The invention is related to a cassette for machining a connector. The cassette is detachably disposed in a tool body having a head and a driving element. The direction of motion of the driving element defines a first axis. The cassette comprises: a cassette body and a machining block. The cassette body is detachably disposed in an opening of the head of the tool body and has a machining opening therein. The machining block is slidably disposed in the cassette body along the first axis and has an engagement element detachably engaged with the driving element of the tool body. Through the engagement element, the driving element drives the machining block to slide along the first axis to move toward or away from the machining opening.

The present disclosure relates to an electric wire connection structure including one or more copper-based conductor covered electric wires having a copper-based conductor covered part and exposed part; and one or more aluminum-based conductor covered electric wires having an aluminum-based conductor covered part and exposed part. An ultrasonic joint part is provided at a conductor stacked part in which the copper-based conductor exposed part and the aluminum-based conductor exposed part are superposed. A total contacting length L which is a summed length of a part at which the copper-based conductor exposed part and the aluminum-based conductor exposed part contact and a summed length x of a contour line of a space S formed at a part at which the copper-based conductor exposed part and the aluminum-based conductor exposed part are separate in a joint interface of the ultrasonic joint part satisfy a relational expression of (x/L)×100≤10% based on cross-section observation.

The present disclosure relates to an electric wire connection structure including one or more copper-based conductor covered electric wires having a copper-based conductor covered part and exposed part; and one or more aluminum-based conductor covered electric wires having an aluminum-based conductor covered part and exposed part. An ultrasonic joint part is provided at a conductor stacked part in which the copper-based conductor exposed part and the aluminum-based conductor exposed part are superposed. A total contacting length L which is a summed length of a part at which the copper-based conductor exposed part and the aluminum-based conductor exposed part contact and a summed length x of a contour line of a space S formed at a part at which the copper-based conductor exposed part and the aluminum-based conductor exposed part are separate in a joint interface of the ultrasonic joint part satisfy a relational expression of (x/L)×100≤10% based on cross-section observation.

A fastener for use in joining dissimilar materials manufactured by the process of producing the fastener with an external surface that forms an electrically insulating oxide layer when subjected to oxidation and, after manufacture and prior to use, subjecting the fastener to a pre-oxidation process to grow the desired oxide layer in situ on the external surface of the fastener. The present invention also provides a dissimilar material joint in which the pre-oxidized fastener is used to mechanically join dissimilar materials with the oxide layer electrically insulating the fastener from at least one of the dissimilar materials. The fastener may be a rivet used in friction self-piercing riveting (F-SPR). The fastener may be fabricated from an alloy capable of forming Al.sub.2O.sub.3 or Cr.sub.2O.sub.3 by thermal oxidation. The fastener may be pre-coated with Al or Cr that functions as a seed layer to form Al.sub.2O.sub.3 or Cr.sub.2O.sub.3.

A manufacturing method for an electric wire with a terminal includes: a first resin supplying step for discharging a curable resin material for internal use through a discharge port at a nozzle distal end after being caulked and crimped, and infiltrating the curable resin material for internal use into gaps between elemental wires while pressing out air in the gaps; a second resin supplying step for discharging a curable resin material for external use through the discharge port at the nozzle distal end, and covering the core wire exposed part in which the curable resin material for internal use is filled into the gaps, a core wire connection body, and a coating connection body with the curable resin material for external use from the outside; and a resin curing step for curing the curable resin material for internal use and external use by operating a resin curing device.

A wire guide system includes a wire guide tool assembly mounted to a die of a press automatically connecting an electrical terminal to a wire subassembly. An upper wire guide has a hemispherical shaped upper wire guide portion. A lower wire guide has a hemispherical shaped lower wire guide portion. The upper wire guide moves reciprocally to the lower wire guide. The hemispherical shaped upper and lower wire guide portions when the upper wire guide contacts the lower wire guide combine to temporarily define a conical wire guide aligned with a terminal barrel of the electrical terminal. A lifter is slidably received in the lower wire guide. The lifter displaces a terminal barrel of the electrical terminal away from contact with the lower wire guide after the electrical terminal is crimped to the wire subassembly, providing clearance to automatically remove the wire subassembly from the wire guide tool assembly.

An electrical connector includes a compression device defining an aperture and is configured to receive a first portion of a base row of wires and a first portion of a core of an electrical conductor within the aperture. An outer tube defines a central through hole and is configured to receive the compression device within the central through hole. A first end of the outer tube is configured to be compressed around the first end of the compression device, and a first portion of the core of the associated electrical conductor to create a compressed assembly. The compressed assembly is contiguous with a second portion of the base row of wires and a second portion of the core of the associated electrical conductor.

An electrical connector includes a compression device defining an aperture and is configured to receive a first portion of a base row of wires and a first portion of a core of an electrical conductor within the aperture. An outer tube defines a central through hole and is configured to receive the compression device within the central through hole. A first end of the outer tube is configured to be compressed around the first end of the compression device, and a first portion of the core of the associated electrical conductor to create a compressed assembly. The compressed assembly is contiguous with a second portion of the base row of wires and a second portion of the core of the associated electrical conductor.

A method of crimping a terminal with a cable which crimps and connects a crimping portion of a crimp terminal to an end of a cable by a crimp die, includes an anticorrosive supply step and a terminal crimping step. In the anticorrosive supply step, an anticorrosive agent is stored in or supplied to an anticorrosive supply portion formed in the crimp die. In the terminal crimping step, the crimping portion of the crimp terminal is crimped to the cable by the crimp die. During or after the terminal crimping step, the anticorrosive agent is applied to a predetermined area around the crimping portion of the crimp terminal by the anticorrosive supply portion of the crimp die.

A telecommunications connector includes a connector body and a shield attached to the connector body, the shield including a main body portion configured for attachment to the connector body and a barrel portion for crimping against a cable to be terminated to the connector. The barrel portion of the shield includes a corrugated side wall made up of a series of bends extending along a direction from the rear end of the barrel toward the front end of the barrel along at least a portion of a length of the barrel, wherein the bends defining the corrugated side wall are provided on the shield at a pre-crimped stage.