Aptiv Technologies Limited

Aptiv Technologies Ag

Aptiv Technologies (2) S.à R.l.

Jonathan D Weidner

David R Peterson

Sean P Krompegel

Joseph Sudik, Jr

Jared Bilas

Nicholas A Durse

Jesse Braun

Adam Wolfgang

Keith B Adkins

Andrew Bohan

Jacob Martin

Jessie Braun

A wiring harness assembly includes a plurality of electrical conductors having wires enclosed within insulative sheaths that are integrally formed of an electrically insulative material. The assembly also includes a lattice support structure that is attached to the insulative sheaths at multiple locations. The lattice support structure is configured to maintain a desired shape of the assembly. The lattice support structure is formed of filaments that may be formed using an additive manufacturing process The filaments may be arranged such that lattice support structure defines a plurality of hexagonally shaped apertures. A process for manufacturing the wiring harness assembly and an apparatus configured to manufacture the wiring harness assembly is also presented.

Electrical wiring harness assembly and process for manufacturing same

A bus bar assembly includes a bus bar formed of a first electrically conductive material having a planar contact portion. The bus bar defines a first bore extending through the contact portion. The bus bar assembly further includes a contact insert formed of a second electrically conductive material that has a greater hardness than the first electrically conductive material. The contact insert defines a first surface that is mechanically and electrically connected to the contact portion of the bus bar. The contact insert defines a second surface this is plated with a third electrically conductive material which is different than the second electrically conductive material. The contact insert defines a smooth second bore coaxial with the first bore and extending from the first surface to the second surface.

Bus bar assembly with plated electrical contact surface

A busbar connection system comprises a plate member formed of a first material having a higher tensile strength than second and third materials of first and second busbars, respectively, and defining first and second apertures and first and second stud members securely inserted through the first and second apertures of the plate member, respectively, the first and second stud members being configured to be securely inserted through first and second apertures, respectively, in each of the first and second busbars, wherein the first and second stud members mitigate rotational movement between the first and second busbars when connected.

Busbar connection systems and methods

An electrical bus bar assembly includes an elongate flexible electrical conductor formed of a strip of electrically conductive material having a generally rectangular cross section and a width to thickness ratio of at least 20:1 and a dielectric material covering a central portion of the electrical conductor such that the electrical conductor has exposed distal portions at each end of the assembly. Further, a method for forming such as assembly includes the steps of forming a flexible strip from an electrically conductive sheet such that the strip has a generally rectangular cross section with a width to thickness ratio of at least 20:1 and covering a central portion of the strip with a dielectric material and leaving distal portions at each end exposed.

Flexible electrical bus bar and method of manufacturing the same

A method of forming an electrical cable assembly includes providing a multiconductor flat cable comprising wires arranged in a coplanar fashion with each other and encased within a planar dielectric structure, cutting a slot in the planar dielectric structure intermediate the wires, thereby forming wing features in the dielectric structure extending from the wires, removing portions of the dielectric structure from ends of the wires, wherein portions of wing features remain, attaching the exposed wires to terminals, wherein the terminals define prongs, and attaching the portions of the wing features to by inserting the prongs within holes defined in the portions of the wing features, thereby retaining the wires to the terminals.

Electrical cable assembly, method and apparatus for making same and electrical terminal for same

A process of manufacturing an electrical wiring assembly includes the steps of cutting an elongate strip from a sheet of metal and cutting a mesial slit in an end of the uninsulated segment, thereby forming a pair of distal projections flanking the mesial slit. The mesial slit and the pair of distal projections form a forked split blade terminal.

Process of manufacturing an electrical wiring assembly and electrical wiring assembly manufactured by said process

An electrical cable assembly is presented herein. The electrical cable assembly includes a multiconductor flat cable including a first and second electrically conductive wire arranged in a coplanar fashion with each other and encased within a planar dielectric structure. A slot is defined in the planar dielectric structure intermediate the first and second wires, thereby forming first wing features in the dielectric structure extending from the first wire and second wing features extending from the second wire. Exposed portions of the first and second wires extend beyond the first and second wing features. A method of forming the electrical cable assembly, an apparatus for forming the electrical cable assembly, and an electrical terminal configured for use in the electrical cable assembly is also presented. The wing features may include holes and the terminals may include prongs to be received in the holes.

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Conneautville, PA, United States of America

Jonathan D Weidner