A method for manufacturing a wiring system includes providing an electric cable having an electric conductor and a contact element with a termination portion, and removing a cable insulation in a first sub-portion of the electric cable. The cable insulation remains on the electric conductor in a second sub-portion of the electric cable offset from the first sub-portion. The electric conductor is welded at the first sub-portion to a termination surface of the termination portion. The first sub-portion is pressed against the termination portion and compressed during welding. A holding device encompasses the second sub-portion at least partially. The holding device supports the second sub-portion at least during the welding and compressing of the first sub-portion and maintains a position of the second sub-portion.

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.

A method of manufacturing a terminal-equipped electric wire, includes: connecting a terminal fitting to one end of an electric wire in which a conductor is covered with a jacket; clamping a range of a predetermined length in a length direction at an intermediate portion of the electric wire with a pair of plate bodies; and performing an ultrasonic joining processing by applying an ultrasonic vibration to the conductor exposed at the other end of the electric wire.

A terminal includes: a tubular box portion to receive a mating terminal; a spring portion extending in a beam shape from a front end portion of the box portion; and a pressing piece configured to restrict a bending range of the spring portion. A free end of the spring portion is inside the box portion, and the spring portion has a contact point with the mating terminal. The pressing piece is placed at a pressing position located inside the box portion and away from the contact point in the bending direction. The pressing piece is configured to restrict the bending range of the spring portion to achieve at least part of the spring portion closer to the free end than the contact point is located on the bending direction side with respect to the pressing position.

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.

A coaxial connector in combination with a coaxial cable is provided with an inner conductor supported coaxial within an outer conductor, a polymer jacket surrounding the outer conductor. A unitary connector body with a bore is provided with an overbody surrounding an outer diameter of the connector body. The outer conductor is inserted within the bore. A molecular bond is formed between the outer conductor and the connector body and between the jacket and the overbody. An inner conductor end cap may also be provided coupled to the end of the inner conductor via a molecular bond.

An ultrasonic metal welding device for welding electrical conductors using a compression chamber that is adjustable at least n height and that is delimited on opposite sides by a section of a sonotrode as a first delimiting surface and by at least one section of a counter electrode (156) as a second delimiting surface, wherein for welding, the counter electrode and the sonotrode are displaced relative to one another. The counter electrode used is one that comprises sections (152, 154) of geometrically different working surfaces or is composed of at least two sections that are displaceable relative to one another.

A wire terminating apparatus and method which allows for determining the quality of a wire termination. The method includes terminating the wire, monitoring the thermal properties of the termination with one or more thermal sensors and comparing the monitored thermal properties to stored thermal properties to determine if the termination is defective. If the termination is defective, the termination is discarded. The apparatus includes a wire termination zone. A thermal sensor is mounted on the wire terminating apparatus proximate the wire termination zone. The thermal sensor monitors the thermal properties of the termination to determine if the termination is defective.

An electrical contact part comprising, a carrier substrate of a metallic material, a metallic coating applied to the carrier substrate, and a coating barrier material applied to the carrier substrate in a partial area of the carrier substrate, wherein the coating barrier material substantially prevents coating of the carrier substrate in the portion.

A connection arrangement comprising a metallic flat conductor having an at least quadrangular cross-sectional profile and at least two mutually opposing first and second surfaces extending at least partially parallel to one another in the longitudinal direction, at least two parts which are flat in the overlap region and which are formed as connecting lugs and which rest on the first surface with an overlap joint and project beyond one or both longitudinal edges of the flat conductor, characterized in that a metallic friction stir welded joint zone is formed starting from the second surface through the flat conductor towards the first surface and projecting into the connecting lugs.