The object is to provide a technology capable of increasing the reliability of a power semiconductor device. A power semiconductor device includes: a substrate including an insulating layer and a circuit pattern that are disposed in this order; a power semiconductor element electrically connected to the circuit pattern; and an electrode terminal having a thinned portion including a welded portion welded to the circuit pattern by a fiber laser. A thickness of the circuit pattern is not less than 0.2 and not more than 0.5 mm, and a thickness of the thinned portion of the electrode terminal is not less than one time and not more than two times the thickness of the circuit pattern.

A power converter module has a switching device with a substrate with a first and a second DC voltage conductor track and a first and a second DC voltage terminal element connected in an electrically conducting manner with the correct polarity, and having a first and a second DC voltage connection element. The first DC voltage terminal element is connected to the first DC voltage connection element in an electrically conducting manner with the correct polarity by means of a first materially-bonded connection, wherein the second DC voltage terminal element is connected to the second DC voltage connection element in an electrically conducting manner with the correct polarity by means of a second materially-bonded connection.

A power electronic arrangement has a power converter module including a switching device with a substrate with a first and a second DC voltage conductor track and a first and a second DC voltage terminal element connected in an electrically conducting manner with the correct polarity, and has a first and a second DC voltage connection element. The first DC voltage terminal element is connected to the first DC voltage connection element in an electrically conducting manner with the correct polarity by means of a first materially-bonded connection. The second DC voltage terminal element is connected to the second DC voltage connection element in an electrically conducting manner with the correct polarity by means of a second materially-bonded connection. The second DC voltage terminal element or the second DC voltage connection element has a continuous welding cavity in the region of the first connection.

Methods and systems for sequentially laser welding terminal tabs of a battery cell to corresponding terminal tabs of a busbar are described using a single laser position and path. The terminal tabs of a battery cell are aligned in contact with terminal tabs of a busbar. A laser welder, from a first position, generates a laser weld beam at a first diameter welding the first terminal tab of the battery cell to the first terminal tab of the busbar. Next, the laser weld beam is narrowed, reducing the first diameter to a smaller second diameter. Without moving the laser welder from the first position, the narrowed laser weld beam burns a hole through the welded first set of terminal tabs, traverses a gap toward a second set of terminal tabs behind the first set and welds the second set together.

A wire harness including: a first electric wire having a first core wire and a second electric wire having a second core wire, the first core wire and the second core wire being joined to each other, wherein: the first core wire has a planar portion extending over an entire length direction of the first core wire, the second core wire has flexibility higher than that of the first core wire, and an end of the second core wire is joined to the planar portion of the first core wire in an overlapped state therewith.

An electrical device including a conductor cable having an electrical conductor embedded in an insulation sheath of the conductor cable in a contact plane. The electrical conductor is stripped of the insulation sheath in a predetermined contact section at least on one contact side, the contact section of the conductor is bent out with the contact side from the contact plane to beyond the insulation sheath. The device further includes an electrical connection counterpart. The contact side of the contact section of the conductor rests on the electrical connection counterpart and is connected directly to the electrical connection counterpart to form an electrical contact.

An electrical device including a conductor cable having an electrical conductor embedded in an insulation sheath of the conductor cable in a contact plane. The electrical conductor is stripped of the insulation sheath in a predetermined contact section at least on one contact side, the contact section of the conductor is bent out with the contact side from the contact plane to beyond the insulation sheath. The device further includes an electrical connection counterpart. The contact side of the contact section of the conductor rests on the electrical connection counterpart and is connected directly to the electrical connection counterpart to form an electrical contact.

Provided is a method of manufacturing an electric wire with terminal formed by connecting a first core exposed portion of an electric wire to a metal terminal having a box portion that is formed by processing a single conductive board into a box shape and has an opening in which a counterpart terminal is inserted, and a spring inside the box portion. After laser-welding opposed portions where parts of the single conductive board forming the box portion are opposed to each other, applying ultrasonic vibration to a second core exposed portion of the electric wire is executed.

A method of manufacturing a terminal-equipped electrical wire includes: inserting a core-wire exposed part of a core wire of an electrical wire at a terminal between inner wall surfaces of a pair of piece parts of a terminal fitting including a core-wire connection body formed of a bottom part and the piece parts protruding from both ends of the bottom part, and placing the core-wire exposed part on an inner wall surface of the bottom part; melting the core-wire exposed part and the core-wire connection body by emitting a laser beam to the core-wire exposed part and the core-wire connection body from a free end side of each piece part; and fixing the core-wire exposed part and the core-wire connection body melted by the laser beam, with the emission of the laser beam stopped.

A terminal-equipped electric wire manufacturing method includes: an electric wire installation step of inserting a core-wire exposed part between inner wall surfaces of piece parts of a core-wire connection body, the core-wire exposed part having a core-wire diameter smaller than an interval between the inner wall surfaces of the piece parts; a melting step of melting the core-wire exposed part and the core-wire connection body by emitting a laser beam to the core-wire exposed part and the core-wire connection body from a free end side of each piece part; and a fixation step of fixing the core-wire exposed part and the core-wire connection body thus melted, with the emission of the laser beam stopped.