Ultrasonic metal welding is widely used in the industry in applications that involve softer and high conductivity alloys or metals like copper or aluminum. In this process the metals are joined by the application of high frequency vibrations, under moderate pressure, in which the vibrations are applied parallel to the interface between the parts. The high frequency relative motion between the parts forms a solid-state weld through progressive shearing and plastic deformation over the surface asperities that disperses oxides and contaminants and brings an increasing area of pure metal contact between adjacent surfaces. The biggest benefit of this technology is that addition materials are not needed. However, in the automotive industry, for applications that involve the ultrasonic welding of cables this is not completely true since after performing the welding a tape or a heat shrinking tube is needed in order to guarantee the performance of the ultrasonic welded splice. Moreover it has been seen that for small configurations, using small cross section cables, the performance of the splices is often under the expectations, causing problems of broken splices with loss of continuity.
Based on that a study was started to check the possibility of using a connector that replaces totally the welding and guarantee the demands on that matter. The connector is still being developed by 3D printing, but when compared with splice some benefits can be identified. Even considered a part that need to be purchased, its cost is significantly low when produced by injection molding, there is no need of adding tape or shrinking tube and corrosion is prevented by the sealant included on the connector.