| FLEXELEC | This project is in progress |
| Large Area Low Cost Flexible Circuits |
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Context The wiring loom of a vehicle is currently the second heaviest single component, and is tending to grow in weight and complexity as more electronic systems are added to vehicles. This weight could be reduced significantly if the harness were replaced with a flexible printed circuit. The loom is normally hand-assembled. Printed circuits are considerably lighter than a loom of equivalent complexity and current carrying capacity, and their manufacture can be fully automated. Small flexible printed circuits are used within the dashboard, but the materials and processes required for high volume manufacture of printed circuits large enough to replace the complete wiring harness are not available. Aims To develop the processes for the manufacture and assembly into a vehicle of large flexible circuits up to 20 sq meters in area. To explore potential materials, process routes and production machinery. To assess the new assembly and test processes required within the vehicle To demonstrate the capability of these printed circuits to combine power, signal and transmission lines To investigate the ruggedness of the circuits during production, assembly and use To incorporate the ability for rapid prototype re-design To define an exploitation route for the technology Method Establish the technological and business processes involved in the manufacture and assembly of large flexible circuits. Develop four workpackages - research solutions, practical application of these solutions, test of the solutions, exploitation path. Produce and test two demonstrators, one exposed to environmental extremes during assembly and service, and the other within the passenger compartment. Benefits The replacement of the wiring harness with a flexible printed circuit will allow manufacturers - To reduce the weight of the vehicle and thus fuel consumption and pollution To introduce modularity and upgradeability into a vehicle To reduce the cost of manufacture through increased automation Participants Pressac Interconnect PRIME Faraday Partnership Loughborough University Yazaki Europe GTS Flexible Materials Daewoo Motor Co |
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