Abstract: A device 10 usable in conjunction with a source of constant amplitude high frequency alternating current of known frequency for providing sufficient thermal energy to melt a fusible electrically conductive material 24 includes an integral member formed from strip 12 of a first metal having a carrier strip section 14 and a plurality of fingers 20 initially integrally coextending therefrom. The carrier strip section 14 further has a thin magnetic layer 18 thereon, transforming the carrier strip into a Curie point heater. The fingers 20 including end portions 22 having layers of solder affixed to opposite sides thereof are adapted to be inserted into apertures 36 defined through a first electrical article 30 from a first surface 32 to a remote surface 34 thereof and adjacent contact pads 40 thereon. The first and second electrical articles 30,46 are placed together with the respective contact pads 40,48 opposed from each other and separated by the finger end portions 22.

Abstract: A method for applying solder to a braided shield of a cable, particularly of a coaxial cable. A cable end portion is dipped into a solder bath a defined depth and for a defined time period prior to the removal of the jacket of the cable.

Abstract: Connectors for attachment to cables including a large number of very small flexible conductors or conductor pairs, in which very small contacts are provided as an array exposed on a flat mating surface. Contacts may be raised slightly above the flat surface by plating conductive metal to form raised bumps on one of a pair of connectors. Individual conductors are placed through apertures defined in a substrate acting as a template, and are potted in place before shaping the mating surface of the connector. Contact bases to be plated may be defined precisely by photoresist lithography on a cover layer attached to the template substrate, and an elastomeric layer may be provided between the cover layer and the template substrate. Pin and socket combinations are used to align mating connectors with each other.

Abstract: Method and apparatus for butt welding a stranded wire to an electrode pin in close proximity to igniter material using laser beams. The wire and electrode pin are preferably part of an initiator assembly used in an airbag system. In a preferred embodiment, the wire is made of copper and the electrode pin is made of a steel alloy. The wire and pin are vertically aligned in contact with each other, without any external force or pressure applied to them. A plurality of beams contact portions of both materials at the same time, causing them to melt, substantially without any melted material extending beyond the width or diameter of the wire.

Abstract: The prior art terminal for making a solder bond between a lead and a bond site is modified so as to enhance the reliability of the solder bond. In one embodiment, this modification entails solder relief terminals: solder relief holes through the terminal, notches, grooves or ridges on the surface of the terminal, or bending of the terminal. In a second embodiment, this modification entails predeposit of a predetermined and controlled amount of solid solder and flux on the terminal.

Abstract: A method is disclosed for terminating a coaxial connector to a coaxial cable. The coaxial connector has an elongated signal pin surrounded in part by an insulating jacket and an elongated shield member surrounding the insulating jacket while the coaxial cable has a signal wire surrounded by an inner insulating member, ground means surrounding the insulating jacket and an outer insulating sheath surrounding the ground means. The method includes providing an elongated conductive shield member having a front portion and a rear portion. The front portion of the shield member is secured onto the insulating jacket surrounding the signal pin whereby a portion of the signal pin is positioned within the rear portion. The ground means is electrically and mechanically bonded to the rear portion of the shield member. The signal wire is then electrically and mechanically bonded to an exposed portion of the signal pin within the rear portion of the shield member while the signal pin is held by the shield member.

Abstract: A forming electrode unit for forming the conductors of the electric wire into the terminal includes a female pressing electrode having an electric wire housing groove, and a male pressing electrode having an electric wire pressing portion which is fitted in the groove in such a manner that a clearance is defined between the pressing portion and the female pressing electrode. To form the conductors together into the terminal, the conductors are set in the groove, and thereafter pressed by the pressing portion as an electrical current is caused to flow through the electrodes and the conductors to heat the conductors. The electric wire is thus integrally provided with the solidly formed terminal.

Abstract: A connection process by welding a braided strip to a contact finger defined by side by side stacking of two elementary blades. The first blade is provided with a semi-open notch cooperating with the juxtaposed flat face of the second blade to define a housing receiving a compacted end of the braided strip, said end being hot encrusted in the housing by welding under pressure, without local deformation of the blades. The second blade comprises an overspill aperture located facing the notch to enable the molten copper from the compacted end to be transferred during the welding operation, the surface of the aperture being smaller than that of the notch. Assembly is performed in a single operation without addition of solder.

Abstract: A coaxial cable side tap assembly of a coaxial cable with pins separately attached to the cable center conductor and braided sheath for connecting to a branch cable and processes for manufacture thereof.

Abstract: A solder-bearing lead for attachment to the surface of a substrate, wherein a discrete mass of solder is mechanically held firmly by the lead in a position permitting close proximity to the substrate surface to connect the lead to the substrate with an electrical and mechanical bond upon melting of the solder, the lead body having a pair of fingers partially encircling the solder mass with a gap between the fingers providing an unobstructed flow for the melted solder to the substrate. The lead may also be used to interconnect a first substrate to a second substrate, forming a bond between conductive areas on both substrates.The present application is a continuation-in-part of application Ser. No. 416,505, filed Oct. 3, 1989, U.S. Pat. No. 5,052,954 which is a continuation of application Ser. No. 129,715, now U.S. Pat,. No. 4,883,435, and is also related to U.S. Pat. No. 4,728,305, U.S. Pat. No. 4,679,889, and U.S. Pat. No. 4,605,278. The disclosure of the parent application, Ser. No.

Abstract: Apparatus and method for making electrical contact with a thin conductive film comprising, in one embodiment, a base with a thin conductive strip and a flexible substrate affixed to the base such that the strip and the substrate abut and form a substantially planar surface. An electrical lead is affixed to the conductive strip and a thin conductive film is applied to the planar surface such that it covers at least a portion of the conductive strip.

Abstract: A connector (10) having one or more arrays of elongate arms (22) of contacts (20) having contact sections (26) on free ends (24) thereof to be soldered to respective traces (94) of a circuit element (90), facilitated by securing a soldering component (40) to free ends (24). Component (40) includes a block member (42) along the outer surface of which is secured a lead frame (60) which includes a corresponding plurality of fingers (66) extending transversely from an elongate body section (62). Block (42) is of thermally insulative material having solder resistive surfaces. On the finger ends (68) are affixed preforms (88) of solder; on body section (62) is defined a thin magnetic layer, transforming the brass carrier strip into a Curie point heater.

Abstract: A flexible electrical connector is attached to a movable contact finger and a stationary termianl by placing the components in a work chamber and positioning a first end of the flexible connector against an attachment surface of the contact finger, preferably in a perpendicular orientation. After evacuating the work chamber, the output of an electron gun is directed toward a joint formed between the flexible connector and the contact finger. The electron beam forms a weld zone which fuses the the flexible connector with the contact finger without degrading the flexibility of the connector or the mechanical strength of the contact finger. A second end of the flexible connector is positioned against an attachment surface of the stationary terminal, such as in a parallel orientation, and attached in a similar manner.

Abstract: A multiple-terminal unit comprises a first and a second group of teeth extending from one edge of a band-shaped. The teeth in the first group and the second group are bent at different positions so that their stem parts are staggered. In another aspect of the invention, the part at which a terminal and wiring pattern on a substrate a fixed by resin, preferably thixotropic resin.

Abstract: A method and apparatus in which the wires from the heads on an actuator arm can be positioned and attached to the arm electronics automatically. A loadspring manufacturing assembly has a pair of wire carrying and positioning tails and a disposable portion. The disposable portion and the wire carrying and positioning tails each have pegs for controlling the position of the wire and for allowing twisting of the wire pairs for purposes of noise suppression. The wires are positioned about the pegs and twisted. The wires are then bonded to the loadspring assembly. A portion of the wire carrying tail has a window or opening therein. The wires are fanned out and spaced apart as they pass across the window. The wire carrying portion also has a living hinge. A portion of the wire carrying tail which includes a latching window which latches a peg is moved about the hinge and positioned at about a right angle to the loadspring. The disposable portion and the unused tail are removed.

Abstract: A connector for electrical and mechanical connection to a coaxial cable wherein an inner lead of the cable is soldered to a ferrule which forms part of the connector. The ferrule is fabricated from a strip of material which includes a stripe of solder which will be adjacent an outer surface of such inner lead when the connector has been assembled so that the application of external heat will effect a solder joint between the ferrule and the inner lead.

Abstract: A receptacle connector and a plug connector for connecting a coaxial cable of 75 ohms or greater to a printed circuit board without affecting the outside configuration of their shells. At one end, the receptacle connector forms a spring contact receiver portion for resiliently retaining the plug end of the plug connector. The plug connector terminates a coaxial cable at its other end. The receiver portion of the receptacle connector is right-angled to a three-legged terminal section for solder connection at the printed circuit board. The receptacle and plug connectors comprise an outer shell member, a dielectric member, and a center conductor. The shell members are stamped and formed to maintain an exact constant inside diameter to the shells. The center conductors are stamped and formed to maintain an exact but variable outside diameter which is used to change the terminating impedance of the respective connector.

Abstract: Method of manufacturing semiconductor elements equipped with leads which are connected to electrodes and formed of wires including the steps of positioning each semiconductor element on a bonding stage, feeding a tip end of the wire under a bonding tool so that the bonding tool presses the tip end against the electrode to bond it to the electrode, shifting the bonding tool to away from the tip end and pressing the wire against wire-cutting section of the bonding stage, and pulling the wire away from the bonding tool to cut the wire.

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 molded electrical connector for connecting electrical conductors comprises a molding section in which a plurality of metallic circuits are arranged in parallel with one another at predetermined intervals and are fixedly molded with resin such that first end portions of the metallic circiuts are exposed as connecting terminals. The molded electrical connector further comprises a connecting section which comprises the connecting terminals. The connecting section is molded with resin simultaneously when the molding section is formed. Electrical conductors are placed on the connecting terminals of the metallic circuits and welded together.

Abstract: A method for forming an fixing end portion of a composite rope comprises the steps of mounting a mold on an end portion of the rope, pouring a molten metal in a cavity defined between the end portion of the rope and the mold under pressure, covering a predetermined part of the end portion of the rope with a cast metal formed from the molten metal, cold-pressing the cast metal and fixing the portion coated with the cast metal to a fixing member.

Abstract: A method of forming a crimp-style terminal and the resulting crimp-style terminal. A solder cream is applied to one or both of the inner surface of the conductor-holding portion of the terminal and the conductor wires which are to be held by the conductor-holding portion. The conductor-holding portion is subsequently deformed by pressing to grip the wire conductors. The solder cream fills the space between the conductor bundle and the inner surface of the conductor-holding portion and the space between conductors of the conductor bundle.

Abstract: A method is described for installing contacts with their rear tail ends soldered to holes of a circuit board and their front mating ends insulative housing layers, which facilitates inspection of the solder connections to the circuit board and defluxing of the assembly after soldering. The front contact portions are partially inserted into holes in an elastomeric housing layer (50, FIG. 3) until a first forwardly-facing shoulder (76) on each contact abuts an abutment (92) on the elastomeric layer. The contact rear ends are inserted into corresponding holes in the circuit board (56) until a second rearwardly-facing shoulder on each contact abuts the front face of the board, and the contacts are then soldered to the board. The distance (H, FIG. 2) between the first and second contact shoulders is sufficient to provide a considerable gap (A) between the board and the elastomeric layer, so the solder connectiosn can be visually inspected.

Abstract: A plurality of terminals already disposed in a housing of an electrical connector, include solder tails extending rearwardly from the housing each of which has a thin foil-like substrate having a layer of magnetic material bonded intimately onto an outer surface thereof, so that respective wire ends may be placed therealong with solder preforms within lengths of heat recoverable tubing may be placed therearound and a high frequency current induced in the magnetic layer of the substrate which then generates thermal energy sufficient to melt the solder and shrink the tubing forming terminations between the wires and the terminals and simultanously sealing the terminations. The magnetic material of the substrate may be nickel-iron alloy, which may comprise the foil or which may be clad to a brass layer of the foil, which is then soldered to a brass solder tail layer.

Abstract: A band of bipartite metal foil is crimped around a portion of a stripped wire end near the insulation and spaced from the portion to be soldered to a terminal solder tail extending from a housing portion, with a first layer of conductive nonmagnetic metal and a thin second layer of high resistance metal having high magnetic permeability. When the wire end is paired with the solder tail with a solder preform placed therearound within a length of heat recoverable tubing extending between the insulated wire portion and the housing of the terminal, and high frequency alternating current is induced in the bipartite metal foil, thermal energy is generated which is conducted along the wire end and radiates outwardly to melt the solder to join the wire end to the solder tail, and to shrink the tubing to grip the insulated wire portion and housing portion to cover and seal the termination thus formed.

Abstract: An electronic circuit with flip-chip mounting of a semiconductor chip (5) on a substrate (1), wherein there is provided between the semiconductor chip (5) and the conductor tracks (2) of the substrate (1) a metallic solder stop layer (3) which is insulated from its environment by an oxide layer (4). With this type of solder stop layer, it is possible to obtain layer thickness which can be exactly reproduced, as a result of which a reliable flip-chip soldering is achieved.

Abstract: A crimp-style terminal and a method of connecting the same is provided in which an exposure portion is provided in the cable conductor-clamping portion of the crimp-style terminal. The exposure portion is used for fusing a cable and the conductor-clamping portion together.

Abstract: A method is described for making an electrical through connection between a first insulated condution line including a flat electrical conductor to a second insulated electrical conduction line.

Abstract: A method and terminal for mass terminating conductors with high reliability combines insulation piercing and solder technology. Terminals are formed with insulation piercing, conductor engaging portions which have a layer of solder integral therewith. Respective conductors are terminated by the terminals in an insulation piercing operation and the solder reflowed to form a permanent bond therebetween. The terminal slot is designed to clean the conductor surface as well as to fixture it for the solder reflow operation.

Abstract: A method of making a current sensor device is disclosed wherein a sensor, having a magnetoresistive element configured into a bridge, an insulating substrate and a conductive member are sub-assembled and then the sub-assembly is heated to bond the components together. The bridge is attached to a first substrate having a first layer of insulation with first vias therein in which are deposited first elements of solder projecting beyond the first layer of insulation. Second elements of (e.g.) solder are deposited in second vias in a second layer of insulation on the second substrate. When the components are sub-assembled, the first elements rest on the second elements to provide a clearance between the first and second layers of insulation.

Abstract: A method for connecting the wires of a high density, flat transmission cable to a connector is provided. A crimp connector for facilitating the practice of the method is also provided. The connector includes one or more rows of contacts mounted thereto. Each contact includes a crimp section extending from the connector housing. The crimp sections are plated with a relatively thick layer of solder. After stripping the end of the cable, selected cable conductors are inserted within the crimp sections. A batch crimping operation secures the conductors to the contacts, after which the crimp sections are heated to fuse the solder. Once the solder has cooled, a reliable connection will be established between the cable and connector. A solder-plated bus bar may also be secured to selected cable conductors by preliminarily mounting the conductors thereto and then heating the bus bar.

Abstract: An electrical contact comprises a first end which is hollow and bullet shaped. The first end is formed by rolling sheet material. A second end, which is solid and formed from wire is affixed to the first end at a crimp joint. The joint is formed at a tail or terminus of the first and is rolled about the second end to form a gas tight seal. To complete the connection, a laser weld fuses the edges of the crimp and penetrates into the second end.

Abstract: To form lead or lead alloy terminals on cables comprising an insulative sheath and an aluminum core, the appropriate length of the core is bared and a metal part is fixed to the bared core. The terminal is then cast over this metal part. The metal part is compatible externally with the lead or the lead alloy forming the terminal and is compatible internally with the aluminum core. No high-resistivity substance is formed between any component layers of the resulting assembly.

Abstract: A self-contained solder delivery device comprises a housing, a quantity of solder together with flux and a pressuring means for forcing the solder from the housing. The device can be used in a connector for use in connecting the conductors of electric power cables.

Abstract: Apparatus for terminating a ribbon cable formed of electrical conductors in a web of electrical insulation during the attaching thereof to a connector. The apparatus comprises a guide member releasably coupleable with the cable at a predetermined location with respect to the end of the cable. The apparatus also comprises means to sequentially couple the guide member and cable end in operative relationship with a series of processing stations whereat the guide member functions to accurately locate the cable end with respect to the operating mechanisms of the processing stations. Such processing stations are operative for the attaching of the cable end to a connector. Also disclosed is the method of terminating a ribbon cable with such apparatus.

Abstract: An inductance element comprises conductive paths of copper and a spool member arranged on a substrate, and insulated winding formed by a fine copper wire whose surface is coated with an insulating film of urethane etc. is wound around the spool member so that both end portions thereof are subjected to ultrasonic vibration by an ultrasonic bonding apparatus to be connected to the conductive paths by ultrasonic bonding. Thus, the end portions of the winding can be processed by local heating with application of ultrasonic vibration, whereby the coil needs not be entirely heated and an inductance element can be readily implemented directly on the substrate.

Abstract: A method for terminating a coaxial electrical cable by dip-soldering a metal ferrule to the outer braided shield surrounding an end.

Abstract: A plurality of terminals already disposed in a housing of an electrical connector, include solder tails extending rearwardly from the housing which have a thin layer of magnetic material deposited on an outer surface thereof, so that respective wire ends may be placed therealong with solder preforms within lengths of heat recoverable tubing may be placed therearound and a high frequency current induced in the magnetic layer which then generates thermal energy sufficient to melt the solder and shrink the tubing forming terminations between the wires and the terminals and simultaneously sealing the terminations. The magnetic material may be nickel-iron alloy clad to a brass solder tail layer. The thermal energy is generated in an amount necessary to raise the temperature of the magnetic layer to its Curie temperature for the given frequency used and maintain that temperature.

Abstract: Magnet wire substrates (1) are described having a layer of polyester tape (2) wrapped thereon, including a layer of spirally wrapped and bonded polyester insulation tape (3) as the outermost layer. The two tape layers are made up of amorphous (4) and crystalline (5) segments unbonded to the wire and bonded to each other to provide the requisite electrical properties and improved physical properties including increased flexibility and ease of strippability. A single multilayer polyester insulation tape can also be used with similar properties and reduced thickness.

Abstract: A method of manufacturing a multiwire lead assembly for a flexible connector between thin film elements and other electronic circuitry during manufacturing thin film heads for computer disc drives includes the process of supporting the multiple wires in spaced locations on retainers, such as terminal boards, and fixing the wires to such terminal boards. The terminal boards are spaced apart a desired distance for making the lead assembly. The wires are separated from the source reel and then the two terminal boards are a supported assembly and the center portions of the multiple wires are twisted together while the end portions are held separated and oriented by the terminal boards. The twisted wire portion of the wires then can be insulated at desired locations, including for example the full length of the twisted portion. The ends of the wires are stipped of their normal insulating coating utilizing a laser stripper in a known manner.

Abstract: The heat coil assembly for a protector unit is formed of a line terminal, an intermediate member and a pin forming a single unit, with a spool mounted on the upper end of the pin and attached by a layer of fusible alloy. A coil on the spool has one end connected to the heat coil assembly and the other end connected to a second line terminal. The coil can be wound on the spool after attaching to the pin to form an assembly for positioning in a base of a protector. A protector may have two such heat coil assemblies, with associated primary gap protectors, and ground member. Back-up protector devices may also be provided, with line members connecting each heat coil assembly to a related back-up protector.

Abstract: A cable connection is described. It is particularly suitable for a piezoelectric cable which has a low melting point conductor. The connection is made by inserting a conductive piercing member such as a wire (14) into the conductor (4), so as to leave a portion of the piercing member extending from the cable. The piercing member (14) is then heated to the softening temperature of the cable conductor (4) to allow local softening of the conductor. The result, on cooling, is a solder joint between the piercing member and the cable conductor.

Abstract: A cable termination assembly with an integral polarizing key, and method of molding the same, includes an electrical cable including at least one conductor, at least one electrical contact, a support body for at least preliminarily supporting the electrical contact, the electrical contact having an insulation displacement connection portion, a contacting portion, and an offset between said portions, and the support body having a land for cooperating with the offset to support the electrical contact during insulation displacement connection connecting of the insulation displacement connection portion to such conductor. Part of the electrical contact and the support body cooperate during the mentioned molding to effect a shut off function blocking flow of molding material of the strain relief into an area of the support body where the contacting portion is located. Molding material fills a cell of the support body during molding of the strain relief body to form a polarizing key.

Abstract: In accordance with the method, a supporting body (21) is formed by arranging contact members (3) so as to be adjacent and mutually parallel in a straight line and by moulding the contact members in a ribbon-like, flexible plastics body (1) while leaving contact portions (5) free. Subsequently, the body is rolled up so as to form a cylinder which is mounted in a bush (19) in order to form the supporting body (21). Prior to rolling up connection portions (7) of the contact member (3) are connected to conductors (9) of a cable (11). Finally, the assembly thus formed is enclosed by a plug body (25) which leaves the contact portions (5) free.

Abstract: A machine for bonding connectors to the edge of a pcb by a Luc process has upper and lower wheels which are translated along the edge of the pcb for engaging the connectors to be applied respectively to the faces of the board. The relative position of the wheels at any given time is determined by mounting one of them to move with a jaw which closes down onto one of the faces.

Abstract: A contact terminal has a termination section at one end thereof including a spaced pair of axially-extending slots within each of which a respective one of a pair of conductor wires is held in interference fit for weld termination such as by laser welding. The terminal can be a ground terminal for the pair of ground conductors of a tri-lead cable. The terminal is stamped from a metal blank and its termination section is formed by striking an axially extending boss upwardly in the center thereof having parallel vertical side surfaces and a selected width, and bending parallel vertical sidewalls upward from side portions of the termination section spaced selected distances from the side surfaces of the central boss. The sidewalls may be higher than the top of the central boss and contain inwardly directed rounded bosses which hold the conductor wires in the respective slots prior to weld termination.

Abstract: A heat activatable sealing piston comprising a cylinder of polymeric material radially expandable on application of heat. The piston can be incorporated into thermal actuators of various types. In a preferred embodiment, the sealing piston is used in an electrical connector, together with a gas generating means to force solder between an electrical conductor inserted into the connector and the walls of the tubular connector.

Abstract: A transitional printed circuit board (10) is disclosed for terminating four multiconductor flat electrial transmission cables (44, 46, 48, 50) wherein only a single substrate (12) is utilized. A first electrical plane (A) is formed on one side of the substrate and a second electrical plane (B) is formed on an opposing side of the substrate with the substrate material in between serving as an insulator. Each electrical plane includes a ground plane (26, 41) and spaced electrical lands (14, 16, 32 ,34). Plated through holes (24) allow the lands from opposing sides to be connected to the opposite side for programmed termination. A series of electrical pads (22, 42) provide for termination to the prongs (52a, 52b) of terminal connector (52). Two cables may be terminated on each electrical plane of the printed circuit board by terminating ground wires of the first cable to the ground plane (26, 41), and the signal wires to the electrical lands (14, 32).

Abstract: An electrical plug connector comprises a dielectric contact-carrying member having signal contact members secured to one side of the contact-carrying member at spaced intervals therealong. A ground contact member is secured to the other of the contact carrying member with contact sections of the signal contact members and the ground contact member extending from a front end of the contact-carrying member. Conductor-connecting sections of the signal and ground contact members extending along the contact-carrying member. Signal conductors and ground conductors of electrical cables are electrically connected respectively to the conductor-connecting sections of the signal contact members and the ground contact member. A dielectric housing member is secured onto the contact-carrying member and part of the electrical cables so that the contact members from their contact sections to their conductor-connecting sections are covered.

Abstract: A direct cable attachment method for directly connecting a flat ribbon cable to a stack of integrated circuit units by pre-tinning the leads of both the ribbon cable and the wiring board with solder. Positioning the ribbon cable on the wiring board and applying sufficient heat to the combination to achieve a physical and electrical connection. Adding epoxy to the assembly structure provides additional strength.