# US 12,763,538 B1 · Systems, devices, and methods for wire harness manufacturing > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,763,538 B1 - Document ID: US12763538B1 - Status: Granted - Kind: B1 - Application number: 19/276,902 - Filed: 2025-07-22 - Granted: 2026-10-13 - Earliest claimed: 2025-07-22 - Assignees: Interconnect Wiring, L.L.P. - Applicants: InterConnect Wiring, L.L.P. - Inventors: Nam D. Tran; Michael Janney - Web page: https://patentgrep.com/patent/US12763538B1 ## CPC - H01R 43/0249: {for simultaneous welding or soldering of a plurality of wires to contact elements} - H01R 43/02: for soldered or welded connections - H01R: ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS ## Abstract A connector and wire connecting system may include an induction heater including an induction coil having a first terminal and a second terminal. The induction coil may be configured in a manner that an electric current flows through the induction coil from the first terminal to the second terminal, the electric current creating an electromagnetic field adjacent to the induction coil forming a heating zone. A wafer holder may be configured to support a multi-socket connector and a plurality of wires along a linear interface, each wire of the plurality of wires being independently connectable to a respective socket of the multi-socket connector, the interface being placeable within the heating zone. The induction coil may be disposed relative to the wafer holder and configured to heat the interface between the multi-socket connector and the plurality of wires within the heating zone. ## Claims ### Claim 1 A connector and wire connecting system, comprising: a work head movable relative to a wafer holder, the work head comprising: a first alignment structure secured in place on the work head and movable with the work head relative to the wafer holder; an induction heater comprising an induction coil having a first terminal and a second terminal, the induction coil having substantially parallel arms, the induction coil being fixed in a position relative to the first alignment structure when the work head is moved relative to the wafer holder, wherein the induction coil is configured in a manner that an electric current flows through the induction coil from the first terminal to the second terminal, the electric current creating an electromagnetic field adjacent to the induction coil forming a heating zone; and the wafer holder configured to directly secure a wafer connector and a plurality of wires in a row to define a linear interface, each wire of the plurality of wires being independently connectable to a respective pin of the wafer connector and being independently connectable to a respective sleeve assembly, the linear interface being placeable within the heating zone when the work head is moved relative to the wafer holder, the wafer holder comprising: a body comprising a wafer support surface directly below the wafer connector when the wafer connector is directly secured by the wafer holder; a wafer restraint configured to directly secure the wafer connector in position on the wafer support surface; a wire restraint configured to directly secure a portion of each wire of the plurality of wires in position relative to the body, the wire restraint spaced apart from the wafer restraint and at least a portion of the wire restraint being fixed in position relative to the wafer restraint; and a second alignment structure comprising a second shape physically engageable with the first shape of the first alignment structure to prevent relative displacement of the work head and the wafer holder in a plurality of directions while giving freedom of movement in another direction and to align the parallel arms of the induction coil at a position adjacent to only one side of the linear interface and substantially parallel to the linear interface, wherein the induction coil is disposed relative to the wafer holder and is configured to heat the linear interface between the wafer connector and the plurality of wires within the heating zone. ### Claim 2 (depends on 1) The connector and wire connecting system of claim 1, wherein the wafer holder comprises a plate configured to be angled at a first angle relative to horizontal, wherein when the electric current flows through the induction coil, at least one linear portion of the induction coil is configured to be angled at a second angle relative to horizontal, the second angle being substantially equal to the first angle. ### Claim 3 (depends on 1) The connector and wire connecting system of claim 1, wherein the induction heater comprises a lift assistance device, comprising: a first arm coupled to a base at a first joint; a second arm coupled to the first arm at a second joint; and a third arm coupled to the second arm at a third joint, and wherein movement of the second arm about the second joint and movement of the third arm about the third joint allow the induction coil to move freely in three dimensions. ### Claim 4 (depends on 1) The connector and wire connecting system of claim 1, wherein the induction coil comprises a U-shaped tube forming a distal end of the induction coil. ### Claim 5 (depends on 4) The connector and wire connecting system of claim 4, wherein the U-shaped tube comprises a length greater than a length of a wafer connector supported by the wafer holder. ### Claim 6 (depends on 1) The connector and wire connecting system of claim 1, wherein the wafer holder is configured in a manner that a connection point between each wire of the plurality of wires and the wafer connector is visible from above by a user when the wafer connector and the plurality of wires are directly secured by the wafer holder and wherein each wire of the plurality of wires is configured to be coupled to the wafer connector with the sleeve assembly, the sleeve assembly comprising a translucent tubing. ### Claim 7 (depends on 1) The connector and wire connecting system of claim 1, wherein the wafer holder is configured to allow accessibility of a user to each wire of the plurality of wires in a manner that each wire of the plurality of wires is configured to be coupled to the wafer connector with a sleeve assembly, the sleeve assembly comprising a solder ring comprising a first metal, wherein the wafer connector comprises an electrically conducting portion comprising a second metal, and wherein the first metal has a lower melting point than the second metal. ### Claim 8 (depends on 1) The connector and wire connecting system of claim 1, wherein the induction coil is selectively disposable adjacent the wires in manner that when the electric current flows through the induction coil, the induction coil is on a single side of the plurality of wires. ### Claim 9 (depends on 1) The connector and wire connecting system of claim 1, wherein the induction coil comprises at least one substantially linear portion spaced from the first terminal and the second terminal. ### Claim 10 A connector and wire connecting system, comprising: a work head movable relative to a wafer holder, the work head comprising: a first alignment structure secured in place on the work head and movable with the work head relative to the wafer holder; an induction heater comprising an induction coil having a first terminal and a second terminal, wherein the induction coil is configured in a manner that an electric current flows through the induction coil from the first terminal to the second terminal, the electric current creating an electromagnetic field adjacent to the induction coil forming a linearly extending heating zone adjacent to and not between the induction coil, the induction coil having substantially parallel arms, the induction coil being fixed in a position relative to the first alignment structure when the work head is moved relative to the wafer holder; a wafer connector with a plurality of wires along a linear interface, the linear interface being placeable within the heating zone, each wire of the plurality of wires being independently connectable to a respective pin of the wafer connector along a linear interface length, the heating zone having a linear length the same as or greater than the linear interface length; and the wafer holder configured to directly secure a wafer connector and a plurality of wires in a row to define a linear interface, each wire of the plurality of wires being independently connectable to a respective pin of the wafer connector and being independently connectable to a respective sleeve assembly, the linear interface being placeable within the heating zone when the work head is moved relative to the wafer holder, the wafer holder comprising: a body comprising a wafer support surface directly below the wafer connector when the wafer connector is directly secured by the wafer holder; a wafer restraint configured to directly secure the wafer connector in position on the wafer support surface; a wire restraint configured to directly secure a portion of each wire of the plurality of wires in position relative to the body, the wire restraint spaced apart from the wafer restraint and at least a portion of the wire restraint being fixed in position relative to the wafer restraint; and a second alignment structure comprising a second shape physically engageable with the first shape of the first alignment structure to prevent relative displacement of the work head and the wafer holder in a plurality of directions while giving freedom of movement in another direction and to align the parallel arms of the induction coil at a position adjacent to only one side of the linear interface and substantially parallel to the linear interface; and wherein the induction coil is disposed relative to the wafer connector and is configured to heat the linear interface between the wafer connector and the plurality of wires within the heating zone. ### Claim 11 (depends on 10) The connector and wire connecting system of claim 10, wherein the induction coil comprises at least two parallel arms disposed to generate a magnetic field extending along the linearly extending heating zone. ### Claim 12 A connector and wire connecting system, comprising: a work head movable relative to a wafer holder, the work head comprising: a first alignment structure secured in place on the work head and movable with the work head relative to the wafer holder; an induction heater comprising an induction coil having a first terminal and a second terminal, the induction coil having substantially parallel arms, the induction coil being fixed in a position relative to the first alignment structure when the work head is moved relative to the wafer holder, wherein the induction coil is configured in a manner that an electric current flows through the induction coil from the first terminal to the second terminal, the electric current creating an electromagnetic field adjacent to the induction coil forming a heating zone; and the wafer holder configured to directly secure a wafer connector and a plurality of wires in a row to define a linear interface, each wire of the plurality of wires being independently connectable to a respective pin of the wafer connector and being independently connectable to a respective sleeve assembly, the linear interface being placeable within the heating zone, the wafer holder comprising: a body comprising a plate, the plate directly below the wafer connector when the wafer connector is directly secured by the wafer holder; a clamp configured to directly secure the wafer connector in position on the wafer support surface; a wire holder configured to directly secure a portion of each wire of the plurality of wires in position relative to the body, the wire holder spaced apart from the plate and at least a portion of the wire holder being fixed in position of the wafer holder relative to the plate; and a second alignment structure comprising a second shape, the second shape of the second alignment structure configured to be physically engageable with the first shape of the first alignment structure to prevent relative displacement of the work head and the wafer holder in a plurality of directions while giving freedom of movement in another direction and to align the parallel arms of the induction coil at a position adjacent to only one side of the linear interface and substantially parallel to the linear interface; and wherein the induction coil is disposed relative to the wafer holder and is configured to heat the linear interface between the wafer connector and the plurality of wires within the heating zone. ### Claim 13 (depends on 12) The connector and wire connecting system of claim 12, wherein the wafer holder comprises a plate configured to be angled at a first angle relative to horizontal, wherein when the electric current flows through the induction coil, at least one linear portion of the induction coil is configured to be angled at a second angle relative to horizontal, the second angle being substantially equal to the first angle. ### Claim 14 (depends on 12) The connector and wire connecting system of claim 12, wherein the induction heater comprises a lift assistance device, comprising: a first arm coupled to a base at a first joint; a second arm coupled to the first arm at a second joint; and a third arm coupled to the second arm at a third joint, and wherein movement of the second arm about the second joint and movement of the third arm about the third joint allow the induction coil to move freely in three dimensions. ### Claim 15 (depends on 12) The connector and wire connecting system of claim 12, wherein the induction coil comprises a U-shaped tube forming a distal end of the induction coil. ### Claim 16 (depends on 15) The connector and wire connecting system of claim 15, wherein the U-shaped tube comprises a length greater than a length of a wafer connector supported by the wafer holder. ### Claim 17 (depends on 12) The connector and wire connecting system of claim 12, wherein the wafer holder is configured in a manner that a connection point between each wire of the plurality of wires and the wafer connector is visible from above by a user when the wafer connector and the plurality of wires are directly secured by the wafer holder and wherein each wire of the plurality of wires is configured to be coupled to the wafer connector with the sleeve assembly, the sleeve assembly comprising a translucent tubing. ### Claim 18 (depends on 12) The connector and wire connecting system of claim 12, wherein the wafer holder is configured to allow accessibility of a user to each wire of the plurality of wires in a manner that each wire of the plurality of wires is configured to be coupled to the wafer connector with a sleeve assembly, the sleeve assembly comprising a solder ring comprising a first metal, wherein the wafer connector comprises an electrically conducting portion comprising a second metal, and wherein the first metal has a lower melting point than the second metal. ### Claim 19 (depends on 12) The connector and wire connecting system of claim 12, wherein the induction coil is selectively disposable adjacent the wires in manner that when the electric current flows through the induction coil, the induction coil is on a single side of the plurality of wires. ### Claim 20 (depends on 12) The connector and wire connecting system of claim 12, wherein the induction coil comprises at least one substantially linear portion spaced from the first terminal and the second terminal. ### Claim 21 (depends on 1) The connector and wire connecting system of claim 1, wherein the attachment of the first alignment structure to the second alignment structure limits movement of the induction coil in at least one horizontal direction. ### Claim 22 (depends on 1) The connector and wire connecting system of claim 1, wherein the wafer restraint is a clamp and the wire restraint is a spring.