Robust Circuit Substrate And Wiring Harness Simplify Automotive Power Seat Switch

Lisle, IL – Tricon Industries, Inc., a leading insert molder and specialized component manufacturer, is producing a robust circuit substrate and wiring harness for automotive power seat controls that greatly simplifies switch module assembly. Using insert molded circuit panels, fewer parts were used to produce a smaller component that can handle more power than previous seat switches. This circuit substrate will be used in power seat control modules on various automotive vehicle platforms.

"Automobile designers wanted to revise the power seat switch module, that contains the switch circuits, module mounting base and motor harness wiring, into a single, smaller package," says Rick Zech, Sales Manager, Tricon Industries. "To meet this objective, we insert molded two stamped copper circuit panels into a flat substrate to form the base of the switch module. The two circuit panels are trimmed in the mold to form multiple circuit paths connecting the three switch locations. Exposed pads are provided to surface mount each switch lead." Flame retardant glass filled polyester (PBT) is used to control the flatness of the copper layers in the thin substrate base.

To further reduce the module size, a wiring harness connector was eliminated from the module edge. Wires from the heavy-duty connector harness are ultrasonically welded by Tricon to circuit pads on the base substrate. A straight molded wire retainer slides over the wire interface to protect the copper weld joints. A flexible tube and tape is added to provide protection for the wires.

To ensure all customer performance requirements have been met, Tricon performs electrical continuity and hi-pot tests on each completed circuit substrate and wiring assembly. The customer completes final assembly of the switch modules by welding three switch bases to the circuit substrate and snapping a cover, containing the switch actuators, over the prewired circuit substrate.

Tricon Industries, Inc. is a QS-9000/ISO 9001 registered manufacturer specializing in insert molding and specialized components for worldwide automotive, mobile communications and appliance markets. Tricon was one of the first in the industry to use insert molding techniques for the manufacture of switch and relay components as well as other electrically oriented parts. Some of Tricon's recent projects include complex insert molded junction blocks and multifunction switch components, sealed tail light bulb and circuit stampings, single bulb light sockets, mobile antenna assemblies and wire terminations to circuit components. Today, Tricon provides comprehensive design, project management and manufacturing capabilities that can be tailored to specific project requirements.