Process of manufacturing an electrical wiring assembly and electrical wiring assembly manufactured by said process

1. A process of manufacturing an electrical wiring assembly, comprising the steps of:

a) cutting an elongate strip from a sheet of metal;

b) cutting a mesial slit in an end of the strip, thereby forming a pair of distal projections flanking the mesial slit;

c) forming an insulative covering over a portion of the elongate strip by laminating the portion of the elongate strip with an insulative material, wherein the portion is an insulated segment and a remaining portion of the elongate strip is an uninsulated segment; and

d) cutting the elongate strip into a desired shape, wherein step d) of the process is performed prior to step c) of the process.

2. The process according to claim 1 , wherein the mesial slit and the pair of distal projections form a forked split blade terminal.

3. The process according to claim 1 , wherein steps a) and b) of the process are performed using a laser cutting process.

4. The process according to claim 1 , further comprising the step of:

e) folding the elongate strip into a desired shape.

5. The process according to claim 1 , further comprising the step of:

f) bending the electrical wiring assembly into a desired shape.

6. The process according to claim 1 , further comprising the step of:

g) winding the sheet of metal from a first reel onto a second reel that is spaced apart from the first reel.

7. The process according to claim 6 , wherein step a) of the process is preformed concurrently with step g) of the process.

8. The process according to claim 1 , further comprising the step of:

cutting a notch into a distal edge of the elongate strip to form a retaining feature configured to cooperate with a terminal lock in a connector body to retain a terminal end of the electrical wiring assembly within the connector body.

9. The process according to claim 8 , wherein the steps of cutting the elongate strip, cutting the mesial slit, and cutting the notch are all performed using a single laser cutting process.

10. An electrical wiring assembly, formed by a process comprising the steps of:

a) cutting an elongate strip from a sheet of metal;

b) cutting a mesial slit in an end of the strip, thereby forming a pair of distal projections flanking the mesial slit;

c) forming an insulative covering over a portion of the elongate strip by laminating the portion of the elongate strip with an insulative material, wherein the portion is an insulated segment and a remaining portion of the elongate strip is an uninsulated segment;

d) cutting the elongate strip into a desired shape, wherein step d) of the process is performed prior to step b) of the process.

11. The electrical wiring assembly according to claim 10 , wherein the mesial slit and the pair of distal projections form a forked split blade terminal.

12. The electrical wiring assembly according to claim 10 , wherein steps a) and b) of the process are performed using a laser cutting process.

13. The electrical wiring assembly according to claim 10 , wherein the process further comprises the step of:

e) folding the elongate strip into a desired shape.

14. The electrical wiring assembly according to claim 10 , wherein the process further comprises the step of:

f) bending the electrical wiring assembly into a desired shape.

15. The electrical wiring assembly according to claim 10 , wherein the process further comprises the step of:

g) winding the sheet of metal from a first reel onto a second reel spaced apart from the first reel.

16. A method of manufacturing an electrical wiring assembly, the method comprising:

cutting an elongate strip from a sheet of metal;

cutting a mesial slit in an end of the strip, thereby forming a pair of distal projections flanking the mesial slit;

cutting the elongate strip into a desired shape; and

after cutting the elongate strip into the desired shape, forming an insulative covering over a portion of the elongate strip by laminating the portion of the elongate strip with an insulative material, wherein the portion is an insulated segment and a remaining portion of the elongate strip is an uninsulated segment.

17. The method of claim 16 , further comprising cutting a notch into a distal edge of the elongate strip to form a retaining feature configured to cooperate with a terminal lock in a connector body to retain a terminal end of the electrical wiring assembly within the connector body.