Abstract: A connector adapter designed to securely hold a connector connected to an elongate conductor within an aperture in a substrate is disclosed herein. The connector adapter includes a frame with an opening to accommodate the elongate conductor, an attachment feature for fastening the frame to the substrate, and a retention feature to firmly hold the connector within the frame. This innovative connector adapter provides a reliable and efficient solution for maintaining the connection between the elongate conductor and the substrate, ensuring stability and functionality in various applications.

Abstract: A wiring harness installation assembly includes a first member and a second member. The first member includes a first arm and a second arm. The first arm has a first rotation feature. The second arm has a set of first ribs. The second member includes a third arm and a fourth arm. The third arm has a second rotation feature rotatably coupled to the first rotation feature. The fourth arm is configured to flex between a first position and a second position. The fourth arm has a set of second ribs configured to engage the set of first ribs to inhibit rotation of the first member relative to the second member when the fourth arm is in the first position. The first rotation feature is configured to rotate relative to the second rotation feature when the fourth arm is in the second position.

Abstract: An end cap for a wiring harness installation sleeve includes a base, a first portion, and a second portion. The base is disposed around a central axis and includes a first end and a second end opposite the first end. The first portion extends from the first end and is disposed about the central axis. The first portion includes an outer surface. The second portion extends from the first end and is disposed about the central axis. The second portion includes an inner surface. The inner surface and the outer surface define a gap configured to receive the wiring harness installation sleeve.

Abstract: A wiring harness installation assembly includes a first member and a second member. The first member includes a locking tab. The second member includes an upper surface and a side surface. The side surface extends from the upper surface. The upper surface and the side surface define an aperture. The aperture includes a first portion and a second portion. The first portion is formed in the side surface. The second portion is formed in the upper surface. The first portion is configured to receive the locking tab. The second portion is configured to receive a tool operable to engage the locking tab.

Abstract: A seal assembly includes a first retainer and a second retainer. The first retainer includes a first base having a first inner surface defining a first aperture and a protrusion extending from the first inner surface. The second retainer is configured for removable connection with the first retainer and includes a second base having an outer surface, a second inner surface opposite the outer surface, and an end surface extending between the outer surface and the second inner surface. The second inner surface defines a second aperture. The end surface defines an opening configured to receive the protrusion. The outer surface defines a groove in communication with the opening and configured to translatably-receive the protrusion upon rotation of the second retainer relative to the first retainer.

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: The present disclosure provides a device designed for the efficient handling and organization of elongated conductors. The device includes a pallet specifically configured for winding an elongated conductor around it, ensuring orderly storage and transport. Connector retaining features are incorporated to secure terminating connectors of the conductor at predetermined locations on the pallet's surface, facilitating easy removal by a robotic device. Additionally, the device is equipped with manipulation features that enable a robotic device to effectively manipulate the pallet, enhancing automation in processes involving the handling of elongated conductors. This configuration allows for streamlined operations in environments where robotic devices are employed for tasks such as assembly, storage, or transportation of conductors.

Abstract: A wiring harness assembly includes a plurality of electrical conductors having wires enclosed within insulative sheaths that are integrally formed of an electrically insulative material. The assembly also includes a lattice support structure that is attached to the insulative sheaths at multiple locations. The lattice support structure is configured to maintain a desired shape of the assembly. The lattice support structure is formed of filaments that may be formed using an additive manufacturing process The filaments may be arranged such that lattice support structure defines a plurality of hexagonally shaped apertures. A process for manufacturing the wiring harness assembly and an apparatus configured to manufacture the wiring harness assembly is also presented.

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: Systems and methods for an electrical connector (e.g., of a vehicle) include a housing and a terminal at least partially disposed in the housing, defining a set of angled blade terminals, and configured to electrically connect to (i) an electrical system along a first axis and (ii) a set of exposed conductive circuit traces of a flexible circuit (FC) arranged along a second axis, wherein an acute angle is defined between the first and second axes and corresponds to the set of angled blade terminals.

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 self-aligning mechanical mount and electrical connection system for an electronic module comprises a mechanical mount assembly configured to be integrated into or attached to a base frame and defining a mount connection position assurance (CPA) feature for self-aligning and securing of the electronic module therein, and an electrical connection assembly configured to be integrated into or attached to the mechanical mount assembly and comprising a modular electrical connector (i) being electrically connected to an electrical backbone wire cable and (ii) defining a connector CPA feature for self-aligning the modular electrical connector with a corresponding electrical connector integrated into or attached to the electronic module when the electronic module is secured in the mechanical mount assembly.

Abstract: Electrical connectors that support coupling of paired wire cables is described. The electrical connector includes an inner terminal cartridge and an insulator body. The inner terminal cartridge includes a pair of terminal cavities configured to retain a pair of inner terminals at elongate sides of the inner terminal cartridge. The inner terminal cartridge is insertable into the insulator body to simultaneously stage the inner terminals in a mating position in the insulator body.

Abstract: A wiring cable and a method of manufacturing a wiring cable are described. The wiring cable includes a plurality of elongate planar electrical conductors electrically insulated from one another and shielded by a protective jacket formed over the elongate electrical conductors. The protective jacket includes a substantially flat outer surface of the wiring cable. The wiring cable further includes a signal conductor with an annular outer profile integrated with the protective jacket at the substantially flat outer surface and at least partially shielded from interference by the protective jacket of the wiring cable. The annular signal conductor may be jacketless, without annular shielding or an annular protective coating.

Abstract: A cable assembly includes coaxially arranged inner and outer barrels. The outer barrel overlaps a portion of the inner barrel. The inner and outer barrels respectively include first and second features that cooperate with one another to form a retention feature. The cable assembly has a cable that has at least one wire surrounded by an inner insulator that is covered in a metallic shield. The metallic shield is arranged in between the inner and outer barrels. The first feature is arranged beneath the metallic shield, and the second feature is arranged over the metallic shield. At least one of the first and second features extends in a radial direction relative to the other of the first and second features to capture the metallic shield with the retention feature.

Abstract: A method of forming an electrical cable assembly includes providing a multiconductor flat cable comprising wires arranged in a coplanar fashion with each other and encased within a planar dielectric structure, cutting a slot in the planar dielectric structure intermediate the wires, thereby forming wing features in the dielectric structure extending from the wires, removing portions of the dielectric structure from ends of the wires, wherein portions of wing features remain, attaching the exposed wires to terminals, wherein the terminals define prongs, and attaching the portions of the wing features to by inserting the prongs within holes defined in the portions of the wing features, thereby retaining the wires to the terminals.

Abstract: An apparatus includes an extruding device configured to dispense a dielectric material though an orifice, a wire feed device configured to feed a conductive wire through the orifice, and a cutting device configured to sever the wire. It also includes an electronic controller configured to control the extruding device, the wire feed device, and the cutting device. The electronic controller commands the extruding device to dispense the dielectric material though the orifice, the wire feed device to feed the wire through the orifice, and the cutting device to sever the wire, thereby forming a dielectric substrate encasing a plurality of wires. The electronic controller further commands the extruding device to form an opening defined in the substrate in which plurality of electrically conductive wires is exposed and a location feature on the substrate located with a positional tolerance less than or equal to 1 mm relative to the opening.

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 method of manufacturing a wiring harness assembly includes the steps of forming a plurality of electrically conductive wires encased within a substrate formed of a dielectric material, forming an opening in the substrate located and sized such that a section of the plurality of electrically conductive wires is exposed within the opening, disposing a support segment within the opening, securing a connector segment including a plurality of terminals to the support segment, and placing the plurality of terminals in mechanical and electrical contact with the plurality of electrically conductive wires.