Systems and methods are provided for fixturing hairpins for joining by welding. A fixture system includes an outer structural ring fixed relative to an inner structural ring and mates with the component around its hairpin type conductor ends. Dielectric rings are disposed between conductor pairs. Clamp rings are disposed on opposite sides of the dielectric rings. One clamp ring and one dielectric ring define an opening receiving one conductor pair. Another clamp ring and another dielectric ring define another receiving another conductor pair. The clamp rings are movable toward one another to align and crowd the conductor pairs between the clamp rings and the dielectric rings prior to welding.

According to an embodiment, a method for manufacturing a safety busbar comprises placing a second conductor on each of two opposite ends of a first conductor, performing linear friction welding between the first conductor and the second conductor, and cutting the first conductor to a predetermined depth.

An electric wire arranging jig (40) has an electric wire arranging groove (16, 31, 41) configured to be inserted the electric wires. The electric wire arranging groove has a pair of arranging surfaces facing each other. The electric wire arranging groove is configured to have a cross-sectional shape, in a section perpendicular to a direction of the electric wires extending within the electric wire arranging groove, having a distance in a width direction of the electric wire arranging groove continuously narrowed from an insertion start portion for the electric wires toward a bottom portion of the electric wire arranging groove and the arranging surfaces each inclining from a vertical direction, at least in a part of a segment between the insertion start portion and the bottom portion.

Electrical connection console for a motor vehicle board net comprising a cable 2 with a metallic stranded conductor 4, and an electrical tap electrically and mechanically connected to the stranded conductor 4, characterized in that the tap is formed from a metallic sleeve 10, in that the sleeve 10 is connected to the stranded conductor 4 in a connection region 8 of the stranded conductor 4, and in that the sleeve 10 has a longitudinal extent in a longitudinal axis parallel to a longitudinal axis of the stranded conductor 4, in that the sleeve 10 has a recess 26 whose longitudinal axis runs transversely with respect to the longitudinal axis of the sleeve 10, and in that a contact sleeve 28 is arranged in the recess 26.

According to one aspect of the present invention, a silver nanowire mesh (Ag NW-mesh) electrode and a fabricating method thereof. The Ag NW-mesh electrode includes a flexible substrate; and a mesh pattern layer which is disposed on the flexible substrate and in which a plurality of first meal lines and a plurality of second metal lines are composed of Ag NWs and intersect each other in an orthogonal or diagonal direction to form a grid pattern, wherein the first metal lines and the second metal lines of the mesh pattern layer form an angle of 35 degrees to 55 degrees with respect to a bending direction.

A core-wire exposed portion in an electric wire and at least one pair of pressure-welding pieces made of an electroconductive material are included. The core-wire exposed portion is a portion is which a core wire composed of a plurality of element wires is exposed. The pair of pressure-welding pieces are provided with a core wire pressure-welding section in which pressure-welding end surfaces are disposed facing each other at a distance and Kate the core-wire exposed portion press-fitted between the pressure-welding end surfaces. The core wire pressure-welding section is formed as a section that brings all of the element wires in the core-wire exposed portion, between the pressure-welding end surfaces, into contact with either of the pressure-welding end surfaces while being in an aligned state.

Provided is a tape-shaped contact member including a tape-shaped contact material. At least one wire-shaped brazing material is bonded to the tape-shaped contact material, at least one projection including the brazing material and protruding from a surface of the contact material is formed in a cross-sectional shape, a diffusion region containing a metal component forming the brazing material is formed along an interface with the brazing material inside the contact material, and the diffusion region has a thickness of 2 μm or more and 10 μm or less. A chip-shaped contact component can be obtained by cutting the tape-shaped contact member to an arbitrary length. The present contact component is useful as a constituent member for a switching electrical contact, and capable of adapting to height reduction of the electrical contact. The present invention can also contribute to reduction of occurrence of poor bonding.

According to the present disclosure, the breakage of an exterior body due to rising deformation of an electrode terminal can be prevented. The manufacturing method herein disclosed includes the steps of: bringing a lower surface of a terminal connecting part into contact with a first terminal, and bringing an upper surface of the terminal connecting part into contact with a second terminal; interposing the terminal connecting part, the first terminal, and the second terminal between a horn and an anvil, and carrying out ultrasonic welding; and accommodating the electrode body into the exterior body. Such a manufacturing method is characterized in that a width dimension of the horn is longer than a width dimension of the second terminal, and a width dimension of the anvil is longer than the width dimension of the second terminal. This can prevent rising deformation of the electrode terminal, and can prevent breakage of the exterior body by the deformed electrode terminal.

A method of joining electrical connections together includes evaluating at least one weld joint between at least two substrates, determining a mismatch between the at least two substrates, and welding the at least two substrates together with a multi-step welding process. The multi-step welding process includes compensating for the mismatch between the at least two substrates by welding on both sides but not overlapping a joint line between the at least two substrate with a first welding step and increasing melt volume and penetration depth of a weld between the at least two substrates with a second welding step.

A system for transmitting power and current includes a power cable having stranded wires and an exposed end. The stranded wires are ultrasonically welded together. Ultrasonically welding the wires creates a bundle of wires at the exposed end that may be free from air pockets, reducing oxidation and improving the current path through the cable.