Abstract: An electric propulsion vehicle has a high voltage electric drive system and a low voltage electrical accessory system. A high voltage battery pack provides electrical power at a relatively higher voltage for a traction motor. A low voltage distribution system is routed within the vehicle carrying a relatively lower voltage for the accessory system. A molded battery enclosure contains the battery pack and extends between predetermined locations in the vehicle body/frame. The low voltage distribution system includes a bus bar retained in the enclosure and electrically isolated from the battery pack. The bus bar has exposed terminal ends accessible at the predetermined locations. Incorporating the low voltage bus bar into the high voltage battery enclosure reduces the packaging space for the low voltage distribution system while simultaneously strengthening the enclosure.

Abstract: An electric propulsion vehicle has a high voltage electric drive system and a low voltage electrical accessory system. A high voltage battery pack provides electrical power at a relatively higher voltage for a traction motor. A low voltage distribution system is routed within the vehicle carrying a relatively lower voltage for the accessory system. A molded battery enclosure contains the battery pack and extends between predetermined locations in the vehicle body/frame. The low voltage distribution system includes a bus bar retained in the enclosure and electrically isolated from the battery pack. The bus bar has exposed terminal ends accessible at the predetermined locations. Incorporating the low voltage bus bar into the high voltage battery enclosure reduces the packaging space for the low voltage distribution system while simultaneously strengthening the enclosure.

Abstract: A stabilized electric distribution system for use in a vehicle having electric assist. The system electrically couples an electric assist bus to an accessory load bus while protecting the first electrical bus from electric assist and regenerative braking induced voltage variations. An energy management controller selectively controls each of a electric motor/generator, a DC/DC converter, and an alternator to affect electric energy distribution within the system. Preferably, the electric energy distribution is controlled to maintain the first electrical bus voltage within a predefined voltage range.

Abstract: A configurable instrument panel design is provided that integrates component designs so that an instrument panel can be configured for a specific vehicle content as late in the vehicle assembly process as possible. An electrical system is provided that utilizes a flat flexible cable that is the same for every vehicle independent of vehicle content. Electronic modules are provided with connectors that only connect to the specific wires required for a particular module. A plurality of different multiplexing links are built-in to the electrical system and wiring arrangement allowing the system to be universal across all possible instrument panel configurations. This allows the system to accommodate lower option vehicles at a lower cost than conventional technology. Thin smart switch units can be installed at a final stage in the instrument panel assembly process to configure the feature content of the instrument panel.

Abstract: A configurable instrument panel design is provided that integrates component designs so that an instrument panel can be configured for a specific vehicle content as late in the vehicle assembly process as possible. An electrical system and modular instrument cluster are provided that utilizes the same flat flexible cable for every vehicle independent of vehicle content. Instrument cluster modules are provided with universal connector arrangement, where the type and function of a particular module determine which connectors are live. A plurality of different multiplexing links are built-in to the electrical system and wiring arrangement allowing the system to be universal across all possible instrument cluster configurations. This allows the system to accommodate lower option vehicles at a lower cost than conventional technology. Instrument cluster features can be configured at the time of assembly, all without customizing the electrical system and wiring arrangement.

Abstract: An electrical connector having a terminal blade that has two spaced legs between which a spring contact strip is received. An L-shaped tab extends from one leg to the other to lock the two legs together in a spaced relationship. The spring contact strip has locking tabs that are received in openings in the terminal blade to hold the contact strip in the blade. Lead in tabs and stops are provided on the contact strip to aid in assembly of the contact strip to the terminal blade.

Abstract: A remotely controlled electrical accessory system for starting an engine of a vehicle and actuating a garage door opener attached to a garage door. The system includes a first transmitter for producing an engine ignition signal and a second transmitter for producing a garage door opener actuation signal. A receiver starts the engine of the vehicle and energizes the second transmitter to produce the garage door opener actuation signal in response to the engine ignition signal. In a preferred embodiment, the system includes a proximity sensor attached to the vehicle for producing a gating signal in response to a closed garage door. Preferably, the receiver starts the engine of the vehicle in response to the engine ignition signal and energizes the second transmitter to produce the garage door opener actuation signal in response to the engine ignition signal and the gating signal.

Abstract: A grommet used with flat flexible cable provides a seal between an inner compartment of an automobile and an exterior environment. This simplifies the use of flat flexible cable in automobile wiring harness assemblies. In another aspect of this invention, a cable connector assembly for joining an end of the cable includes a closed cell foam seal to provide a water-tight seal between the cable, the terminals and the exterior environment.

Abstract: An electrical terminal connection is made by interconnecting two identical terminals having U-shaped blades. In the past, electrical connections have typically been made by inserting a blade terminal into a receptacle terminal. One embodiment of the inventive connection includes a terminal having a spring contact strip with a plurality twisted contact louvers within each U-shaped blade. Another embodiment of the inventive connection includes a terminal having a U-shaped blade with corrugated sides. Both embodiments increase the contact area while reducing the engagement force necessary to mate the terminals.