Flexible circuits for electrical harnesses
First Claim
1. An electrical harness assembly comprising:
- a connector; and
a first conductor trace, comprising a first conductor lead and a first connecting end, wherein;
the first conductor lead and the first connecting end are monolithic; and
the first connecting end is electrically coupled to the connector,the first connecting end has a width-to-thickness ratio less than the width-to-thickness ratio of the first conductor lead.
1 Assignment
0 Petitions
Accused Products
Abstract
Provided are electrical harness assemblies and methods of forming such harness assemblies. A harness assembly comprises a conductor trace, comprising a conductor lead with a width-to-thickness ratio of at least 2. This ratio provides for a lower thickness profile and enhances heat transfer from the harness to the environment. In some examples, a conductor trace may be formed from a thin sheet of metal. The same sheet may be used to form other components of the harness. The conductor trace also comprises a connecting end, monolithic with the conductor lead. The width-to-thickness ratio of the connecting end may be less than that of the conductor trace, allowing for the connecting end to be directly mechanically and electrically connected to a connector of the harness assembly. The connecting end may be folded, shaped, slit-rearranged, and the like to reduce its width-to-thickness ratio, which may be close to 1.
16 Citations
19 Claims
-
1. An electrical harness assembly comprising:
-
a connector; and a first conductor trace, comprising a first conductor lead and a first connecting end, wherein; the first conductor lead and the first connecting end are monolithic; and the first connecting end is electrically coupled to the connector, the first connecting end has a width-to-thickness ratio less than the width-to-thickness ratio of the first conductor lead. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
-
-
11. An assembly comprising:
- a heat sink, comprising a surface; and
an electrical harness assembly, directly contacting the surface of the heat sink, wherein;
the electrical harness assembly comprises a first insulator, a conductor trace, and a second insulator, the conductor trace is disposed between the first insulator and the second insulator, and the first insulator is adhered to the surface of the heat sink using a thermally conductive mounting adhesive, wherein the electrical harness assembly further comprises a connector, comprising a contact interface, the conductor trace, comprises a conductor lead and a connecting end, the contact interface is electrically coupled to the connecting end, and the connecting end has a width-to-thickness ratio less than the width-to-thickness ratio of the conductor lead. - View Dependent Claims (12, 13)
- a heat sink, comprising a surface; and
-
14. A method of forming an electrical harness assembly, the method comprising:
-
laminating a conductor to a supporting substrate; while the conductor remains laminated to the supporting substrate, patterning the conductor thereby forming a first conductor trace, comprising a first conductor lead and a first connecting end; and shaping the first connecting end of the first conductor trace, wherein, after shaping, the first connecting end has a width-to-thickness ratio less than the width-to-thickness ratio of the first conductor lead. - View Dependent Claims (15, 16, 17, 18, 19)
-
Specification