Ford Global Technolgoies, LLC

Paul J Nicastri

Glenn Richard Reed

Amin Emrani

Senate Ghanim

Systems devices and methods are disclosed for a vehicle power distribution system having a flat wire harness with integrated voltage converters. An example power distribution system includes a battery having a nominal voltage, a plurality of electrical loads, each corresponding to a respective rated voltage, and a flat wire harness. The flat wire harness includes a plurality of wire branches, each configured to couple the battery to a respective electrical load. The flat wire harness also includes a plurality of voltage converters, each integrated into a respective wire branch, configured to provide the respective rated voltage to each electrical load.

Integrated flat wire power distribution system for a vehicle

An electrical distribution apparatus is adapted for use in a wiring harness of an automotive electrical system. A flat flexible cable has an insulating substrate embedding a plurality of flat wires. The flat cable has a cable end wherein the wires extend as exposed blade fingers, each finger having at least one lateral fold stacking a thickness of the respective finger. A ferrule is crimped over each stacked finger. A plurality of contact bodies each has a coupler end and a crimp end. Each crimped end has a pair of legs crimped onto a respective ferrule. A carrier block has a plurality of bores each receiving a respective coupler end. The carrier block carrying the coupler ends is configured to plug into an electronic module connector in the automotive electrical system.

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Dearborn, MI, United States of America

Paul J Nicastri