Delphi Technologies, Inc.

Aptiv Technologies Limited

Gm Global Technolgoy Operations, Inc.

John Thomas Kightlinger

David R Peterson

George Albert Drew

Robert Alan McFall

John C McLane

Jared Bilas

Andrew Frank Rodondi

Kurt Paul Seifert

Gerald A Rhinehart, Jr

Nick M Loprire

James A Gourash

Therese G Stevens

Doyeon Y Sohn

Christopher G Reider

Edward M Bungo

Christopher Adrian Margrave

James D Daugherty

Don E Bizon

Michael L Mellott

Gina Sacco

Shao Chung Hsieh

Jeffrey M Handel

Theodore Raymond Schmidt

Mark J Vanden Wymelenberg

Kurt P Seifert

Keith B Adkins

Thomas E McLain

Jonathon D Weidner

Randall Sumner

Donald L McConnell

Gerald A Rhinehart Jr

Robert A Mcfall

Theodore R Schmidt

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

A splice connector assembly configured to conduct more than 1 kilowatt of electricity includes a terminal having a connection portion configured to interconnect with a corresponding mating terminal. The terminal also has an attachment portion. The attachment portion has a planar shape. The attachment portion is attached to a first wire electrical cable and is also attached to a second wire electrical cable. The first cable has a different cross-sectional area than the second cable. The splice connector assembly also includes a dielectric housing defining a cavity in which the terminal is disposed.

Splice connector

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.

A wire cable configured to be attached to a wire cable terminal. An uninsulated end of the wire cable is formed into a nugget having a shape that generally defines a rectangular cuboid or rectangular prism. The nugget includes one face that defines a longitudinal concavity, indentation, or channel, which is oriented generally parallel to the longitudinal axis of the wire cable. The nugget may be formed by ultrasonically welding the wire strands together. The concavity reduces the occurrence of fracturing the nugget when it is attached to the terminal by wire crimping wings. The wire cable may be formed of aluminum-based material. An apparatus for forming an end of a wire cable into a nugget shape having a longitudinal concavity and a method of attaching a wire cable having an end formed into a nugget shape having a longitudinal concavity to a terminal is also presented.

Method of attaching a wire cable terminal to a multi-strand wire cable

A single machine configured to manufacture a wire cable assembly including an twisted wire pair and a drain wire having a conductive tape and an insulative tape spirally wrapped about said wire pair. The machine includes a first clamp that secures an end of the wire pair and a second clamp that secures the other end of the wire pair. The second clamp rotates while the first clamp is fixed thereby twisting the wires of the wire pair one about the other. The second clamp can also rotate synchronously with the first clamp thereby rotating the wire pair without twisting. The machine also has a tape reel configured to move parallel to the clamps as they rotate, wrapping tape around the wire pair. The apparatus can be configured to apply the tapes simultaneously to electromagnetically shield and insulate the cable assembly. A method of operating the apparatus is also provided.

Integrated wire cable twisting, wrapping, and testing apparatus and method of operating same

An electrical connection system comprises a connector shell and a plurality of wafer connectors that plug into the connector shell. Each wafer connector holds a plurality of electric terminals that are attached to ends of electric cables, and a lock bar that is attached to the connector shell to retain the wafer connectors in the connector shell. The connector shell has an upper wall, a lower wall and side walls that are spaced apart to define a stack of wafer connector compartments that extends from the upper wall to the lower wall, an uppermost compartment being defined in part by the upper wall and an lowermost compartment being defined in part by the lower wall. The side walls each have slots in their confronting surfaces for each compartment in the stack of wafer connector compartments for locating a wafer connector in each compartment, the slots being longitudinal and open ended so that a wafer connector can be inserted longitudinally into each compartment from an insertion end of the shell.

Electrical connection system having wafer connectors

An automated wire harness machine is capable of manufacturing a wire harness in an automated process. The wire harness is generally a plurality of bundled, preferably un-stripped, insulated wires. Each un-stripped end portion of each wire is preferably terminated by an electrical terminal in one of a series of electrical connectors of the wire harness. Each connector has at least one wafer which houses a plurality of terminals. The wire harness machine utilizes a pallet that holds all of the wafers of one wire harness. A conveyor transports the pallet and wafers through a series of stations which perform automated manufacturing steps. The first station is a terminal inserter which inserts and locks the terminals within pre-assigned cavities of the wafers. The next station is an automated wire loader which measures, cuts and crimps the two ends of each wire into the respective terminals of the loaded wafer assembly. A third station, or ultrasonic welder, then galls an un-stripped non-ferrous core of the crimped wire to the terminal. The pallet with the loaded wafers, crimped terminals, and terminated wires are then transported to a wire marker station which marks each wire, preferably via a laser, for identification purposes.

Wire marker

Wire loader

The present invention is an automated wire harness machine () capable of manufacturing a wire harness () unique in-part due to the automation process. The novel wire harness is generally a plurality of bundled, preferably un-stripped, insulated wires (). Each un-stripped end portion () of each wire is preferably terminated to one of a series of electrical connectors () of the wire harness. Each connector has at least one wafer () which houses a plurality of terminals () preferably crimped and electrically terminated to the ends of the wires. The wire harness machine preferably utilizes a pallet () which holds all of the wafers of one wire harness. A conveyor () transports the pallet and wafers through a series of stations which perform automated manufacturing steps. The first station is a terminal inserter () which inserts and locks the terminals within pre-assigned cavities () of the wafers. The next station is an automated wire loader () which measures, cuts and crimps the two ends of each wire into the respective terminals of the loaded wafer assembly. A third station, or ultrasonic welder (), the galls an un-stripped non-ferrous core () of the crimped wire to the terminal. The pallet with the loaded wafers, crimped terminals, and terminated wires are then transported to a wire marker station () which marks each wire, preferably via a laser (), for identification purposes.

Wire harness manufacturing machine

A one piece, low profile plastic connector assurance member for use with plug and socket connectors having a lock arm and ramp to provide a primary lock when connected together. The assurance member has a generally rectangular frame and a pair of deflectable bridge portions extending between its sides. The deflectable bridge portions engage the ramp and snap over keeper projections on the lock arm with an audible click when the connectors are properly connected to provide assurance of proper connection.

Low profile connector position assurance

Growing community of inventors

Canfield, OH, United States of America

John Thomas Kightlinger