Abstract: A crimping die includes a first die for constraining the wire crimping portion by a concave die surface shaped in conformity with the wire crimping portion, and a second die including a convex die surface paired with the concave die surface. A width of a recess on the concave die surface and that of a projection on the convex die surface are equal to an outer diameter of the wire crimping portion. The wire crimping portion is pressed by the concave die surface of the first die and the convex die surface of the second die, whereby the wire crimping portion and the wire inserted into the cylindrical interior of the wire crimping portion are crimped and fixed.

Abstract: In a method for connecting an electrical conductor to an electrical contact part, wherein the contact part has deformable legs the legs are deformed by means of a bending die in such a way that the legs press the conductor with the contact part in a force-locked manner, wherein the contact part is acted upon in so that at least the legs are materially connected to each other. A device includes a bending die for connecting an electrical conductor to an electrical contact part, wherein the contact part has deformable legs and the bending die is designed to deform the legs in such a way that the legs press the conductor with the contact part in a force-locked manner, and wherein the device also includes a laser welding device designed to act on the contact part so that at least the legs are materially connected to each other.

Abstract: A method for manufacturing an electric wire with a terminal, includes crimping a barrel portion of the terminal onto a core wire constructed of metal wires and creating a crack in a metal oxide layer immediately before the crimping. The metal oxide layer is formed on a metal surface of the core wire. The creating of crack is accomplished by applying a mechanical force to the metal oxide layer.

Abstract: A locator and wire stop device arranged to be mounted on a hand operated crimping tool outside of and adjacent to a crimp opening defined by crimping dies on the hand operated crimping tool and arranged to locate and retain at least one crimpable connector part between at least two crimping dies of the hand operated crimping tool. The locator and wire stop device includes a positioning mechanism for cooperation with a connector comprising the crimpable connector part, an axially protruding connection part, and an intermediate connector body comprising a transversal protrusion. The positioning mechanism comprises a pivotable connector and wire stop element, a first resilient locator element and a second locator element. The first resilient locator element has respective through holes arranged to receive and radially retain the connection part of the connector.

Abstract: Methods for forming female connectors integral with stator winding conductors, thereby avoiding the necessity of using a separate female connector. A typical connector in accordance with the present invention has a first length of the wire adjacent an end of the wire striped of insulation, and a second length of the wire adjacent the end not greater than the first length of wire being bent in a substantially closed loop, the loop preferably being pressed flat so as to have a thickness less than the wire. Also preferably the wire bends in a first direction and then bends in a circular arc to form the loop, the center of the loop being substantially aligned with a center of the wire. Various embodiments are disclosed as are exemplary simple methods for forming the female connector.

Abstract: A waterproof wire connector comprising a push in wire connector having a wire chamber therein for receiving and forming electrical engagement with an electrical wire axially inserted therein with the wire connector having a wire port with a self healing member extending across the entry to the wire port to prevent moisture from entering the wire connector whereby pushing the wire into the wire connector forces the end of an electrical wire to pierce the self healing member.

Abstract: A hydraulic compression tool for securing a compression type cable connector to a prepared end of a coaxial cable. The tool can include a hydraulic assembly having an axially extendable ram, and a connector frame detachably attached to the hydraulic assembly. The connector frame can include a cable cradle configured to accommodate cables of various sizes and a sleeve for engaging a cable connector. The connector frame can further include a sliding guide structure attached to the cable cradle. The sliding guide structure can include a sliding bar and one or more sliding guides. The sleeve can be attached to the sliding bar. The sleeve can be configured to accommodate connectors of various sizes. Activating the hydraulic assembly can cause the ram to extend, which, in turn, can cause the sliding bar to move along the longitudinal axis of the cable connector compressing the compression member and connector body into operative engagement with the cable.

Abstract: An electrical contact assembly has a plurality of formed elongate closed seam tubular elements attached to a carrier with each of the elongate tubular elements attached to the carrier via a tab. Scored creases are formed in the tabs for separating the elongate tubular elements from the assembly and scored creases are formed in the carrier for defining carrier strips. The carrier strip had a plurality of grouped elongate tubular elements. The electrical contact assembly is placed in a crimping die where at least one or more wires are inserting into selected elongate tubular elements. Pressure is applied to least one or more of the selected elongate tubular elements to produce bulk material deformation along a substantial portion of the elongate tubular elements to crimp the elongate tubular elements to the wires as electrical contacts.

Abstract: A fitting, for terminating an electrical cable having two or more conductors, a central insulation portion, and a braided outer portion, includes a substantially tubular fitting body having a central bore extending therethrough, a forward end, and a cable receiving end. A tubular sleeve is positioned within the central bore of the fitting body and configured for insertion between the center insulation portion and the braided outer portion of an installed electrical cable. A clamping ring is positioned within the central bore of the fitting body about the tubular sleeve. Upon assembly of the fitting, the clamping ring is configured to clampingly engage the central bore of the fitting body and the tubular sleeve to secure the braided outer portion of the installed electrical cable to the fitting.

Abstract: A tool for installing compression connectors of various sizes and types on the end of a coaxial cable has a base mounting a pair of movable anvils for engaging two different lengths of connectors. The base further incorporates a fixed anvil for engaging a third length of connector. The movable anvils define an aperture which is shaped to permit easy entry and exit of a cable while still applying a suitable retention force to an inserted cable. A connector seating holder is formed in the front of the tool. A slidably mounted plunger cooperates with the anvils to compress a connector. The plunger has a push head and a slide rod. A lock nut is threaded on the push head and is engageable with the slide rod to prevent rotation of the push head.

Abstract: A method of waterproofing a crimping part of a crimp terminal where a wire is crimped includes a step of forming a waterproof structure. The waterproofing structure seals a crimping region containing the crimping part with an adhesive tape. The adhesive tape has waterproofing performance and has a thickness no more than a predetermined value.

Abstract: A method includes providing a cable connector and a compression tool that includes a hydraulic assembly, the hydraulic assembly having an axially extendable ram. The compression tool further includes a connector frame detachably attached to the hydraulic assembly, the connector frame having a cable cradle configured to accommodate the cable, and a sliding guide structure mounted to the connector frame assembly, the sliding guide structure comprising a sliding bar and one or more sliding guides, and a sleeve attached to the sliding bar. The method including locating the cable connector into the compression tool and disposing one end of the prepared cable into one end of the compression member, activating the hydraulic assembly, so that extending the axially extendable ram along the longitudinal axis causes the sliding bar to move along the longitudinal axis producing compression of a compression member and a connector body into operative engagement with the cable.

Abstract: A clamping apparatus, for a crimping machine (1), which comprises a crimping tool head (2) with an end wall (9), in a cable feed direction, a crimping tool base body (3) with an anvil (4) and a front knife (21), an insulation stripping apparatus (5); a contact element feed apparatus (6); and a coupling part (7) for coupling the crimping machine (1) to the crimping tool head (2). The clamping apparatus (10) clamping the electric cable (8) to be processed both during the insulation stripping and crimping processes. The clamping apparatus (10) is connected to the crimping tool head (2) via its end wall (9) and is movable vertically with the crimping tool head (2). At least one of the clamping apparatus (10) and the crimping tool head (2) is arranged centrally in a longitudinal direction of the cable path (8?) above the anvil (4) and the front knife (21).

Abstract: It is an objective to enhance sealing performance of a resin mold without subjecting a connector housing to special work. In an electric wire connection structure of a connector terminal in which an end of an electric wire (W) is connected to a rear portion of a connector terminal (10) and in which the electric wire connection is sealed of a resin mold (20), a step (d) that makes an underside (13b) of a rearmost end of the connector terminal (10) higher than an underside of an area ahead of the rearmost end is provided between the underside (13b) of the rearmost end and the underside (12b) ahead of the rearmost end, thereby assuring space (22) that enables filling of a resin which makes up a resin mold (20).

Abstract: A crimped terminal attached electric wire comprising an electric wire, which is made by covering a conductor part with an insulative coating, and a crimped terminal including a conductor crimping part which is crimped to the conductor part when a pair of crimping strip parts form a joint along the extending direction of the conductor part, wherein the conductor crimping part is swelled in a direction perpendicular to the extending direction of the conductor part, and is formed into a barrel form while the joint is the only joint, when the conductor crimping part is crimped to the conductor part.

Abstract: To provide a method for shaping an electric wire end and a mold for shaping electric wire end, capable of shaping a distal end with a rectangular shape in sectional view by smoothly pressing conductors of plural electric wires without causing a reduction in strength.

Abstract: A hydraulic compression tool for securing a compression type cable connector to a prepared end of a coaxial cable. The tool can include a hydraulic assembly having an axially extendable ram, and a connector frame detachably attached to the hydraulic assembly. The connector frame can include a cable cradle configured to accommodate cables of various sizes and a sleeve for engaging a cable connector. The connector frame can further include a sliding guide structure attached to the cable cradle. The sliding guide structure can include a sliding bar and one or more sliding guides. The sleeve can be attached to the sliding bar. The sleeve can be configured to accommodate connectors of various sizes. Activating the hydraulic assembly can cause the ram to extend, which, in turn, can cause the sliding bar to move along the longitudinal axis of the cable connector compressing the compression member and connector body into operative engagement with the cable.

Abstract: A hydraulic compression tool for securing a compression type cable connector to a prepared end of a coaxial cable. The tool can include a hydraulic assembly having an axially extendable ram, and a connector frame detachably attached to the hydraulic assembly. The connector frame can include a cable cradle configured to accommodate cables of various sizes and a sleeve for engaging a cable connector. The connector frame can further include a sliding guide structure attached to the cable cradle. The sliding guide structure can include a sliding bar and one or more sliding guides. The sleeve can be attached to the sliding bar. The sleeve can be configured to accommodate connectors of various sizes. Activating the hydraulic assembly can cause the ram to extend, which, in tum, can cause the sliding bar to move along the longitudinal axis of the cable connector compressing the compression member and connector body into operative engagement with the cable.

Abstract: A hydraulic compression tool for securing a compression type cable connector to a prepared end of a coaxial cable. The tool can include a hydraulic assembly having an axially extendable ram, and a connector frame detachably attached to the hydraulic assembly. The connector frame can include a cable cradle configured to accommodate cables of various sizes and a sleeve for engaging a cable connector. The connector frame can further include a sliding guide structure attached to the cable cradle. The sliding guide structure can include a sliding bar and one or more sliding guides. The sleeve can be attached to the sliding bar. The sleeve can be configured to accommodate connectors of various sizes. Activating the hydraulic assembly can cause the ram to extend, which, in turn, can cause the sliding bar to move along the longitudinal axis of the cable connector compressing the compression member and connector body into operative engagement with the cable.

Abstract: An applicator ram includes a ram body configured to hold crimp tooling, and a ram adaptor coupled to the ram body. The ram adaptor is configured to be coupled to a terminator ram. The ram adaptor includes an adaptor hub having a hub chamber configured to receive a ram post of the terminator ram. A latch mechanism is movably received in the hub chamber. The latch mechanism is movable between a latched position and an unlatched position. The latch mechanism is configured to engage the ram post in the latched position. The latch mechanism allows the ram post to be released from the hub chamber in the unlatched position. An adaptor stud extends from the adaptor hub and is configured to be coupled to the applicator ram.

Abstract: An electrical connector for use with coaxial cables includes deformable cylindrical casing and a slidably engaged barrel.

Abstract: An improved connector for ACSR cable includes a connector core having an axial bore dimensioned to receive the steel core of the cable. A connector body has a substantially cylindrical outer surface and a substantially cylindrical cavity. A distal portion of the cavity having a first substantially cylindrical inner surface is dimensioned to receive the connector core. A second portion of the cavity proximally adjacent to the distal portion has a substantially cylindrical second inner surface dimensioned to receive the aluminum conductor strands of the cable. The connector body may be configured with one or more additional portions of the cavity having substantially cylindrical inner surfaces with progressively increasing diameters, the number of such portions depending on the size of the cable. The connector body is compressed with a swaging tool at several axially spaced-apart locations to grip the aluminum conductor strands and also to compress the connector core.

Abstract: A method for straightening, constraining, cutting and terminating a multi-stranded, non-parallel cable. The cable filaments are aligned. A binder is then applied to the cable to maintain the alignment. The cable is then cut to a desired length. Each strand or group of strands is then placed in an individual termination. Each individual termination is then attached—either directly or through intermediate devices—to a collector.

Abstract: A coaxial connector for interconnection with a coaxial cable with a solid outer conductor by ultrasonic welding is provided with a monolithic connector body with a bore. An annular flare seat is angled radially outward from the bore toward a connector end of the connector, the annular flare seat open to the connector end of the connector. An inner conductor cap is provided for interconnection with an inner conductor of the coaxial cable by ultrasonic welding. The ultrasonic welding of each of the inner and outer conductor interconnections may be performed via inner conductor and outer conductor sonotrodes which are coaxial with one another, without requiring the cable and or connector to be removed from their fixture.

Abstract: A crimp connection includes a contact element and a wire cable. The wire cable is disposed along a longitudinal axis and configured to axially receive the contact element. When the contact element receives the wire cable the crimp connection is formed that attaches the wire cable with the contact element so that at least a portion of the crimp connection includes at least one indention arrangement deformed therein. The indention arrangement contains a pair of humps separated by a groove therebetween. The crimp connection may be applied to a wire cable assembly that includes an inner and an outer ferrule in a manner that prevents protrusions from forming thereon so that undesired RF energy is not electrically transmitted out from crimp connection of the wire cable assembly. Methods to construct a crimp connection that includes the pair of humps separated by a groove therebetween are also further presented.

Abstract: A cable includes at least one conductor to transmit electrical signals and a shield layer positioned about the at least one conductor. The shield layer shields an environment external to the cable from electromagnetic radiation generated by the electrical signals. The cable also includes a first retention sleeve positioned about the shield layer and a second retention sleeve coupled with the first retention sleeve and to the shield layer.

Abstract: A coupling body for a coaxial connector is dimensioned to couple with connector body at a connector end. An inner body of the coupling body is provided with a bore dimensioned to receive the coaxial cable. The inner body is formed of transparent material partially covered in an opaque material. An uncovered portion of the inner body functions as a visual installation portal. Methods of installation include inserting the coaxial cable into the cable end of the bore of the inner body until a desired portion of a prepared end of the coaxial cable is visible.

Abstract: A terminal crimping device where an electric wire is moved from a wire stripping section to a terminal crimping section, with both ends of the wire held by two wire holding hands of a wire conveying hand, and is subjected to terminal crimping processing by terminal crimping pressing devices. The terminal crimping device has the second wire conveying hand for conveying the wire at the terminal crimping section. The wire conveying hand conveys the wire without passing it from one side of the wire crimping pressing devices to the other side, so that an occurrence of a holding failure of the wire is suppressed even if the number of the terminal crimping pressing devices is increased or the conveyance speed of the wire is increased.

Abstract: The present invention is to provide an apparatus for crimping a terminal to an electrical wire, which have respective part numbers, and allows miniaturization of the apparatus. The apparatus includes a base, a drive portion, a plurality of applicators, a plurality of connection/disconnection portions and a control device. The drive portion drives the associated applicator to crimp the terminal to the electrical wire. The connection/disconnection portions each are disposed in one-to-one relation ship against the respective applicators. The each connection/disconnection portion is positionable at a connection and a disconnection position, where a driving force is transmitted to or released from the associated applicator. The control device controls the associated connection/disconnection portion so that the applicator corresponding to the part numbers of the electrical wire and the terminal can achieve crimping with the driving force from the drive portion.

Abstract: An apparatus for crimping a terminal with a wire includes a first crimper and a second crimper. The first crimper presses the terminal with the wire at a first position of the wire. The second crimper presses the terminal with the wire at a second position of the wire after the first crimper presses the terminal at the first position. The first position is disposed between a tip end of the wire and the second position in an extending direction of the wire.

Abstract: A junction box adapted to provide an electrical connection to an electrical wire attached to a photovoltaic panel. The junction box has a lower portion which has an entry slot to allow entry of the wire into the junction box and a raised protrusion over which the wire is bent and formed to be substantially in the same shape as the raised protrusion. The junction box also has a clamp adapted to be attachable to said lower portion, whereby the clamp holds the wire in place for providing the electrical connection. The wire is preferably bus ribbon. The lower portion preferably has an elastic polymeric element disposed between the raised portion and the wire. The raised protrusion may have an elastic polymeric element.

Abstract: Provided is a coaxial cable connector compression tool comprising a resilient coaxial cable retaining mechanism, having a tool mounting portion, affixed to said compression tool and a compliant cable receiving portion configured to releasably retain a coaxial cable, wherein the cable retaining mechanism, which may be comprised or one or multiple pieces, bears minimal compression forces while positioned on said compression tool to hold said coaxial cable in proper alignment when said compression tool is operated. Moreover, a method is provided for retaining a coaxial cable in proper alignment during compression of a coaxial cable connector onto said coaxial cable.

Abstract: A method for crimping terminals of an electric wire includes conveying an electric wire from one side of a plurality of electric wire crimping units to another side allocated in a row in a conveying direction of the electric wire, without the electric wire being grip-substituted. The method also includes crimping the terminal by stopping conveyance of the electric wire at a discretional one of the plurality of electric wire crimping units. The method also includes the following steps carried out in this order: measuring the electric wire and cutting the electric wire in a predetermined length; stripping a jacket at both ends of the electric wire; crimping the terminal to an end of the electric wire; regulating a position of the terminal of the terminal-attached electric wire; and inserting the terminal-attached electric wire to a connector housing.

Abstract: A terminal insertion apparatus having a connector housing holding unit, a terminal insertion unit, and a control unit. The connector housing holding unit holds a connector housing movably in horizontal and vertical directions. The terminal insertion unit inserts a terminal attached to an electric wire into a terminal accommodating chamber of the connector housing. After the terminal insertion unit has inserted an end of the terminal into the terminal accommodating chamber, the control unit controls a movable supporting unit of the connector housing holding unit so as to move a holding jig by amounts of movement in horizontal and vertical directions so that the terminal is not caught on an inner surface of the terminal accommodating chamber, and then the terminal is completely inserted in the terminal accommodating chamber.

Abstract: In order to promote the adhesion of a crimp terminal (10) to an aluminum electric wire (100) by virtue of crimping to thereby realize an improvement in electric connecting performance, the thickness of tin plating applied to an inner surface of a conductor crimping portion (13) of the crimp terminal (10) is set to be in the range from 2.1 ?m to 5.0 ?m, and then, the conductor crimping portion (13) is crimped to a conductor (100a) of the aluminum electric wire (100).

Abstract: A method of installing a plug on a cable having insulated wire pairs includes stripping insulation from a cable end to expose the wires and arranging the wires into a plug configuration. A wiring block having a back end leading to a cavity and a front end having pass through holes respectively leading to wire troughs extending between the cavity and front end is provided. The cable end is inserted through the back end such that the wires are inserted into the wire troughs corresponding with the plug configuration and such that the ends of the wires protrude out through the pass through holes. The protruding wire ends are cut off after being pulled until the cable insulation adjacent to the cable end seats itself inside the cavity. The cable is removed from the block such that the cable end can be inserted into a plug to be crimped thereto.

Abstract: A terminal fitting (10) includes a wire barrel (12) to be crimped and connected to a core (61) at an end portion of a wire (60). An insulation barrel (13) is located behind the wire barrel (12) and is to be crimped and connected to an insulation coating (62) at the end portion of the wire (60). The inner surface of the insulation barrel (13) is formed with a close-contact portion (18) to be held in close contact with the insulation coating (62) and a recessed groove (19) spaced from the insulation coating (62) and extending over the entire circumference. The recessed groove (19) has an opening (21) that is open at the front end of the insulation barrel (13) and a waterproof material (40) flows into the recessed groove (19) through the opening (21). The waterproof material (40) adheres to the outer surface of the core (61).

Abstract: A contact magazine loader for guiding the insertion of individual electrical contacts into a crimping section of a crimping tool. A magazine is adapted to be placed in removable and rotatable engagement with a hand-held crimping tool. The magazine is approximately cylindrical, has a plurality of channels evenly dispersed around the radial periphery of the magazine, and is preloadable with electrical contacts. Each preloaded electrical contact is positioned within an individual insert casing. Each insert casing is adapted to being linearly slideably received into one of the channels. As a shuttle assembly is moved into compressed configuration, an insert casing guides the preloaded electrical contact into the crimping section of the hand-held crimper. A trigger assembly allows a user, with a single movement, to cause the shuttle assembly to return to its released configuration, and to rotate the magazine to axially align a subsequent casing with the crimping section of the hand held crimper.

Abstract: A battery connector includes a first end terminal, at least one intermediate terminal and a second end terminal. The at least one intermediate terminal is in communication with the first end terminal via a first flexible cable. The first flexible cable is affixed to the at least one intermediate terminal and the first end terminal. The second end terminal is in communication with the at least one intermediate terminal via a second flexible cable, the second flexible cable being affixed to the at least one intermediate terminal and the second end terminal.

Abstract: The present invention is to provide a wire harness capable of improving productivity and reducing cost as well as enhancing waterproof performance to secure reliability, and a method for manufacturing the wire harness. The wire harness comprises an electronic wire having a core wire and a covering part covering the core wire, a male terminal attached to the core wire exposed out of the covering part of the electric wire, a housing attached to the covering part and formed to lay the male terminal therein, and a ring-shaped waterproof member disposed between the housing and the covering part, filling a gap therebetween, and made of soft resin.

Abstract: A method for enhancing the dielectric properties of an electrical cable segment having a central stranded conductor encased in a polymeric insulation jacket and an interstitial void volume in the region of the conductor, including filling the interstitial void volume with a dielectric property-enhancing fluid at a pressure below the elastic limit of the polymeric insulation jacket, and confining the fluid within the interstitial void volume at a residual pressure greater than about 50 psig, with the pressure being imposed along the entire length of the segment but below the elastic limit of the polymeric insulation jacket. Preferably, the residual pressure is sufficient to expand the interstitial void volume along the entire length of the cable segment by at least 5%.

Abstract: A crimping terminal fitting has a wire barrel (21) to be crimped and connected to core strands (31) of a wire (30). The wire barrel (21) has a base plate (23) continuously extending from a ground terminal (11) in a longitudinal direction. Two core crimping pieces (25) extend from the opposite sides of the base plate (23). A thinned portion (27) is formed at least at a leading end of each core crimping piece (25) and is thinner than the base plate (23).

Abstract: A coaxial connecter and a method for assembling the same are provided, in which there is little variation in the amount of holding an inner conductor between connection terminals and the connection between the inner conductor and the connection terminals is achieved with high reliability. The coaxial connector includes a housing, an inner contact, and an outer contact. The inner contact is secured to the housing and includes a conductor mounting portion and a conductor holding arm with a lock. The conductor holding arm is integrally formed with the conductor mounting portion. The outer contact is secured to the housing, as well. Either the housing or the conductor mounting portion is provided with a holding portion into which the lock is press-fitted when the conductor holding arm is folded toward the conductor mounting portion.

Abstract: Methods of making a sealed crimp connection attaching a terminal to a wire conductor are provided. A layer of fluid conformal coating is applied to overlie a terminal and underlie at least a lead of the wire conductor upon at least the lead being received into the terminal. The terminal, the fluid layer, and at least the lead of the wire conductor are crimped to form the crimp connection. Fluid conformal coating is displaced where an abutting surface of the terminal makes contact with at least the lead of the wire conductor. The fluid conformal coating is cured to a non-fluid state. The fluid conformal coating may be formed of an acrylated urethane material that may provide an increased pull force and a low crimp resistance in the crimp connection. The crimp connection may be constructed using a manufacturing process on an automated assembly line.

Abstract: Methods and systems for securing electrode leads are disclosed. An electrode system in accordance with one embodiment includes an electrode contact, a connector attached to the electrode contact, and an electrical lead. The electrical lead can be received in an opening of the contact, with an inner surface of the opening applying a generally uniform radial pressure around a circumference of the electrical lead. For example, the contact can have a tubular shape, optionally with an elongated slit, and can be crimped around the lead to apply the generally uniform radial pressure.

Abstract: Coaxial connectors include a connector body and an inner contact post. A compression sleeve is also provided that is configured to impart a generally circumferential compressive force to secure one or more elements of a coaxial cable between the connector body and the inner contact post when the compression sleeve is in a seated position. The compression sleeve or the connector body includes a first disengagement mechanism that is configured to assist moving the compression sleeve from the seated position to an unseated position in which at least some of the circumferential compressive force is eliminated.

Abstract: A method for forming a protective jacket over a connection region includes connecting the leads of an electronic device to conductors such that the connections are in a connection region, placing the connection region in a mold, injecting molten protective material into the mold to cover the connection region, allowing the molten material to cool and harden and removing the connection area from the mold.

Abstract: A method for attaching a ring electrode to the shaft of the tip section of a catheter comprises passing an electrode lead wire through a lumen in the catheter and out an exit hole in the tip section. The portion of the electrode lead wire extending out of the exit hole is stripped of non-conductive coating and wrapped around the shaft and secured in a clove hitch arrangement. The wrapped electrode lead wire is pulled tight while the material of the shaft is heated to embed the electrode lead wire in the shaft so that its outermost surface is generally flush with the surface of the shaft. The exit hole is sealed and a ring electrode, having a flared skirt is slipped over the shaft to a position over the wrapped electrode lead wire and exit hole. It is then swaged to reduce its outer diameter to about that of the outer diameter of the shaft of the tip section to thereby create a low ohmic connection with the electrode lead wire.

Abstract: A method of manufacturing a deflectable electrophysiological catheter includes constructing a shaft having a distal end and at least one lumen. The method further includes inserting a component into the lumen, and processing at least a portion of the distal end to reduce the cross-sectional profile of the lumen to capture/confine the component. A catheter manufactured using this method includes a shaft having at least one lumen. The lumen comprises a longitudinally-extending trough defined by a longitudinally-extending recess, within which a component is disposed, and a longitudinally extending open edge. The lumen further comprises a longitudinally-extending channel defined by a longitudinally-extending cavity and by the open edge of the trough. A planarity wire is disposed within the cavity and is configured to close the open edge of the trough to within a pre-defined tolerance that is less than the size of the component to retain the component in the recess.

Abstract: An electrical contact assembly has a plurality of formed elongate closed seam tubular elements attached to a carrier with each of the elongate tubular elements attached to the carrier via a tab. Scored creases are formed in the tabs for separating the elongate tubular elements from the assembly and scored creases are formed in the carrier for defining carrier strips. The carrier strip had a plurality of grouped elongate tubular elements. The electrical contact assembly is placed in a crimping die where at least one or more wires are inserting into selected elongate tubular elements. Pressure is applied to least one or more of the selected elongate tubular elements to produce bulk material deformation along a substantial portion of the elongate tubular elements to crimp the elongate tubular elements to the wires as electrical contacts.