Patent Description:
An example of a wiring harness assembly is disclosed in publication <CIT>.

In accordance with one example, a wiring harness assembly includes a plurality of electrically conductive wires encased within a substrate formed of a dielectric material, an opening defined in the substrate, a lower support segment disposed within the opening, and an upper connector segment secured to the lower support segment. A section of the plurality of electrically conductive wires is exposed within the opening. The lower support segment includes a cradle feature that is in mechanical contact with a lower portion of the plurality of electrically conductive wires, thereby supporting the plurality of electrically conductive wires. The upper connector segment includes a plurality of terminals in mechanical and electrical contact with the plurality of electrically conductive wires.

Presented herein is an assembly that includes a number of conductors that a separated from one another and are encased or embedded within a substrate. The substrate defines a location feature. The substrate also defines an opening that has a predetermined size and shape. A section of the plurality of separated conductors is exposed within the opening. The opening is precisely located relative to the location feature. The assembly, particularly a portion of the substrate that defines the location feature and the opening, may be advantageously formed by an automated additive manufacturing process, e.g. 3D printing, stereolithography, digital light processing, fused deposition modeling, fused filament fabrication, selective laser sintering, selecting heat sintering, multi-jet modeling, multi-jet fusion, electronic beam melting, and/or laminated object manufacturing.

The examples presented herein are directed to assemblies in which the conductors are wire electrical conductors.

<FIG> illustrates an example of an automotive wiring harness assembly, which can be used according to an embodiment of this invention, hereinafter referred to as the assembly <NUM>. The assembly <NUM> includes a plurality of wires <NUM> that are formed of an electrically conductive material, e.g. a metallic alloy, carbon nanostructures, and/or electrically conductive polymers. These wires <NUM> are separated from one another and are enclosed within, i.e. surrounded by, a substrate <NUM> that is integrally formed of an electrically insulative material, e.g. a dielectric polymer. As shown in <FIG>, the substrate <NUM> also defines an aperture <NUM> that extends through the substrate <NUM> and in which a section of the wires <NUM> are exposed. Referring again to <FIG>, the substrate <NUM> defines a location feature <NUM>, e.g. a fiducial mark, an edge, a corner, a notch, a slot, or a hole on/in the substrate <NUM>, that can be used by a human operator or preferably an automated assembly robot (not shown) to determine the location of the aperture <NUM>. The aperture <NUM> is precisely located relative to the location feature <NUM>. As used herein, "precisely located" means that the position tolerance of the opening relative to the location feature datum is <NUM> millimeter or less. The position tolerance of the opening may be determined by the capability of the manufacturing technology and/or the capability of the automated assembly robot. This locational relationship between the location feature <NUM> and the aperture <NUM> provides the benefit of adding connectors or electronic modules to the assembly <NUM> using robots rather than requiring human assembly operators. The wires <NUM> are also precisely located relative to one another and relative to the edges of the aperture <NUM>. As shown in <FIG>, the substrate <NUM> surrounds the aperture <NUM>. The exposed section of the wires <NUM> within the aperture <NUM> in this example have an electrically conductive surface that is not covered by an insulative jacket. The wires <NUM> are arranged and maintained by the substrate <NUM> in a predetermined order. In alternative embodiments, the exposed section of the wires <NUM> within the aperture <NUM> may be covered by an insulative jacket. As shown in <FIG>, the assembly <NUM> includes several apertures <NUM> in which several subsets of the wires <NUM> are exposed. As further shown in <FIG>, different sections of the same wires may be exposed in more than one aperture. This provides the benefit of allowing multiple connectors to be attached to the same wires. This may provide easy access to power or signal busses that are connected to more than one connector or electronic module.

This assembly <NUM> lends itself to being manufactured using an automated additive manufacturing process, such as 3D printing, stereolithography, digital light processing, fused deposition modeling, fused filament fabrication, selective laser sintering, selecting heat sintering, multi-jet modeling, multi-jet fusion, electronic beam melting, and/or laminated object manufacturing. The assembly <NUM> may be produced by the automated additive manufacturing process having a shape that is pre-formed to be placed within the packaging accommodation for the wiring harness within a vehicle. The assembly <NUM> is also well suited for robotic placement of the assembly <NUM> within the vehicle.

As illustrated in <FIG>, the wires <NUM> may have different diameters depending on the current carrying capabilities required by circuits formed by the wires <NUM>.

As illustrated in <FIG>, the assembly <NUM> further includes a connector <NUM> having a lower support segment <NUM> disposed within the aperture <NUM> that is secured to the substrate <NUM> by a lower locking feature <NUM>. The lower support segment <NUM> defines cradle features <NUM>, shown in <FIG> and <FIG>, having a plurality of concave arcuate surfaces that contact a lower portion of the each of the wires <NUM>, thereby supporting the wires <NUM> within the aperture <NUM>. In alternative examples, the lower support segment <NUM> may be integrally formed with the substrate <NUM>.

Returning to <FIG>, the connector <NUM> further includes an upper connector segment <NUM> that is received within the lower support segment <NUM> and is secured to the lower support segment <NUM> by an upper locking feature <NUM>. The upper connector segment <NUM> includes a plurality of terminals <NUM>. The terminals <NUM> have a first end <NUM> that is in mechanical and electrical contact with the wires <NUM> and a second end <NUM> that is configured to mate with a corresponding mating terminal (not shown) to form an electrical connection with a separate electrical device (not shown), e.g. an electronic control module, a lighting module, an electronic sensor, and/or another electrical wiring harness. In alternative embodiments, the upper connector segment <NUM> may be integrally formed with the substrate <NUM> and connected to the substrate <NUM> by a living hinge. As illustrated in <FIG>, the assembly <NUM> includes several connectors. The terminals <NUM> in one of these connectors may be connected to wires <NUM> common with the terminals <NUM> in another connector <NUM>. Alternatively, one of these connectors may not include terminals <NUM> that are connected to wires <NUM> common to any of the other connectors.

As illustrated in <FIG>, the first end <NUM> of each terminal <NUM> defines a forked end <NUM> that has two tines <NUM>. A wire <NUM> is received between the two tines <NUM>. The walls of the two tines <NUM> are angled so that the two tines <NUM> are in compressive contact with the wire <NUM> when the upper connector segment <NUM> is fully seated within the lower support segment <NUM>. In alternative embodiments in which the exposed section of the wires <NUM> within the aperture <NUM> is covered by an insulative jacket, the two tines <NUM> are also configured to cut through and displace the insulative jacket so that the terminal <NUM> can make compressive electrical contact with the wire <NUM> within. As shown in <FIG>, the lower support segment <NUM> defines a plurality of recesses in which the ends of the two tines <NUM> of the plurality of terminals <NUM> are received. The cradle features <NUM> of the lower support segment <NUM> support the wires <NUM> to inhibit bending of the wire <NUM> as the wire <NUM> is received within the two tines <NUM> of the terminal <NUM> and the two tines <NUM> come into compressive contact with the wires <NUM>.

In an alternative embodiment of the assembly <NUM>, the wires <NUM> have a coating that is formed of an electrically conductive material (e.g. pure tin or a tin-based solder) that has a lower melting point than the conductive material forming the wires <NUM>. The terminals <NUM> are metallurgically bonded to the wires <NUM> by a soldering or welding process due to localized heating of a portion of the coating. This heating may be performed using a laser, resistive heating of the terminal <NUM> and the wire <NUM>, application of a soldering iron, or other means.

In alternative embodiments of the assembly <NUM>, the upper connector segment <NUM> may be replaced by an upper modular segment that itself contains a relay, an electronic controller, an electronic sensor, a lighting device, and/or other electronic devices. The upper modular segment includes terminals <NUM> that have the first end <NUM> that is in mechanical and electrical contact with the wires <NUM> but the second end of the terminal is directly connected to circuitry or electrical or electronic devices within the upper modular segment rather than corresponding mating terminals.

As shown in <FIG> and <FIG>, the lower support segment <NUM> defines a lower lip <NUM> that extends laterally from the lower support segment <NUM> and engages a lower surface of the substrate <NUM> around a perimeter of the aperture <NUM>. The upper connector segment <NUM> likewise defines an upper lip <NUM> engaging an upper surface of the substrate <NUM> around the perimeter of the opening. The lower and upper lips <NUM>, <NUM> sandwich the substrate <NUM> therebetween to further secure the lower support segment <NUM> within the aperture <NUM>. This provides the benefit of limiting longitudinal movement of the connector <NUM> within the aperture <NUM>.

The lower lip <NUM> defines a lower groove <NUM> that contains a lower seal <NUM> that is formed of a compliant material (e.g. a silicone rubber). The lower seal <NUM> engages the lower surface of the substrate <NUM> around the perimeter of the aperture <NUM> and seals the interface between the lower support segment <NUM> and the substrate <NUM> to inhibit intrusion of contaminants, such as dust and fluids, into the aperture <NUM>, thereby protecting the terminals <NUM> and the wires <NUM> within the aperture <NUM>. The upper lip <NUM> similarly defines an upper groove <NUM> that contains an upper seal <NUM> that is also formed of a compliant material, such as silicone rubber, that engages the upper surface of the substrate <NUM> around the perimeter of the aperture <NUM> and seals the interface between the upper connector segment <NUM> and the substrate <NUM> to inhibit intrusion of contaminants into the aperture <NUM>, thereby protecting the terminals <NUM> and the wires <NUM> within the aperture <NUM>. A single seal design and construction may be used for the lower seal <NUM> and the upper seal <NUM> in order to provide the benefit of reduced number of unique parts in the assembly <NUM>.

In alternative embodiments of the assembly <NUM>, the assembly <NUM> may further include a first inner seal <NUM> that is located intermediate the lower support segment <NUM> and an inner surface of the aperture <NUM> that engages both the lower support segment <NUM> and the substrate <NUM>. The assembly <NUM> may also include a lower seal <NUM> that is formed of a compliant material and sealingly engages a lower inner surface of the substrate <NUM> within the aperture <NUM> to inhibit intrusion of contaminants, such as dust and fluids, into the aperture <NUM>. The first inner seal <NUM> may be used in addition to, or instead of, the lower seal <NUM>. In this or other alternative embodiments, the assembly <NUM> may additionally include a second inner seal <NUM> that is formed of a compliant material located intermediate the upper connector segment <NUM> and the lower support segment <NUM> to further inhibit intrusion of contaminants into the aperture <NUM>.

As shown in <FIG>, a first region <NUM> of the substrate <NUM> surrounding the opening is thicker than a second region <NUM> of the substrate <NUM> remote from the opening. This greater thickness of the substrate <NUM> in the first region <NUM> than the second region <NUM> provides increased stiffness in the first region <NUM> relative to the second region <NUM>. The increased stiffness in the first region <NUM> around the aperture <NUM> provides the benefit of a secure connection between the connector <NUM> and the substrate <NUM> while the decreased stiffness in areas remote from the aperture <NUM> allow the assembly <NUM> to flex in order to be installed within a vehicle. There may also be other regions of varying stiffness in the harness. These variations may provide benefits of providing mounting features or reducing the probability of the assembly <NUM> rattling when installed in the vehicle.

In alternative embodiments of the assembly <NUM>, the increased stiffness in the first region <NUM> relative to the second region <NUM> may be provided by the substrate <NUM> being formed in a particular shape, e.g. including a stiffening rib or beam. The stiffness may also vary due to differences in the structure of the material, e.g. a lattice structure vs. a solid structure, differences in thickness of the material, or use of different polymer materials having different stiffness properties e.g. polyamide and polypropylene.

In alternative illustrative examples of the assembly <NUM> not according to the invention, the substrate <NUM> is a structural portion of a motor vehicle <NUM>, such as a headliner, trim panel, body panel, floor liner, or hood liner as shown in <FIG>.

As shown in <FIG>, the assembly <NUM> also includes attachment features <NUM> that are incorporated into the substrate <NUM>. These attachment features <NUM> may be used to secure the assembly <NUM> to the structural portion of a motor vehicle <NUM>. The attachment features <NUM> may be integrally formed by the substrate <NUM> or they may be discrete parts that are incorporated into the substrate <NUM> during the forming of the substrate <NUM> by forming the substrate <NUM> around a portion of the attachment feature <NUM>. The attachment features <NUM> shown in <FIG> are eyelets that receive a stud, bolt, push pin or other attachment device having a shaft and a head. In alternative embodiments, the attachment features <NUM> may be smooth studs, treaded studs, barbed pins, "fir trees" or other attachment features <NUM> known to those skilled in the art.

Also presented herein is an apparatus that can be used to manufacture the assembly <NUM> described above. <FIG> illustrates an 3D printing apparatus according to an illustrative example not according to the invention, hereinafter referred to as the apparatus <NUM>. The apparatus <NUM> includes an extruding device <NUM> with a dispensing head <NUM> that selectively dispenses a dielectric thermoplastic material though an orifice <NUM> in the dispensing head <NUM>. The thermoplastic material may be provided to the dispensing head <NUM> in the form of a thermoplastic filament, as used in filament deposition modeling, thermoplastic pellets, or a thermoplastic powder.

The apparatus <NUM> also includes a wire feed device <NUM> that selectively feeds an electrically conductive wire, hereinafter referred to as the wire <NUM>, through the orifice <NUM>. A cutting device <NUM> that is configured to selectively sever the wire <NUM> after it passes through the orifice <NUM> is also included in the apparatus <NUM>. The wire <NUM> may already be surrounded by an insulative jacket prior to passing through the orifice <NUM>.

This apparatus <NUM> further comprises an electromechanical device <NUM>, such as a robotic arm, that holds the extruding device <NUM>, the wire feed device <NUM>, and the cutting device <NUM> and is configured to move the extruding device <NUM>, the wire feed device <NUM>, and the cutting device <NUM> within a 3D space.

The apparatus <NUM> additionally encompasses an electronic controller <NUM> that is in communication with the extruding device <NUM>, the wire feed device <NUM>, the cutting device <NUM>, and the electromechanical device <NUM>. The electronic controller <NUM> has one or more processors and memory. The processors may be a microprocessors, application specific integrated circuits (ASIC), or built from discrete logic and timing circuits (not shown). Software instructions that program the processors may be stored in a nonvolatile (NV) memory device (not shown). The NV memory device may be contained within the microprocessor or ASIC or it may be a separate device. Non-limiting examples of the types of NV memory that may be used include electrically erasable programmable read only memory (EEPROM), masked read only memory (ROM), and flash memory. The memory device contains instructions that causes the electromechanical device <NUM> to move the extruding device <NUM>, the wire feed device <NUM>, and the cutting device <NUM> within the 3D space. The instructions also cause the extruding device <NUM> to selectively dispense the dielectric material though the orifice <NUM>. The instruction further cause the wire feed device <NUM> to selectively feed the wire <NUM> through the orifice <NUM> and cause the cutting device <NUM> to selectively sever the wire <NUM>.

The memory device may further contains instructions that causes the extruding device <NUM> to selectively dispense the dielectric material though the orifice <NUM> as the electromechanically device moves the extruding device <NUM> in the 3D space to form the substrate <NUM>. The instructions additionally cause the wire feed device <NUM> to selectively feed the wire <NUM> through the orifice <NUM>, and the cutting device <NUM> to selectively sever the wire <NUM> as the electromechanically device moves the wire feed device <NUM> and the cutting device <NUM> in the 3D space to form a plurality of wires <NUM> formed of the wire <NUM> that are subsequently encased within the substrate <NUM> by the extruding device <NUM>. The instructions further cause the electrotechnical device and the extruding device <NUM> to define a location feature <NUM> in the substrate <NUM> and define an aperture <NUM> in the substrate <NUM> which has a predetermined size and shape in which a portion of the wires <NUM> is exposed. This aperture <NUM> is precisely located relative to the location feature <NUM>.

According to an alternative illustrative example of the apparatus <NUM> not according to the invention, the apparatus <NUM> further includes a 3D curved surface <NUM> upon which the extruding device <NUM> selectively dispenses the dielectric material and the wire feed device <NUM> to selectively deposits the conductive wire. This 3D curved surface <NUM> provides the benefit of forming the assembly <NUM> with a predetermined shape.

This alternative example may also include a heating device <NUM> in communication with the electronic controller <NUM> and is configured to heat a portion of the 3D curved surface <NUM>. The memory device further contains instructions that causes the cooling device <NUM> to selectively heat the portion of the curved surface <NUM>. This feature provides the benefit of heating the thermoplastic material while forming the substrate <NUM> in order to produce a desired shape or material properties.

This alternative example may additionally or alternatively include a cooling device <NUM> that is also in communication with the electronic controller <NUM> and is configured to cool a portion of the 3D curved surface <NUM>. The memory device further contains instructions that causes the cooling device <NUM> to selectively cool the portion of the curved surface <NUM>. This feature provides the benefit of cooling the thermoplastic material while forming the substrate <NUM> in order to produce a desired shape or material properties. The heating device <NUM> and the cooling device <NUM> may be the same device, e.g. a thermoelectric device.

Additionally, a method <NUM> of operating the apparatus <NUM>, as described above, to manufacture the assembly <NUM>, also as described above is presented herein. <FIG> illustrates an example of a method <NUM> of forming a wiring harness assembly <NUM> using an apparatus <NUM> comprising an extruding device <NUM> having a dispensing head <NUM>, a wire feed device <NUM>, a cutting device <NUM>, an electromechanical device <NUM>, and an electronic controller <NUM> in communication with the extruding device <NUM>, the wire feed device <NUM>, the cutting device <NUM>, and the electromechanical device <NUM>.

The steps of the method <NUM> of operating the apparatus <NUM> are described below:.

STEP <NUM>, DISPENSE A DIELECTRIC MATERIAL USING AN extruding device <NUM>, includes selectively dispensing a dielectric material though an orifice <NUM> in the dispensing head <NUM> by operating the extruding device <NUM> in accordance with a command from the electronic controller <NUM>;.

STEP <NUM>, FEED A CONDUCTIVE WIRE USING A WIRE FEED DEVICE, includes selectively feeding a wire <NUM> through the orifice <NUM> by operating the wire feed device <NUM> in accordance with a command from the electronic controller <NUM>;.

STEP <NUM>, SEVER THE CONDUCTIVE WIRE USING A CUTTING DEVICE, includes selectively severing the wire <NUM> by operating the cutting device <NUM> in accordance with a command from the electronic controller <NUM>;.

STEP <NUM>, MOVE THE EXTRUDING DEVICE, THE WIRE FEED DEVICE, AND THE CUTTING DEVICE WITHIN A 3D SPACE BY OPERATING AN ELECTROMECHANICAL DEVICE, includes moving the extruding device <NUM>, the wire feed device <NUM>, and the cutting device <NUM> within a 3D space by operating the electromechanical device <NUM> in accordance with a command from the electronic controller <NUM>;.

STEP <NUM>, FORM A PLURALITY OF ELECTRICALLY CONDUCTIVE WIRES, includes forming a plurality of wires <NUM> by operating the wire feed device <NUM>, the cutting device <NUM>, and the electromechanical device <NUM> in accordance with a command from the electronic controller <NUM>;.

STEP <NUM>, FORM A SUBSTRATE, includes forming a substrate <NUM> made of the dielectric material that encases the plurality of wires <NUM> by operating the extruding device <NUM> and the electromechanical device <NUM> in accordance with a command from the electronic controller <NUM>;.

STEP <NUM>, FORM A LOCATION FEATURE, includes forming a location feature <NUM> in the substrate <NUM> by operating the extruding device <NUM> and the electromechanical device <NUM> in accordance with a command from the electronic controller <NUM>; and.

STEP <NUM>, FORM AN OPENING IN THE SUBSTRATE, includes forming an opening or an aperture <NUM> in the substrate <NUM> having a predetermined size and shape in which a portion of plurality of wires <NUM> is exposed by operating the extruding device <NUM> and the electromechanical device <NUM> in accordance with a command from the electronic controller <NUM>, wherein the opening or aperture <NUM> is precisely located relative to the location feature <NUM>.

In an alternative illustrative example of the method <NUM> not according to the invention, the apparatus <NUM> further includes a 3D curved surface <NUM> and the method <NUM> further includes a step of selectively dispensing the dielectric material onto the curved surface <NUM> by operating the extruding device <NUM> and the electromechanical device <NUM> in accordance with a command from the electronic controller <NUM>. This embodiment may further include a cooling device <NUM> in communication with the electronic controller <NUM> and configured to cool a portion of the curved surface <NUM> and the method <NUM> further comprises the step of cooling the portion of the curved surface <NUM> by operating the cooling device <NUM> in accordance with a command from the electronic controller <NUM>. This embodiment may alternatively or additionally include a heating device <NUM> in communication with the electronic controller <NUM> and configured to heat a portion of the curved surface <NUM> and the method <NUM> further comprises the step of heating the portion of the curved surface <NUM> by operating the heating device <NUM> in accordance with a command from the electronic controller <NUM>.

Claim 1:
A wiring harness assembly (<NUM>), comprising;
a plurality of electrically conductive wires (<NUM>) encased within a substrate (<NUM>) formed of a dielectric material;
an opening defined in the substrate (<NUM>), wherein a section of the plurality of electrically conductive wires (<NUM>) is exposed within the opening;
a lower support segment (<NUM>) disposed within the opening (<NUM>), wherein the lower support segment (<NUM>) includes a cradle feature (<NUM>) that is in mechanical contact with a lower portion of the plurality of electrically conductive wires (<NUM>), thereby supporting the plurality of electrically conductive wires (<NUM>); and
an upper connector segment (<NUM>) secured to the lower support segment (<NUM>), wherein the upper connector segment (<NUM>) includes a plurality of terminals (<NUM>) in mechanical and electrical contact with the plurality of electrically conductive wires (<NUM>).