Patent ID: 7219423

Claim:
A manufacturing process for assembling a flexible electrical conductor having a flat multi-wire intermediate cable defined by one or more cable sections and having plugs at opposite ends thereof, the method comprising the steps of: providing a flat cable section having an outer insulative covering and internal parallel conductor wires which project outwardly of said covering; providing a supply of electrical terminals which are configured to be positioned within said plug and connect to a respective end of a respective one of said wires; providing at least one weld station comprising a pair of weld units configured to weld said terminals to said wire ends; operating said weld station to weld one said terminal to said respective wire end; incrementally displacing said cable section and welding further said terminals to another of said wires and repeating said displacement and welding process to weld one said terminal to each of said wire ends; and positioning said cable section and said attached terminals within a housing of said plug and fixedly securing said housing to said cable section with said terminals disposed in side by side relation within said plug for engagement with a current-carrying electrical component.