Patents by Inventor Earl J. Hayes

Earl J. Hayes has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).

  • Patent number: 8651698
    Abstract: A cable lighting assembly comprising two electrically isolated electrical conductors, and at least one light emitting diode comprising an anode lead and a cathode lead. An electrical joint is formed between the anode lead and one of the electrical conductors, an electrical joint is formed between the cathode lead and the other electrical conductor, and a thermal joint is formed between the light emitting diode and one of the electrical conductors.
    Type: Grant
    Filed: May 21, 2012
    Date of Patent: February 18, 2014
    Assignee: 3M Innovative Properties Company
    Inventors: Earl J. Hayes, Jens J. Puetter
  • Publication number: 20120230031
    Abstract: A cable lighting assembly comprising two electrically isolated electrical conductors, and at least one light emitting diode comprising an anode lead and a cathode lead. An electrical joint is formed between the anode lead and one of the electrical conductors, an electrical joint is formed between the cathode lead and the other electrical conductor, and a thermal joint is formed between the light emitting diode and one of the electrical conductors.
    Type: Application
    Filed: May 21, 2012
    Publication date: September 13, 2012
    Inventors: Earl J. Hayes, Jens J. Puetter
  • Publication number: 20120194101
    Abstract: Electrical component assembly (30) comprising a first electrical component (32) comprising an electrical connection protrusion (34) (e.g., a solder bump) made of a first metal solder composition having a first melting point, and a second electrical component (36) comprising an electrical contact (38). A second metal solder composition (40) having a second melting point is formed or otherwise disposed so as to function as an electrical connection between at least a portion of the electrical connection protrusion (34) and the electrical contact (38) of the second electrical component (36). The second melting point is lower than the first melting point, and there is a distinct interface of demarcation between the electrical connection protrusion (34) and the second metal solder composition (40).
    Type: Application
    Filed: September 23, 2010
    Publication date: August 2, 2012
    Inventors: Karl M. Kropp, Earl J. Hayes
  • Patent number: 8182111
    Abstract: A cable lighting assembly (10) comprising a flexible electrical cable (14, 47) and an LED (43). The electrical insulation of the electrical cable has a portion that is removed to expose at least one surface mounting area on the surface of an electrical conductor (45) of the flexible electrical cable (47). Two lengths of the electrical conductor (59, 61) are electrically isolated so as to form at least two electrically isolated surface mounting areas that are electrically isolated from each other. The LED (43) is surface mounted to the electrical conductor (45). A solder joint (67) is formed between the anode lead (55) of the light emitting diode and one of the electrically isolated surface mounting areas (61). Another solder joint (69) is formed between the cathode lead (57) of the light emitting diode and the other electrically isolated surface mounting area (59).
    Type: Grant
    Filed: December 19, 2008
    Date of Patent: May 22, 2012
    Assignee: 3M Innovative Properties Company
    Inventors: Earl J. Hayes, Jens J. Puetter
  • Publication number: 20110007509
    Abstract: A cable lighting assembly (10) comprising a flexible electrical cable (14, 47) and an LED (43). The electrical insulation of the electrical cable has a portion that is removed to expose at least one surface mounting area on the surface of an electrical conductor (45) of the flexible electrical cable (47). Two lengths of the electrical conductor (59, 61) are electrically isolated so as to form at least two electrically isolated surface mounting areas that are electrically isolated from each other. The LED (43) is surface mounted to the electrical conductor (45). A solder joint (67) is formed between the anode lead (55) of the light emitting diode and one of the electrically isolated surface mounting areas (61). Another solder joint (69) is formed between the cathode lead (57) of the light emitting diode and the other electrically isolated surface mounting area (59).
    Type: Application
    Filed: December 19, 2008
    Publication date: January 13, 2011
    Inventors: Earl J. Hayes, Jens J. Puetter
  • Patent number: 7485982
    Abstract: A system for making up wiring harnesses includes a base harness having a set of flexible multi-conductor cables and a set of supplementary wiring harnesses adapted to connect in a particular location of said base harness. The connection area does not have a multi-conductor replaceable connector to the base harness, so that the cost of unused connectors is not incurred. Each supplementary wiring harness connects to a reserved location. The reserved locations may be shared between mutually exclusive options.
    Type: Grant
    Filed: February 13, 2007
    Date of Patent: February 3, 2009
    Assignee: FCI Americas Technology, Inc.
    Inventor: Earl J. Hayes
  • Patent number: 7199487
    Abstract: A system for making up wiring harnesses includes a base harness having a set of flexible multi-conductor cables and a set of supplementary wiring harnesses adapted to connect in a particular location of said base harness. The connection area does not have a multi-conductor replaceable connector to the base harness, so that the cost of unused connectors is not incurred. Each supplementary wiring harness connects to a reserved location. The reserved locations may be shared between mutually exclusive options.
    Type: Grant
    Filed: March 21, 2003
    Date of Patent: April 3, 2007
    Assignee: FCI Americas Technology, Inc.
    Inventor: Earl J. Hayes
  • Patent number: 6835089
    Abstract: An electrical wiring harness assembly including a flex cable comprising electrical conductors; and a plurality of insulation displacement connection (IDC) terminals connected to the conductors of the flex cable. The IDC terminals each include a base section, wire insulation displacement sections connected to the base section and having insulation displacement slots, and sets of teeth extending from the base section which extend through the conductors and are outwardly deformed on an opposite side of the flex cable from the base section. The IDC terminals are adapted to connect electrical wires directly to the conductors of the flex cable.
    Type: Grant
    Filed: November 27, 2002
    Date of Patent: December 28, 2004
    Assignee: FCI Americas Technology, Inc.
    Inventors: Earl J. Hayes, Michael J. Alloway, Raymond B. McLauchlan
  • Publication number: 20040183375
    Abstract: A system for making up wiring harnesses includes a base harness having a set of flexible multi-conductor cables and a set of supplementary wiring harnesses adapted to connect in a particular location of said base harness. The connection area does not have a multi-conductor replaceable connector to the base harness, so that the cost of unused connectors is not incurred. Each supplementary wiring harness connects to a reserved location. The reserved locations may be shared between mutually exclusive options.
    Type: Application
    Filed: March 21, 2003
    Publication date: September 23, 2004
    Applicant: FCI Americas Technology, Inc.
    Inventor: Earl J. Hayes
  • Publication number: 20040102079
    Abstract: An electrical wiring harness assembly including a flex cable comprising electrical conductors; and a plurality of insulation displacement connection (IDC) terminals connected to the conductors of the flex cable. The IDC terminals each include a base section, wire insulation displacement sections connected to the base section and having insulation displacement slots, and sets of teeth extending from the base section which extend through the conductors and are outwardly deformed on an opposite side of the flex cable from the base section. The IDC terminals are adapted to connect electrical wires directly to the conductors of the flex cable.
    Type: Application
    Filed: November 27, 2002
    Publication date: May 27, 2004
    Applicant: FCI Americas Technology, Inc.
    Inventors: Earl J. Hayes, Michael J. Alloway, Raymond B. McLauchlan
  • Patent number: 6726502
    Abstract: A lighting assembly including a flex cable; and a plurality of lighting devices directly connected to conductors of the flex cable. The lighting devices each comprise leads placed against an exterior side of the flex cable and have teeth which pierce through insulation of the flex cable and the conductors to make a mechanical and electrical connection with the flex cable.
    Type: Grant
    Filed: March 21, 2003
    Date of Patent: April 27, 2004
    Assignee: FCI Americas Technology Inc.
    Inventor: Earl J. Hayes
  • Patent number: 6488520
    Abstract: An electrical connector including a housing; electrical contacts connected to the housing; and electrical shorting members connected to the housing. Each contact includes a male contact area to form a male electrical connector. Each shorting member is adapted to electrically connect at least two of the contacts to each other. Each one of the contacts is connected to at least one other contact of the contacts in the connector by the shorting member. The shorting members are each movable to a position spaced from the contacts. The contacts are aligned in an array of at least two rows with multiple ones of the contacts in each row.
    Type: Grant
    Filed: December 27, 2001
    Date of Patent: December 3, 2002
    Assignee: FCI Americas Technology, Inc.
    Inventors: Earl J. Hayes, Raymond B. McLauchlan
  • Patent number: 6467942
    Abstract: A lamp assembly for use with a vehicle's electrical system, the electrical system including a plurality of terminals each having a wire insulating portion and an end connector portion. A main elastomeric housing includes a socket for receiving a bulb. A front seal encircles an exterior surface of the socket and seals around a periphery of the socket. A first plurality of sealing ridges extend along an open facing side of the main housing, opposite the bulb socket, and within which are received the wire insulating portions of the terminals and the end connector portions of each terminal conmmunicating with the bulb socket upon the terminals being located within the main housing. A back cap matingly aligns over an open facing side of the main housing and includes an opposingly facing side with a second plurality of sealing ridges which align with the first plurality of sealing ridges and to sandwich therebetween the wire insulating portions of the terminals.
    Type: Grant
    Filed: April 18, 2001
    Date of Patent: October 22, 2002
    Assignee: Alcoa Fujikura Limited
    Inventors: Michael J. Alloway, Earl J. Hayes, Christopher J. Dillon, Thomas F. Rahrig
  • Publication number: 20020093830
    Abstract: A lamp assembly for use with a vehicle's electrical system, the electrical system including a plurality of terminals each having a wire insulating portion and an end connector portion. A main elastomeric housing includes a socket for receiving a bulb. A front seal encircles an exterior surface of the socket and seals around a periphery of the socket. A first plurality of sealing ridges extend along an open facing side of the main housing, opposite the bulb socket, and within which are received the wire insulating portions of the terminals and the end connector portions of each terminal communicating with the bulb socket upon the terminals being located within the main housing. A back cap matingly aligns over an open facing side of the main housing and includes an opposingly facing side with a second plurality of sealing ridges which align with the first plurality of sealing ridges and to sandwich therebetween the wire insulating portions of the terminals.
    Type: Application
    Filed: April 18, 2001
    Publication date: July 18, 2002
    Inventors: Michael J. Alloway, Earl J. Hayes, Christopher J. Dillon, Thomas F. Rahrig
  • Patent number: 6340249
    Abstract: An apparatus and method for securing fiber optic cable to a connector, comprising providing a cable, said cable having an outer surface, an end section, a cable jacket, and a strengthening material; positioning a strain relief boot on said outer surface of said cable, said strain relief boot having an inner surface, wherein said inner surface has a first geometric pattern; providing a connector assembly, said connector assembly having a connector assembly part, a plug end, a cable end, and an exterior surface, wherein said exterior surface has a second geometric pattern which cooperates with said first geometric pattern on said inner surface of said strain relief boot, said connector part being located on said cable end; positioning said end section of said cable in a manner such that said cable jacket and said strengthening material touch, and cover said outer surface of said connector part; and using a simple tool to slide said strain relief boot toward said connector, and over said connector part, thereby
    Type: Grant
    Filed: September 13, 1999
    Date of Patent: January 22, 2002
    Assignee: Alcoa Fujikura Limited
    Inventors: Earl J. Hayes, Thomas A. Hall, III, Bo M. Wang
  • Patent number: 5703757
    Abstract: A junction box for motor vehicles in which first and second housing portions are provided for receiving and containing, respectively, low and high electrical current circuitboards. The housing portions extend in a generally common plane when connected together to form a housing unit. A planar insulating panel member containing buses and integral insulation displacement terminals are located between the housing portions and in a plane generally perpendicular to the common plane of the housing portions. The first and second housing portions are abutted and fastened together on opposed sides of the panel member with the buses and integral insulation displacement terminals. The insulation displacement terminals are effective to directly receive insulated wires of an electrical harness and electrically connect the same to the buses and to circuits of and electrical components associated with the circuitboards.
    Type: Grant
    Filed: January 31, 1996
    Date of Patent: December 30, 1997
    Assignee: Alcoa Fujikura Limited
    Inventors: Earl J. Hayes, Timothy A. Hutchinson, David A. Hein, Alexander Shen, Michael J. Pike-Biegunski
  • Patent number: 5620291
    Abstract: A device used to fasten and retain two or more conducting elements with sufficient normal force to insure a reliable electrical contact. The device consists of three individual parts: a bolt, a nut, and a spring washer. The bolt of this invention differs from conventional bolts in that it has no threads and has a keying feature. The nut is distinguishable from a standard nut in that it also has no typical thread, but has a keying feature and internal ramps. The spring washer provides a linear increase in force proportional to deflection. Like the bolt and nut, the spring washer also has a keying feature.
    Type: Grant
    Filed: February 16, 1996
    Date of Patent: April 15, 1997
    Assignee: Alcoa Fujikura Ltd.
    Inventors: Earl J. Hayes, Stefano Spadoni, Jason E. Porter
  • Patent number: 5529509
    Abstract: Disclosed is a ring terminal connector which includes a pair of like circular, substantially flat apertured terminals. Each terminal has a raised bump or nib on its upper surface and a nib opening on its upper surface such that the pair of terminals may be interlocked by fixing the raised nib of each terminal in the nib opening of the other terminal. The terminals also each have a pair of inwardly directed slotted flanges and an elongated opening or groove to properly orient one terminal with respect to the other. One of the terminals may be turned over and engaged with the other terminal such that by rotating one relative to the other, the terminals may be interlocked. Further, the terminals each have an integral outwardly directed crimping arm to receive wires and maintain a positive connection between the connector and the wires and/or the bolt to which the connector is attached.
    Type: Grant
    Filed: May 12, 1995
    Date of Patent: June 25, 1996
    Assignee: Alcoa Fujikura Limited
    Inventors: Earl J. Hayes, Stefano Sapdoni, Dhananjay B. Kulkarn
  • Patent number: 5342226
    Abstract: A female blade terminal assembly including a female blade terminal having a cage structure adapted to receive a male blade terminal and a shroud of seamless tubular cross sectional configuration adapted to fit over the cage structure in surrounding relation to the beam portions of the cage structure. The female blade terminal is formed from a single piece of conductive sheet material of a given thickness and the beam portions have a thickness less than the given thickness. The cage portion further includes front and rear annular collar portions of the given thickness with the reduced thickness beam portions extending between the annular collar portions. The shroud precludes outward splaying of the cage structure in response to insertion of the male blade terminal, limits the outward deflection of the beam portions to preclude plastic deformation of the beam portions, and precludes the entry of contaminants into the electrical interface between the beam portions and the male blade terminal.
    Type: Grant
    Filed: June 21, 1993
    Date of Patent: August 30, 1994
    Assignee: Electro-Wire Products, Inc.
    Inventors: Earl J. Hayes, Christopher J. Volpe
  • Patent number: 5199900
    Abstract: An electrical connector assembly has a frame member which is positioned on a housing and is movable between an terminal insertion position and a terminal lock position. The frame member has resilient fingers with extend into terminal receiving cavities of the housing to properly position and maintain the terminals in the terminal receiving cavities when the frame member is in the terminal lock position. The frame member has anti-rattle projections which cooperate with a panel when the assembly is mounted therein. The anti-rattle projections ensure that a positive electrical connection will be effected and maintained over time.
    Type: Grant
    Filed: February 21, 1992
    Date of Patent: April 6, 1993
    Assignee: AMP Incorporated
    Inventor: Earl J. Hayes, Sr.