Foamed-in harnesses
First Claim
Patent Images
1. A method for forming a wire harness, the method comprising the steps of:
- (a) shaping a cavity of a mold using a sealing means such that said cavity has a shape that approximates a mounting surface of a vehicle component;
(b) installing a wire harness into said cavity of said mold;
(c) surrounding said wire harness with foam; and
(d) curing said foam about said wire harness.
5 Assignments
0 Petitions
Accused Products
Abstract
A wire harness for use on contoured, mounting surface includes individual wires bundled together. In an effort to protect these wires from mechanical wear, vibration, and water the wire harness is encased in foam. The foam is molded about the wire harness so that is surrounds the harness in the shape of the mounting surface. The foamed-in wire harness may have an elastic memory, so that it can be bent and resiliently recover to its molded shape.
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Citations
28 Claims
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1. A method for forming a wire harness, the method comprising the steps of:
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(a) shaping a cavity of a mold using a sealing means such that said cavity has a shape that approximates a mounting surface of a vehicle component; (b) installing a wire harness into said cavity of said mold; (c) surrounding said wire harness with foam; and (d) curing said foam about said wire harness. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9)
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10. A wire harness adapted to be mounted adjacent a contoured surface of a vehicle component, said wire harness comprising:
a wire bundle; and
a closed cell foam sheath molded around said bundle, said sheath having a shape matching that of the contoured surface;
said sheath further having an elastic shape memory of said shape, rendering said sheath highly deformable and resilient to allow said sheath to be bent and to thereafter resiliently recover to said shape.- View Dependent Claims (11, 12, 13, 14, 15, 16)
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17. A method for forming a wire harness, the method including the steps of:
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(a) positioning a plurality of wires between first and second mold portions of a mold, said first and second mold portions having first and second mold bodies, respectively, and first and second sealing means, respectively, disposed adjacent said first and second mold bodies, respectively, said sealing means being cooperable to define a cavity; (b) closing said mold such that said sealing means define said cavity; (c) introducing a foamable polymer into said cavity; and (d) allowing said polymer to foam and expand in said cavity, thereby surrounding said plurality of wires. - View Dependent Claims (18, 19, 20, 21, 22, 23)
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24. A method for forming a wire harness, the method including the steps of:
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(a) positioning a plurality of wires between first and second mold portions of a mold, said first and second mold portions having first and second mold bodies, respectively, and first and second sealing means, respectively, engaged with said first and second mold bodies, respectively, said sealing means being cooperable to define a cavity having a shape corresponding to a mounting surface of a vehicle component, each of said sealing means having at least one end wall for separating said cavity into a foam-receiving portion and at least one non-foam-receiving portion, one of said sealing means having a rib, and the other of said sealing means having a groove for receiving said rib; (b) closing said mold such that said first and second sealing means define said cavity, and such that said rib is received within said groove; (c) introducing a foamable polymer into said cavity and around said plurality of wires; (d) allowing said polymer to foam and expand around said plurality of wires, thereby surrounding said plurality of wires; and (e) curing said polymer about said plurality of wires.
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25. A wire harness comprising:
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a closed cell foam sheath having a molded shape matching that of a contoured surface of a vehicle component; a plurality of bundled wires insert molded in said foam sheath; and at least one electrical connector connected to at least one of said plurality of bundled wires. - View Dependent Claims (26)
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27. A wire harness comprising:
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an open cell foam sheath having a molded shape matching that of a contoured surface of a vehicle component; a plurality of bundled wires insert molded in said foam sheath; and at least one electrical connector connected to at least one of said plurality of bundled wires. - View Dependent Claims (28)
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Specification