Sonic welding is now being used to crimp wires, cables, flex circuits, and other products where gas-tight and moisture-resistant connections are needed. The Sonicrimp technique, developed by Methode Development Co. (www.methode.com/mdc/), is said to be the first that works with these products, using a combination of high pressure and sonic energy to complete the electrical connection. Problems—including solder bridging and silver migration—are eliminated with the Sonicrimp technique, which can even be used on flat flex cables often used in automotive applications.
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