A method for manufacturing an electrical connection assembly includes a connector preparing step of preparing a connector (CN), in which each of plural terminals (20) has a conductor connection surface (27a) exposed outside an insulating housing (30). A connecting step of connects parts of conductors and the conductor connection surfaces (27a) corresponding thereto while tension is applied to a wiring material (10) by holding the wiring material (10) including the conductors arrayed at intervals from each other in an array direction at holding positions separated from each other in a longitudinal direction of the wiring material. A cutting step sandwiches and cuts the wiring material (10) by two cutting tools (62, 65) at a cutting position between one of the holding positions and the parts to be connected with the wiring material (10) kept held after the completion of the connecting step.

A stator of an electric rotary machine includes a first abutting portion and a second abutting portion. The first abutting portion and the second abutting portion are welded by laser welding in a state where the abutting portions abut against each other, and the first abutting portion and the second abutting portion include bonding surfaces which are bonded to each other. In the axial direction, a height from an insulating cover film to the bonding surface in one abutting portion is greater than a height from an insulating cover film to the bonding surface in the other abutting portion, and in a radial direction, a protruding distance from the insulating cover film to the bonding surface in the one abutting portion is greater than a retraction distance from the insulating cover film to the bonding surface in the other abutting portion.

A conductive terminal for a flat flexible cable comprises a first contact surface, and a second contact surface opposing the first contact surface. The first and second contact surfaces define a space therebetween for receiving a flat flexible cable along a longitudinal direction of the terminal. A structure of protruding elements is defined on the first contact surface and includes a plurality of protruding elements extending from the first contact surface in a direction of the second contact surface. The structure of protruding elements includes at least one protruding element having a first height, and at least one protruding element having a second height, distinct from the first height.

A method to manufacture an electrical connection assembly includes: preparing a wiring material (10) that has conductors and an insulation coating, and preparing a connector (CN) including terminals (20) each having an outward projecting portion (24) with a conductor connection surface (27a) and an insulating housing (30). The method proceeds by setting solder on the conductor connection surfaces (27a) and then removing the insulation coating covering parts to be connected from surfaces of the conductors by melting or dissolving the insulation coating. The method also electrically connects the conductors of the parts to be connected to the conductor connection surfaces (27a) by the solder by heating the parts of the respective conductors to be connected together with the solder while holding a state where the conductors of the wiring material (10) are arrayed at intervals from each other in an array direction.

Provided is an electric cable with terminal and a manufacture method thereof to suppress the shedding of wire strands from a core wire. An electric cable with terminal in which an end of an electric cable is connected to a terminal, the electric cable includes a core wire that is a bundle of a plurality of wire strands. The terminal includes a connection portion in which the core wire is exposed at the end of the electric cable. The core wire is placed on the connection portion including a welded portion that is to be ultrasonic welded to the connection portion. The welded portion includes a high compression portion in which the core wire is compressed, and a low compression portion in which a position that is closer than the high compression portion to the end of the core wire is compressed at a compression lower than that of the high compression portion.

A device capable of improving quality of welding by improving estimation precision of coating removal completion of a conductor which is an ultrasonic welding target is provided. An ultrasonic vibration energy (E) of a horn (11) is adjusted based on magnitude of a displacement amount (a reference displacement amount (Z)) of the horn (11) during at least a partial period of a period from a state in which an FFC and a PCB are interposed by the horn (11) and an anvil (12), through a first stable state in which a displacement speed (v) of the horn (11) is stable in a first speed zone in a course in which the displacement speed (v) of the horn (11) increases, until a second stable state in which the displacement speed (v) is stable in a second speed zone of a higher speed zone than the first speed zone.

Systems and methods are provided for wire processing. In certain examples, a wire processing system is disclosed. The wire processing system includes an electrical wire and solder sleeve joining system. The electrical wire and solder sleeve joining system includes an end effector configured to hold a solder sleeve and a split funnel configured to guide insertion of wire into the solder sleeve, allow movement of the solder sleeve through the split funnel in a second position, and prevent movement of the solder sleeve through the split funnel in a first position. The end effector can additionally be configured to remove a slug from the wire.

A metal terminal where a connecting portion has a receiving portion which receives a wire and a contact segment which extends from the receiving portion by way of a bending scheduled portion is prepared. By applying heat and pressure in a state where the wire is placed on the receiving portion for temporarily fixing the wire, the wire is adhered to the receiving portion using a molten or softened insulating resin coating as an adhesive agent. Next, the connecting portion is bent by way of the bending scheduled portion such that the contact segment faces the receiving portion by way of the wire and the contact segment is brought into contact with the wire. Next, by irradiating a laser beam to a portion of the metal terminal, the wire and the metal terminal are welded to each other.

A contact assembly includes a contact having an upper surface and a lower surface. The contact has a drill hole therethrough. The contact has a flashing collar surrounding the drill hole. The contact assembly includes a mating interposer bonded to the flashing collar to mechanically and electrically connect the mating interposer to the contact. The mating interposer has a mating interface configured to be mated to a terminal to electrically connect the terminal to the contact.

A method for producing an electrical feedthrough with an inner conductor arranged in some sections in a metallic outer pipe and electrically insulated from this outer pipe by an electrically insulating material. The inner conductor of the feedthrough has a contact section projecting out of the metallic outer pipe. The metallic outer pipe, the electrically insulating material, and the sections of the inner conductor, which are already arranged in the metallic outer pipe, are compressed with each other to form a module, in which the contact section projecting out of the metallic outer pipe is joined to the inner conductor only after completion of the compression of the metallic outer pipe, the electrically insulating material, and the sections of the inner conductor, which are already arranged in the metallic outer pipe. The contact section is positioned such that it is oriented along the center axis of the metallic outer pipe.