Patent Description:
The subject invention relates to an overmolded wiring harness for providing a pre-formed harness to facilitate installation within a vehicle and protecting a bundle of wires against the adverse effects of vibrations, abrasions, moisture, and/or debris corresponding with automotive electronic systems.

A wiring harness for an automotive electronics system used to electrically connect electrical components is provided. The wiring harness includes a hollow trunk sleeve including one or more notches along a length between a pair of opposing ends. The hollow trunk sleeve also includes one or more bends along the length between the pair of opposing ends positioned in a desired pre-defined pattern, with each of the one or more bends spaced from the one or more notches. The wiring harness also includes a hollow branch sleeve coupled to the hollow trunk sleeve at each corresponding notch of the one or more notches to interconnect the hollow branch sleeve to the hollow trunk sleeve, with each hollow branch sleeve open to the hollow trunk sleeve through the respective notch. The wiring harness also includes a bundle of wires extending through the hollow trunk sleeve, with a sub-set of the bundle of wires extending through each notch and each corresponding hollow branch sleeve.

The wiring harness also includes a first encapsulation layer disposed about a portion of the hollow trunk sleeve and a portion of each of the hollow branch sleeves at each interconnection to separately secure the hollow branch sleeve to each hollow trunk sleeve. Still further, the wiring harness also includes a second encapsulation layer disposed about each bend to maintain the hollow trunk sleeve in the desired pre-defined pattern with each second encapsulation layer being separate and spaced from the first encapsulation layer on the hollow trunk sleeve such that at least a portion of the hollow trunk sleeve is free of the encapsulation layers.

In further exemplary embodiments, one or more of the hollow branch sleeves includes one or more bends along its wiring harness. In these embodiments, the wiring harness further includes an auxiliary encapsulation layer disposed about each bend of the hollow branch sleeve to a maintain the hollow branch sleeve in the additional desired pre-defined pattern.

In any of these embodiments, each respective encapsulation layer may have a modulus of elasticity that is less than the modulus of elasticity of hollow trunk sleeve and/or less than any one of the respective hollow branch sleeves. In addition, in any of these embodiments, any two respective encapsulation layers can be made of the same or different materials, and have the same or different respective modulus of elasticity, while still having a modulus of elasticity that is less than the modulus of elasticity of the hollow trunk sleeve and/or the hollow branch.

The embodiments below are described with reference to the drawings. The relationship and functioning of the various elements of the embodiments are better understood by the following detailed description. However, the embodiments as described below are by way of example only, and the invention is not limited to the embodiments illustrated in the drawings. It should also be understood that the drawings are not drawn to scale and, in certain instances, details which are not necessary for an understanding of the embodiments have been omitted.

In the subject invention, a wiring harness includes one or more overmolded portions (i.e.. , encapsulated portions) for protecting a bundle of wires from the adverse effects of vibration, abrasion, moisture, and/or debris. The harness can be comprised of less material and produced by less expensive manufacturing processes, as compared to entire wiring harnesses that are produced by known Reaction Injection Molding ("RIM") processes. Furthermore, the wiring harness is pre-formed with its various overmolded portions to facilitate assembly of automotive electronic systems and installation of the wiring harness within a vehicle.

As provided herein, the term "overmolded" and the term "encapsulated", and any alternative forms thereof such as "encapsulation" or the like, may be used interchangeably and refer to the material that is applied onto the hollow trunk sleeve and hollow branch sleeves to maintain the wiring harness in a desired position, as further discussed below.

As generally shown in <FIG>, a non-limiting example of a vehicle <NUM> having an automotive electronic system <NUM> comprises a wiring harness <NUM> and a plurality of electronic components <NUM> coupled to the wiring harness <NUM> for communicating with one another. Non-limiting examples of electronic components <NUM> can include power distribution centers (PDCs), fuse boxes, electronic control units, battery management systems, DC/DC converters, and timer and flasher relays. However, it is contemplated that the wiring harness can be used for coupling any suitable electronic components of automotive electronic systems.

Referring to <FIG> and <FIG>, an enlarged view of one portion of the exemplary wiring harness <NUM> is illustrated. The wiring harness <NUM> includes a hollow trunk sleeve <NUM> and one or more hollow branch sleeves <NUM> (shown as five hollow branch sleeves 112a-112e in <FIG> and <FIG>) for containing a bundle <NUM> of wires <NUM> (shown as five wires <NUM> in <FIG> and <FIG>) that electronically connect corresponding electronic components <NUM> to one another.

As best shown in <FIG>, which illustrates a partial perspective view of the wiring harness <NUM> prior to assembly, the hollow trunk sleeve <NUM> and one or more hollow branch sleeves <NUM>, sometimes alternatively referred to as convolutes in certain embodiments, are substantially tubular in shape (i.e., are a tubular hollow trunk sleeve <NUM> and one or more tubular hollow branch sleeves <NUM>) and of the type that do not include a slit along their respective lengths, with each of the hollow trunk and branch sleeves <NUM>, <NUM> including opposing open ends (with opposing open ends <NUM> and <NUM> corresponding to the hollow trunk sleeve <NUM>, and with opposing open ends <NUM> and <NUM> corresponding to the one or more hollow branch sleeves <NUM>.

As also illustrated in <FIG>, each one of the hollow trunk and branch sleeves <NUM>, <NUM> can be formed of a material having a modulus of elasticity that permits the respective hollow trunk sleeve <NUM> or any one or more of the hollow branch sleeves <NUM> to be bent or arranged in any suitable curved pattern, linear pattern, or combination thereof (collectively referred to as a desired pre-defined pattern), which corresponds with the available vehicle space receiving the wiring harness <NUM> such that the automotive electronics system can be installed within the vehicle <NUM>. However, in other embodiments, portions of the length of the hollow trunk sleeve <NUM>, or the length of any one or more of the hollow branch sleeves <NUM>, may have varying thicknesses or compositions such that the modulus of elasticity varies for the desired end use. In certain embodiments, the material forming the hollow trunk sleeve <NUM> and/or any one or more hollow branch sleeves <NUM> also has electrical insulation properties. In the example of <FIG>, the entire length of the hollow trunk sleeve <NUM> and each of the entire lengths of the hollow branch sleeves 112a-112e are formed from the same material and have a uniform modulus of elasticity.

In the example illustrated in <FIG> and <FIG>, the wiring harness <NUM> includes one hollow trunk sleeve <NUM> and five hollow branch sleeves <NUM> (also designated by reference numbers 112a-112e) prior to and separately coupled to the hollow trunk sleeve <NUM>, although in other embodiments the number of hollow branch sleeves <NUM> may vary from one or more hollow branch sleeves.

As also illustrated in <FIG> and <FIG>, in one exemplary embodiment, the hollow trunk sleeve <NUM> is bent along its length between its opposing open ends <NUM>, <NUM>. In particular, the first and second portions 118a, 118b of the hollow trunk sleeve <NUM> can be bent or moved to positions providing two generally <NUM>-degree bends. Furthermore, third and fourth portions 118c, 118d of the hollow trunk sleeve <NUM> can be bent or moved to positions providing two generally <NUM>-degree bends. As also illustrated in <FIG> and <FIG>, one hollow branch sleeve 112e is also bent along its length between its opposing ends <NUM>, <NUM>. In particular, a portion <NUM> of the hollow branch sleeve 112e is bent or moved to an additional desired pre-defined pattern providing a generally <NUM>-degree bend. While not illustrated, one or more of the other hollow branch sleeves 112a-d may also be provided with portions bent or moved to a position providing a <NUM>-degree bend, or a <NUM>-degree bend, or any other degree bend to form any one of the hollow branch sleeves in the additional desired pre-defined pattern.

The hollow trunk sleeve <NUM> can include one or more notches <NUM>, shown as four separate spaced apart notches 121a, 121b, 121c, 121d in the exemplary embodiment of <FIG> and <FIG>, for communicating with an open end <NUM> of a corresponding one of the hollow branch sleeves 112a-d. In addition, one of the open ends (shown as open end <NUM> in <FIG>) of the hollow trunk sleeve <NUM> can further define an additional notch for communicating with the open end <NUM> of hollow branch sleeve 112e. The notches 121a, 121b, 121c, 121d are preferably spaced from each portion 118a-d corresponding to the bends of the hollow trunk sleeve <NUM> along the length between the opposing open ends <NUM>, <NUM>. While the notches <NUM> are shown as circular openings in <FIG> and <FIG>, the shapes of such notches <NUM> as illustrated are schematic in nature and not limited to the circular openings provided.

As noted above, and as illustrated in <FIG>, the wiring harness <NUM> also includes a bundle <NUM> of wires <NUM> that are coupled within the hollow trunk sleeve <NUM> with separate sub-sets 107a, 107b, 107c, 107d, 107e of the wires <NUM> also extending within each respective one of the plurality of hollow branch sleeves 112a-112e through each one of the respective notches 121a-121d or through the open end <NUM>.

In particular, the bundle <NUM> of wires is inserted within the hollow trunk sleeve <NUM> at the first open end <NUM>. Once inserted, one of the respective sub-sets 107a, 107b, 107c, 107d, 107e of the bundle <NUM> of wires <NUM>, corresponding to the second end <NUM> of the wires <NUM>, can be separated from the bundle <NUM> extending within the hollow trunk sleeve <NUM> and inserted into one respective one hollow branch sleeve 112a-e while extending through the corresponding respective one notch 121a, 121b, 121c, 121d, or through the open end <NUM> of the hollow trunk sleeve <NUM>. As defined herein, each one respective one of the sub-sets 107a, 107b, 107c, 107d, 107e of the bundle <NUM> can include a single wire <NUM> or multiple wires (shown as a single wire <NUM> in each sub-set 107a, 107b, 107c, 107d, 107e in <FIG>), and the number of wires <NUM> in any one respective sub-set 107a, 107b, 107c, 107d, 107e may be the same or different from any other one respective sub-set 107a, 107b, 107c, 107d, 107e of the bundles of wires <NUM> (i.e., the number of wires <NUM> in any one or more of the sub-sets 107a, 107b, 107c, 107d, 107e may be a single wire <NUM> as in <FIG> or could be two or more wires <NUM> in any one or more of the sub-sets 107a, 107b, 107c, 107d, 107e in alternative embodiments (not shown)).

Once fully inserted, each end <NUM>, <NUM> of any individual one respective wire <NUM> of the sub-set 107a, 107b, 107c, 107d, 107e of the bundle <NUM> of wires <NUM>, and any combination of wires <NUM> of the respective sub-sets 107a, 107b, 107c, 107d, 107e of the bundle <NUM> of wires <NUM>, may be electronically coupled to a respective one or more corresponding electronic components <NUM> in the vehicle <NUM>. In particular, the first end <NUM> of each of the wires <NUM> extends outwardly from the first open end <NUM> of the hollow trunk sleeve <NUM> and may be electronically coupled to a respective one or more corresponding electronic components <NUM> in the vehicle <NUM>, whereas the second end <NUM> of the wires <NUM> extends outwardly from a respective open end of one of the one or more hollow branch sleeves 112a-e and may be electronically coupled to a respective one or more corresponding electronic components <NUM> in the vehicle <NUM>.

Further, the length of each wire <NUM> of the bundle <NUM> of wires <NUM> between each respective open end <NUM>, <NUM> may include a coating to electrically insulate (i.e., an electrical insulation coating (not shown)) each of the respective wires <NUM> from each of the other respective wires <NUM> in the bundle <NUM> or respective sub-set 107a-107e of the bundle <NUM>. Stated another way, each of the wires <NUM> within the bundle <NUM> or the respective sub-set 107a-107e of the bundle <NUM> may be electrically insulated from each other wire <NUM>. The ends <NUM>, <NUM> of the wires <NUM> do not include the insulating coating so that they may be electrically coupled to the one or more corresponding electronic components <NUM> in the vehicle <NUM>, as noted above.

Other examples of hollow trunk sleeve <NUM> can include any number of notches <NUM> at any point along the length of hollow trunk sleeve <NUM> for separating one or more wires <NUM> from the bundle <NUM> of wires <NUM>. Moreover, portions 118e-<NUM> of hollow trunk sleeve <NUM> can include respective Tee union connector (not shown) that separately couples hollow trunk sleeve <NUM> to each respective one of the one or more hollow branch sleeves <NUM>. It is contemplated that the wiring harness <NUM> can have any number of hollow trunk sleeves <NUM> and/or hollow branch sleeves <NUM> that include portions arranged in any pattern suitable for installing the wiring harness <NUM> in a corresponding available space of the vehicle. Each one of the hollow trunk sleeve <NUM> and one or more hollow branch sleeves <NUM> can further comprise a plurality of corrugations <NUM> to facilitate bending to the desired pattern while maintaining an open passage for the bundle of wires <NUM> and preventing the hollow trunk sleeve <NUM> and/or one of the one or more hollow branch sleeves <NUM> from impinging on the wires <NUM>, and thus may each alternatively be defined as corrugated tubes <NUM>, <NUM> (or corrugated trunk tubes <NUM> and corrugated branch tubes <NUM>). However, it is contemplated that one, or both, of the hollow trunk sleeve <NUM> and one or more hollow branch sleeves <NUM> may not have any corrugations <NUM>. Further, the corrugations <NUM> can be formed on the exterior, interior, or both, of the hollow trunk sleeve <NUM> and/or the one or more hollow branch sleeves <NUM>.

The wiring harness <NUM> further comprises one or more encapsulation layers <NUM> (i.e., overmolded layers or otherwise applied layers) coupled to corresponding portions of the hollow trunk sleeve <NUM> and/or the one or more hollow branch sleeves <NUM> in the desired pre-defined pattern for installing the wiring harness <NUM> within the available vehicle space and/or protecting portions of the wiring harness <NUM> from vibration, abrasion, moisture, and/or debris. As one example, the encapsulation layers <NUM> may protect portions of the hollow trunk sleeve <NUM> and/or the one or more hollow branch sleeves <NUM> that pass through sharp sheet metal holes of a vehicle door.

As illustrated in <FIG>, one example of the wiring harness <NUM> includes nine separate encapsulation layers 122a-122i (i.e., overmolded layers 122a-122i), which are coupled to, and preferably surround, corresponding portions 118a-118i of the hollow trunk sleeve <NUM> and/or one or more of the hollow branch sleeves <NUM>. In this embodiment, at least a portion of the hollow trunk sleeve <NUM> is free from the encapsulation layers 122a-122i, which reduces the weight and the cost of the wiring harness <NUM>.

Each of the encapsulation layers 122a-122i can have a modulus of elasticity that is less than the modulus of elasticity of the hollow trunk sleeve <NUM> and/or one or more of the hollow branch sleeves <NUM>. Moreover, at least one of the encapsulation layers 122a-122i is spaced apart from at least another one of the encapsulation layers 122a-122i such that the entire length of the hollow trunk sleeve <NUM> and/or one or more of the hollow branch sleeves <NUM> is not surrounded by a single encapsulation layer <NUM>, which reduces the weight and the cost of the wiring harness <NUM> as noted above. More preferably, each one of the encapsulation layers 122a-122i are spaced apart from each other one of the encapsulation layers 122a-122i.

As provided herein and corresponding to <FIG>, the one or more encapsulation layers <NUM> for coupling a respective hollow branch sleeve <NUM> to the hollow trunk sleeve <NUM> may alternatively be referred to as the first encapsulation layers <NUM> (and are illustrated in one exemplary embodiment in <FIG> as first encapsulation layers 122e-<NUM> for coupling the hollow trunk sleeve <NUM> to a respective one or more of the hollow branch sleeves 112a-e in <FIG>). Further, the one or more encapsulation layers <NUM> for coupling to a corresponding bent portion <NUM> (shown as 118a-d in <FIG> and <FIG>) in the hollow trunk sleeve <NUM> may alternatively be referred to as the second encapsulation layers <NUM> (and are illustrated as second encapsulation layers 122a-d for coupling to a corresponding bend 118a-d of the hollow trunk sleeve <NUM> in <FIG>). Still further, the one or more auxiliary encapsulation layers <NUM> for coupling to a bend in a respective one of the one or more hollow sleeves <NUM> may alternatively be referred to as an auxiliary encapsulation layer <NUM> (and are illustrated by an auxiliary encapsulation layer 112i coupled to the bent portion <NUM> of the hollow branch sleeve 112e in <FIG>). Further, and as best illustrated in <FIG>, each of the respective encapsulation layers 122a-122i are overmolded/coupled/applied in a manner wherein they are separated from each other along the hollow trunk sleeve <NUM> and/or along the respective one or more hollow branch sleeves 112a-e.

As illustrated in <FIG>, each of the first encapsulation layers 122e-h are disposed about, and preferably surround, a respective portion 118e-h of the hollow trunk sleeve <NUM> and also are disposed about, and preferably surround, a respective portion (i.e., a respective one end <NUM>) of a respective hollow branch sleeve 112a-e. Further, in the case of encapsulation layer <NUM>, this encapsulation layer is disposed about, and preferably surrounds, each one of the ends <NUM> of two hollow branch sleeves 112d and 112e. Still further, in other exemplary embodiments, the respective first encapsulation layer is sized such that it is larger than the corresponding notch 121a-d, or the end <NUM>, of the hollow trunk sleeve <NUM> and therefore ensures that there are not open gaps for exposure of any wire corresponding to the interface between the hollow trunk sleeve <NUM>, the respective hollow branch sleeve 112a-e, and the respective first encapsulation layer 112e-h that provides expose to the wires <NUM> extending through the respective notch 121a-d or open end <NUM>.

As also illustrated in <FIG>, the second encapsulation layer 122a-d is disposed about, and preferably surrounds, each respective portion 118a-d corresponding to the bend in the hollow trunk sleeve <NUM> to maintain the hollow trunk sleeve in the desired pre-defined pattern. Still further, in certain embodiments, each of the second encapsulation layers are separate and spaced from each first encapsulation layer 122e-h on the hollow trunk sleeve <NUM> such that at least a portion of the hollow trunk sleeve <NUM> is free of the encapsulation layers. Even still further, in certain embodiments, at least one, and more preferably each one, of the second encapsulation layers 112a-d is separate and spaced from each other one of the second encapsulation layers 112a-d.

Even still further, in certain embodiments, the auxiliary encapsulation layer 122i is disposed about, and preferably surrounds, the portion <NUM> of one of the hollow branch sleeve 112e to a maintain the hollow branch sleeve in the additional desired pre-defined pattern. Still further, auxiliary encapsulation layer 122i is preferably separate and spaced from is separate and spaced from each other one of the first encapsulation layers 122e-g along the hollow trunk sleeve <NUM>.

Preferably, the encapsulation layers 122a-122i are formed of known or standard polyurethane overmold material. However, it is contemplated that one or more of the encapsulation layers 122a-122i can be formed of nitrile butadiene rubber (NBR), polyvinyl chloride or any other suitable material. In certain embodiments, the one or more of the encapsulation layers 122a-122i may be formed from the same material, or different materials, from any other one of the one or more encapsulation layers 122a-122i, and in certain embodiments also have a modulus of elasticity that is less than the modulus of elasticity of the respective hollow trunk sleeve <NUM> and/or one or more of the hollow branch sleeves <NUM>. Preferably, as noted above, the overmold material for forming the encapsulation layers 122a-122i is polyurethane, and it is applied through a reaction injection molding (RIM) process or other similar molding or forming process.

Referring to <FIG>, a flowchart for a method <NUM> of manufacturing the overmolded wiring harness <NUM> of <FIG> is illustrated.

At step <NUM>, the hollow trunk sleeve <NUM> and the one or more hollow branch sleeves 112a-e are provided, with the hollow trunk sleeve <NUM> already including the notches 121a-d. Alternatively, as a preliminary step, the notches 121a-d may be introduced to the hollow trunk sleeve <NUM> by cutting an opening in the hollow trunk sleeve <NUM> or otherwise punching a hole into the hollow trunk sleeve <NUM> for each of the respective notches 121a-d.

Further, the bundle <NUM> of wires <NUM> is inserted and extends within the provided hollow trunk sleeve <NUM> and a respective sub-set 107a, 107b, 107c, 107d, 107e of these bundles <NUM> of wires <NUM> is separated from the bundle <NUM> of wires <NUM> in the hollow sleeve <NUM> and inserted through a respective one notch 121a, 121b, 121c, 121d in the hollow trunk sleeve <NUM>, or through the open end <NUM> of the hollow trunk sleeve <NUM>, and through a respective one of the provided hollow sleeves 112a-112e.

The insertion of the bundle <NUM> of wires <NUM> in step <NUM> is such that one end <NUM> of the wires <NUM> extends through one opposing end <NUM> of the hollow trunk sleeve <NUM> while the opposite end <NUM> of the wires <NUM> extends through the opposing open end <NUM> of a respective one of the hollow sleeves 112a-112e. More in particular, the ends of the respective sub-set 107a, 107b, 107c, 107d, 107e of these bundles <NUM> of wires <NUM> extends from a respective one of the open ends <NUM> of a respective one of the hollow branch sleeves 112a-e.

At step <NUM>, one or more portions (such as portions 118a, 118b, 118c, 118d as shown in <FIG>) of the hollow trunk sleeve <NUM> and/or any portions of one or more of the hollow branch sleeves <NUM> (such as the bent portion <NUM> of hollow branch sleeve 112e as shown in <FIG>) may be bent or moved to positions that provide the desired pre-defined pattern corresponding with the available vehicle space within which the wiring harness <NUM> is installed in the vehicle <NUM>. In certain embodiments, the bending of the hollow trunk sleeve <NUM> and/or the bending of one or more of the hollow branch sleeves <NUM> of step <NUM> can be performed prior to step <NUM>.

At step <NUM>, one or more encapsulation layers 122a-122i are coupled to corresponding portions 118a-<NUM> of the hollow trunk sleeve <NUM> and/or the one or more of the hollow branch sleeves <NUM> for holding the harness <NUM> in the desired pattern and protecting the wires <NUM> from the adverse effects of vibration, abrasion, moisture, and/or debris within the vehicle. In this example, each encapsulation layers 122a-122i are respectively overmolded (or otherwise encapsulated or applied) onto of the hollow trunk sleeve <NUM> and/or any portions of one or more of the hollow branch sleeves <NUM> so as to protect the same and hold the wiring harness <NUM> in the desired pre-defined pattern for installation in the vehicle <NUM>. Preferably, the overmolding is done via a reaction injection molding process.

As a part of step <NUM>, each one of the hollow branch sleeves 112a-112d is positioned such that one opposing end <NUM> is positioned adjacent to a corresponding notch 121a, 121b, 121c, 121d, in the hollow sleeve <NUM> and the opposing open end <NUM> of the hollow branch sleeve 112e is positioned adjacent to the open end <NUM> of the hollow trunk sleeve <NUM> prior to overmolding or encapsulation. As noted above, a portion of the wires <NUM> of each respective portion 107a-d of the bundle <NUM>, inward of its respective end <NUM>, extends through the other opposing open end <NUM> of the hollow sleeves 112a-112e at this interface with the adjacent respective notch 121a, 121b, 121c, 121d or at the interface with the open end <NUM> of the hollow trunk sleeve <NUM>.

In certain embodiments, step <NUM> is performed in a sequential manner, with one or more of the one or more encapsulation layers 122a-122i overmolded/coupled/applied in a first step and one or more of the other one or more encapsulation layers 122a-122i overmolded/coupled/applied in a second or subsequent step. Alternatively, in certain embodiments, step <NUM> is performed in a single step, with each of the encapsulation layers 122a-122i applied in a single step at the same time.

At step <NUM>, the wiring harness <NUM> is installed within the available vehicle space of the vehicle <NUM>. Examples of the available vehicle space can include a front dashboard or instrument cluster, a vehicle door, or any other portion of the vehicle <NUM>.

At step <NUM>, the opposing ends <NUM>, <NUM> of each wire <NUM> may be coupled to corresponding one or more electrical components <NUM> of the automotive electronics system <NUM>.

It is to be appreciated that the above embodiments of the wiring harness <NUM> may be used individually, as described above, or in combination with one another to simultaneously operate a pump and inflate or deflate the upper and lower air cells.

Claim 1:
A wiring harness (<NUM>) for coupling electronic components, said wiring harness (<NUM>) comprising:
a hollow trunk sleeve (<NUM>) including one or more notches (<NUM>) along a length between a pair of opposing ends (<NUM>, <NUM>), said hollow trunk sleeve (<NUM>) also including one or more bends along said length between said pair of opposing ends (<NUM>, <NUM>) to form a desired pre-defined pattern, with each of said one or more bends spaced from said one or more notches (<NUM>);
a hollow branch sleeve (<NUM>) coupled to said hollow trunk sleeve (<NUM>) at each corresponding notch (<NUM>) of said one or more notches to interconnect said hollow branch sleeve (<NUM>) to said hollow trunk sleeve (<NUM>), with each hollow branch sleeve (<NUM>) open to said hollow trunk sleeve (<NUM>) through said respective notch (<NUM>);
a bundle (<NUM>) of wires (<NUM>) extending through said hollow trunk sleeve (<NUM>), with a sub-set of said bundle (<NUM>) of wires (<NUM>) extending through each notch (<NUM>) and each corresponding hollow branch sleeve (<NUM>);
a first encapsulation layer (122e - <NUM>) disposed about a portion of said hollow trunk sleeve (<NUM>) and a portion of each of said hollow branch sleeves (<NUM>) at each interconnection to separately secure said hollow branch sleeve (<NUM>) to each hollow trunk sleeve (<NUM>); and
a second encapsulation layer (122a - 122d) disposed about each bend to maintain said hollow trunk sleeve (<NUM>) in said desired pre-defined pattern with each second encapsulation layer (122a - 122d) being separate and spaced from said first encapsulation layer (122e - <NUM>) on said hollow trunk sleeve (<NUM>) such that at least a portion of said hollow trunk sleeve (<NUM>) is free of said encapsulation layers.