Delphi Technologies, Inc.

Aptiv Technologies Limited

William J Palm

Kurt Paul Seifert

Eric B Poma

George Albert Drew

Leslie L Jones

Bruce S Gump

Jared Bilas

Dominic Anthony Messuri

Bruce D Taylor

Bruce J Serbin

Michael Messuri

James P Schuster

Lisa L Flauto

Mark David Baranski

Terry A George

Nicole L Liptak

John R Metzger

Jeremy Richardson

Gert Droesbeke

Brian K Dew

Kurt P Seifert

Frank W O'Malia

Jeremy M Richardson

John Raymond Metzger

A cable assembly includes coaxially arranged inner and outer barrels. The outer barrel overlaps a portion of the inner barrel. The inner and outer barrels respectively include first and second features that cooperate with one another to form a retention feature. The cable assembly has a cable that has at least one wire surrounded by an inner insulator that is covered in a metallic shield. The metallic shield is arranged in between the inner and outer barrels. The first feature is arranged beneath the metallic shield, and the second feature is arranged over the metallic shield. At least one of the first and second features extends in a radial direction relative to the other of the first and second features to capture the metallic shield with the retention feature.

Barrel crimp retention feature for connector with braided wire

A cable assembly includes coaxially arranged inner and outer barrels. The outer barrel overlaps a portion of the inner barrel. The cable assembly further includes a cable that has at least one wire surrounded by an inner insulator that is covered in a metallic shield. The metallic shield is arranged in between the inner and outer barrels. The inner barrel includes a retention feature that is arranged beneath the metallic shield. The retention feature protrudes radially outward from the inner barrel to an outermost diameter. The outer barrel includes a crimped portion that is arranged adjacent to the retention feature and has an innermost diameter that is less than the outermost diameter to capture the metallic shield therebetween and prevent the outer barrel from axial movement relative to the inner barrel.

A wire cable assembly, such as those used in electric or hybrid electric vehicles, having a plurality of shielded wire cables spliced together. The center conductors are joined together and enclosed in an inner insulator. The shield conductors of the cable are joined by an electrically conductive sleeve enclosing the inner insulator and attached to the shield conductors of the shielded wire cables. The sleeve separates the outer insulating layers of the shielded wire cables. The sleeve is encased by an outer insulator that is sealed to the outer insulating layers of the shielded wire cables. A method of splicing shielded wire cables together is also presented.

Device and method for splicing shielded wire cables

An electrical shield connector configured to be attached to an end of a shielded cable having a conductive wire and a shield conductor longitudinally surrounding the conductive wire. The shield connector includes a connection portion that is configured for connection with a corresponding mating electrical shield connector and a cable attachment portion that is configured to longitudinally receive an end of the shield conductor. The connection portion defines a shroud surrounding an electrical terminal attached to the conductive wire. The cable attachment portion and/or crimp wings projecting therefrom define a projection that is configured to contact and indent the shield conductor, thereby mechanically and electrically connecting the shield connector to the shield conductor. The cable attachment portion may also define a knurled pattern in an interior surface of the cable attachment portion, such as a knurled pattern having a number of rhomboid-shaped indentations.

Electrical shield connector

A method is provided for attaching a termination arrangement to a shielded cable which includes a conductive core, a core insulation layer, a conductive shield layer, and an outer insulation layer. A length of the outer insulation layer is removed to expose an end portion of the conductive shield layer and a length of the core insulation layer is removed to expose a portion of the conductive core. The termination assembly is provided having a terminal, a core crimp section in electrical communication with the terminal, and an inner ferrule section connected to the core crimp section. The core crimp section is positioned adjacent to the exposed conductive core and crimped around said conductive core in electrical contact therewith. The inner ferrule section is positioned adjacent to the exposed conductive shield layer and crimped around the core insulation layer. The core crimp section is separated from the inner ferrule section.

Termination assembly for a shielded cable and method of assembling

A wire cable assembly including a wire cable and a contact element. The contact element is configured to axially receive the wire cable and is formed to attach the wire cable to the contact element. A portion of the contact element is formed to define a single pair of indentation arrangements. The pair of indentation arrangements consists of a first indentation arrangement that diametrically opposes a second indentation arrangement. The contact element may also define a pair of humps adjacent to each of the grooves in the single pair of grooves. The wire cable may further include a conductive inner core, a first insulation layer surrounding the inner core, and an outer wire layer surrounding the first insulation layer. The wire cable assembly may further include an inner ferrule and an outer ferrule with the outer wire layer disposed between the inner ferrule and the outer ferrule.

Wire cable assembly

An electrical contact includes at least one grooved channel defined in an interior surface of the electrical contact along at least a portion the electrical contact disposed along a longitudinal axis. The portion is configured to axially receive a lead of a wire cable for attachment thereto and thereby allow the attached lead to at least engagingly make contact against a recessed surface of the grooved channel. The grooved channel has a depth and includes at a least one sidewall extending along the depth. The sidewall includes at least one section that angularly extends from the interior surface to a point recessed from the interior surface disposed on the sidewall along the depth.

Electrical contact having channel with angled sidewalls and romboid knurl pattern

An electrically-conducting contact element includes a section of the contact element defining an aperture. The section is configured to receive a wire cable within the aperture for attachment thereto. The section includes an internal surface with at least one groove having sharp edges formed therein. A wire assembly that includes the electrically-conducting contact and a method to construct the electrically-conducting contact are also presented. The method includes a step of providing the contact element and forming at least one cutout groove on the internal surface of the contact element. A further step in the method includes altering material on the internal surface of the contact element by a forming means. The forming means may be one of milling, rifling, machining, cutting, indenting, or stamping. A wire assembly and a vehicular electrical wiring harness that respectively include the contact element are also further presented.

Electrically-conducting contact element with an aperture with an internal surface having a groove with sharp edges

An electrical contact includes a knurl pattern disposed along at least a portion of an interior surface of the electrical contact. The portion receives a lead of a wire cable along a longitudinal axis and is attached thereto to form a crimp connection. The knurl pattern includes a plurality of recessed elements and each recessed element has a rhombus shape that includes inner corners. An orientation of a first pair of opposing, generally axial inner corners define an axial minor distance therebetween and an orientation of a second pair of opposing, inner corners define a major distance therebetween. The axial minor distance is less than the major distance. The recessed elements of the knurl pattern are especially suitable for engagement with an aluminum wire cable to form the crimp connection. A wire assembly that includes the crimp connection is associated with a cable harness disposed in a motorized vehicle.

Electrical contact having knurl pattern with recessed rhombic elements that each have an axial minor distance

A cable assembly includes a terminal crimped to a conductor. The terminal has a plurality of crimps spaced from one another and a transition crimp disposed therebetween. A method includes deforming the terminal about the conductor to define the plurality of crimps having different crimp heights, and deforming the terminal about the conductor to define the transition crimp between each of the plurality of crimps. The transition crimp has a crimp height different than each of the plurality of crimps.

Multi-level electrical terminal crimp

A connection mechanism includes a metal segment in mechanical and electrical communication with the remainder of the connection mechanism on at least one side. The segment includes at least one tab protruding from the segment on a first side and a central area of the segment with a plurality of metal deformations. When the metal deformations are pressed into aluminum, they are capable of piercing through corrosion on the surface of the aluminum in order to make electrical contact with the aluminum.

Electrical connection system for use on aluminum wires

A system for validating a proposed crimp includes a pre-crimp modeler configured to establish a geometry for the proposed crimp, a plurality of virtual testing modules configured to determine at least one characteristic of the proposed crimp, and a virtual validation module configured to compare results from each of the plurality of virtual testing modules to predetermined criteria.

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Warren, OH, United States of America

William J Palm