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There is a trend toward integration of several components in automobiles into modules and we have developed a new wiring system suitable for module components. This new wiring harness consists of multi core flat cable that has zero-halogen insulation. The features are weight reduction and simplification of the manufacturing process. The connector for this system is IDC (Insulation Displacement Contact) and hotmelt overmold is used for waterproofing the IDC. The mechanics of the waterproofing is adhesion between surfaces of cable insulation, connector housing and hotmelt. We have developed a new hotmelt material that can adhere to both nonpolar compounds (zero-halogen cable insulation) and polar compounds (connector housing), and is a highly reliable waterproof IDC connector that can be used in engine compartments. We also discuss a compact facility that can simultaneously operate both IDC and a hotmelt molding process.

In the automotive industry there is currently a trend toward modularization, integrating several functional components into a single module. Among a variety of wiring materials, the flexible printed circuit (FPC) is a remarkable advance for the module wiring. However, the present FPC connectors have the current capacity of a few amperes, hence applications of the FPC have been limited. This paper describes the design and performance of an FPC connector intended for middle level currents, especially the connection between the terminal and the copper foil.