtained by the ignition of an aluminothermic welding composition. When the molten metal solidifies, the inserts are secured to the hanger, thus providing a low cost and significantly improved voltage drop contact between the aluminum hanger and a conductor.

Abstract: An electrical conductor connecting arrangement connecting a plurality of assembled conductors to each other and to an electrical bus bar. First and second electrical connector conductors have first portions connected to the electrical bus bar and second portions which extend outwardly from the bus bar with a spacing selected to snugly accommodate a dimension of the assembled conductors. The assembled conductors are disposed only between the second portions of the first and second electrical connector conductors, with the ends of the assembled conductors substantially aligned with selected flat surfaces of the first and second electrical connector conductors. A fusion of metal is disposed over the ends of the assembled conductors and adjoining flat surfaces of the first and second electrical connector conductors.

Abstract: An electrical tang type terminal for use in fusing aluminum or aluminum alloy wire thereto. The terminal includes an enlargement to absorb part of the active electrode pressure during heat and pressure application, thereby peventing shearing or undue weakening of the softened wire. Prior to fusing, the enlargement is spaced from the opposite portion of the tang or body to which it is to be fused to permit localized heating and some wire deformation. During fusing, the enlargement helps control the mechanical pressure on the softened wire.

Abstract: A corona discharge wire made of electrically conducting wire of high tensile strength to which is connected a metallic fixing element on both sides of the discharge portion. The element forms a fused mass disposed in a zone surrounding the wire and solidified around it. The fixing element may consist of two parallel pieces of wire interconnected by an annular extension.

Abstract: A method of making a multilayered circuit assembly from a plurality of flat, flexible circuit elements, wherein each circuit element includes a substrate having conductive means to define an electrical path of travel which is formed between a base layer made of insulation material and a cover layer made of insulation material. Each circuit element has a connecting station associated with the conductive means.

Abstract: A connection comprising two electrical conductor ends and a connection member fastened between them. The connection member does not extend beyond the external cross-sectional contour of the conductor ends, and preferably is formed of a material, such as silver, having higher electrical conductivity than the material of the conductor ends. The contact surfaces may be coated with gold. Alternatively, the connector member may be formed of copper, and the contact surfaces coated with silver. The connector member may overlap the end portions of the conductor ends, and pins arranged in aligned holes in the connector member and end portions. The connector member may be stepped, with a pin at each step, and may be formed of one piece or a series of strips one upon another. The pins may be formed as one piece with the connector member. The spacing between the pins may be greater than the holes which accommodate them.

Abstract: The containment, splicing, or termination of the line is achieved by selective crimping along a housing. In a preferred form, the housing comprises a crimp barrel having a series of axially displaced apertures formed therein. A line, e.g. a wire, is inserted in the barrel, and a force is applied in registration with each aperture to deform the barrel and the line so that the deformed portion of the barrel maintains the deformed portion of the line against the aperture. The line scrapes against edges of the aperture to form a tight joint.

Abstract: A selectively applied crimping force is utilized to provide a stepped crimp to an electrical connection to create a discrete sacrificial anode from base conductor material thereby providing a controlled zone of corrosion which substantially increases the integrity and life of the electrical connection. This effect is achieved by crimping one portion of the connector to a greater extent than the remaining portion thereby extruding and work hardening a given length of the conductor to a predetermined degree to selectively alter the physical characteristics thereof. The degree to which each segment of the wire receiving portion of the connector is compressed may be defined as a ratio encompassing a given range of values designed to optimize the selective corrosion effect. Also disclosed are crimping dies for effecting the selectively stepped crimp, which dies are suitably proportioned to provide the necessary ratio of maximum to minimum crimp height.

Abstract: A system for electrically terminating two or more insulated or uninsulated wires comprising forming a terminal about the wires with a ram and die cavity such that the terminal and wire configuration cross sectional profile is elongated in one direction, withdrawing the ram and die and engaging the terminal with a pair of electrodes to fuse the same under pressure and heat such that the terminal and wire configuration cross sectional profile becomes elongated in a direction generally perpendicular to said first direction.

Abstract: The invention is directed to a method and gauge for nondestructively testing and certifying the workable qualities of a casting. The guage comprises a tab cast at the same time as the remaining portion of the casting located in a nonfunctional location, when considered in the light of the later use to be made of the casting, and also in such a position that it can be bent as by striking with a percussive instrument or by the application of a continuous bending force without damage to the remaining portion of the casting. The tab or guage will be subjected to a strain greater than the maximum strain to which the remaining portion of the casting will be subjected, during its installation or use, and determining by visual inspection whether or not the tab, at its bend has cracked, the overall ductility of the casting can be judged and it can be projected, that the casting will be able to withstand the forces to which it will be subjected when employed in a desired manner.