Induction welding method for termining FFC / pfc cable to variable terminals

Abstract

A method of attaching a flat flexible cable (FFC) (10) to a plurality of terminals (180) of an electrical connector (140) includes the step of arranging the plurality of terminals (180) within a connector housing (140, 141), where each terminal defines a solder region (182) adapted to be electrically connected to a conductor (12) of the FFC (10). The FFC (10) is then positioned proximate to the connector housing (140, 141) such that the solder region (182) of each terminal (180) is disposed directly adjacent to a respective one of the plurality of exposed conductors (12) of the FFC (10). At least the solder region (182) of the plurality of terminals (180) is heated with an induction heating source (270) for electrically connecting the plurality of conductors (12) of the FFC (10) to the plurality of terminals (180).

Description

Technical Field

[0001] The subject matter of the present document relates to electrical connectors and, more particularly, to systems and methods for electrically connecting a flat flexible cable to conductive terminals of an electrical connector. Background Art

[0002] As will be appreciated by those skilled in the art, a flat flexible cable (FFC) or a printed flexible cable (PFC) is an electrical component composed of at least one conductor (e.g., a metal foil conductor) embedded within a thin flexible insulating tape. Flat flexible cables have gained popularity in many industries due to the advantages they offer over their conventional "round wire" counterparts. Specifically, in addition to having a smaller form factor and a lighter weight, FFCs are able to implement large circuit paths much more easily compared to round wire-based architectures. Accordingly, FFCs are implemented in many complex and / or high-capacity applications, including, for example, wire harnesses used in automotive manufacturing.

[0003] Key obstacles hindering the implementation of FFCs in these applications include the need to develop fast, robust, and low-resistance termination techniques that enable FFCs to mate with various components. A particular challenge includes reliably and effectively terminating the fragile conductors of an FFC to the conductive terminals of a connector. Existing methods include using laser or resistive heating techniques. However, laser heating is generally less reliable and difficult to implement. Similarly, resistive heating has proven relatively difficult to implement reliably, and furthermore, it is time-consuming and requires regular maintenance (e.g., replacing the heating tip). Current methods are also not suitable for the large-scale termination and / or automation desired by the industry.

[0004] Accordingly, improved methods for terminating FFC assemblies are desired. Summary of the Invention

[0005] In one embodiment of the present disclosure, a method of attaching a flat flexible cable (FFC) to a plurality of terminals of an electrical connector includes the step of arranging the plurality of terminals within a connector housing, wherein each terminal defines a soldering area adapted to be electrically connected to a conductor of the FFC. The FFC is positioned adjacent to the connector housing such that the soldering area of each terminal is arranged in direct adjacency to a respective one of the plurality of exposed conductors of the FFC. At least the soldering areas of the plurality of terminals are heated with an induction heating source to electrically connect the plurality of conductors of the FFC to the plurality of terminals. Brief Description of the Drawings

[0006] The present invention will now be described by way of example with reference to the accompanying drawings, in which:

[0007] Figure 1 is a side perspective view of an FFC connector assembly in a mated state for describing an embodiment of the present disclosure;

[0008] Figure 2 is a cross-sectional view of a connector assembly in an initial alignment state; Figure 1 of the connector assembly;

[0009] Figure 3 is a cross-sectional view of a connector assembly in a mated state; Figure 1 of the connector assembly;

[0010] Figure 4 is a bottom perspective view of a cable sub-assembly including an FFC and a cable reinforcement element mounted on the FFC;

[0011] Figure 5 is Figure 4 a front view of the cable sub-assembly;

[0012] Figure 6 is a bottom perspective view of a terminal used in the connector assembly of the foregoing figures;

[0013] Figure 7 is Figure 6 a bottom view of the terminal;

[0014] Figure 8 is Figure 7 a side view of the terminal;

[0015] Figure 9 is a partial side view of another terminal that can be used in embodiments of the present disclosure;

[0016] Figure 10 is a top view of a plug of a connector assembly into which a plurality of terminals are inserted;

[0017] Figure 11 is Figure 10 a bottom view of the plug;

[0018] Figure 12 is Figure 4 and Figure 5 a bottom perspective view of the cable sub-assembly including solder applied across exposed conductors of the FFC;

[0019] Figure 13 is including Figure 4 and 4 a side perspective view of a cable assembly of the cable sub-assembly in an initial mating position with the Figure 10 and 11 plug;

[0020] Figure 14 is Figure 13 a bottom view of the cable assembly illustrating a soldering operation or method for electrically connecting the FFC to a terminal of the connector;

[0021] Figure 15 is a side view showing a welding operation performed by a system according to an embodiment of the present disclosure;

[0022] Figure 16 is a diagram of an exemplary system that can be used to perform the welding operations described herein; and

[0023] Figure 17 is a cross-sectional view of a connector according to another embodiment of the present disclosure, which utilizes graphite fingers to improve induction welding of its terminals. Specific Embodiments

[0024] Exemplary embodiments of the present disclosure will be described in detail below with reference to the accompanying drawings, where like reference numerals represent like elements. However, the present disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the concept of the present disclosure to those skilled in the art.

[0025] In the following detailed description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the disclosed embodiments. However, it will be apparent that one or more embodiments may be practiced without these specific details. In other instances, well-known structures and devices are shown schematically in order to simplify the drawings.

[0026] Referring to Figures 1 to 3 , an exemplary FFC connector assembly 100 that can be used to describe a termination method according to an embodiment of the present disclosure is shown. The connector assembly 100 includes a flexible flat cable (FFC) 10, a cable reinforcement element or cable stiffener 120, a plug 140, and a header 160. The assembly 100 is adapted to electrically connect the FFC 10 to a substrate 11, such as a printed circuit board (PCB). Figure 1 and Figure 3 shows the connector assembly 100 in a fully mated state, where a cable assembly 101 including the FFC 10, the reinforcement element 120, and the plug 140 is mated with the header 160. In Figure 2 , the assembly 100 is in an initial alignment or partial mating position, where the reinforcement element 120 and the plug 140 have not yet been mated or electrically engaged with the header 160. As shown, the cable assembly 101 is inserted into the front opening of the header 160. In this way, the assembly 100 includes a so-called "front-loading" connector system.

[0027] As Figure 2As further shown, a plurality of conductive terminals 180 are held within the plug 140 and are electrically connected to the corresponding plurality of conductors 12 of the FFC 10 via, for example, a soldering process according to an embodiment of the present disclosure. As the plug 140 is inserted into the header 160, each terminal 180 may also be connected to a corresponding one of a plurality of conductive header tabs or contacts 190 disposed on or within the header 160, as Figure 3 shown. The ends of each header tab 190 are exposed through the bottom of the header 160 such that they may be electrically connected to a substrate or PCB 11 (e.g., via soldering (soft soldering or welding) to conductive traces or pads formed thereon).

[0028] Now referring to Figure 4 and Figure 5 , a cable reinforcement or strengthening element 120 is adapted to structurally support the FFC 10 and to securely fasten the FFC 10 to the plug 140. The strengthening element 120 defines a slotted opening 122 sized to receive the FFC 10 therethrough, a pair of guiding protrusions 124, and a pair of latching arms 126. In one embodiment, the FFC 10 is fixed to the strengthening element in an initial step of a termination or assembly method (e.g., an adhesive is applied between the FFC 10 and the strengthening element). The guiding protrusions 124 and the latching arms 126 are disposed on opposite lateral sides of the strengthening element 120. The guiding protrusions 124 are adapted to guide the cable assembly as the cable assembly mates with the header 160. The latching arms 126 are adapted to fix or attach the cable strengthening element 120 to the plug 140, as Figure 13 and Figure 14 shown. Referring to Figure 5 , the strengthening element 120 may also include a soldering window 121 formed through the strengthening element 120 (one exemplary window is shown) to facilitate soldering (welding or soft soldering) of the FFC 10 and the terminals 180 from the top side of the cable assembly 101.

[0029] Still referring to Figure 4 and Figure 5 , the conductors 12 of the exemplary FFC 10 are embedded within an insulating material 14. The conductors 12 may include metal sheets or foils, such as copper foils, and may be patterned in any desired configuration. The insulating material 14 (such as a polymeric insulating material) may be applied to either side of the conductors 12 via an adhesive, thereby creating an embedded conductor arrangement. The insulating material 14 may be selectively removed or initially not applied in regions where the conductors 12 are desired to be exposed, such as in a window 165 defined on the underside of the exemplary FFC 10 shown. The exposed portions of each conductor 12 are then connected (e.g., soldered) to the corresponding terminals 180 held within the plug 140, as more fully elaborated herein.

[0030] Figures 6 - 8Exemplary terminal 180 is shown in more detail. Terminal 180 defines a central slot or opening adapted to slidably receive a header contact 190 therein along an insertion direction I. The opening includes a front end or front opening 188 and a slotted contact region 181 in communication therewith. Terminal 180 further defines a welding region 182 adapted to be electrically connected to the exposed conductor 12 of the FFC 10 via welding (fusion welding or soldering). More specifically, terminal 180 may include a generally inverted U-shaped cross-section including a top wall 183 and two generally parallel side walls 184 (or spring elements) extending perpendicularly from the top wall. The welding region 182 includes a generally planar or flat surface defined on the top wall 183. As Figure 8 shown, the region directly below the welding region 182 defines a void space 185.

[0031] In an exemplary embodiment, one of the side walls 184 defines an integral bracket or support 187 that extends across the central opening and engages the other of the side walls 184. More specifically, the bracket 187 may bend across the slotted opening or contact region 181 defined between the side walls 184 on the bottom side of the terminal 180 opposite the top wall 183. The bracket 187 may engage or be received by a corresponding recess 189 formed in the other of the side walls 184 such that its free end is opposite the side wall 184 in a direction perpendicular to the longitudinal axis of the contact region 181. Thus, as the header contact 190 is inserted into the slotted contact region 181, the bracket 187 is adapted to prevent the slotted contact region 181 from over-expanding or opening. This ensures sufficient and consistent electrical contact force between the terminal 180 and the header contact 190.

[0032] As can be seen from the figure, terminal 180 can be formed by a combination of sheet metal forming operations (such as stamping and bending). Stamping finally defines the regions of the side walls 184 adjacent to the welding region 182 for effectively widening the welding region. Similarly, stamping the region corresponding to the top wall 183 is used to form the slotted contact region 181. Each of the side walls 184 may be bent or curved inwardly toward the central axis of the terminal in the contact region 181 to apply sufficient elastic tension or normal force on the inserted header piece 190. In some embodiments, the side walls 184 define inwardly facing, opposing raised contact protrusions 186 adapted to provide further engagement force on the header piece 190. In any embodiment, the terminal 180 and the contact region 181 are adapted to generate sufficient normal force to effectively work with the tin or silver plating on the mating terminal. In still some other embodiments, welding (soldering or fusion welding) may also be used to connect the terminal 180 to the corresponding FFC conductor 12 without departing from the scope of the present disclosure. It should be understood that the separation between the side walls 184 ensures that no thermal stress relaxation occurs during the welding (soldering or fusion welding) operation performed on the terminal 180.

[0033] Figure 9 shows another terminal 190 that can be used in a plug or connector assembly according to an embodiment of the present disclosure. As shown, the terminal 190 includes a flat welding (soldering or fusion welding) area 192 formed near its first end, and a contact area 191 (e.g., a concave contact area adapted to receive a pin terminal) on its second end. It should be understood that the embodiments of the present disclosure are not limited to Figures 6 - 9 the two types of terminals shown in

[0034] Figure 10 and Figure 11 shows a plug 140 into which an exemplary terminal 180 is inserted. Specifically, as Figure 10 shown, the plug 140 includes a plug body 141 that defines a plurality of terminal openings 142. The terminal 180 is inserted into the opening 142 formed in the rear of the plug body along the insertion direction I'. Once the terminal 180 has been inserted, the slidable cover 144 can be translated from an open position (not shown) to the closed position shown, closing the opening 142 and fixing the terminal within the body 141. The plug body 141 is adapted to position each of the welding areas 182 of the terminal 180 in the same plane extending in the lateral direction.

[0035] The plug body 141 also defines elongated alignment protrusions or guides 149 formed on each of its lateral sides. The guides 149 are adapted to align the plug 140 relative to the header 160 and guide the plug 140 to be inserted therein along the insertion direction (see Figures 1 - 3 ). The guides 149 are also used to align the plug body 141 and the header 160 in the mated state. The plug body 141 also defines latch recesses 148 formed on each of its lateral sides. The recesses 148 are adapted to receive the latch arms 126 of the reinforcement element 120 and engage firmly with the latch arms 126 of the reinforcement element 120 for fixing the reinforcement element 120 (and the FFC 10) to the plug 140. In the fixed or latched position, the reinforcement element 120 is adapted to hold or position the conductors 12 of the FFC 10 in contact with the terminal 180 (e.g., its welding area 182).

[0036] Figure 10 The top wall of the plug body 141 shown defines a welding tab opening 152 through which the welding area 182 of the terminal 180 is exposed on the cable side of the plug 140. As Figure 11As shown, the bottom side of the plug 140 defines a plurality of windows 154, and the lower side of the soldering area 182 of the terminal 180 is exposed through the windows 154. The soldering area 182 can be heated through the windows 154 to solder (fusion weld or soft solder) the terminal 180 to the conductor 12 of the FFC10, for example. The plug body 141 further includes a plurality of slots 156 that are formed through the bottom wall of the plug body 141 and extend from the front end of the plug 140 in a direction opposite to the insertion direction I'. The slots 156 are adapted (e.g., sized, shaped, and positioned) to slidably receive the header contacts 190 passing therethrough during the mating of the plug 140 and the header 160.

[0037] Figure 12 A bottom perspective view of a cable sub - assembly in an intermediate step of a termination process according to an embodiment of the present disclosure is provided. Specifically, after the cable reinforcement element 120 has been attached to the FFC10 (e.g., as shown, glued to the FFC10 via an adhesive), solder 50 is applied to the exposed conductors 12 of the FFC10. The solder 50 can take the form of a solder foil or a solder paste (each with or without flux, e.g., a pre - fluxed foil or paste, or a foil or paste with separately dispensed flux). In other embodiments, the FFC10 can be provided with pre - applied solder, such as in the form of solder balls or solder pads.

[0038] In a particularly advantageous embodiment, the solder 50 is applied continuously and uniformly from one lateral side of the FFC10 to the other lateral side, or from the outer exposed conductors 12 of the FFC10 to the outer exposed conductors on the opposite side of the FFC. Compared to embodiments where solder is deposited only on the exposed conductors, this arrangement simplifies the solder application process (e.g., a single deposition of a solder foil strip or a solder paste). As will be elaborated in more detail herein, during the soldering operation, the soldering process according to an embodiment of the present disclosure is adapted to wick solder from between the conductors 12 of the FFC10 and from between the corresponding terminals (e.g., the terminal 180 to which it is to be soldered).

[0039] Now referring Figure 13 , a method for constructing a cable assembly 101 for a connector assembly 100 is provided. As Figure 13 shown, with the cable reinforcement element 120 fixed (e.g., via an adhesive) to the FFC10, the FFC and the reinforcement element are assembled into the plug 140. Specifically, from a separated position, the reinforcement element 120 is biased in the downward direction V such that the latch arms 126 engage with the recesses 148 of the plug body 141 in a snap - fit manner. Thus, the exposed conductors 12 of the FFC10 are positioned opposite or directly adjacent (e.g., adjacent) to the soldering areas 182 of the terminals 180. As Figure 14As shown, from the lower side of the plug 140, the conductors 12 and the terminals 180 are heated by an induction heating element through the window 154. In one embodiment, the target heating region A has a length of at least 3 mm in the axial direction of each terminal 180 and / or conductor 12.

[0040] Referring Figure 15 , the terminals 180 and the FFC 10 during a soldering operation are shown. Notably, for clarity, the connector plug 140 has been removed, and the terminals and the cable have been reversed from their orientation as described above. The melting of the solder 50 disposed between the conductors 12 of the FFC and the soldering regions 182 of each terminal 180 is achieved via at least one induction heating coil or induction coil 270. The exemplary coil 270 is disposed on the side of the terminal 180 opposite to the FFC 10 (i.e., disposed on the bottom side of the plug or terminal, as Figure 14 shown). The melted solder 50 transfers heat to the conductors 12 of the FFC 10 to produce a stable and fully wetted solder joint. For thicker conductors and / or unique terminal geometries, a second induction coil 270 can be disposed on the other side of the terminal 180 to heat the conductor as needed, thereby avoiding overheating the terminal. The surface tension and capillary action of the solder 50 pull the solder from between the terminal 180 and the conductor 12 and into each joint space. Additionally, during soldering, at least one of the plug 140 or the FFC 10 can be vibrated to facilitate the capillary action of the solder from between the terminals 180 and into the joint spaces. After the soldering cycle is completed, cold air can be blown to further ensure that the terminals are not heated to the point of stress relaxation. In other embodiments, cold air can be continuously blown even during the soldering operation to ensure that the front portion of the connector remains relatively cool.

[0041] Referring Figure 17 , in some embodiments, depending on the terminal geometry, graphite fingers can be used to direct or concentrate heat as needed during the induction soldering operation of the FFC 10. In an exemplary simplified embodiment, a connector 300 having a cover or housing 310 formed with an access opening 320 is shown. The access opening 320 can expose the soldering regions 382 of a plurality of terminals 380, as described above with respect to the previous embodiments. As will be understood by those of ordinary skill in the art, induction heating is caused by the flow of current within the workpiece. To achieve the same heating effect, graphite requires several orders of magnitude less current than, for example, copper. For this reason, using graphite fingers 330 positioned on the soldering regions 382 of the terminals 380 can increase the soldering efficiency and improve the targeting of the region to be heated. It should be understood that, Figure 17The connector 300 is a simplified representation to show the application of the graphite fingers 330. It should be understood that many other variations can be made to the illustrated embodiments. For example, the number of openings 320 exposing the terminals 380 and / or the FFC conductors can vary (e.g., there can be one such opening for each solder area 382 or each terminal 380). Similarly, while multiple graphite fingers 330 are shown, a single graphite element can be inserted into the openings 320. The graphite fingers 330 can also be present on either side of the connector 300 or used for any of the above connectors without departing from the scope of the present disclosure.

[0042] While the above embodiments of the present disclosure describe using induction welding techniques to join the FFC to the terminals, it should be understood that other forms of welding can be used with the terminals described herein. For example, resistance welding techniques or soldering can be utilized without departing from the present disclosure. As will be understood by those of ordinary skill in the art, such techniques will require access to each side of the joint and the application of a fusible joining alloy between the elements to be joined (i.e., the terminal and the FFC conductor). Similarly, other techniques such as laser welding (e.g., so-called "blue" laser welding) can offer distinct advantages over other welding techniques in terms of speed and precision and generally result in very small spot sizes and low solder usage.

[0043] The welding method according to an embodiment of the present disclosure can be performed in whole or in part by one or more automated control systems that implement and / or control a welding system or machine, as well as additional hardware and software features. For example, generally referring to Figure 16 , an exemplary control system 200 of a welding system or machine 202 that can be used to perform the operations of an embodiment of the present disclosure is shown. The control system 200 can be under full automatic control or controlled fully or in part via one or more user input devices 205 (e.g., touch screen / buttons / keyboard, etc.). The control system 200 includes at least one processor 210, such as a digital microprocessor responsive to instructions stored on a memory device 220, for performing the methods or operations described herein. The processor 210 is operatively coupled to the induction coil 270 and / or its power source for selectively powering the coil under voltage and / or current control. The system 200 can also include a current and / or frequency monitor or sensor 230, which can operate with the processor 210 to monitor and / or control the frequency and current in or through the induction coil 270.

[0044] System 200, and more specifically processor 210, can control the operation of the feed wheels, vibration generator, and / or blower 260 of machine 202 for selectively feeding a cable through the machine, vibrating the cable and connector assembly during welding, and cooling the joint. Similarly, control system 200 can include one or more actuators 240 (e.g., linear actuators) operatively attached to induction coil 270 for selectively moving the coil relative to the connector assembly being welded. In one embodiment, one or more actuators 240 can be multi-directional, capable of not only changing the longitudinal position of induction coil 270 along the length of the connector assembly, but also changing the radial or lateral distance between the connector assembly and the induction coil, further enhancing the ability to accurately control heat generation in a predetermined area of the assembly.

[0045] Control system 200 also includes temperature sensing means and / or imaging means, such as a thermal imaging device, and more specifically, by way of example only, an infrared (IR) temperature sensor and / or camera 250. In other embodiments, control system 200 can include separate temperature sensing means and imaging means. Additionally, without departing from the scope of the present disclosure, imaging device 250 can be optical, such as a digital camera or video capture device. Thermal imaging device 250 can be mounted to induction coil 270, or to another part of machine 202 suitable for achieving the desired operation. As shown, each component of control system 200 and / or machine 202 can communicate via a shared power / force / data bus 215.

[0046] Control system 200 (including processor 210 operating with associated instructions pre-stored on memory device 220) enables several additional operating modes of the operation modes described above with respect to the foregoing figures. By way of example, using current and / or frequency monitor 230 and predetermined values stored on memory device 220, processor 210 is operable to determine or estimate characteristics such as the size of FFC conductors and / or terminals, and automatically adjust various operating parameters based on that determination. System 200 can change the heating time, periodic cycle parameters, frequency, voltage, and / or current associated with the operation of induction coil 270 according to the detected characteristics for achieving optimal operation. These parameters can be pre-stored in memory device 220 such that when processor 210 determines the relevant characteristics of the connector and / or FFC layout structure, the function of coil 270 can be automatically controlled without additional user input.

[0047] According to an embodiment, power is supplied to the induction coil 270 for a specified amount of time based on the application. The frequency of the induction coil 270 can be varied to control the depth of heating. For example, a higher frequency allows control of the depth of induction heating such that the penetration of the induction heating is shallower. Conversely, a lower frequency allows the induction heating to penetrate deeper into the component to be welded.

Claims

1. A method of attaching a flat flexible cable (10), i.e., an FFC (10), to a plurality of terminals (180), comprising: Arranging a plurality of terminals (180) within a connector housing (140), each terminal (180) defining a soldering area (182) adapted to be electrically connected to a conductor (12) of the FFC (10); Positioning the FFC (10) adjacent to the connector housing (140) such that the soldering area (182) of each terminal (180) is arranged directly adjacent to a respective one of the plurality of exposed conductors (12) of the FFC (10); And Heating at least the soldering area (182) of each of the plurality of terminals (180) using an induction heating source (270) for electrically connecting the plurality of conductors (12) of the FFC (10) to the plurality of terminals (180).

2. The method according to claim 1 further comprises the following steps: Before positioning the FFC (10) adjacent to the connector housing (140), a strengthening element (120) is assembled to a side of the FFC (10) opposite to the plurality of exposed conductors (12).

3. The method according to claim 2 further comprises the following steps: Before the heating step, the strengthening element (120) is fixed to the connector housing (140) such that the exposed conductors (12) of the FFC (10) are aligned with the soldering area (182) of the terminals (180).

4. The method according to claim 3, wherein The connector housing (140) includes: A plurality of first openings (152) defined in a first side of the connector housing and exposing the soldering area (182) of each of the terminals (180); and A plurality of second openings (154) defined in a second side of the connector housing and exposing a lower side of each soldering area (182).

5. The method according to claim 4, wherein, The induction heating source (270) is arranged adjacent to the second side of the connector housing (140).

6. The method according to claim 5, wherein The heating step is also performed by a second induction heating source (270) arranged adjacent to the first side of the connector housing (140).

7. The method according to claim 6, wherein The strengthening element (120) includes a plurality of strengthening element openings (121) formed through the strengthening element (120) and adapted to be aligned with each of the plurality of conductors (12) of the FFC (10), and the second induction heating source (270) heats the soldering area (182) of the plurality of terminals (180) through the plurality of strengthening element openings (121).

8. The method according to claim 4, further comprising a plurality of third openings (156) defined in the second side of the housing (140) and exposing a contact area (181) of each of the terminals (180) for electrical engagement with a respective one of a plurality of contacts (190) of a complementary mating connector (160).

9. The method according to claim 1, wherein At least one of solder balls or solder pads (50) is formed on the exposed conductors (12) of the FFC (10).

10. The method according to claim 1 further comprises the following steps: Before the step of positioning the FFC (10), solder (50) is applied to the exposed conductors of the FFC (10).

11. The method according to claim 10, wherein, The step of applying the solder (50) includes applying a single continuous solder layer over the plurality of exposed conductors (12).

12. The method according to claim 11, wherein, Control the heating step such that the solder (50) is drawn from between adjacent ones of the plurality of exposed conductors (12) and the plurality of terminals (180).

13. The method according to claim 11, wherein, The step of applying the single continuous solder layer (50) includes applying a solder foil across the plurality of exposed conductors (12).

14. The method according to claim 11, wherein The step of applying the single continuous solder layer (50) includes applying a solder paste across the plurality of exposed conductors (12).

15. The method according to claim 1, further comprising the step of blowing air (260) onto at least one of the plurality of terminals (180) or the connector housing (140).

16. The method according to claim 1, further comprising the steps of: detecting the temperature (250) of the solder joint area (182) of at least one of the plurality of terminals (180); and controlling (210) at least one of the duration, current, or frequency of operation of the induction coil of the induction heating source (270).

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