A wiring harness assembly includes a plurality of electrical conductors having wires enclosed within insulative sheaths that are integrally formed of an electrically insulative material. The assembly also includes a lattice support structure that is attached to the insulative sheaths at multiple locations. The lattice support structure is configured to maintain a desired shape of the assembly. The lattice support structure is formed of filaments that may be formed using an additive manufacturing process The filaments may be arranged such that lattice support structure defines a plurality of hexagonally shaped apertures. A process for manufacturing the wiring harness assembly and an apparatus configured to manufacture the wiring harness assembly is also presented.

A wire harness routing method is provided. A wire harness is routed on a protector base. A protective tape is wound around an outer periphery of the wire harness at a position outside an end portion of the protector base in a longitudinal direction. A cover is put on the protector base under the above state. The wire harness is fixed to, by winding a binding band at a position where the tape is wound, a wire harness-fixed protruding piece protruding outward in the longitudinal direction from an end portion of the cover in the longitudinal direction.

A wire harness includes a group of electric wires, an electric wire protection tube covering the plurality of electric wires, and connectors provided at both end sides of the group of electric wires, respectively, and each having a dimension larger than an inner dimension of the electric wire protection tube. The electric wire protection tube is constituted of shape-memory polymer and is mounted on the electric wires while it is expanded to have the inner dimension larger than the outer dimensions of the connectors. After the electric wire protection tube is mounted on the electric wires, the electric wire protection tube is heated to a temperature equal to or higher than a glass-transition point such that it is restored to a shape-memory shape.

A method of manufacturing a wiring harness assembly includes the steps of forming a plurality of electrically conductive wires encased within a substrate formed of a dielectric material, forming an opening in the substrate located and sized such that a section of the plurality of electrically conductive wires is exposed within the opening, disposing a support segment within the opening, securing a connector segment including a plurality of terminals to the support segment, and placing the plurality of terminals in mechanical and electrical contact with the plurality of electrically conductive wires.

A wiring harness assembly includes a plurality of electrically conductive wires encased within a substrate formed of a dielectric material, a location feature integrally formed with the substrate, and an opening defined in the substrate located within a predetermined tolerance relative to the location feature. A section of the plurality of electrically conductive wires is exposed within the opening.

There is provided an electric wire having a conductor total cross-sectional area of 2 mm.sup.2 or less and high reliability. The electric wire includes: a twisted wire conductor (2) including a plurality of strand conductors (21 to 27) twisted together with each other and having a total cross-sectional area of the plurality of strand conductors of 2 mm.sup.2 or less; and a covering member (3) made from a resin material having a flexural modulus of 0.6 GPa or more and covering the twisted wire conductor so that an inner wall thereof is in contact with an outer peripheral surface of the twisted wire conductor, wherein the twisted wire conductor (2) has, on an outer peripheral surface thereof, recesses having a maximum depth of 5% or less of a maximum diameter of the twisted wire conductor in a cross section perpendicular to a length direction of the twisted wire conductor and containing boundaries of the plurality of strand conductors.

Wire holders removably retaining at least one wire for assembling a wire harness and methods for assembling a wire harness are provided. In one example, the wire holder includes a base section having a base bottom for positioning on a wire harness layout sheet. The wire harness layout sheet includes a wire routing pattern for forming the wire harness. A clip section extends generally upwardly from the base section and at least partially surrounds a clip channel having a channel diameter. The base section has a base height defined from the base bottom to a lowest point of the clip channel. A ratio of the channel diameter to the base height is from about 6:1 to about 9:1.

The invention relates to a device for manufacturing a sheath (1) for electrical cables (2), in particular a sheath (1) for cables (2) in automobiles, comprising at least one manipulator (9) and a nozzle (10) connected to the manipulator (9) for dispensing a curable liquid plastic material in the course of a generative manufacturing method. The plastic material comprises a radiation-crosslinkable, acrylate-based polymer as the main constituent.

A wire harness including: a wire including a core wire and an insulating covering that covers the core wire; an electromagnetic shield that covers and electromagnetically shields at least the core wire; a path regulator that has higher flexural rigidity than the wire and that is formed in an elongated shape; and a cover that covers the wire, the electromagnetic shield, and the path regulator, wherein the wire is fixed along the path regulator.

A bent portion of electric wires is protected at a high versatility by a protective member having a simple shape. A wire end of a wire harness 11 is protected. The wire harness 11 includes a wire bundle 13 and a connector 14 connected therewith. The wire bundle 13 includes the wire end, and the wire end includes a bent portion 13a and faces the connector 14. First, a sheet member 15a is folded perpendicularly to a wire lead-out surface 14a of the connector 14, thereby forming, concurrently, counter sides 31 facing the wire lead-out surface 14a, side surface covering portions, and a tip end protection portion 33. Next, the side surface covering portions are folded along a top protection portion formation portion 44, thereby forming, concurrently, side surface protection portions 32, a top protection portion 34 and an extending portion 35. Next, a wire end protection portion 15 is secured, with a pressure-sensitive adhesive tape or the like, to a wire bundle 13 portion while the relative position of the counter sides 31 with respect to the wire lead-out surface 14a is maintained. The wire end protection portion 15 is secured only to the wire bundle 13 portion, but is not secured to the connector 14.