Tricon taillight backplate and bulb sockets are tougher, more user-friendly

DETROIT, March 5, 2001 – Tricon's success in developing more reliable and robust vehicle parts is evident in the Textron taillight appearing on the DaimlerChrysler 2001 minivans. A simplified circuit backplate and ergonomically-friendly bulb socket improve performance in a harsh automotive environment.

The universal socket assembly consists of an insert-molded backplate that mounts to the taillight housing and receives plug-in bulb sockets. "This backplate, containing stamped circuits, simplifies wiring between the three bulb sockets and provides protection to the electrical circuits," said Rick Zech, Tricon sales manager. "A plug-in socket connects each bulb to the backplate circuits and positions the bulb filament in the taillight reflector."

This plug-in bulb socket, as opposed to a "twist in place" socket, is ideal for robotic insertion and allows for easy bulb replacement. The socket design allows automatic loading of a bulb into the socket before assembly into the backplate, which reduces bulb breakage, factory assembly cost and the hazard associated with broken glass bulbs. Robot tooling pushes a bulb into the socket contact area where a metal clip grips the bulb base to hold the bulb secure against road vibration or shock.

Stamped circuits connect all bulb locations to a single input connector, simplifying wiring between the three bulb sockets. "These stamped circuits and terminals eliminate wire splices and reduce wire placement errors, cutting assembly cost and improving reliability," said Zech. The metal stamped circuit paths handle high currents with low voltage drop through the backplate. All circuits leave the bulb sockets through a single connector molded into the backplate.

The socket assembly uses high-temperature molded nylon near the hot bulb, with acetal plastic used in the adjacent socket part. Copper alloy contacts are used at the bulb interface and a stainless steel retention clip holds the bulb in place. This universal socket assembly can be plugged into different backplate configurations designed for automotive or truck taillights, front signal lights and side lighting applications in a wide range of vehicle models.

Tricon also offers o-ring sealed bulb sockets to eliminate moisture paths into lens assemblies, preventing a short between circuit paths. Stamped one-piece metal circuits to these sealed sockets are protected by insert molding them into the backplate.

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.