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: A process of manufacturing an electrical wiring assembly includes the steps of cutting an elongate strip from a sheet of metal and cutting a mesial slit in an end of the uninsulated segment, thereby forming a pair of distal projections flanking the mesial slit. The mesial slit and the pair of distal projections form a forked split blade terminal.

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 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 modular retainer assembly is presented herein. The modular retainer assembly includes a first retainer module defining a flexible first retaining finger and a second retainer module that is distinct from and joined to the first retaining module. The second retainer module defines a flexible second retaining finger. When the first and second retainer modules are mated together, the first retaining finger is arranged opposite the second retaining finger. The first and second retaining fingers are configured to receive and retain an elongate article, such as a wire cable, between them.

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 electrical cable assembly is presented herein. The electrical cable assembly includes a multiconductor flat cable including a first and second electrically conductive wire arranged in a coplanar fashion with each other and encased within a planar dielectric structure. A slot is defined in the planar dielectric structure intermediate the first and second wires, thereby forming first wing features in the dielectric structure extending from the first wire and second wing features extending from the second wire. Exposed portions of the first and second wires extend beyond the first and second wing features. A method of forming the electrical cable assembly, an apparatus for forming the electrical cable assembly, and an electrical terminal configured for use in the electrical cable assembly is also presented. The wing features may include holes and the terminals may include prongs to be received in the holes.

Abstract: A modular retainer assembly is presented herein. The modular retainer assembly includes a first retainer module defining a flexible first retaining finger and a second retainer module that is distinct from and joined to the first retaining module. The second retainer module defines a flexible second retaining finger. When the first and second retainer modules are mated together, the first retaining finger is arranged opposite the second retaining finger. The first and second retaining fingers are configured to receive and retain an elongate article, such as a wire cable, between them.

Abstract: A modular retainer assembly is presented herein. The modular retainer assembly, includes a first retainer module defining a flexible first retaining finger and a second retainer module that is distinct from and joined to the first retaining module. The second retainer module defines a flexible second retaining finger. When the first and second retainer modules are mated together, the first retaining finger is arranged opposite the second retaining finger. The first and second retaining fingers are configured to receive and retain an elongate article, such as a wire cable, between them.

Abstract: A modular retainer assembly is presented herein. The modular retainer assembly, includes a first retainer module defining a flexible first retaining finger and a second retainer module that is distinct from and joined to the first retaining module. The second retainer module defines a flexible second retaining finger. When the first and second retainer modules are mated together, the first retaining finger is arranged opposite the second retaining finger. The first and second retaining fingers are configured to receive and retain an elongate article, such as a wire cable, between them.

Abstract: An electrical cable assembly is presented herein. The electrical cable assembly includes a multiconductor flat cable including a first and second electrically conductive wire arranged in a coplanar fashion with each other and encased within a planar dielectric structure. A slot is defined in the planar dielectric structure intermediate the first and second wires, thereby forming first wing features in the dielectric structure extending from the first wire and second wing features extending from the second wire. Exposed portions of the first and second wires extend beyond the first and second wing features. A method of forming the electrical cable assembly, an apparatus for forming the electrical cable assembly, and an electrical terminal configured for use in the electrical cable assembly is also presented.

Abstract: A process of manufacturing an electrical wiring assembly includes the steps of cutting an elongate strip from a sheet of metal and cutting a mesial slit in an end of the uninsulated segment, thereby forming a pair of distal projections flanking the mesial slit. The mesial slit and the pair of distal projections form a forked split blade terminal.

Abstract: A method is disclosed of sealing a wire terminal assembly including a conductive cable core connected to a conductive terminal along a conductive connection interface. According to the method, a coating composition is dispensed over the conductive connection interface. The coating composition includes (1) a polymerizable compound with an unsaturated bond, and (2) a free radical photoinitiator. The dispensed coating composition is then subjected to actinic radiation for a duration of less than 0.7 seconds.

Abstract: A method of manufacturing a twisted pair wire cable includes the step of arranging a first wire cable in a parallel orientation with a second wire cable. The first and second wire cables each have a conductive inner core and an insulative jacket surrounding the inner core. The method further includes the steps of applying a curable adhesive, such as a urethane acrylate oligomer based adhesive, to the jackets of the first and second wire cables, twisting the first and second wire cables one about the other, and curing the adhesive.

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 method is disclosed in which a self-healing layer is disposed over a conductive connection interface between a conductive terminal and a conductive cable core. The self-healing layer is the product of a free radical polymerization reaction of a coating composition that is applied over the conductive connection interface by depositing a coating by spray application of a fluid coating composition having a viscosity of 200 to 2500 centipoise over the conductive connection interface. The coating composition comprises (1) a polymerizable compound comprising an unsaturated bond and (2) greater than 4 parts per hundred by weight of a free radical photoinitiator, based on the total weight of polymerizable compound.

Abstract: A method of manufacturing a twisted pair wire cable includes the step of arranging a first wire cable in a parallel orientation with a second wire cable. The first and second wire cables each have a conductive inner core and an insulative jacket surrounding the inner core. The method further includes the steps of applying a curable adhesive, such as a urethane acrylate oligomer based adhesive, to the jackets of the first and second wire cables, twisting the first and second wire cables one about the other, and curing the adhesive.

Abstract: A wire terminal assembly is disclosed for a cable conductive core. A conductive terminal is connected to the conductive cable core along a conductive connection interface. A coating is disposed over the conductive connection interface. The coating includes the free radical addition polymerizate of a coating composition including: (1) a polymerizable compound comprising an unsaturated bond, and (2) greater than 4 parts per hundred by weight of a free radical photoinitiator, based on the total weight of polymerizable compound.

Abstract: A method is disclosed of sealing a wire terminal assembly including a conductive cable core connected to a conductive terminal along a conductive connection interface. According to the method, a coating composition is dispensed over the conductive connection interface. The coating composition includes (1) a polymerizable compound with an unsaturated bond, and (2) a free radical photoinitiator. The dispensed coating composition is then subjected to actinic radiation for a duration of less than 0.7 seconds.

Abstract: A coated article is disclosed in which a self-healing layer is disposed over a substrate. The self-healing layer is the product of a free radical polymerization reaction of a coating composition applied over the substrate, the coating composition including: (1) an oligomer comprising at least two active unsaturated bonds, (2) a monomer comprising an unsaturated bond, and (3) a compound comprising a plurality of thiol groups.