Bundled cables and methods for preparing bundled cable are disclosed herein. In the method, a plurality of subunits is wound about a central member. The subunits include a subunit jacket made of a first thermoplastic composition and has a first outer surface, and the central member includes a central member jacket made of a second thermoplastic composition and has a second outer surface. A metal element is provided at an interface of the second outer surface and the first outer surface of the subunits. The metal element is heated such that at least one of the first thermoplastic composition or the second thermoplastic composition forms bonds with the other of the first thermoplastic composition or the second thermoplastic composition.

A composite conductive film is provided that includes a layer of cross-linked polymer having a surface and an inorganic mesh comprising a plurality of nanowires of an inorganic material. The nanowires are, in isolated form, characterized by a first conductivity stability temperature. Further, the plurality of nanowires is embedded within at least a region of the layer of cross-linked polymer, where the region is continuous from the surface of the layer of cross-linked polymer. The layer of cross-linked polymer and the inorganic mesh are arranged to form the composite conductive film having a second conductivity stability temperature that is greater than the first conductivity stability temperature.

A cable harness is surrounded in certain regions by a sheath made of a casting compound. In order to ensure a defined delimitation of the casting compound, even if there is an insert part protruding from the sheath, the method for sealing a tool opening provides that a pressure element is pressed in the radial direction against the insert part. The insert part is clamped between the pressure element and a support element, and the support element remains in the cable harness as a consumable element. The insert part is particularly designed as a heat protection element. The cable harness is used particularly in a thermally stressed environment for a motor vehicle.

An improved plastic-cladding filament structure includes a combined arrangement of a base layer, thermosetting polymer glue, and at least one conductive filament. The thermosetting polymer glue is combined with the base layer. The at least one conductive filament is enclosed and housed in the thermosetting polymer glue to allow the conductive filament to be attached to the base layer through heating and setting of the thermosetting polymer glue. By means of the property the thermosetting polymer glue that the thermosetting polymer glue gets set after being heated to a predetermined temperature and melted and shaped and once heated to get set and shaped, further heating does not change the shape, the thermosetting polymer glue that encloses and houses the conductive filament can be set to form any desired shape to facilitate combination thereof with the base layer.

A wire harness manufacturing method prevents inadvertent deformation of thermoplastic material and separation of thermoplastic material. A predetermined part of an electric wire 91 is accommodated in a through hole of a tubular body formed by connection between a first and second nest members (123, 124) of a nozzle (12), by integrally connecting first and second case body members (121, 122) of the nozzle (12), with the predetermined part of the electric wire 91 therebetween. An approximately tubular covering member (92) covering the predetermined part of the electric wire (91) is molded integrally with the thermoplastic material, by discharging thermoplastic material plasticized by a material plasticizing unit (11) from thermoplastic material discharge orifices (1213) and (1223) in the nozzle (12) to the outer periphery of the electric wire (91), while moving the electric wire (91) and the nozzle (12) relatively to each other.

Method for jacketing elongate material such as more particularly leads or cable looms, where an adhesive tape comprising a carrier, more particularly textile carrier with a curative composition applied to its top side and a reactive composition to its bottom side, is passed in a helical line around the elongate material, or the elongate material is wrapped in the axial direction by the adhesive tape in such a way that the curative composition and the reactive composition come into contact, the elongate material together with the adhesive tape wrapping is brought into the desired disposition, more particularly into the cable loom layout, the elongate material is held in this disposition, the curative composition reacts with the reactive composition, to produce a curing layer of composition.

A wire harness manufacturing method prevents inadvertent deformation of thermoplastic material and separation of thermoplastic material. A predetermined part of an electric wire 91 is accommodated in a through hole of a tubular body formed by connection between a first and second nest members (123, 124) of a nozzle (12), by integrally connecting first and second case body members (121, 122) of the nozzle (12), with the predetermined part of the electric wire 91 therebetween. An approximately tubular covering member (92) covering the predetermined part of the electric wire (91) is molded integrally with the thermoplastic material, by discharging thermoplastic material plasticized by a material plasticizing unit (11) from thermoplastic material discharge orifices (1213) and (1223) in the nozzle (12) to the outer periphery of the electric wire (91), while moving the electric wire (91) and the nozzle (12) relatively to each other.

An exterior member includes a flexible tube part having flexibility and an inflexible tube part having flexibility lower than that of the flexible tube part. The inflexible tube part has a plurality of protruding parts formed to protrude from an outer surface thereof. The protruding parts are formed so as to extend in a circumferential direction of the outer surface and arranged at intervals in an axial direction of a tube of the exterior member.

A composite bicycle frame which comprises of a main frame including interconnected tubes and substantially composed of a composite material and having a composite layup structure. At least one electric wire electrically interconnects electrical components mounted to or in the frame. The at least one electric wire is embedded in the composite material structure forming the composite main frame. The electric wire has connectable conductive ends at each of the opposed ends thereof.

A reel-to-reel flex circuit manufacturing process can be used to manufacture an FFC or flex circuit products. The processes use a laser ablation technique to generate layer patterns. The reel-to-reel process can be performed to manufacture flexible flat cables that have conductive traces that have different widths and that also have openings, such as pads, at desired locations.