A robotic wire termination system for efficiently connecting a plurality of wires to an electrical connector. The robotic wire termination system generally includes a frame, a connector support attached to the frame, a robot manipulator having at least one arm, a heating device attached to the at least one arm and a control unit in communication with the robot manipulator to control the operation of the robot manipulator. The arm of the robot manipulator is adapted to move the heating device so that the heating device can apply heat to a selected connector pin of the electrical connector.

A flat plate connector including a glass substrate, a conductive silver printing, an adhesion material for electrical connection, an insulated film, a conductive metal strip, and an additional adhesion tape. The flat connector having a dedicated cut-out, where the flat connector before mechanical and electrical bounding with the adhesion material can be fixed with a tape which, depending on its type, can also enhance pull-off resistance and ageing tests. The area is then defined as the surface where the connector adheres to the glass, including the different adhesion materials. The dedicated cut is made in the flat connector to generate a symmetric tensile stress on this adhesion area when the connector is submitted to a pull-off tensile force, the symmetry axis being defined by this pull force axis.

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.

The present invention relates to a high-current plug-in connector component and a high-current plug-in connector. The high-current plug-in connector component comprises a plug body provided with a center hole and a cable connecting hole in an inner cavity thereof, a silver cap which is welded to an outer side of an opening of the center hole, an elastic rubber arranged in the center hole, and a preset soldering tin arranged at a bottom of an inner side of the cable connecting hole, wherein the plug is slotted into three to six petals so that the plug is expanded to form an expansion plug; a head of the high-current plug-in connector component and a heel part of the plug are in a plugging engagement with a socket component of a corresponding plug-in connector, so that the high-current plug-in connector component is in electrical contact with corresponding plug-in connector component.

A method for inserting preformed solder members into connector pins for use with electrical connectors. The method generally includes a connector pin having an open cavity at one end, into which a preformed solder member can be first inserted and then pressed, rather than melted, in place, such that voids and air spaces within the cavity are substantially eliminated. The method allows for inserting solder members in high quantities, where the preformed solder members are placed in a fixture and the fixture is placed on a shaker table, so that solder members can be inserted into large numbers of connector pins that are pre-installed in connector grommets, largely simultaneously.

An electrical connector includes an insulative housing with a plurality of passageways extending through opposite upper and lower surfaces of the housing. A plurality of electrical contacts are received within the corresponding passageways, respectively. Each contact includes a first main body and a second main body side by side arranged with each other with a bridge transversely linked therebetween. At least one of the first main body and the second main body includes a retaining barb for retaining contact in the passageway. Two soldering pads are formed on the corresponding bottom ends of the first main body and the second main body, respectively. The two soldering pads intimately confront each other either in a horizontal direction or in a vertical direction, and are joined together via a solder ball located under the two soldering pads.

A preformed solder-in-pin system for use with electrical connectors. The preformed solder-in-pin system generally includes a connector pin having an open cavity at one end, into which a preformed solder member can be first inserted and then pressed, rather than melted, in place, such that voids and air spaces within the cavity are eliminated. The preformed solder-in-pin system can be assembled in high quantities, where the preformed solder members are placed in a fixture and the fixture is placed on a shaker table, so that large numbers of connector pins, pre-installed in connector grommets, can be inserted largely simultaneously.

A preformed solder-in-pin system for use with electrical connectors. The preformed solder-in-pin system generally includes a connector pin having an open cavity at one end, into which a preformed solder member can be first inserted and then pressed, rather than melted, in place, such that voids and air spaces within the cavity are eliminated. The preformed solder-in-pin system can be assembled in high quantities, where the preformed solder members are placed in a fixture and the fixture is placed on a shaker table, so that large numbers of connector pins, pre-installed in connector grommets, can be inserted largely simultaneously.

A method for inserting preformed solder members into connector pins for use with electrical connectors. The method generally includes a connector pin having an open cavity at one end, into which a preformed solder member can be first inserted and then pressed, rather than melted, in place, such that voids and air spaces within the cavity are substantially eliminated. The method allows for inserting solder members in high quantities, where the preformed solder members are placed in a fixture and the fixture is placed on a shaker table, so that solder members can be inserted into large numbers of connector pins that are pre-installed in connector grommets, largely simultaneously.

A method of producing a vehicle glass assembly includes (A) providing a harness including a metal wire, a connector at a terminal of the metal wire, including a flat portion made of a metal plate, and a block of lead-free solder, containing tin as a major component, soldered on the flat portion of the connector; (B) providing a glass substrate layer over which a conductive layer, including an electrically conductive wire pattern and a connecting terminal, is formed; (C) sandwiching the block between the flat portion of the connector and the connecting terminal of the conductive layer, and then melting the block to form a solder connection between the connector and the connecting terminal; wherein the amount of the lead-free solder is between 4 mg and 13 mg.