Method of mounting electrical contacts in connector body

Claim 1

In a method of fixing an electrical contact into a connector body, said electrical contact having a first portion with a first major dimension, a second portion with a second major dimension, and a third portion extending from said second portion in a direction opposite to said first portion; said connector body having an aperture with a first section formed to receive said first portion of said electrical contact and a second section formed to receive said second portion of said contact; a boss surrounding said second section of said aperture and extending above a surface of said connector body whereby said second portion is positioned in a well, the steps comprising: inserting said electrical contact into said aperture with said first portion of said contact in said first section and said second portion in said second section; positioning said contact and connector body at a work station which includes an ultrasonic horn; causing relative movement between said connector body and said horn until said third portion of said contact engages a horn aperture in said horn and a depression surrounding said horn aperture engages said boss; and ultrasonically vibrating said horn to melt said boss and cause said melting material to flow into and substantially fill said well, thereby securing said contact.