Abstract: An insulated electric wire having a conductive core and an insulation jacket is center stripped by cutting a pattern in one side of the insulation jacket with a laser beam, and then cutting a coordinated pattern in an opposite side of the insulation jacket with a laser beam to produce two axially spaced circumferential cuts connected by a plurality of generally axial cuts that define at least two removeable insulation slugs for exposing the conductive core while the insulation jacket on either side of the exposed conductive core is left intact. An in-line center stripping device or a multiple wire rotation device may be used for center stripping the insulated electric wire. The insulated slugs may by removed by an insulation removal device on an offal removal assembly.

Abstract: An automated wire harness machine is capable of manufacturing a wire harness in an automated process. The wire harness is generally a plurality of bundled, preferably un-stripped, insulated wires. Each un-stripped end portion of each wire is preferably terminated by an electrical terminal in one of a series of electrical connectors of the wire harness. Each connector has at least one wafer which houses a plurality of terminals. The wire harness machine utilizes a pallet that holds all of the wafers of one wire harness. A conveyor transports the pallet and wafers through a series of stations which perform automated manufacturing steps. The first station is a terminal inserter which inserts and locks the terminals within pre-assigned cavities of the wafers. The next station is an automated wire loader which measures, cuts and crimps the two ends of each wire into the respective terminals of the loaded wafer assembly.

Abstract: An insulated electric wire having a conductive core and an insulation jacket is center stripped by cutting a pattern in one side of the insulation jacket with a laser beam, and then cutting a coordinated pattern in an opposite side of the insulation jacket with a laser beam to produce two axially spaced circumferential cuts connected by a plurality of generally axial cuts that define at least two removeable insulation slugs for exposing the conductive core while the insulation jacket on either side of the exposed conductive core is left intact. An in-line center stripping device or a multiple wire rotation device may be used for center stripping the insulated electric wire. The insulated slugs may by removed by an insulation removal device on an offal removal assembly.

Abstract: An automated wire harness machine is capable of manufacturing a wire harness in an automated process. The wire harness is generally a plurality of bundled, preferably un-stripped, insulated wires. Each un-stripped end portion of each wire is preferably terminated by an electrical terminal in one of a series of electrical connectors of the wire harness. Each connector has at least one wafer which houses a plurality of terminals. The wire harness machine utilizes a pallet that holds all of the wafers of one wire harness. A conveyor transports the pallet and wafers through a series of stations which perform automated manufacturing steps. The first station is a terminal inserter which inserts and locks the terminals within pre-assigned cavities of the wafers. The next station is an automated wire loader which measures, cuts and crimps the two ends of each wire into the respective terminals of the loaded wafer assembly.

Abstract: The present invention is an automated wire harness machine (40) capable of manufacturing a wire harness (42) unique in-part due to the automation process. The novel wire harness is generally a plurality of bundled, preferably un-stripped, insulated wires (46). Each un-stripped end portion (180, 182) of each wire is preferably terminated to one of a series of electrical connectors (44) of the wire harness. Each connector has at least one wafer (52) which houses a plurality of terminals (54) preferably crimped and electrically terminated to the ends of the wires. The wire harness machine preferably utilizes a pallet (56) which holds all of the wafers of one wire harness. A conveyor (58) transports the pallet and wafers through a series of stations which perform automated manufacturing steps. The first station is a terminal inserter (64) which inserts and locks the terminals within pre-assigned cavities (114) of the wafers.

Abstract: The present invention is an automated wire harness machine capable of manufacturing a wire harness unique in-part due to the automation process. The novel wire harness is generally a plurality of bundled, preferably un-stripped, insulated wires 46. Each un-stripped end portion of each wire is preferably terminated to one of a series of electrical connectors of the wire harness. Each connector has at least one wafer which houses a plurality of terminals preferably crimped and electrically terminated to the ends of the wires. The wire harness machine preferably utilizes a pallet which holds all of the wafers of one wire harness. A conveyor transports the pallet and wafers through a series of stations which perform automated manufacturing steps. The first station is a terminal inserter which inserts and locks the terminals within pre-assigned cavities of the wafers.

Abstract: An environmentally protected (sealed) BEC (10) at the upper and lower housing seams (16u, 16l) and at each of the connector receptacle (18a, 18b, 18c). A lower housing (14) of the BEC is formed conventionally, as for example by plastic injection molding and may carry a printed circuit board (PCB) (70), a spacer plate (72) and an electrical assemblage (74) including upstanding blade terminals (76). An upper housing (14) of the BEC is formed in two shots. Firstly, an upper housing body (14b) is formed by a plastic injection molding process using a first upper mold member (42) mated to a lower mold member (44). Next, the first upper mold member is removed, and a second upper mold member (52) is mated to the lower mold member. A liquid injection molding process now injects a resilient seal (silicone) over all mating surfaces of the upper housing body, including the upper housing seam (16u) and each connector receptacle.

Abstract: An environmentally protected (sealed) BEC (10) at the upper and lower housing seams (16u, 16l) and at each of the connector receptacle (18a, 18b, 18c). A lower housing (14) of the BEC is formed conventionally, as for example by plastic injection molding and may carry a printed circuit board (PCB) (70), a spacer plate (72) and an electrical assemblage (74) including upstanding blade terminals (76). An upper housing (14) of the BEC is formed in two shots. Firstly, an upper housing body (14b) is formed by a plastic injection molding process using a first upper mold member (42) mated to a lower mold member (44). Next, the first upper mold member is removed, and a second upper mold member (52) is mated to the lower mold member. A liquid injection molding process now injects a resilient seal (silicone) over all mating surfaces of the upper housing body, including the upper housing seam (16u) and each connector receptacle.

Abstract: A fastener comprising a T-shaped plastic planar member has a base which can be taped to a wiring assembly or harness and a normally extending trunk which has a pressure sensitive adhesive pad secured to a portion thereon adjacent the base and which has a releasable cover overlying the adhesive pad to protect the same during handling, but which can be unfolded to expose the adhesive pad to enable the pad to be fastened to a panel of the vehicle by merely pressing it onto the panel.

Abstract: A cylinder pressure sensor of the annular insert type disposed within an access well to measure the flexure of a first wall relative to a second wall along a response axis has low-cost components thereof requiring only simple sequential assembly in axial stacked fashion providing contaminant protection and electrical shielding of the sensing element.

Abstract: An electrical sleeve terminal of one piece construction comprises a split sleeve for engaging a mating terminal and a crimp barrel for attaching the terminal to an electric cable. The split sleeve has six circumferentially spaced beams that have contact dimples in an alternatively staggered arrangement to biasingly engage the mating terminal in two planes. The split sleeve has flanges at the respective edges of the split that are securely fastened together. The crimp barrel is an integral extension of one flange and a separate finger that is an integral extension of the other flange is fixed in the crimp barrel to engage the conductor of the electric cable.

Abstract: An electrical power distribution center includes stacked circuit arrays of varying current carrying capacity located between an upper housing and a lower housing, each having terminal access holes therein for receiving terminals formed on pre-stamped metal circuit elements. The terminals are selectively connected to either electrical or electronic devices carried on top of the upper housing or to wiring connectors connected to the outer surface of the lower housing. The pre-stamped metal circuit elements are removably mounted in recesses in a plurality of stacked electrical insulation boards supported within the lower housing and centered therein by guide stems formed integrally of the lower housing. Each of the electrical insulation boards includes raised surfaces thereon congruent with the recesses on an adjacent electrical insulation board for holding the metal circuit elements in place therein while insulating each of the metal circuit elements from adjacent metal circuit elements.

Abstract: An insulation displacement terminal assembly comprises an insulation displacement terminal having a U-shaped insulation displacement portion which has two plate sections that are connected by a bight and insulation displacement slots that extend through the bight and down into the plate sections in aligned pairs of insulation piercing slot portions. A plurality of insulated electric cables are disposed in the insulation piercing slot portions and retained therein to form a sub-assembly. The sub-assembly is assembled into a slide-in insulator housing portion which has slots in its opposed side walls through which the insulated electric cables of the sub-assembly extend and a retention tongue that is cantilevered from a back wall of the housing portion and runs parallel to the slotted side walls to project between the insulated electric cables and the bight of the insulation displacement terminal to retain the electric cables down in the insulation displacement slot portions.

Abstract: A female terminal of unitary sheet metal construction is attached to a flexible printed circuit by crimped tabs at the outer edges of a pair of lateral mounting flanges. The flanges are prevented from being spread apart during terminal use by a clamping arrangement on upright posts connecting the ends of the flanges. The female contact portion is provided by spring blades which accept a mating blade from either side and spread without effecting the portions securing the terminal to the flexible printed circuit.

Abstract: A spade terminal of unitary sheet metal construction comprises a flanged forward portion, a triple layer median portion and a rearward attachment portion. The flanges extend in opposite direction to a height equal to a layer thickness. The triple layer median portion comprises upper and lower wings which terminate short of opposite longitudinal sides so that each longitudinal side is a double layer. This configuration permits use with an insulator body having guide channels for the forward and median portions of the terminal which can be made in a butt cored mold.

Abstract: The drawings illustrate an electrical connector including elastomeric male and female bodies, each having flanged terminals mounted therein. Each of the bodies is adapted to having a lock member mounted thereon such that, when the bodies are interconnected, the lock members also interconnect to retain the bodies in their assembled condition. Additionally, transverse locking pins, formed on the lock members and extended through both the bodies, obstruct outward movement of the flanges of the terminals, and thus serve to prevent removal of the terminals from the bodies.

Abstract: A unitary molded housing of electrically insulative material has an integrally hinged cover which is retained in the closed position by primary and secondary latch means. The secondary latch means is adjacent the integral hinge and serves to retain the cover in the closed position in conjunction with the primary latch means in the event the integral hinge fractures in service.The housing is illustrated in conjunction with a quick splice electrical connector and features bifurcated projections on the cover which during closure of the cover aid in piercing insulation of electrical lead wires by pushing the lead wires into slotted terminals in the housing.The housing is heat staked to retain the terminals therein and also includes means for strain relieving the lead wires having their insulation pierced by the terminals.

Abstract: A flexible printed circuit is connected to a hardboard printed circuit by a cap which receives an end portion of the hardboard printed circuit having continuous portions at one end of the flexible printed circuit wrapped longitudinally thereabout. The hardboard printed circuit has a longitudinal latch portion which extends through aligned slots in the flexible printed circuit and cap and engages an extending finger of the cap. A portion of the flexible printed circuit disposed in the cap carries a resilient pad for biasing the conductor strips of the printed circuits into engagement.