Abstract: A power distribution box has a holder with inner, deflectable lock arms for securing bus bars within the holder. When the bus bars are correctly and completely installed within the holder, engaging portions of the lock arms are received in apertures of the bus bars and the lock arms are in a locked position. A cover can fit over and properly seat on the holder. The cover has projections that slide behind the lock arms and retain the lock arms in the locked position, preventing further movement. The projections each include a blocking surface. If one or more of the bus bars are not correctly and completely installed in the holder, the related latch arms are in a deflected, unlocked position. The blocking surface of a corresponding projection abuts against the deflected lock arm and prevents proper and complete assembly of the cover onto the holder.

Abstract: A spacer or retainer secures two circuit boards in a back-to-back configuration. The spacer has opposite first and second sides, each having a peripheral rim against which the circuit boards fit. Each side is recessed to a depth enabling any component terminals or connections from rear surfaces of the circuit boards to be received in the recesses. Pins on ends of the spacer are received in apertures in the circuit boards to guide the circuit boards into position on the spacer. Two clips are positioned next to each other on one wall forming the peripheral rim. Each clip extends beyond an opposite side, and the clips have resilient tabs biased to press the circuit boards against the rims. The circuit boards are connected by electrical wire extending around an opposite wall of the peripheral rim. The spacer and circuit boards form a subassembly, such as for a vehicle instrument cluster.

Abstract: A fuse device for fitting over and around a corner of a battery housing has a top wall and two side walls extending downward from the top wall. The side walls are joined at a corner. A battery terminal for mechanical and electrical attachment to a battery post is provided in the top wall. Electrical connectors for connection to terminals on the ends of electrical cables are mounted on the side walls of the fuse device. The electrical connectors are linked through the walls to the battery terminal by fuses. Ribs extending down the side walls from the top wall pass close by each electrical connector to strengthen the structure of the fuse device and prevent rotation of the terminals on the ends of the cables as they are secured to the fuse device. Recessed strengthening ribs in the top wall extend radially outward from the battery terminal.

Abstract: A connector assembly has a first part with an interior for receiving right-angle electrical terminals through an insertion end. Wire-connect segments of the terminals seat within cradle-like members aligned in sets of rows extending across the width of the interior. Electrical mating segments of the terminals extend perpendicularly from the wire-connect segments. A second part of the connector assembly has chambers for receiving the mating segments of the terminal and a compartment with inner cradle-like members aligned in sets of rows across the compartment. The cradle-like members of the first and second parts are arranged to correspond in position to each other when the second part is assembled on the first part so the wire-connect segments are clamped within the cradle-like members, reducing vibrational and other motion of the terminals within the assembly.

Abstract: A sealing system for a connector assembly used to house one-piece right-angle electrical terminals. The assembly has a first part for receiving the terminals and allowing the terminals to be turned such that wire-connect portions of the terminal are seated in the first part and electrical mating portions of the terminals perpendicular to the wire-connect portions extend through a second part. The second part has an insertion section for receipt in an opening and recess of the first part and a chamber section for accommodating the mating portions of the terminals. A gap is formed by the relative sizes and shapes of the parts around the insertion section at an engagement area between the first and second parts. Latch features within the first part and on the insertion section secure the two parts together internally from the gap. A resilient gasket fits into the gap and seals the engagement area.

Abstract: An electrical terminal is sealed for use in high voltage vehicle systems. The terminal has a cylindrical section positioned between a contact section for mating with another electrical contact or terminal and a crimp section for mechanically and electrically securing the terminal to an electrical wire. The cylindrical section is integral with both the contact section and the crimp section, and includes an outer surface with a circumferential groove. The groove receives and retains an o-ring seal for preventing contaminant seepage between the contact section and the crimp section when the contact section is inserted into a connector for mating with the other contact or terminal. The contact section may be either a substantially flat eyelet contact, a male contact or female contact.

Abstract: A light guide has a series of light channels passing through the guide between an outer planar surface and a base. Two resilient arms extend from opposite ends of the guide. The arms have free ends with cap elements for fitting over bosses within an instrument cluster mask. The base of the guide, through a flex action of the resilient arms, forces a dial or appliqué against the mask for viewing through a display window in the mask. In a vehicle instrument cluster assembly, the light guide is located between the mask and a printed circuit board (PCB). The PCB has light emitting diodes for fitting into the channels at the planar surface of the guide and backlighting the appliqué. The PCB presses against the cap elements of the resilient arms, causing the base of the guide to force the appliqué against sides of the mask window.

Abstract: An electrical terminal has a frame with an inner spring element for making electrical contact. The spring element has a base section near a wire connect portion of the terminal and an elevated section extending from the base section toward a mating end of the terminal. A raised projection is formed between the base and elevated sections to strengthen the spring element where it bends. The projection is made by punching an indentation in adjacent lower surfaces of the base and elevated sections. The elevated section has an apex with a center contact strip bordered on each side by a recess in the elevated section to avoid a sudden increase in a mating terminal insertion force. A guide member on the frame blocks a mating terminal from being inserted under the elevated section. A support member on the frame underneath the elevated section prevents excessive deflection of the spring element.

Abstract: A pointer for a display snaps into a hub device. The hub device has a body including a cap, a light shield and a pointer stem molded together as one part. A passage within the body receives an insertion section of the pointer. A latch arm extending into the passage from the body snaps into a slot within the insertion section of the pointer. An area of the insertion section of the pointer is exposed to directed light through a cavity in an underside of the body. The area transmits the light to an indicating section of the pointer. The light shield is arranged on the body to prevent the directed light from reflecting off the hub device onto the display. The pointer stem receives a drive shaft that rotates the hub device and positions the indicating section of the pointer on the display according to measured parameters.

Abstract: An assembly provides a direct electrical connection between a relay and a fusible link on the surface of a vehicle junction block. A fuse housing for the fusible link has a first, female terminal located near a top portion of the fuse housing. The first terminal is connected to a second terminal in the fuse housing by the fusible link. The junction block surface is configured such that the relay is mounted slightly above the fuse housing, whereby the top portion of the fuse housing forms a partial seat for the relay. An opening in the top portion of the fuse housing enables a male contact blade from the relay to be received by the first terminal. The second terminal in the fuse housing is connected to a power supply, or the relay is directly connected to the power supply and the second terminal electrically connects a different circuit directed into the junction block with the relay.

Abstract: A male terminal has spring elements bent back from a rounded end above a flat portion of the terminal and separated by a centrally located opening. An aperture extends through the flat portion under the opening. Elongated ridges protrude from an underside of the flat portion. A female terminal has arms overhanging a base to form receptacles for the spring elements. Down-turned alignment ribs on the arms are received in the opening in the male terminal to properly align the terminals during electrical connection. Dimples protrude from the arms to contact the spring elements of the male terminal as the spring elements are inserted. The elongated ridges on the underside of the flat portion of the male terminal contact the base of the female terminal. A lock tab in the base between the ribs snaps into the aperture to latch the terminals together when the spring elements are fully inserted.

Abstract: A one-piece retainer has a base with an integral band clip and a fastener for securing an electrical cable or wire harness to a vehicle component, as well as a pair of arms for supporting another cable or a hose on the component. The base has a cradle extending along a length of the base. The arms extend from each end of the base outward from the cradle. The arms have curved sections creating interior spaces aligned with and spaced away from the cradle. Ledges extend from the base opposite each arm, forming an opening to each interior space between the ledge and a tapered edge of the curved section of the arm. The openings face in opposite directions. A cable or hose is twisted or turned relative to the base such that part of the cable or hose can be rested on the ledges in alignment with each opening. Then the cable or hose is twisted or turned back and inserted or snapped into the interior of each arm to seat along the cradle. The arms resiliently clasp the cable or hose in the cradle.

Abstract: A grommet routes a wire harness from an inner side of a vehicle door into a vehicle body. A depression wraps around an edge of the door with a first part on a hinge surface of the door and a second part on the inner side. The grommet has an elastic member for fitting within the first part and a rigid retainer member extending around the edge into the second part. The members are secured together. The elastic member has a grooved periphery for receiving a flange surrounding an opening linked to the first part of the depression. The retainer member is secured in the second part of the depression by a fastener inserted into an aperture in the second part. The members have passageways to route the harness around the edge of the door. Fins on an underside of the elastic member seal against the first part.

Abstract: An intermediate portion of the outer insulation of a shielded electrical cable is removed near an end of the cable. A remaining small segment of the outer insulation at the cable end is moved axially inward along the cable to bunch up an exposed conductive braid of the cable. The bunched up braid is pinched to form a flattened, bell-shaped element on two opposite sides of inner conductive wires of the cable. The inner wires are attached to electrical terminals and the terminals are inserted into an insulator mounted within a conductive connector shield. The flattened elements are simultaneously aligned between opposite crimp arms extending from sides of the connector shield. The arms are crimped onto the flattened elements using an ultrasonic/vibration type crimping process or a shear lock crimping process. Since the flattened braid elements extend away from the cable, the crimping process is offset from the inner wires.

Abstract: A connector has a first section for receiving an inner electrical terminal, an outer electrical contact, and a dielectric member separating the inner terminal and outer contact. A second section of the connector extends at an angle from the first section and receives a conductive core and an inner insulation layer of a coaxial cable. The second section has an end for sliding between the inner insulation layer and an outer conductive sheath. The outer contact includes a ferrule for extending through an aperture in the first section and partially around an outer jacket of the cable, the conductive sheath and the second section. The ferrule has appendages for crimping on the jacket. The appendages have serrations for cutting through the jacket and electrically connecting the conductive sheath directly with the outer contact. The second section prevents the appendages and serrations from penetrating to the inner insulation layer.

Abstract: An electrical terminal connection system includes first and second terminals that are interlocked by placing the first terminal on top of the second terminal and rotating the first terminal. The first terminal has a planar ring section with an outer perimeter and a centrally located aperture. The perimeter has cut-out portions. Inclined spring elements extend from the ring section near the outer perimeter. The second terminal includes a semi-circular part with an outer periphery and a centrally located collar. Curved walls extend perpendicularly from the outer periphery. The walls have ledges projecting over the semi-circular part. Aligning the cut-out portions of the first terminal with the curved walls and ledges of the second terminal enables the planar ring section of the first terminal to be placed on the semi-circular part of the second terminal, with the aperture receiving the collar. Rotating or twisting the first terminal causes the spring elements to contact and slide under the ledges.

Abstract: A wire shield has a first tubular section for attachment to a fixed component. A second tubular section is integrally joined to the first tubular section along a common longitudinal axis. The second tubular section has an outer diameter with an outer surface. A small key protrudes from the outer surface. A third tubular section has an inner diameter slightly larger than the outer diameter of the second tubular section. An opening having spaced borders extends through the third tubular section. The third tubular section is fit around, and is able to slide upon, the second tubular section with the key positioned in the opening. A mounting device and a support for an electrical connector extending from the third tubular section are adjustable in longitudinal and angular position relative to the first and second tubular sections within limits defined by contact of the key with the borders of the opening.

Abstract: An electrical terminal connection system has a first terminal for attachment to a high-current cable. The first terminal is formed to include a wire-connect section for direct attachment to the wire and an intermediate stem section joining the wire-connect section to a contact section. The contact section has two opposite sides and deflectable arms extending along each side in parallel relation to each other. The arms are raised from the contact section and extend to free ends adjacent to an end of the contact section. A second terminal extends from a device-side of the connection, such as from a power distribution module (PDM). The second terminal has an initial seating section joined to a bus bar extending from within the PDM and a retaining section having two opposite edges. A short wall extends perpendicularly from each edge of the retaining section and a ledge extends from a top of each wall to overhang part of the retaining section. Each ledge has a portion slanted toward the seating section.

Abstract: A right-angle connector for a coaxial cable has two main components. A first component and second component are made of electrically conductive material. The second component is attached to the first component such that the second component can rotate relative to the first component. The components are temporarily latched in an initial in-line configuration. In this configuration, the two components have a common, straight central axis and receive a terminal crimped on a stripped end of a coaxial cable. The terminal is fastened within a block of dielectric material in the first component at a mating end of the connector. The second component is then rotated to bend the cable end. The second component locks into a second configuration wherein a central axis of the second component is perpendicular to a central axis of the first component. An exposed braided conductive sheath of the cable end is clamped on a section of the second component by a cylindrical ferrule.

Abstract: A clip has a retainer for securing the clip and a wire harness to a bolt protruding from a vehicle surface. The retainer includes a beam having an aperture with an inner wall. The aperture receives the bolt. A flange projects into the aperture from the wall. An opening in the wall opposite the flange communicates with a passage in the beam. A sliding component of the retainer has a flanged end for insertion into the passage and through the beam into the aperture. The flange and the flanged end of the component are received between selected threads of the bolt to clamp the bolt in the aperture. Projections extending from opposite edges of the sliding component are received in cavities along side walls of the beam passage in positions corresponding to the size of the bolt. The projections and cavities cooperate to secure the sliding component in the beam.