Abstract: A double row connector terminates transmission cable, with selected terminals for grounding to provide programming. Signal conductors are terminated to terminals in a housing by being held in interference fit in longitudinal slots of respective terminals and laser welded thereto. Ground conductors are similarly held in grooves of a ground bus in the housing and are laser welded thereto. Selected signal conductors are also laser welded to the ground bus as well as respective terminals to convert the terminals to grounds. The conductors are disposed in a termination plane transverse to the connector requiring right angle termination to the terminals. The insulated cable is then doubled back over a dielectric spacer secured to the housing over the terminations, and a retainer is latched to the housing to clamp the cable and provide strain relief. Terminals and a ground bus are specially designed for the connector and the laser welding termination method.

Abstract: The invention relates to a method of arranging flexible, insulated conductors of a bundle of unaligned electrical conductors into an aligned mutual position before soldering the stripped ends of the conductors (27) to conduction paths of a contact member, for example of a printed circuit board. The unaligned conductors (25) are drawn from an unaligned position between the flush teeth (13, 14) of two combs (9, 11) until the transitions of the insulated parts of the conductors (26) to the stripped parts (27) have just passed the first comb (11), whereupon the conductors are clamped in narrow spaces (15, 16) between the teeth (13, 14). The two combs (9, 11) are arranged on a base plate (3). The teeth are thin at the top (17, 19) and become broader at the base (21, 23).

Abstract: A corrosion resistant electrical interconnect system has a flexible circuit with buried conductor patterns in an insulative film coating which is juxtaposed to a feed-through connector having inlet/outlet electrical contact pins therethrough. Sharp ends are present on the pins which pierce the insulative film and permit spot welding of the pin tips to portions of the conductor pattern. Other portions of the conductor pattern extend exteriorly of the flexible circuit and are electrically connected on to bond pads of an integrated circuit chip such as a sensor chip utilized in a mass flow meter.

Abstract: A DC kickless water cooled cable used in welding is disclosed in which the cable strand ends are crimped into the cable terminations with the aid of a D-clip, and then the D-clip, crimped cable end, and termination are press resistance welded together to form a low cost substantially integral connection.

Abstract: Connectors for terminating and splicing high voltage power cables comprise a metallic tubular sleeve having an open end for receiving an electrical conductor and a closed end. The inner wall of the sleeve is pretinned. The sleeve can be provided with a slug of solder proximate to the closed end. A connection is made by inserting the conductor into the sleeve, heating the solder, and as the solder melts, relatively moving the connector and the conductor toward each other. The connector can be provided with an insert to accommoduate conductors that are non-circular in cross-section.The connector can be provided with means for pressuring the slug of solder toward the open end of the sleeve at the temperature at which the slug of solder melts. With this connector, no relative movement between the conductor and the connector is required. Merely by melting the solder, the means for pressuring causes the solder to extrude around the conductor.

Abstract: A flexible coaxial cable has a special plug connector with a tensile strength comparable to that of the cable at the connecting point to the cable. This plug connector (14) consists of a nipple (1) which is threaded with a plug sleeve (3). Between these two plug elements is arranged a contact ring (2) which is soldered to the covering (23). This contact ring (2) includes a bore (13), through which the soldering can be optically controlled and the vapors can be vented during soldering. The end surfaces of the contact ring (2) and the cable dielectric (21) are face-turned. Accordingly, the cable lengths can also be precisely determined. The exposed inner conductor (20) is soldered to a plug pin (4). The plug dielectric (5), plug pin (4) and the plug housing (3) itself are held in rigid positions in the plug housing (3) by means of a bore (10) filled with epoxy resin (9) and by a constriction (11) in the plug pin (4).

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 side 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 starter solenoid for electric starting apparatus and its method of manufacture. The solenoid has hold-in and pull-in coils and a cap formed of insulating material that carries a start switch terminal and a motor terminal. Both terminals have axially extending internal bores and when the cap is moved into engagement with the case of the solenoid to secure it thereto end lead wires of the coils are inserted into the bores of the terminals. The terminals are radially crimped into engagement with the wires and the crimped portions are then welded to the wires. The ground connection for one end of the hold-in coil is made by inserting an end lead wire of the hold-in coil into the bore of a hollow metallic terminal that is carried by a metallic plate member, crimping the terminal to the wire and then welding the crimped portion to the wire.

Abstract: A coaxial cable feed thru reduces the required cable trough width to about 0.400 inches. A feed thru body has a flange and a threaded tube for holding the coaxial cable as it passes without electrical interruption from the trough to a shielded RF device. A nut is placed on the threaded tube which is inserted through a slot in the trough wall. The feed thru flange is compressed against the wall closing the slot when the nut on the opposite side of the wall has been torqued.

Abstract: A serving dish having a heater, and a method for assembling the dish. An electric heater including a resistance element enclosed in a heat conducting and electrical insulating material is adhesively bonded against the bottom of a serving dish of ceramic or the like. Holes through the material covering the resistance element provide for electrical contact with the resistance element, and these holes are filled with solder. A bottom plate of stainless steel or other electrically conductive sheet is adhesively bonded over the heater, and the bottom plate is heated to melt the solder and cause the solder to fuse to the bottom plate. The entire bottom plate has its edges sealed by a silicone rubber sealant or the like to encapsulate the heater. The resulting dish has a bottom plate to give a neat appearance, the bottom acting as electrical contacts to energize the heater and heat the contents of the serving dish.

Abstract: A method of manufacturing a solar battery by serially connecting a plurality of solar battery elements arranged spaced from each other. A pair of flexible films are used to sandwich the arrangement of the solar battery elements, and each of the flexible films has a plurality of conductive members formed thereon at positions respectively corresponding to the solar battery elements. However, each conductive member has one end portion extended beyond the surface of the corresponding solar battery element in the direction of the alignment of the solar battery elements. Thus, when the pair of flexible films are disposed to sandwich the solar battery elements, the extended end portion of the conductive member on the side of the light receiving surface of one solar battery element is positioned in the space between adjacent solar battery elements opposite the end portion of the conductive member on the side of the back surface of the next solar battery element.

Abstract: The individual conductors of a cable are connected to a P.C. board under utilization of an auxiliary member having a plate in which are inserted solder pins. The conductors of the cable are connected to one side of the pins, an insulated body is molded around that connection including the conductor ends and the end of the cable; the pins project in a particular pattern from the auxiliary member and are inserted in a matching pattern of solder sleeves in the P.C. board and the pins are soldered to the sleeves. The auxiliary member is separately bolted to the P.C. board.

Abstract: A cased electrical component, such as a multiple electrical outlet strip, has a greatly simplified construction. A single structure provides for passage of an electrical cord through the metal casing and grounding of the electrical component within the casing to the casing. The casing over and base are attached together with a simple snap-action provided by interfering projections and openings formed on cooperating portions of the base and cover. Temporary mounting openings are formed directly in the base, and a stiff sheet of plastic material is disposed between the base and the electrical component to prevent access to the electrical component through the temporary mounting openings.

Abstract: This insulation applicator applies electrical insulation to a thin conductive strap that is attached to and extends transversely of wire being wound into a coil. The applicator comprises two applicator segments between which is a feed passage through which two strips of insulation are fed. The segments are moved transversely of the wire from a first position at one side of the wire to a second position at the other side, thus introducing the strap into the feed passage. Holding means releasably holds the strips respectively to the segments while the strips extend through the feed passage, thus carrying the strips with the segments and holding apart the forward ends of the strips during the above-described transverse movement of the segments. Means on the segments acts when the insulating strips have been so moved to force the strips together about the strap and effect bonding between the strips.

Abstract: An improved electrical terminal designed to eliminate arcing and corona effects has a substantially spherical post with one or more circumferential slots perpendicular to the longitudinal axis of the terminal. In one embodiment, each slot is adapted to receive a wire of predetermined gage in a close-fitting wrapped configuration. The outer diameter of the wire does not extend beyond the circumference of the sphere. The number and size of the slots depends on the number and gage of the wire(s) to be connected. More than one wire can be connected in a single slot, either by wrapping the wires concentrically or in parallel planes within the same slot. Solder is applied to the wrapped wires to form a secure, smooth and rounded connection.

Abstract: A heat-resistant insulated electric wire and cable which comprises an electric conduction; the first coating layer thereon consists of a mixture of a binder and a finely ground and unmelted inorganic substance; and the second organic insulating coating layer formed on the first coating layer. Said heat-resistant insulated electric wire can advantageously be used for a coil of a magnet or a motor.

Abstract: A method of forming a conductive connection between predominantly miniature members by pressing the members together and heating by means of electrodes through which three successive pulses of electric current are passed. First and second pulses act to break a flowable insulation coating of one of the members, melt a solder alloy in the location of the connection and effect a weld, while a third current pulse is applied to the electrodes prior to their raising from the members to thereby melt the solder alloy and flowable insulation coating, whereafter the electrodes are withdrawn from the members and the third current pulse is quenched.

Abstract: A miniaturized bus bar is presented wherein a plurality of distribution prongs or fingers are mechanically and electrically bonded to a ribbon type capacitor which is defined by a pair of bus conductors and a ceramic spacer.

Abstract: In an apparatus for the assembly of microcomponents semiconductor devices, an improvement is provided for the step involving wire bonding of thin gold wires between conductor pads on the semiconductor chip and the external leads. In this type of apparatus generally, the wire bonding step involves the bonding of thin gold conductor wires between the conductor pads and the external leads. In the type apparatus wherein the present invention is provided, a lower anvil articular upward to a position underneath and supporting the semiconductor chip during the bonding process and then articulates downward away from the chip after bonding. The wires are placed and bonded by a capillary tube which articulates between positions above the bonding pads of the chip and the leads. The improvement comprises a wall disposed from the lower anvil and surrounding the chip between the conducting pads and the leads, whereby the wires are supported by the wall as they are withdrawn from the capillary tube.

Abstract: A cable is prepared for mounting a connector, by initially deforming a helically wound strip of the cable to prevent it from unwinding. Then, an outer braided conductor and an outer sheath are cut and stripped from the cable end. Next, a sleeve is inserted beneath the braided conductor, a ferrule is positioned around the cable at the sleeve and the ferrule is clamped to the sleeve. The sleeve can have a flange for mounting the connector in clamped relation on the flange.

Abstract: Several flat cable assembly embodiments (10, 30, 60) are disclosed, as are methods for terminating and connectorizing the terminating ends of ribbon-shaped conductors (13, 33, 34, 63) arranged in at least one laterally disposed array in a flat cable (12, 32, 62). In accordance with all of the flat cable assembly embodiments, terminated insulation-stripped conductor end portions (13a', 33a', 34a', 63a') are twisted angularly a predetermined number of degrees from their initial orientation, as originally confined within the cable, prior to being secured to respectively associated connector mating elements of either the solder type (19, 44), or solderless type (64).

Abstract: A crystal is mounted on a low, centrally located pedestal. Connections to the lower side of the crystal are made by way of conductive areas on the pedestal. Multiple wiring connections are made at the edges of the crystal by allowing the bonding tool to depress the edge of the crystal so that the crystal bonding pad is supported by the base structure only during the bonding process, then released thereafter to allow free vibration of the crystal plate. Complex circuitry, possibly involving more than one frequency can thus be put onto one plate.

Abstract: An electric resistance heating element of the hairpin type is provided by a molybdenum disilicide resistance wire loop transversely connected to molybdenum disilicide terminals. The resistance wire is sandwiched between the ends of two pieces of terminal wire and the ends of these pieces are butt welded together on the resistance wire, to form each terminal.

Abstract: A first cable is spliced to an intermediate portion of a second cable by inserting an end of the first cable and a stripped intermediate portion of the second into a metallic tube, then forging the tube and cable portions together, then bending the first cable at a desired angle relative to the second cable, then soldering the cables and tube together, and then molding a plastic cover over the tube and exposed conductive portions of the cables.

Abstract: A sound, low resistance joint is provided between two electrically conductive members, at least one having a bonded insulation coating thereon. In one form of the method of the present invention, a continuous metallic penetrator having sharp edges or burrs, such as a brass screen, is interwoven about at least two bonded insulation coated conductive members. The coated conductive members and interwoven penetrator are placed in a conductive connector member having chamfered holes therein. Welding electrodes subject the connector member to heat and pressure with welding current flowing between the welding electrodes. At least some of the welding current flows through the continuous metallic penetrator before the penetrator makes electrical contact to the insulation coated conductive members. The penetrator becomes heated by thermal heat from the welding electroides and resistance heat as the welding current passes therethrough.

Abstract: An aluminum electrical conductor is electrically joined to a copper electrical conductor by a cold weld lap joint which is substantially free of copper-aluminum intermetallic compounds. The overlapped portions of the conductors are deformed at least 74% and no greater than 82% to achieve a weld joint which has both excellent physical properties and excellent electrical properties. The cold weld lap joint is a reliable electrical connection for electrical circuits experiencing current densities of more than 1000 amperes per square inch and a sustained high temperature of 125.degree. C. and above.

Abstract: To organize and electrically terminate both ends of a plurality of wires, an apparatus comprising an array of interconnected, substantially parallel passageways is placed over the wires proximate to the first ends of the wires. The first ends of the wires are electrically terminated, and then the array is slid along the wires toward the second ends thereof for organizing the wires. The second ends of the wires are then electrically terminated.

Abstract: In an electrical switchboard, the body of an aluminum connector is welded to a riser bus. Bolts clamp a horizontal busbar in electrical connection with the connector body and, at the same time, fixture the horizontal busbar with a projection of the connector body protruding through an opening in the horizontal busbar. The projection is then welded to the horizontal busbar along the edges of the opening therein to create a bolted/welded joint electrically connecting the horizontal busbar to the riser bus. The projection is of sufficient height to accommodate plural coextensive horizontal busbars of a multiple bar bus run, common, bolted/welded electrical connection with the riser bus.

Abstract: A connector-cable assembly in which a flat, multiple wire cable is secured in a connector body through a transverse, sharply angled rib, and the stripped wire ends are terminated into a plurality of plate members disposed in parallel planes and spaced longitudinally of the wires to provide mounting and working space. Each wire is terminated by being progressively urged and then forced into an open throated slot formed in one of the plate members. The slots are formed so that there is intimate, large area contact, and wedge resistance to linear pull-out. The plate members are plated for corrosion resistance and a heating step following mechanical connection causes melting or intermetallic diffusion. The rib not only provides strain relief, but also indexes the cable end for assembly and anchors the cable for partial stripping--the latter permitting simultaneous and convenient positioning of the wires.

Abstract: The invention is an apparatus and method for aligning a very fine wire relative to a workpiece. It comprises an alignment fixture supporting a pair of spaced-apart lead screws for receiving the wire in the threads thereof. The wire is affixed to spacer arms oppositely protruding from the fixture and spans the spacing between the screws. The workpiece is supported between the spacer arms and may be raised or lowered to provide alignment with the wire which is then translated or oriented by turning either or both of the lead screws until the relative alignment is achieved. The wire is affixed to each of the arms in a slackened condition and a tiny weight is suspended from the wire for yieldably tensioning the same across the threads, but providing for translation without fracture.

Abstract: A method for manufacturing an encapsulated probe or measuring head on sheathed thermocouples, in which thermocouple wires are imbedded in an outer metal sheath with the interposition of an insulating material, and wherein a thermal bead is produced by either an electric or autogeneous process at the sections of the thermocouple wires projecting from the metal sheath at the measuring head end of the wire.

Abstract: The invention contemplates a unitary magnetically sensitive circuit element or network and a flexibly articulatable elongate assembly of a plurality of such elements or networks, with electrical interconnection of the same, such assembly being inherently suited to precision operation as a function of length, whatever the length selected for a particular application or use. In one application to liquid-depth indication within a tank, the longate assembly is merely inserted into the tube along which a float-borne permanent magnet is guided, and the magnetically sensitive element of each successive unit is actuated as the float tracks liquid level and is displaced from actuating relation with one and then to the next-adjacent one of the circuit-element units. The connection of circuit-element units is such that electrical-resistance observation from one end of the assembly provides a direct indication of the liquid level at which the float magnet is currently operative.

Abstract: This method makes an electrical coil from conductive wire having an insulating coating bonded thereto and provides the coil with at least one conductive lead. The coil winding operation is stopped when a predetermined wire region is located at a work station, where a section of the insulating coating is removed, thereby exposing a section of bare wire. Then there is placed in contact with the section of bare wire and cold-welded thereto a thin conductive strap that extends transversely of the wire and forms said lead. Then the cold-weld joint and a portion of the lead are covered with electrical insulation by applying to opposite faces of the lead two strips of insulating material that extend transversely of the wire on opposite sides of the wire. Then the strips are bonded together, following which the winding operation is continued to complete the coil with said strips extending generally parallel to the coil axis.

Abstract: An electrical wiring device comprising an insulated flat cable having a plurality of parallel electrical conductors disposed in a plane and encased in a flexible insulation with at least one connector assembly permanently attached for plug-in service is provided. Also provided is a method of making the device in which insulation-piercing interconnecting elements are passed through the insulation, have a tight bight of conductor formed outside the insulation and are permanently bonded to tines in each interconnecting element, and the associated parts are enclosed in a dielectric housing.

Abstract: A speed control subassembly is made by providing a generally flat heat sink plate having a laterally-formed collector strip at its upper edge. A double-sided-adhesive insulator tape strip is stuck to the heat sink, this tape having a hole large enough to receive a thyristor chip so that the thyristor anode contacts the heat sink with solder paste therebetween. Two formed terminal strips extending in opposite directions are stuck to the tape so that one contacts the cathode and the other contacts the gate of the thyristor chip with solder paste therebetween. A chip capacitor is placed across the terminal strips with solder paste therebetween. A small force is applied to the capacitor and then heat is applied to the stack of parts to solder the parts together and to the heat sink and to set the adhesive resin. This subassembly is then placed into a trigger switch housing and connected to the contacts and variable resistor thereof to provide a trigger speed control switch for portable tools.

Abstract: Apparatus and method for making a wire lead which comprises a pair of insulated stranded conductors encased in an insulating jacket, with a two-pronged plug at one end and either untwisted or twisted bare or tinned wires with or without terminals at the other end. The apparatus comprises mechanisms to cut and convey a cable segment, strip the insulating jacket from both ends and trim cut the exposed insulated wires, preshape them, strip and twist the stranded wires at the plug end, attach the plug at that end, and strip and perform appropriate processing operations at the other end, i.e., twist, tin, or terminate.