Patent ID: 8668506

Claim:
A method of manufacturing a charger receptacle, the charger receptacle configured to facilitate interconnecting a cordset having a first plurality of electrical terminals with a second plurality of electrical terminals of an electrical system, the charger receptacle having a barrel and a base, the barrel having a plurality of connection openings shaped to guide the first plurality of electrical terminals into an electrically conducting mating arrangement with the second plurality of electrical terminals of the electrical system and the based being configured to be mounted to the electrical system, the method comprising: frictionally heating an interface between the barrel and the base to a temperature sufficient to cause formation of a welded connection therebetween, wherein frictionally heating the interface is by one of spinning the barrel relative to the base and spinning the base relative to the barrel such that a first alignment feature on the barrel aligns with a second alignment feature on the base, such that the base and the barrel have a desired rotational alignment relative to each other.