An electrical connector consists of a connector housing (10) and at least one electrical contact element (1). The connector housing (10) and/or the electrical contact element (1) have a lead content of <0.1 weight percent. A method for manufacturing a contact element from a blank which has a lead content of <0.1 weight percent, uses the following method steps: Loading the blank into a manufacturing machine; producing a pin region or a socket region for electrically contacting another, opposite contact element; producing a fixing region for fixing the contact element in an insulating body; producing a crimp region for electrically connecting a conductor to the contact element or finishing the crimp region if the blank has already been previously prepared on a different machine; and removing the finished contact element from the manufacturing machine.

An electrical device having a stranded wire contact. The device includes a stranded wire with individual wires and a contact piece for electrical contacting of the stranded wire. The stranded wire contact is produced by thermal diffusion bonding.

A method of assembling a connector for automotive applications, comprising the steps of: providing a cable having at least one inner conductor; connecting an elongated inner signal contact of the connector to a stripped end of the at least one inner conductor; surrounding the elongated inner signal contact by an insulating element; placing a first shielding part of the connector around a first portion of the insulating element from a first radial direction; placing a second shielding part of the connector around a second portion of the insulating element from a second radial direction generally opposite to the first radial direction; and joining the first and second shielding parts to form a shielding contact of the connector surrounding the insulating element.

A terminal coupled to an electric wire includes a terminal body and a shell. The shell includes a tubular portion and pressing portions 25A and 25B that protrudes from an inner wall of the tubular portion. The tubular portion includes a bottom wall, a first sidewall that projects upward from a first side edge of the bottom wall, a second sidewall that projects upward from a second side edge of the bottom wall, a ceiling that extends from the first sidewall to the second sidewall and is opposite the bottom wall, and a restricting portion that extends from the second sidewall to the first sidewall and overlaps an outer surface of the ceiling.

A terminal coupled to an electric wire includes a terminal body and a shell. The shell includes a tubular portion and pressing portions 25A and 25B that protrudes from an inner wall of the tubular portion. The tubular portion includes a bottom wall, a first sidewall that projects upward from a first side edge of the bottom wall, a second sidewall that projects upward from a second side edge of the bottom wall, a ceiling that extends from the first sidewall to the second sidewall and is opposite the bottom wall, and a restricting portion that extends from the second sidewall to the first sidewall and overlaps an outer surface of the ceiling.

An electric wire with a terminal includes: an electric wire having a core wire, and a cover; a crimp terminal having a core wire crimping portion which is crimped to the core wire, a cover crimping portion which is crimped to the cover, and a connecting portion which extends from the core crimping portion to the cover crimping portion; and a resin which integrally covers the core wire and the crimp terminal. The core wire has an intermediate portion which extends between the core crimping portion and the cover crimping portion. The connecting portion has a bottom wall portion and a pair of side wall portions which extend in a height direction of the crimp terminal from end portions of the bottom wall portion in a width direction.

The present invention is provided with: a terminal metal fitting to which a core wire exposed portion of a core wire of a terminal of a wire is physically and electrically connected; a housing inside which the terminal metal fitting and the terminal of the wire are housed and from which the wire is drawn outside from inside; and a wire holding member that holds, inside the housing, the terminal of the wire, in which the wire holding member has a fixed portion that is fixed to a fixing portion inside the housing, and a holding portion that holds the terminal of the wire so that the terminal of the wire does not move relatively to the housing when the fixed portion is fixed to the fixing portion.

A method for producing an electrical connection between an electrical conductor, which includes a plurality of individual wires, and a contact element. The electrical conductor is arranged in a contact portion of the contact element, and the contact portion and the electrical conductor are subsequently pressed together so that the contact portion surrounds the electrical conductor. A a plurality of mutually spaced elongate welded connections between the contact portion and the electrical conductor are produced by laser irradiation of the contact portion, or by laser irradiation of the electrical conductor through an opening in the contact portion. The elongate welded connections extend in an irradiation direction from an irradiated region of the contact portion, or from an irradiated region of the electrical conductor, through an entire cross-section of the pressed electrical conductor to a region of the contact portion opposite to the irradiated region, such that the electrical conductor is connected to this area of the contact portion; and the irradiated regions are arranged in the form of a grid.

A compact electrical power connector including a cable with cores surrounded by cable insulation. Each core includes a wire surrounded by core insulation. Removed cable insulation exposes each core and removed core insulation exposes each wire. Each wire is reverse crimped to a corresponding terminal placed within a cable holder that supports and routes each core. The assembled cable holder is inserted into a housing including housing terminal slots corresponding to each terminal. An inner mold is injected around the exposed end of the cable holder, any exposed core and a first portion of the terminal end of the cable. An over mold with integrated flange is injected around the exposed surfaces of the housing, the inner mold and a second portion of the terminal end of the cable adjacent the first portion.

A compact electrical power connector including a cable with cores surrounded by cable insulation. Each core includes a wire surrounded by core insulation. Removed cable insulation exposes each core and removed core insulation exposes each wire. Each wire is reverse crimped to a corresponding terminal placed within a cable holder that supports and routes each core. The assembled cable holder is inserted into a housing including housing terminal slots corresponding to each terminal. An inner mold is injected around the exposed end of the cable holder, any exposed core and a first portion of the terminal end of the cable. An over mold with integrated flange is injected around the exposed surfaces of the housing, the inner mold and a second portion of the terminal end of the cable adjacent the first portion.