Delphi Exhibits E/E Packaging Solutions With Flat Wire at SAE 2000
2 March 2000
Delphi Exhibits E/E Packaging Solutions With Flat Wire at SAE 2000
DETROIT, March 2 -- When vehicle packaging space and mass are
critical factors, Delphi Automotive Systems has the solution --
flat wire products are alternatives to round wire, with extensive design and
connection system integration capabilities.
A Delphi-designed overhead console will be on display at the Society of
Automotive Engineers (SAE) 2000 World Congress & Exposition here, March 6-9,
demonstrating many functions that can be integrated using a flexible printed
circuit (FPC) containing switches and electronics.
Flat wire technology includes FPC and Flexible Flat Cable (FFC). Both
offer vehicle manufacturers the ability to design with smaller gauge
equivalent conductors than 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.
David Siegfried, Delphi supervisor of flat wire, said that flat wire
technology is ideal for modular products, such as overhead consoles, because
it allows more functions to be integrated than round wire or stamped metal,
resulting in a cost benefit.
Features designed into the SAE display include a vacuum fluorescent
display for pager and vehicle-to-roadside communication information,
integrated lamp connections and switches, and a Delphi Dock & Lock connector.
Some additional devices that can be integrated into overhead consoles are:
sensors for glass breakage, temperature and humidity sensors, antennas for
devices such as global positioning systems, passenger occupant detection,
hands-free and noise cancellation microphones, emergency roadside assistance
systems, and radio frequency (RF) modules such as garage door openers and
remote entry modules.
"Based on the design of the overall vehicle, flat wire can provide the
necessary system flexibility," Siegfried 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."
Delphi integrated the functions into the overhead console using two
different FPCs that contain switches and electronics. One FPC uses a higher
cost material, polyimide, because electronic devices are attached by a high
temperature soldering process. The other FPC uses a lower cost material,
polyester, since only mechanical or hand assembly is required.
"The careful selection of the correct material for an application means
FPC can be more cost-effective for complete systems integration," Siegfried
said.
FPC integration eliminates a number of electrical interfaces, and the
overhead console attaches to the vehicle with Delphi's patented Dock & Lock
connection system. This connection can contain power, data, ground and even
fiber optic network links for applications such as multimedia. Using a single
Dock & Lock connection in the overhead console provides for a more reliable
assembly that helps reduce cutting, pinching and chafing as well as improves
assembly and service.
Siegfried said Delphi is also developing the use of flat wire in the
center stack console of the dashboard, a major congestion point in the
vehicle. Using FPC in the console provides switch and electronic display
integration, reducing the packaging area required.
In addition to instrument panel and headliner applications, flat wire
technology is also used in door wiring, tail lamp wiring, rear window
defoggers and heated mirrors. Delphi provides flat wire applications in high
volume production today in both the United States and Europe. Delphi is
currently using flat wire technology for headliner wiring in Europe, and soon
expects to expand this application into the United States.
"While many competitors use flat wire technology, Delphi's advantage is
its connection system experience and integration capabilities. We can bring
the whole package together," Siegfried 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."
Delphi Automotive Systems, headquartered in Troy, Mich., USA, is a world
leader in transportation and mobile electronics components and systems
technology. Delphi's three business sectors -- Dynamics & Propulsion; Safety,
Thermal & Electrical Architecture; and Electronics & Mobile Communication --
provide comprehensive product solutions to complex customer needs. Delphi has
approximately 213,500 employees, and operates 175 wholly owned manufacturing
sites, 41 joint ventures, 53 customer centers and sales offices and 27
technical centers in 38 countries. Regional headquarters are located in
Paris, Tokyo and Sao Paulo, Brazil. Delphi can be found on the Internet at
http://www.delphiauto.com