A method for the production of an electric contact carrier includes producing a basic profile from a basic material. A contact material is applied on a contact accepting area of the basic profile. The contact material is formed into a contact of the contact carrier. Then, the contact carrier is removed from the basic material.

A wiring harness assembly is presented. The wiring harness assembly is formed by a method that includes the steps of crimping an electrical wire cable within a crimping feature of an electrical terminal having wire strands protruding from the crimping feature and fusing the wire strands of protruding portion, or wire brush so that the wire strands are in intimate contact, thereby eliminating voids between individual wire strands of the wire brush. The wires may be fused by laser welding, soldering, or brazing. The method may be especially beneficial for wire strands having an insulative oxide layer, such as aluminum. The bonding reduces the resistance between the wire strands due to insulating oxide layers on the surface of the wire strands and inhibiting of corrosion by eliminating inter-strand gaps where electrolytes in solution may enter and cause galvanic corrosion.

A method of making a stimulation lead includes attaching multiple segmented electrodes to a carrier. Each of the segmented electrodes has a curved form extending over an arc in the range of 10 to 345 degrees. The method further includes attaching conductors to the segmented electrodes; forming the carrier into a cylinder with segmented electrodes disposed within the cylinder; molding a lead body around the segmented electrodes disposed on the carrier; and removing at least a portion of the carrier to separate the segmented electrodes.

A method for the tension proof closing of the end of an energy cable in which an energy cable is used whose center axis containing the electrical transmission elements is surrounded by a tension proof reinforcement of metal wires. Initially, the reinforcement at the end of the energy cable is removed over a predetermined length. Subsequently, a pipe piece of metal, which tightly surrounds the end of the remaining reinforcement, is placed onto the end of the remaining reinforcement. Finally, a cup shaped tubular elongated sleeve of metal is pushed onto the end of the energy cable and is connected in a tension proof manner to the pipe piece which has, at its free end facing away from the pipe piece, a device suitable for mounting a tension element. In addition, a device manufactured by the method is proposed.

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.

A coaxial connector fore 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 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 fabrication process of a stepped circuit board comprises A) cutting a circuit board substrate, printing patterns on an inner layer of the circuit board substrate, stepped groove milling of the inner layer, washer milling a washer between the inner layer and an outer layer, brownification and lamination processing on the inner layer, and then drilling holes on an outer layer of the circuit board substrate; B) electroplating the entire circuit board substrate by depositing copper on the outer layer of the circuit board substrate with drilled holes; C) performing pattern transfer by means of through-hole plating of the drilled holes on the circuit board substrate processed by the copper depositing and the electroplating; D) after pattern transferring, grinding a shape of a connecting piece (SET) on the circuit board substrate after the electroplating; E) plugging the drilled holes to form plug holes and printing a solder mask and texts in a silk-screen manner after forming the plug holes; F) depositing nickel immersion gold on the entire circuit board substrate, then printing characters in a silk-screen manner, thereby forming the stepped circuit board; and G) testing and inspecting an electric performance and appearance of the stepped circuit board to fabricate a finished product of the stepped circuit board.

This invention relates to an electrical connection device on a plate-type or strip-type material (1, 1), which cannot be soldered or is difficult to solder or which is provided with a surface that cannot be soldered or is difficult to solder, having the following characteristics: A self-clinching bolt (5) is provided with a bolt head (7) that, relative to the bolt body (9) beneath, has a tapered cross section such that the bolt head (7) transitions, by way of a conical or shoulder-like sloping flank (11), into the bolt body (9) having an outer circumference (9) that has a diameter larger than that of the bolt head (7). The outer circumference (9) of the bolt body (9) is of smooth design, or is provided with a knurling (15). In the penetration area of the self-clinching bolt (5), the plate-type or strip-type material (1, 1) is provided with a non-flanged material edge (101). Within the material edge (101), the self-clinching bolt (5) is press-fit with a peripheral area of the bolt body (9) thereof, thus creating a force fit.