Gm Global Technolgoy Operations, Inc.

Delphi Technologies, Inc.

Delco Electronics Corporation

Jeffrey Michael Hickox

Joseph Howard Gladd

Andrew Frank Rodondi

Sean Michael Kelly

Richard Louis Kidd

Raymond J Blasko

William C Ketterer

Robert Alan McFall

Paul Di Liello

George W Powell, Jr

Gary R Thompson

Thomas Alan Lubert

William Shane Murphy

A wireless power transfer system that transmits electrical power from an electrical power supply to an electrical load using a source transducer and a capture transducer. The wireless power transfer system may be part of a wireless charging system for an electric vehicle. The source resonator coil in the source transducer and the capture resonator coil in the capture transducer are substantially identical and are interchangeable. The structures that hold the resonators in the transducers and the plates that provide a ground plane for the resonators in the source transducer and the capture transducer are also substantially identical and are interchangeable. Each resonator is formed of a carrier-winder, or bobbin, that has two substantially identical and interchangeable halves enclosing a magnetic core and is wound with a wire coil.

Wireless power transfer system transducers having interchangeable source resonator and capture resonator

A non-contact charging device for charging a battery in a vehicle includes a source resonator, and a foreign object detector. The source resonator is configured to transfer electrical energy to a capture resonator in a vehicle. The foreign object detector is configured to detect a foreign object proximate to the source resonator. The foreign object detector includes a vertical antenna configured to detect a foreign object above the source resonator, and a horizontal antenna configured to detect a foreign object beside the source resonator.

Foreign object detector for non-contact charging device

A source resonator includes a housing having a convex shape. The source resonator is associated with a vehicular electrical charging system used to electrically charge an energy storage device disposed on a vehicle. The source resonator is adapted for attachment to a ground surface with the convex shaped cover extending outwardly away therefrom. The convex shaped cover of the source resonator, when disposed beneath an undercarriage of a vehicle, fills a space intermediate the source resonator and the undercarriage of the vehicle such that animals, such as a dog or a cat, are discouraged from overlyingly residing thereon. External surface segments of the convex shaped cover depend or slope away from a peak point of the convex shaped cover so that foreign objects, like a soda can or a tool that engage the convex shaped cover, may passively slide off of the housing to ensure optimal performance of the source resonator.

Wireless electrical charging system resonator housing

An animal deterrent device (ADD) includes a non-yielding base containing an array of animal deterring elements extending outwardly away therefrom. The base of the ADD is configured for deployment on at least one external surface of a transducer associated with a electrical charging system (ECS) used to electrically charge an energy storage device (ESD) on a vehicle. An array of animal deterring elements are respectively spaced apart a sufficient distance one-to-another and have respective heights so as to fill a space so that animals, such as a dog or a cat, are discouraged from residing on, or adjacent to at least one external surface of the transducer when the transducer that includes the ADD is disposed within a ground clearance of the vehicle. A method of using the ADD is also presented that includes a step of the ADD being formed in a mold in a single molding operation.

Animal deterrent device for electrical charging system

An electrical coil assembly includes a first housing and a second housing that surroundingly encloses the first housing. The coil assembly includes a ferrite layer and a thermally-conductive silicone layer that overlies the ferrite layer. A wire conductor surrounds the first housing. A structure is received in an opening defined in the first housing to be in thermal communication with the thermally-conductive silicone layer. Another thermally-conductive silicone layer overlies the first housing and the structure so that the structure is also in thermal communication therewith. A metal layer further overlies the thermally-conductive silicone layer that overlies the first housing. The second housing includes a non-dielectric cover and a dielectric cavity portion that receives the first housing. The coil assembly is associated with an electrical charging system that electrically charges an energy storage device disposed on a motorized vehicle.

Electrical coil assembly including a ferrite layer and a thermally-conductive silicone layer

An insulated electric wire having a conductive core and an insulation jacket is center stripped by cutting a pattern in one side of the insulation jacket with a laser beam, and then cutting a coordinated pattern in an opposite side of the insulation jacket with a laser beam to produce two axially spaced circumferential cuts connected by a plurality of generally axial cuts that define at least two removeable insulation slugs for exposing the conductive core while the insulation jacket on either side of the exposed conductive core is left intact. An in-line center stripping device or a multiple wire rotation device may be used for center stripping the insulated electric wire. The insulated slugs may by removed by an insulation removal device on an offal removal assembly.

Electric wire insulation center stripping method and device

A terminal for a coaxial cable includes an electrically conductive core mounted in a dielectric member. The dielectric member along with the conductive core are positioned within an electrically conductive ground shield. The ground shield includes two identical split-barrel housing members which are joined together. When joined, the housing members form a cylindrical channel having surfaces which intimately contact an exposed length of cable outer conductor layer, creating a conductive connection between the outer conductor layer and the ground shield and structurally maintaining the outer conductor layer concentric to the dielectric sheath and inner conductor of the cable.

Terminal assembly for a coaxial cable

An environmentally protected (sealed) BEC ( ) at the upper and lower housing seams ( ) and at each of the connector receptacle ( ). A lower housing ( ) of the BEC is formed conventionally, as for example by plastic injection molding and may carry a printed circuit board (PCB) ( ), a spacer plate ( ) and an electrical assemblage ( ) including upstanding blade terminals ( ). An upper housing ( ) of the BEC is formed in two shots. Firstly, an upper housing body ( ) is formed by a plastic injection molding process using a first upper mold member ( ) mated to a lower mold member ( ). Next, the first upper mold member is removed, and a second upper mold member ( ) is mated to the lower mold member. A liquid injection molding process now injects a resilient seal (silicone) over all mating surfaces of the upper housing body, including the upper housing seam ( ) and each connector receptacle.

Method of making an upper housing for a bussed electrical center

An electrical distribution center including a printed circuit board having electronic components thereon and a first and second through hole formed in the print circuit board. A terminal is provided which may be a female tuning fork, male blade or blank for insertion in the first through hole. A solderable spring tab is stamped, bent and formed from the body the terminal. The solderable spring tab is inserted in the second through hole. The solderable spring tab compensates for movement of components due to the difference in thermal expansion of the printed circuit board, solder joint, and terminal material.

Printed circuit board with pass through bussed terminal system for a

A connector mechanical assist system incorporating a mating tool and a connector configured for being squeezably interfaced with the mating tool. The connector is composed of first and second components having a conventional interlock mechanism, wherein a passage is provided in each of the first and second components which align when the first and second components are initially mated to form a passageway through the connector. The mating tool is composed of a head and two blades pivotally mounted on a common pivot in a cammed and slidable relation to the head. The blades have opposingly oriented hooks at the distal end portions thereof, wherein the hooks are retracted when the blades are mutually parallel. Each blade has a cam surface which interfaces with a respective boss of the head. With the connector pre-staged and the blades parallel, the blades are inserted through the passageway of the connector so that the distal end portions project therefrom at an exit side of the connector. Next, the blades are rearwardly drawn in relation to the head, whereupon the blades mutually cross and the hooks become opposingly exposed so as to contact the connector. Further rearward movement of the blades results in a mating force being applied which forces the first and second components into full mating.

Connector mechanical assist system

An electrical connector includes a molded plastic connector body, a flexible printed circuit, a plurality of plastic cable trays, an elastomeric pad and a molded plastic cap. The flexible printed circuit includes a main section and two side sections that are attached to respective longitudinal sides of the main section by flexible webs. A plastic cable tray is attached at a rearward end of each section. Thin copper conductors are arrayed in the flexible printed circuit so that each copper conductor is attached to a raised feature pressure contact in a forward contact portion of the main section of the flexible printed circuit at one end and disposed in a cable channel of one of the plastic cable trays at the other end. Electric cable ends are secured in the cable channels and electrically connected to exposed contact pads of the copper conductors. A first side section is folded over the main section with its cable tray stacked on the top of the cable tray of the main section. The second side section is folded over the first side section with its plastic tray stacked on top of the plastic tray of the first side section. The folded subassembly is disposed in the connector body with the forward contact portion of the main section folded over the elastomeric pad which lies against the front wall of the connector body. The plastic cap is attached to the front of the connector body with the raised feature pressure contacts exposed in an opening in the face of the cap.

Fold flex electrical connector

An integrated BEDC and PCB provided through a low cost, highly reliable interconnect system. The upper and/or lower half of the main insulation assembly of a BEDC is provided with a recess for accommodating at least an edge portion of the substrate of a PCB. The PCB is provided with apertures such as holes for receiving therethrough a buss wire and/or terminal slots through which terminals having wire slots are fixedly staked. The apertures on the PCB are arranged in a predetermined pattern so as to align with corresponding respective apertures in the form of corresponding holes and/or terminal slots on the BEDC at the recess thereof. Accordingly, with the PCB seated in the recess, as the buss wires are laid, they will pass through the holes in the PCB and/or pass through the wire slot of the terminals and thereby provide interconnection therebetween when the two halves of the main insulation assembly are united and the PCB is sandwiched therebetween.

Interconnect system for intergrating a bussed electrical distribution

The invention includes an electrical connection system utilizing a terminal/cavity combination. The system includes a connector housing having a bay for receiving a plurality of the terminal/cavity combination units in a stacked relationship. The terminal/cavity combination unit includes a metal terminal, preferably having a tuning fork configuration, that is received in an electrically insulative carrier. The insulative carrier has a terminal cavity defined in part by two spaced apart side walls and a floor extending between the side walls for supporting the terminal. The carrier also includes a front wall having an opening for receiving a portion of a second terminal therethrough and so that the second terminal makes electrical contact with the terminal in the carrier. At least one indexing rail extends downwardly from a portion of the floor. Carriers can be stacked one on top of the other wherein the rail or rails are received between the two spaced apart walls of the carrier below. A plurality of terminal/cavity combination units in the stacked relationship are then inserted into the bay of the connector housing. Simple mating lock features on the terminal/cavity combination unit and the housing keep the units in place.

Connection system with terminal/cavity combination

A tuning fork according to the present invention is made from a relatively thin blank of stamping stock. A plurality of tuning fork units are stamped out of the blank and carried on a continuous strip for further processing. The tuning fork units include integral first and second terminal portions with a first arm extending therebetween. The first terminal portion includes a first core body having first and second spaced apart contact beams extending from one end and a cable mounting portion extending from the other end of the first core body. Likewise, the second terminal portion includes a second core body and third and fourth spaced apart contact beams extending from one end, and preferably a tail extending from the other end of the second core body. The first arm is bent so that the second core body overlies the first core body and the contact beams of the second terminal portion overlie the contact beams of the first terminal portion. The four contact beams are positioned to provide a slot between the contact beams for receiving a portion of another terminal.

Tuning fork inline connection system

The invention includes a product and process involving a routed wire plate subassembly designed to utilize conventional routing of wire onto the subassembly and thereafter allows for bending of the subassembly to accommodate packaging needs. The end product can be formed by providing first and second wire route plate sets pivotally connected together. Each plate set has at least a top surface with wire receiving channels and passages formed therein. Wire is deposited into the wire receiving channels and passages and at least one wire extends across a portion of the top surface of both sets of plates. Terminals are stitched into terminal slots formed through either or both of the plates so that the terminal makes connection to a selected wire as desired. Thereafter, one of the plates is pivoted with respect to the other to a final location that meets the packaging needs for the wire routed plate subassembly.

Growing community of inventors

Middlefield, OH, United States of America

Jeffrey Michael Hickox