Patent ID: 8623226

Claim:
A method of making a shaped electrical conductor comprising: providing a first sheet of metal having a first thickness; applying a first thermoplastic adhesive pattern to a first surface of the first sheet; applying a second thermoplastic adhesive pattern to a second surface of the first sheet, the second pattern being fully justified with the applied first pattern; etching the first sheet to remove metal not covered by the thermoplastic adhesive patterns so that no metal bridges remain between disconnected coated portions of the first sheet; providing a second sheet of metal having a second thickness; applying a third thermoplastic adhesive pattern to a first surface of the second sheet; applying a fourth thermoplastic adhesive pattern to a second surface of the second sheet, the fourth pattern being fully justified with the applied third pattern; etching the second sheet to remove metal not covered by the thermoplastic adhesive patterns so that no metal bridges remain between disconnected coated portions of the second sheet; selecting a first contact region in the second adhesive pattern; selecting a second contact region in the third adhesive pattern; bonding the second and third adhesive patterns to each other at more than one point; and mating the first and second sheets so that the first contact region is in electrical contact with the second contact region.