Delphi to Exhibit E/E Packaging Solutions With Flat Wire At Frankfurt Motor Show

    FRANKFURT, Germany, Sept. 5 As vehicle manufacturers
continue to look for ways to improve vehicle packaging, Delphi Automotive
Systems , the global leader in supplying electrical/electronic
(E/E) distribution systems, continues to find alternative solutions for
customers.

    (Photo:  http://www.newscom.com/cgi-bin/prnh/20001019/DELPHIAS )
    One alternative to round wire electrical distribution systems is Delphi's
flat wire products, which demonstrate many functions that can be integrated
using a flexible printed circuit (FPC) containing switches and electronics.
   
 On display at the 2001 IAA, Sept. 11-21, Delphi's flat wire technology
includes FPC and Flexible Flat Cable (FFC).  Both offer vehicle manufacturers
the ability to design with smaller gauge equivalent conductors than are used
on today's vehicles.  This reduces packaging area requirements, allowing for
the incorporation of smaller connection systems like those used for computers
and other commercial devices, and reduces harness weight.
   
 Dr. Wulf Bramesfeld, Delphi engineering supervisor for flat wire
harnesses, said that typical flat wire harness applications include wiring
systems for headliner, doors and cockpits, and classical FPC applications for
instrument clusters, mirror heaters and window connectors.  In addition to
these, a new group -- flat wire E/E-systems -- is growing rapidly.
   
 Currently, Delphi provides flat wire applications in high volume
production today in both Europe and the United States.  For Opel, Delphi has
been supplying flat wire harnesses for headliners for the current Vectra.
Opel is the first OEM to introduce flat wire technology into series production
for a headliner application.
    
"All expectations of increased quality and smoother assembly processes
have been exceeded," Bramesfeld said.  "This leads to an increased interest of
nearly all OEMs in that technology."
   
 Since the beginning of August 2001, all Opel Astra vehicles are being
equipped with a Delphi flat wire headliner harness.  Delphi is currently
preparing start-up of production for several other car manufacturers,
demonstrating that flat wire harnesses are a viable technology for all new car
designs.
  
  "Based on the design of the overall vehicle, flat wire can provide the
necessary system flexibility," Bramesfeld said.  "Vehicle system designers can
use the lower profile and reduced component counts provided by flat wire to
improve their vehicle designs, as well as provide creative ways of packaging
new features and options."
   
 This is only the first step.  Additional advantages can be achieved when
the flat wire harness transforms into an E/E system by integrating devices
into the harness.  This means more than simple pick and place of electronic
devices to FPC material -- a whole range of new base materials, design and
production processes needs to be developed, understood and controlled in order
to meet the cost and quality targets of the automotive industry.  Delphi is
aggressively pursuing development work in this area.
    
"While many competitors use flat wire technology, Delphi's advantage is
its connection system experience and integration capabilities.  Since Delphi's
acquisition this past spring of Eaton Corp.'s Vehicle Switch & Electronics
Division (VS/ED), we are better prepared to bring the whole package together,"
Bramesfeld said.  "And because of Delphi's global presence, we can provide
capabilities anywhere in the world to meet our customers' requirements.  We
have a wide range of suppliers around the world who work closely with us to
develop cost-effective, integrated solutions for our customers."