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.

A flat cable includes at least one cable portion and at least one rib portion. The at least one cable portion has a plurality of conductor wires arranged in parallel at predetermined intervals on a plane, and a coating portion that collectively covers the plurality of conductor wires arranged in parallel. The coating portion is made of an insulating resin. The at least one rib portion is provided in parallel with the cable portion on the plane. bus bar is to be fixed to the at least one rib portion and the at least one rib portion is made of only the same resin as the coating portion. A body including the at least one cable portion and the at least one rib portion is substantially bilaterally symmetrical in a cross-sectional structure of the body.

A wire harness includes a power trunk line, a power branch line, a communication trunk line, and a communication branch line. The power trunk line is connected to a power source mounted on a vehicle and extend in a longitudinal direction of the vehicle. The power branch line branches off from the power trunk lines and extends in a direction intersecting with the longitudinal direction. The communication trunk line is arranged along the power trunk lines or also serves as the power trunk lines. The communication branch line branches off from the communication trunk line and extends in a direction intersecting with the longitudinal direction.

A wiring harness assembly includes a plurality of separated conductors formed of an electrically conductive material, a substrate formed of a dielectric material encasing the plurality of separated conductors, a location feature integrally formed with the substrate and an opening defined in the substrate having 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.

A branch structure of a laminated flat electric wire includes: a laminated flat electric wire in which two or more plate-shaped flat electric wires are laminated; and a branch box. The laminated flat electric wire has tabs each extending from each of the flat electric wires. Each of the tabs is provided with a hole. The branch box has the same number of rod-shaped members as the number of tabs, and the rod-shaped members are disposed at positions corresponding to the positions of the holes of the tabs. Two or more laminated flat electric wires are fixed to each other by passing each of the rod-shaped members through a corresponding hole of the tabs in a state where the two or more laminated flat electric wires extend from the branch box in opposite directions from each other or directions orthogonal to each other.

The present disclosure provides a method for producing a wire harness, and a wire harness. The method for producing a wire harness includes: Step S10: arranging a plurality of wire harness conductors; and Step S20: forming an insulator by additive manufacturing, gaps being disposed between the wire harness conductors, and the insulator wrapping the wire harness conductors and being filled in the gaps. The present disclosure alleviates the technical problems of complex production process and high processing cost of wire harnesses.

A conductive tape formed by laying a conductive pathway on a tape layer is disclosed. Various apparatus and methods for laying conductive pathways to form conductive tape are disclosed. The conductive pathways may be laid by varying the lateral position of the conductive pathway on the tape substrate. Such patterns all stretchable conductive tape to be realized. Multiple conductive pathways may be laid in the tape and the lateral separation of the pathways in the tape may vary. In some embodiments the pathways are formed from conductive yarn or by printing or laying conductive ink.

A flat cable includes at least one cable portion and at least one rib portion. The at least one cable portion has a plurality of conductor wires arranged in parallel at predetermined intervals on a plane, and a coating portion that collectively covers the plurality of conductor wires arranged in parallel. The coating portion is made of an insulating resin. The at least one rib portion is provided in parallel with the cable portion on the plane. bus bar is to be fixed to the at least one rib portion and the at least one rib portion is made of only the same resin as the coating portion. A body including the at least one cable portion and the at least one rib portion is substantially bilaterally symmetrical in a cross-sectional structure of the body.

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.

A percutaneous connector assembly including a feedthrough assembly having a body and a plurality of electrically conductive feedthroughs extending through the body from a first end toward a second end thereof. A cable assembly having a plurality of conductors arranged side-by-side within a first plane to form a substantially flat portion thereof is included, each conductor being connected to a corresponding feedthrough of the feedthrough assembly and the flat portion extending from the body.