Abstract: A system and method for shaping a flexible circuit (FC) having a set of conductive traces disposed within a set of insulation layers and a shaped FC, each involve using a non-conductive tool defining complimentary first and second tool portions and a shape therebetween, the tool being configured to receive a portion of the FC therebetween the first and second tool portions, a set of conductive heating elements arranged substantially in parallel with each other and disposed within the first and second tool portions, and a power source configured to provide power to the conductive heating elements causing the conductive heating elements to generate heat energy to shape the FC portion without removing any of the FC portion.

Abstract: A flexible planar wire cable includes a first flexible planar wire having first conductor segments contained in a first longitudinal plane and second conductor segments contained in a second longitudinal plane. First connection segments extend between the first conductor segments and the second conductor segments. The first conductor segments alternate with second conductor segments along a longitudinal axis of the wire harness assembly. The cable further includes a second flexible planar wire having third conductor segments contained in the second longitudinal plane and fourth conductor segments contained in the first longitudinal plane. Second connection segments extend between the third conductor segments and the fourth conductor segments. The third conductor segments alternate with the fourth conductor segments along the longitudinal axis of the flexible planar wire cable. The cable also includes an insulating layer separating and encasing the first and second flexible planar wires.

Abstract: A system and method for shaping a flexible circuit (FC) having a set of conductive traces disposed within a set of insulation layers and a shaped FC, each involve using a non-conductive tool defining complimentary first and second tool portions and a shape therebetween, the tool being configured to receive a portion of the FC therebetween the first and second tool portions, a set of conductive heating elements arranged substantially in parallel with each other and disposed within the first and second tool portions, and a power source configured to provide power to the conductive heating elements causing the conductive heating elements to generate heat energy to shape the FC portion without removing any of the FC portion.

Abstract: Electrified vehicle electrical systems and formatting methods include arranging a first layer including one or more first electrical transmission lines each configured to carry electrical power at a first voltage to one or more electrical powertrain components of the electrified vehicle, arranging a second layer above at least a portion of the first electrical connection layer, wherein the second layer includes one or more second electrical transmission lines each configured to carry electrical power at a second voltage to one or more electrical power distribution components of the electrified vehicle, and arranging a third layer above at least a portion of the first and second layers, wherein the third layer includes one or more third electrical transmission lines each configured to carry electrical power at a third voltage to one or more input/output device components of the electrified vehicle.

Abstract: A flexible planar wire cable includes a first flexible planar wire having first conductor segments contained in a first longitudinal plane and second conductor segments contained in a second longitudinal plane. First connection segments extend between the first conductor segments and the second conductor segments. The first conductor segments alternate with second conductor segments along a longitudinal axis of the wire harness assembly. The cable further includes a second flexible planar wire having third conductor segments contained in the second longitudinal plane and fourth conductor segments contained in the first longitudinal plane. Second connection segments extend between the third conductor segments and the fourth conductor segments. The third conductor segments alternate with the fourth conductor segments along the longitudinal axis of the flexible planar wire cable. The cable also includes an insulating layer separating and encasing the first and second flexible planar wires.

Abstract: A wiring harness assembly includes a first flexible planar wire cable having a first plurality of separated conductors formed in a first insulating layer comprising a first substantially flat exterior surface, a second flexible planar wire cable having a second plurality of separated conductors formed in a second insulating layer comprising a second substantially flat exterior surface, and a first plurality of apertures formed in the first substantially flat exterior surface and a second plurality of apertures formed in the second substantially flat exterior surface. The first and second plurality of apertures are sized, shaped, and arranged such that an electrical connection is made between the first and second plurality of separated conductors through the first and second plurality of apertures.

Abstract: Electrified vehicle electrical systems and formatting methods include arranging a first layer including one or more first electrical transmission lines each configured to carry electrical power at a first voltage to one or more electrical powertrain components of the electrified vehicle, arranging a second layer above at least a portion of the first electrical connection layer, wherein the second layer includes one or more second electrical transmission lines each configured to carry electrical power at a second voltage to one or more electrical power distribution components of the electrified vehicle, and arranging a third layer above at least a portion of the first and second layers, wherein the third layer includes one or more third electrical transmission lines each configured to carry electrical power at a third voltage to one or more input/output device components of the electrified vehicle.

Abstract: A flexible circuit (FC) and a method of forming the FC each include providing a first dielectric layer, applying a plurality of conductive circuit traces that are substantially parallel to each other to the first dielectric layer, providing a second dielectric layer atop the first dielectric layer and the plurality of conductive circuit traces to form a third dielectric layer having the plurality of conductive traces disposed therein and being configured to support and insulate the plurality of conductive traces, and forming a plurality of channels extending at least partially through a thickness of the third dielectric layer, wherein the plurality of channels are arranged between the plurality of conductive circuit traces and substantially parallel thereto and are configured to provide increased flexibility of the FC.

Abstract: A flexible circuit (FC) and a method of forming the FC each include providing a first dielectric layer, applying a plurality of conductive circuit traces that are substantially parallel to each other to the first dielectric layer, providing a second dielectric layer atop the first dielectric layer and the plurality of conductive circuit traces to form a third dielectric layer having the plurality of conductive traces disposed therein and being configured to support and insulate the plurality of conductive traces, and forming a plurality of channels extending at least partially through a thickness of the third dielectric layer, wherein the plurality of channels are arranged between the plurality of conductive circuit traces and substantially parallel thereto and are configured to provide increased flexibility of the FC.

Abstract: A wiring harness assembly includes a first flexible planar wire cable having a first plurality of separated conductors formed in a first insulating layer comprising a first substantially flat exterior surface, a second flexible planar wire cable having a second plurality of separated conductors formed in a second insulating layer comprising a second substantially flat exterior surface, and a first plurality of apertures formed in the first substantially flat exterior surface and a second plurality of apertures formed in the second substantially flat exterior surface. The first and second plurality of apertures are sized, shaped, and arranged such that an electrical connection is made between the first and second plurality of separated conductors through the first and second plurality of apertures.

Abstract: A wiring harness assembly includes a first flexible planar wire cable. The first flexible planar wire cable has a first plurality of separated conductors formed in a first insulating layer. The first insulating layer includes a first flat exterior surface. The first flat exterior surface defines first apertures that expose at least a portion the first plurality of separated conductors. The first apertures are sized, shaped, and arranged such that arranging a second flat exterior surface of a second flexible planar wire cable in contact with the first flat exterior surface enables an electrical connection between the first plurality of separated conductors and a second plurality of separated conductors formed in a second insulating layer of the second flexible planar wire cable.

Abstract: A flexible circuit (FC) and a method of forming the FC each include providing a first dielectric layer, applying a plurality of conductive circuit traces that are substantially parallel to each other to the first dielectric layer, providing a second dielectric layer atop the first dielectric layer and the plurality of conductive circuit traces to form a third dielectric layer having the plurality of conductive traces disposed therein and being configured to support and insulate the plurality of conductive traces, and forming a plurality of channels extending at least partially through a thickness of the third dielectric layer, wherein the plurality of channels are arranged between the plurality of conductive circuit traces and substantially parallel thereto and are configured to provide increased flexibility of the FC.

Abstract: Electrified vehicle electrical systems and formatting methods include arranging a first layer including one or more first electrical transmission lines each configured to carry electrical power at a first voltage to one or more electrical powertrain components of the electrified vehicle, arranging a second layer above at least a portion of the first electrical connection layer, wherein the second layer includes one or more second electrical transmission lines each configured to carry electrical power at a second voltage to one or more electrical power distribution components of the electrified vehicle, and arranging a third layer above at least a portion of the first and second layers, wherein the third layer includes one or more third electrical transmission lines each configured to carry electrical power at a third voltage to one or more input/output device components of the electrified vehicle.

Abstract: A wiring harness assembly includes a first flexible planar wire cable. The first flexible planar wire cable has a first plurality of separated conductors formed in a first insulating layer. The first insulating layer includes a first flat exterior surface. The first flat exterior surface defines first apertures that expose at least a portion the first plurality of separated conductors. The first apertures are sized, shaped, and arranged such that arranging a second flat exterior surface of a second flexible planar wire cable in contact with the first flat exterior surface enables an electrical connection between the first plurality of separated conductors and a second plurality of separated conductors formed in a second insulating layer of the second flexible planar wire cable.

Abstract: A blind assembly electrical connective arrangement is provided for mating an electrical component with a first structure to a flexible circuit, the flexible circuit being positioned adjacent a second structure, the second structure having first and second surfaces penetrated by an aperture, the arrangement including a male slider, the slider having a platform projecting in a first direction, the platform providing a presentation surface for the flexible circuit, the slider also having at least one set of fingers juxtaposing the second structure, at least one of the fingers being compliant, and the male slider also having an alignment post; and a female housing connected with the electrical component, the female housing having a cavity to receive the platform in the alignment post of the male slider, the female housing having at least one terminal biased for contact with the flexible circuit and wherein movement of the electrical component in a second direction opposite the first direction toward the second st

Abstract: An automotive light arrangement is provided including a cartridge bulb which is generally cylindrical with a terminal cup at first and second ends; a terminal having two opposed arms, the arms having a first section of a bulb receiving end, the arms having a bulb clasping second section for compliantly holding a bulb terminal cap between the arms, the arms having a third section extending away from each other to a central plane section, the central plane section having first and second ends, the central plane section having at the first and second ends a pair of opposed ears extending in a direction toward the bulb cap generally perpendicular to the central plane section, each ear having an aperture, and the opposed ears at the first end being spaced from the opposed ears of the second end of the central section, and the terminal having a finger cut out from the plane section extending downwardly toward the cartridge bulb; a terminal housing mounting the terminal, the terminal housing having two apertures bif