Electrical connector and method of interconnecting flat power cables

A method of interconnecting two flat power cables each having at least one flat conductor therein, comprising the steps of:

• stacking selected sections of first and second flat cables one atop the other with the at least one conductor parallel with the at least one conductor of the other, said selected sections to be interconnected, and said parallel at least one conductors defining a corresponding at least one pair of conductors to be electrically interconnected;
• selecting at least one interconnecting structure assembly corresponding to each said at least one pair of conductors, each said assembly having an upper structure and a lower structure with said selected sections of said first and second cables disposed therebetween, each said assembly having a plurality of shearing wave shapes alternating with relief recesses along a cable-proximate surface of said upper structure and coextending transversely with said corresponding pair of conductors, and a cooperating plurality of shearing wave shapes and alternating relief recesses along a cable-proximate surface of said lower structure and coextending transversely with said corresponding pair of conductors, each said wave shape being opposed by a said relief recess, and said shearing wave shapes of said upper and lower structures having vertical shearing edges which cooperate upon being pressed together with said first and second cables therebetween to shear strips of said corresponding pair of conductors and create thus-sheared conductor edges;
• placing a said lower structure beneath said stacked cables extending transversely thereunder along a major surface of the lower one of said first and second cables, and placing a said upper structure atop said stacked cables extending transversely thereacross along a major surface of the upper one of said first and second cables and vertically aligned with said lower structure, with said wave shapes of each of said upper and lower structures vertically aligned with said relief recesses of the other thereof;
• and
• pressing said upper and lower interconnecting structures together, with said alternating wave shapes shearing said corresponding conductors and extruding thus-sheared strips of said conductors into opposed said relief recesses forming a series of interlocking wave joints transversely across said corresponding pair of conductors and moving said thus-sheared edges of said conductors adjacent electrical engagement surfaces of said upper and lower interconnecting structures defined by vertical side edges of adjacent ones of said wave shapes for electrical connection therewith.