An electrical assembly may include an electrically conductive first member, a magnetic second member, and/or a housing molded on the first member and the second member. A method of assembling an electrical assembly may include disposing the first member in contact with a first mold, disposing the second member in contact with the first mold, moving a second mold into contact with the first mold, and/or inserting a housing material (e.g., liquid plastic) into the first mold and the second mold to form the housing.

Lighting systems are described. A lighting system includes a first lead frame portion and a second lead frame portion. The first lead frame portion has at least a top surface, a bottom surface, and an opening. The second lead frame portion is within the opening of the first lead frame portion and has at least a top surface and a bottom surface. Light-emitting diode (LED) devices are each mechanically and electrically coupled to the top surface of the first lead frame portion and the top surface of the second lead frame portion. An electrically insulating and optically reflective material is disposed over exposed regions of the top surfaces of the first and second lead frame portions.

A molded body is molded into a prescribed three-dimensional shape. A protective film covers at least a portion of a surface of the molded body. A circuit film is integrally molded with the molded body. An electric circuit is installed in the circuit film and causes a physical change outside of a molded article or causes an electric signal to be generated in accordance with a physical change outside of the molded article. The protective film or the circuit film has a contact area disposed on the surface of a contact portion. The molded body includes a hot melt adhesive: which is disposed on the surface of the molded body which is opposite skin, with the contact area therebetween; and which defines a three-dimensional shape of the contact area within the prescribed shape. The hot melt adhesive covers at least a portion of the circuit film.

A method for manufacturing a sensor for a motor vehicle. The method includes placing a sensor core in a lower indentation of a mold; the sensor core having a metal lead frame, including connection pins and lateral retention members, and an integrated circuit, including at least one measurement cell and being overmolded on a support zone of the metal lead frame so the lateral retention members and the connection pins are exposed, and an electrically conductive terminal on each connection pin; placing a magnet in line with the overmolded integrated circuit; placing two lateral indentations of the mold on either side of the magnet and the integrated circuit so the lateral indentations retain the lead frame in the vicinity of the lateral retention members; overmolding the integrated circuit, the magnet and part of the lead frame to allow the free end of the terminals to project; and removing the mold.

A foamable cross-linkable thermoplastic material comprises a matrix polymer of any one or a mixture of two or more of polyethylene (PE), ethylene vinyl acetate copolymer (EVA) and polypropylene (PP), a cross-linking agent, and a foaming agent. A weight ratio of the cross-linking agent to the matrix polymer is 1-5:100. A weight ratio of the foaming agent to the matrix polymer is 1-5:100. A cross-linking foaming temperature of the thermoplastic material is equal to or higher than the melting point of the matrix polymer.

An implantable medical device includes a header configured to be mounted to an end of a device housing that contains an electronics module therein. The header includes an antenna, a sensing electrode, and a header body that at least partially surrounds the antenna and the sensing electrode. The sensing electrode includes a first body portion, a second body portion, and a bridge portion that mechanically and electrically connects the first and second body portions. The first body portion is at least partially exposed to an external environment along a first side of the header, and the second body portion is at least partially exposed to the external environment along a second side of the header that is different from the first side.

A method for manufacturing a polymeric electrical machine includes manufacturing a stator including a laminated stator core and a plurality of windings including winding overhangs; applying a surface treatment to the stator core constructed to reduce defects at an interface between a polymeric material and the stator core and enhance adherence between the polymeric material and the stator core; mounting the stator onto a mandrel; inserting the stator into an electrical machine housing mold; molding an electrical machine housing including a stator band with an integral non-drive end endplate, including overmolding the stator and winding overhangs within the stator band; molding a drive end endplate, including forming polymeric ribs in the drive end endplate and overmolding a metallic structure into the endplate, the metallic structure enhancing mechanical stiffness of the endplate; installing a rotor assembly into the electrical machine housing; and installing the endplate onto the electrical machine housing.

A method for use in making an electrode assembly (20) comprises the steps of applying an electrode (24) on a first layer of material (22); laser welding a lead (23) to the electrode; applying an adhesive backfill (26) over the electrode and the lead; and applying a second layer of material (28) over the adhesive backfill and a portion of the first layer to prevent a leakage path between the electrode and the second layer.

The resin molded article is molded by using an electrode sheet as an insert in a state where one surface of the electrode sheet is closely attached to an inner surface which serves as the inner side of the operation surface. The electrode sheet is formed by using, as a base material, a thermoplastic synthetic resin sheet which outputs an electrical signal according to the amount of change of electrostatic capacitance generated by a contact operation with respect to the operation surface. At least a whole or a part of the inner surface is formed in a three-dimensionally curved surface, and a passage is formed in the electrode sheet so as to allow a molten resin following in through a gate formed in a die which comes into contact with the other surface of the electrode sheet during molding to pass toward one surface side of the electrode sheet.

An ignition coil includes a not-illustrated coil, a plate assembly, and a case assembly. The plate assembly and the case assembly are combined with each other by laser welding at a recess and a rib (projection) which are respective abutting portions, thereby forming storage spaces for storing the coil.