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OE wire connection...how'd they do that?

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Old 11-11-2015, 10:20 AM
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Default OE wire connection...how'd they do that?

I have to replace the front brake light switch on my Dyna so I was getting everything ready. The right turn signal is connected to the orange/white wire on the brake light switch. When I pulled the shrink tub off the connection this is what I found. Pretty slick, anyone know how it's done?

 
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Old 11-11-2015, 10:24 AM
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Looks like an Ultrasonic Weld.
 
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Old 11-11-2015, 10:26 AM
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Or maybe crimped with the aid of some adhesive?
 
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Old 11-11-2015, 10:34 AM
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I believe J929626 is correct, I just googled it. That is awesome!
 
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Old 11-11-2015, 10:48 AM
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Chinese school children work at Wire Concern #6 and braid stranded wires into harnesses for various products.
 
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Old 11-11-2015, 11:12 AM
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Originally Posted by Brewmany
Chinese school children work at Wire Concern #6 and braid stranded wires into harnesses for various products.
Nice try, but the wired are obviously not braided.
 
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Old 11-11-2015, 11:38 AM
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I was gonna guess that two underwear gnomes held the wires together and a unicorn farted on it.
That ultrasonic thing sounds ridiculous.
 
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Old 11-11-2015, 02:38 PM
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Ultrasonics will weld soft metals. Twenty years ago I used to have to visit ATT Oklahoma City 5ESS/D4 Channel Bank plant and find where someone had placed an ultrasonic cleaning bath after PCB assembly and welded the relay contacts. Always the same story... "There are no ultrasonics on the assembly floor. QA allows no ultrasonics. Company policy forbids ultrasonics. Etc, etc, etc." Take the group out to the wave soldering machines and every time there was an ultrasonic bath. Everybody goes palms-up and looks sheepish. They never learned...
 
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