Multifunction switch components for steering column

DETROIT, March 5, 2001 – Tricon Industries is manufacturing insert-molded parts used in multifunction production switch modules mounted on automotive steering columns in the 2001 Chrysler Sebring and Dodge Stratus. Insert molding is used to make circuit platforms that provide interconnections between stem controls and car harness wiring connectors. Circuits are provided for the hazard switch, wiper speed, high-low headlight switch and washer mist operation.

Insert molding helps reduce costs in a complex assembly. Combining complex stamped circuits and plastic structures provides more switch and structural functions, as well as improved reliability by using fewer parts.

Multifunction switches are incorporated in steering column locations to handle the increasing number of electrical functions offered to the driver. By insert molding circuits, connector terminals and sliding contact surfaces into structural modules, Tricon has provided multi-functional parts without increasing the size of the switch envelope. Separate circuit plates are insert molded with stamped circuits creating terminals for connectors and wiping surfaces for sliding contacts. Turn signal and wiper levers on the steering column move sliding contacts over these molded-in circuits.

Insert molding provides a robust structure supporting the circuitry for increased cycle life. In addition, mounting bosses and flexible latches are created during the molding process to mate with other parts to make the complete module. Bearing posts and keying features also are molded at the same time. Contacts formed from the stamped circuits become part of a receptacle to connect with a plug-in signal flasher module. The large size and number of interconnections requires precise registration of the circuit structure to other parts of the multi-function switch. Careful molding of the plastic carrier over these metal parts locates each contact surface under the appropriate control lever.

High conductivity copper is used for one-piece circuit paths and connector terminals while copper alloy is stamped to form leaf springs for wiping surfaces. These one-piece connectors and wiper circuits are insert molded to provide reliable electrical paths to make these modules function. Molded glass fiber-reinforced nylon plastic produces structural circuit carriers that meet long-term performance requirements.

Both complex circuit plates that control wiper functions fit into a module surrounding the steering column. This module provides multiple connectors, wiper surfaces and latches in a precise location to respond to the actuating levers. Precision stampings and moldings provide the control needed to meet the customer's tolerances in this three-dimensional circuit module.

Manufacture of parts that provide circuits in plastic structures is a core business for Tricon. Complex assemblies, like the multifunction switch, require intense cooperation between the insert molder and product designers to create a product designed for manufacture. Tricon assistance in product designs is typical of the problem solving approach we take with our customers. Tricon has the design ability, manufacturing skills and experience in insert molding to form a partnership with customers interested in improving their products.

Tricon Industries, Inc. specializes 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 taillight bulb sockets and circuit stampings, single-bulb sockets, insert-molded alternator parts, encapsulated components and mobile antenna assemblies. Today, Tricon is a QS-9000 / ISO 9001-registered manufacturer with comprehensive design, project management and manufacturing capabilities that can be tailored to specific project requirements.