Another Way to Crimp Two Jumper Wires?

Silver solder or spot weld.

You could try putting a non insulated bootlace and crimping it then feed that into the cricuit board for soldering. That would be my solution. Non insulated bootlace Ferrules come in various diameters available from Multicomp (DUCE0505 = 0.5mm, DUCE1010=1.0mm) through RS Components or Farnell.

Hope that helps.

Cherrs

Pez

If it is a flat type cable with 2 cores I would crimp a RJ 9 or 11 onto it(depending on current) available from Molex/ Amphinol etc. The pcb would also have to have a pairing receptacle to match. If the design is already finished i would seek other wire types to avoid tinsel(have had endless grief in the past with this) but flexibility might be of concern. Lastly if it is a MUST for the wire type, boot-lace ferrules and a mechanical strain relief to limit flexing at the joint.

hope this helps

I don't know if ths helps, the tinsel wire I had is home to a core to very thin strands of copper. A quick singe with a lighter, a clean and you could solder them. More a quick fix than a manufacturing solution.

Assuming you are using tinsel wire and not Chrismas tree tinsel, and depending on the base material the wire is made from, you may be able to solder it reliably. You can also do a patent search with the USPTO under patent #3696322. Also, NASA-STD-8739.4 is available on-line. It provides various options.

Thank you all for your answers, they are very helpful. I will make some research on these.

So many unknown variables to contend with...

My first choice would be to try an IDC connector on the tinsel directly. You might be able to bring the tinsel wire this way directly to a PC board that has the IDC mate. Mounting the interface PC board to a convenient stable surface could then provide the mechanical support for the tinsel wire and stranded wire. (An accidental tug of the stranded wire would pull on the mounted PC board and not the tinsel.) Better yet, get an IDC style D connector for the tinsel, and mount the connector to the stable surface.