Aptiv Technologies Limited

Delphi Technologies, Inc.

Gerald A Rhinehart, Jr

David R Peterson

Jared Bilas

John R Morello

George Albert Drew

Kurt Paul Seifert

John Thomas Kightlinger

Christopher G Reider

Doyeon Y Sohn

Therese G Stevens

James M Rainey

Bao Q Le

Robert J Seidler

Scott P Cohen

Eric James Smoll

William G Strang

Joon Lee

Thomas Gilbert Morello

An apparatus includes an extruding device configured to dispense a dielectric material though an orifice, a wire feed device configured to feed a conductive wire through the orifice, and a cutting device configured to sever the wire. It also includes an electronic controller configured to control the extruding device, the wire feed device, and the cutting device. The electronic controller commands the extruding device to dispense the dielectric material though the orifice, the wire feed device to feed the wire through the orifice, and the cutting device to sever the wire, thereby forming a dielectric substrate encasing a plurality of wires. The electronic controller further commands the extruding device to form an opening defined in the substrate in which plurality of electrically conductive wires is exposed and a location feature on the substrate located with a positional tolerance less than or equal to 1 mm relative to the opening.

Apparatus and method for manufacturing assembly having multiple separated conductors embedded within a substrate

An electrical connector is presented herein. The electrical connector includes an insulator that is formed of a dielectric material and defines a cavity extending therethrough. The cavity has a plurality of cylindrical sections. A first cylindrical section of the plurality of cylindrical sections has a diameter that is larger than a diameter of adjoining second and third cylindrical sections of the plurality of cylindrical sections on each side of the first cylindrical section. The insulator is preferably formed using an additive manufacturing process, such as stereolithography, digital light processing, fused deposition modeling, fused filament fabrication, selective laser sintering, selecting heat sintering, multi-jet modeling, multi-jet fusion, electronic beam melting, laminated object manufacturing, or 3D printing.

Electrical connector assembly and method of manufacturing same using an additive manufacturing process

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

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.

An apparatus includes an electronic controller having a memory device and an extruding device connected to the electronic controller. The extruding device has a dispensing head configured to dispense a dielectric material though an orifice in the dispensing head as commanded by the electronic controller. A wire feed device is connected to the electronic controller and the extruding device and is configured to feed a conductive wire through the orifice as commanded by the electronic controller. A cutting device is connected to the electronic controller and the extruding device. The cutting device severs the wire after it is fed through the orifice as commanded by the electronic controller. An electromechanical device is connected to the electronic controller and to the extruding device. The electromechanical device is configured to move the extruding device, the wire feed device, and the cutting device within a 3D space as commanded by the electronic controller.

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 electrical connector assembly includes a connector body that is formed of a first dielectric material defining a terminal cavity configured to receive an electrical terminal. The connector body defines a chamber that is separate from the terminal cavity. The chamber contains a second dielectric material that has a lower dielectric constant property than the first dielectric material, such as air. The connector body may be formed by as additive manufacturing process, such as 3D printing, stereolithography, digital light processing, fused deposition modeling, fused filament fabrication, selective laser sintering, selecting heat sintering, multi-jet modeling, multi-jet fusion, electronic beam melting, and laminated object manufacturing.

Electrical connector with dielectric properties suitable for high speed data transmission

A method of producing engineered-components using an additive manufacturing process includes the steps of, providing a build-platform, forming a first engineered-component, forming support-structures, forming a second engineered-component, and removing the support-structures. The step of providing a build-platform includes providing a build-platform on which to form an engineered-component. The step of forming a first engineered-component includes depositing a first plurality of layers of a material onto the build-platform and solidifying the first plurality of layers. The step of forming support-structures includes forming a plurality of support-structures by depositing a second plurality of layers of the material onto the build-platform and solidifying the second plurality of layers. The step of forming a second engineered-component includes depositing a third plurality of layers of the material onto the plurality of support-structures and solidifying the third plurality of layers. The step of removing the support-structures includes removing the support-structures from the second engineered-component.

Method of producing a plurality of engineered-components using an additive manufacturing process

An electrical connector assembly includes a connector body having a plurality of terminal receiving cavities formed therein and a plurality of flexible retaining arms integrally formed with a cavity wall and projecting from the cavity wall into the terminal receiving cavity toward a centerline of the terminal receiving cavity. The retaining arm defining a lock surface extending from a first free end of the retaining arm in a direction toward the centerline of the terminal receiving cavity. The assembly also includes a plurality of terminals having an end configured to connect with a corresponding mating terminal and a second end configured to be secured to a wire. The end defines a lock edge. The terminal is received in the terminal receiving cavity such that the first lock surface and the second lock surface engages the lock edge, thereby inhibiting the terminal from being withdrawn from the terminal receiving cavity.

Electrical connector assembly

An electrical connector system including a first connector having a lock nib extending from a floor into a terminal cavity and a flexible member overlying the floor. The beam has two terminal hold down bumps extending into the terminal receiving cavity. The electrical connector system also includes a terminal having a lock edge. The terminal is received in the terminal cavity such that the hold down bumps engage a top surface of the terminal, applying a force that biases the terminal towards the rigid floor. The lock nib engages the lock edge, thereby preventing the terminal from being inadvertently withdrawn from the terminal cavity. A second connector defines a shroud into which a portion of the first connector is inserted, wherein the beam compressively contacts an inner surface of the second connector further increasing the force applied to the terminal. The connectors may be formed by an additive manufacturing process.

Electrical connector system with enhanced terminal retaining beam

An interior trim component configured for use in a vehicle including a housing formed of a dielectric material and an electrical conductor encased within the housing being surrounded by and in intimate contact with the dielectric material forming the housing. The electrical conductor defines two exposed contact points. An exterior surface of the housing has a desired trim color and desired trim texture. The trim component may be manufactured using a 3D printing process or an insert molding process.

Interior trim components with integrated electrical wiring

An electrical connector has terminals that are retained in terminal cavities of a connector body by rigid lock nibs that project into the terminal cavity from a rigid wall and rigid lock nibs that are attached to a flexible beam that is opposite the rigid wall and that project into the terminal cavity.

Growing community of inventors

Lordstown, OH, United States of America

Gerald A Rhinehart, Jr