An electrical terminal includes a planar base portion having a base portion outer surface, a base portion inner surface, and two securing tabs extending from an edge of the base portion. The electrical terminal also includes a planar attachment portion having an attachment portion outer surface, an attachment portion inner surface, and an attachment member extending from the attachment portion outer surface. The attachment member is configured to secure a wire cable to the electrical terminal. The base portion inner surface is arranged such that it is in contact with the attachment portion inner surface and the two securing tabs are bent over the attachment portion outer surface. The electrical terminal may be especially well suited for making an electrical connection to components disposed on a glass surface. A method for forming such a terminal is also presented.

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.

A connector of an electrical connection assembly includes terminals (20) corresponding respectively to wires (10) arranged in a wire arrangement direction, an insulating housing and connecting members (70) applied to the terminals (20). Each terminal (20) has a wire connection surface (27a). The connecting member (70) is made of solder and is fixed to the wire connection surface (27a) to electrically connect a conductor (12) of the wire (10) and the wire connection surface (27a). A surface of the connecting member (70) has a convex-concave shape including restricting portions (73, 74) for restricting displacement of the wire (10) with respect to the wire connection surface (27a) in the wire arrangement direction, thereby ensuring high connection reliability by stabilizing relative positions of the wires and terminals in the connector.

A method is provided for manufacturing an electrical connection assembly includes preparing a connector (CN) in which each terminal (20) has a conductor connection surface (27a) exposed from an insulating housing (30), bringing parts of conductors and the conductor connection surfaces (27a) corresponding thereto into contact and connecting both while tension is applied to a wiring material (10). The method further includes fixing the wiring material (10) to the insulating housing (30) by bringing the wiring material (10) and the insulating housing (30) into contact with each other at the fixing positions separated in the longitudinal direction of the wiring material (10) from the parts to be connected and solidifying the fixing portions (34) of the insulating housing (30) after melting the fixing portions at the fixing positions.

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.

The present disclosure relates to a process for integrally joining an electrical line to an electric contact part by means of a material bond. An exposed end of the line is inserted into a receiving sleeve of the contact part. Then a friction welding tool is rotated on an open end face of the receiving sleeve for the cohesive connection of the line end with the receiving sleeve. According to the disclosure, a powdery metal filler material is introduced into the receiving sleeve before rotation in such a way that the metal filler material is at least partially arranged between the line end and/or the receiving sleeve and the friction welding tool. Furthermore, the disclosure also concerns an electrical line arrangement which is manufactured with the aid of the metal filler material.

An electrical connection assembly and a connection method enable conductors of first and second wires (10A, 10B) to be connected by a simple structure. The electrical connection assembly has first and second wires (10A, 10B) and first and second terminals (20A, 20B) corresponding to the first and second wires (10A, 10B). First and second connecting members (70A, 70B) made of solder are fixed to wire connection surfaces (27a) of the first and second terminals (20A, 20B), and an insulating housing holds the terminals. The first connecting member (70A) includes a bulging portion (72A) bulging from the wire connection surface (27a) of the first terminal (20A) and to be connected electrically to the conductor of the second wire (10B).

A wire soldered structure includes a substrate including a main body, a first conducting layer disposed on the main body, and a through hole extending through the main body and the first conducting layer; a wire including a soldered portion that is disposed on the first conducting layer and that is adjacent to the through hole; and a solder disposed in the through hole; wherein the soldered portion of the wire is soldered to the first conducting layer of the substrate via the solder.

Provided is a joint of a copper terminal and an aluminum conductor. A copper terminal connecting member of the joint is connected to a conductive core of the aluminum conductor by means of a transition welding layer, and the joint can also be provided with a reinforcing welding layer. Further provided is a method for preparing the joint using plasma arc welding. According to the invention, the connection portion of the copper terminal with the aluminum conductor is filled with solder in a plasma arc welding manner, such that copper and aluminum are connected by means of the solder. Damage to an aluminum oxide layer during welding increases the conductivity and can also isolate the copper terminal and the aluminum conductor, thus preventing an electrochemical reaction between the copper and the aluminum.

An electrical connection assembly includes a connector (CN) and a wiring material with conductors. The connector (CN) includes terminals (20) and an insulating housing (30) having a terminal holding portion (32) for holding the wiring material (10) such that the conductors are connected to the respective terminals (20). Each terminal (20) includes a held portion (22) and an outward projecting portion (24) projecting out from a surface (32a) of the terminal holding portion (32). The outward projecting portion (24) includes a first projecting portion (26) projecting in a first direction and a second projecting portion (27) extending from the first projecting portion (26) in a second direction closer to a direction parallel to the surface of the terminal holding portion (32) than the first direction. An outer surface of the second projecting portion (27) has a conductor connection surface (27a) connectable to the conductor extending in the second direction.