Patent ID: 6064026
Filing Date: 2000-05-16
Classification: B23K,H01R

Abstract:
A method for producing an electrical bond between a contact element of an electrical connector and a conductor, the contact element having a portion that is bifurcated such that the conductor is positioned between the furcations, the method comprising the steps of:(a) providing a system comprising a power source and a weld head, the weld head having a first input and a second input for connection to a first polarity output and a second polarity output, respectively, of the power source, the system further including first and second electrodes movably attached to the weld head and electrically connected to the first and second inputs, respectively;(b) positioning the electrodes on the weld head to create a space between the electrodes that is sized for receiving both furcations of each contact element;(c) moving the weld head toward the furcations to effect contact between the first electrode and one of the furcations and between the second electrode and the other furcation, the contact being made at a predetermined force that causes the furcations to bend toward each other; and(d) allowing a current of a predetermined magnitude to flow through (i) the first input, (ii) the first electrode, (iii) the furcation in contact with the first electrode, (iv) the conductor, (v) the furcation in contact with the second electrode, (vi) the second electrode and (vii) the second input.