Method for making an electrical connection

Abstract

A high density electrical termination assembly made by forming a terminal assembly including separate thermoplastic sections having confronting surfaces. An in-line array of conductor receiving slots open through the confronting surface of one of the sections and a plurality of elongate spaced apart energy directors project from and extending along the confronting surface of the other of the sections. Stacking within the grooves portions of the conductors to be connected are stacked within slots in the terminal section. The thermoplastic sections positioned in juxtaposed stacked relationship to each other along the confronting surfaces with the energy directors extending across the slots in axially transverse relationship to the conductors stacked within the slots. Compressive force applied to the thermoplastic sections urge the confronting surfaces toward engagement with each other and cause the energy directors to apply compressive force at axially spaced apart locations to the conductors stacked within the slots. High frequency vibratory energy applied to the sections while the sections are maintained under compression softens the thermoplastic energy directors and the thermoplastic surfaces engaged by the energy directors providing molten thermoplastic material at the interface between the sections. The application of high frequency vibratory energy cases while the sections are maintained under compression.