Delphi Technologies, Inc.

Aptiv Technologies Limited

Gm Global Technolgoy Operations, Inc.

Aptiv Technologies Ag

George Albert Drew

David R Peterson

Thomas Hubert Van Steenkiste

Kurt Paul Seifert

Daniel William Gorkiewicz

John Thomas Kightlinger

Bryan A Gillispie

Yang-Tse Cheng

Jared Bilas

William J Palm

Gina Sacco

Bruce S Gump

Robert A Smith

Joseph Sudik, Jr

Nicholas A Durse

Gerald A Rhinehart, Jr

Therese G Stevens

Gerd Rudolph

Duane Lee Brantingham

Thomas J Schoepf

Doyeon Y Sohn

Christopher G Reider

John Robert Smith

Steven A Musick

Evangelia Rubino

Sean P Krompegel

Zachary J Richmond

Wen Jin Meng

Martin Stier

Eric B Poma

Neil R Aukland

Eric E Shasteen

Randall C Sumner

Kurt P Seifert

Mark David Baranski

Frank W O'Malia

Randall Sumner

Jonathon D Weidner

Robert A Suchanek

Mark S Ricketts

Gregory V Churley

Gerald A Rhinehart Jr

A high-voltage electrical cable assembly includes a central wire strand containing at least seven wires formed of a first alloy and a plurality of outer wire strands twisted around the central strand. At least one outer wire strand of the plurality of outer wire strands contains at least seven wires formed of a second alloy different from the first alloy. There is an electrochemical potential of about 2 volts between the first alloy and the second alloy. A method of assembling a high-voltage electrical cable assembly is also presented herein.

High-voltage electrical cable with mixed conductors

A method of manufacturing a wiring harness assembly includes the steps of forming a plurality of electrically conductive wires encased within a substrate formed of a dielectric material, forming an opening in the substrate located and sized such that a section of the plurality of electrically conductive wires is exposed within the opening, disposing a support segment within the opening, securing a connector segment including a plurality of terminals to the support segment, and placing the plurality of terminals in mechanical and electrical contact with the plurality of electrically conductive wires.

Wiring harness assembly having multiple separated conductors embedded within a substrate

An electrical connector for connecting to flat-wire conductors of a flexible circuit (FC) is described. The electrical connector includes an elongated body, a split-blade terminal, and a spring terminal. The elongated body has a longitudinal axis. The split-blade terminal has two prongs separated by a distance and is configured to interface with an electrical terminal of an electrical device. The spring terminal is configured to mate with one or more of the flat-wire conductors within a connection area of the FC. The spring terminal and the split-blade terminal are positioned on the longitudinal axis at opposing ends of the electrical connector.

Electrical connector for connecting to flat-wire conductors of a flexible printed circuit

A wiring harness assembly includes a plurality of electrically conductive wires encased within a substrate formed of a dielectric material, a location feature integrally formed with the substrate, and an opening defined in the substrate located within a predetermined tolerance relative to the location feature. A section of the plurality of electrically conductive wires is exposed within the opening.

A wiring harness assembly includes a plurality of separated conductors formed of an electrically conductive material, a substrate formed of a dielectric material encasing the plurality of separated conductors, a location feature integrally formed with the substrate and an opening defined in the substrate having a predetermined size and shape. A section of the plurality of separated conductors is exposed within the opening. The opening is precisely located relative to the location feature.

An attachment device includes a central body formed of a plastic material and defining a cavity configured to receive a temperature probe and a plurality of straps extending from the central body. Each strap of the plurality of straps is configured to secure a cable to the central body. The central body defines a wall having a first side configured to be in contact with the temperature probe and a second side in contact with a cable. This attachment device may notably be used in an electrical connection assembly having a connector, a temperature sensor disposed within the device, and at least two cables.

Electrically conductive carbon nanotube wire having a metallic coating and methods of forming same

A wire terminal assembly is disclosed for a cable conductive core of a first metal core. A conductive terminal of a second metal is connected to the conductive cable core along a conductive connection interface. A coating is disposed over the conductive connection interface. The coating includes the free radical addition polymerizate of a coating composition of: (1) an oligomer comprising at least two active unsaturated bonds, and (2) an acrylic monomer.

Sealed electric terminal assembly

An electrically-conducting contact element includes a section of the contact element defining an aperture. The section is configured to receive a wire cable within the aperture for attachment thereto. The section includes an internal surface with at least one groove having sharp edges formed therein. A wire assembly that includes the electrically-conducting contact and a method to construct the electrically-conducting contact are also presented. The method includes a step of providing the contact element and forming at least one cutout groove on the internal surface of the contact element. A further step in the method includes altering material on the internal surface of the contact element by a forming means. The forming means may be one of milling, rifling, machining, cutting, indenting, or stamping. A wire assembly and a vehicular electrical wiring harness that respectively include the contact element are also further presented.

Electrically-conducting contact element with an aperture with an internal surface having a groove with sharp edges

A cable assembly includes a terminal crimped to a conductor. The terminal has a plurality of crimps spaced from one another and a transition crimp disposed therebetween. A method includes deforming the terminal about the conductor to define the plurality of crimps having different crimp heights, and deforming the terminal about the conductor to define the transition crimp between each of the plurality of crimps. The transition crimp has a crimp height different than each of the plurality of crimps.

Multi-level electrical terminal crimp

A cable includes a plurality of cable strands, an insulator disposed on a portion of the plurality of strands such that the plurality of strands are at least partially exposed, and a sealant disposed between gaps of the plurality of strands and at least partially under the insulator. Moreover, a method includes stripping an insulator from an end of the cable to expose a plurality of cable strands, and applying a sealant to the cable strands such that the sealant is drawn under the insulator and fills in gaps between the cable strands by capillary action.

Sealed cable and terminal crimp

A connection mechanism includes a metal segment in mechanical and electrical communication with the remainder of the connection mechanism on at least one side. The segment includes at least one tab protruding from the segment on a first side and a central area of the segment with a plurality of metal deformations. When the metal deformations are pressed into aluminum, they are capable of piercing through corrosion on the surface of the aluminum in order to make electrical contact with the aluminum.

Electrical connection system for use on aluminum wires

Disclosed is a process for applying a kinetic spray coating of powder particles onto a substrate covered in a plastic-type material without first removing the plastic-type material. In one use of the process a mask is used to enable a single kinetic spray pass to both remove the plastic covering and bind particles having average nominal diameters of from 60 to 250 microns to the underlying substrate. In another use of the process the particles have an average nominal diameter of from 250 to 1400 microns and the use of a mask is optional because the particles can penetrate the plastic material and bind directly to the substrate. The process finds special use in forming electrical connections or solderable pads anywhere along the length of a flexible circuit.

Kinetic spray application of coatings onto covered materials

The present invention is directed to electrical contacts that comprise spaced electrically conductive particles embedded and bonded into the surface of conductors in which the particles have been kinetically sprayed onto the conductors with sufficient energy to form direct mechanical bonds between the particles and the conductors in a pre-selected location and particle number density that promotes high surface-to-surface contact and reduced contact resistance between the conductors.

Kinetic sprayed electrical contacts on conductive substrates

A contact structure for a sliding switch includes a conductive stationary contact disposed on a base and a conductive movable contact for electrically contacting the stationary contact. The movable contact is movable along a path between a non-contact position and a make-contact position with respect to the stationary contact, and at least one of the contacts has a protruding portion that provides an electrical interface for discharge of arcing as the movable contact breaks from the stationary contact. As a result, the invention prevents or substantially reduces degradation in switch performance which might otherwise be caused by debris accumulation associated with arcing.

Contact structures for sliding switches

A new kinetic spray process is disclosed that enables the coating to withstand severe bending and stress without delamination. The method includes use of a low pressure kinetic spray supersonic nozzle having a throat located between a converging region and a diverging region. A main gas temperature is raised to from 1000 to 1300 degrees Fahrenheit and the coating particles are directly injected into the diverging region of the nozzle at a point after the throat. The particles are entrained in the flow of the gas and accelerated to a velocity sufficient to result in partial melting of the particles upon impact on a substrate positioned opposite the nozzle and adherence of the particles to the substrate. The coating also has a desirable shinny surface. The method finds special application in coating substrates for use in formation of electrical connections.

Growing community of inventors

Warren, OH, United States of America

George Albert Drew