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R & D Review

No.102

No.102 October 2005

Development of an Automotive 0.64 mm Unsealed Connector

In recent years, as electrical apparatuses for vehicles have become more diverse and multifunctional, the number of circuits for wire harnesses has increased. In such circumstances, in order to further expand the possibilities of automotive design, issues of space saving, weight reduction, and higher circuit density have become increasingly important when designing automotive connectors that use wire harnesses. This report relates to the development of a non-waterproofing connector using a 0 .64 mm terminal (tab size: 0 .64 mm, also known as an 025 ): the smallest standard automotive connector. It shows how we addressed the issues of declining mechanical strength and handleability and developed a newly configured 025 connector with superior connective reliability.
[Key words] Connector, Wire harness, Caselanceless, Compact design, Weight reduction, Laborsaving, Strength, Reliability

Development of an Automotive 0.64 mm Sealed Connector

As explained in our "Development of an Automotive 0 .64 mm Unsealed Connector" report in this Review p.9 ,connectors with 0 .64 mm terminals (tab size: 0 .64 mm, also known as an 025) are the smallest automotive connectors are available and are effective for space saving, weight reduction, and higher circuit density following the increase of the use of wire harness circuits in the field of waterproof connectors. Therefore it is expected that 50% or more of all the current connectors will be changed to connectors of this size in the future. In the development of this connector, we aimed for compact design and performance improvement. By interweaving several new technologies and adopting this size terminal, we were able to achieve these aims with the development of our super-small sealed connector with superior connective reliability
[Key words] Connector, Wire harness, Compact design, Weight reduction, Shutter system, Special molding technology, Pre-set, Style front holder, Reliability

Performance Improvement of Vespel® SP Seal Ring for Automatic Transmission

In recent years, as requirements for low emission control and higher performance is demanded in the automotive industry, specifications for automotive parts tends to be strict and has become difficult to satisfy. Automatic transmission seal rings are no exception and strict requirements for stable oil leakage control have been imposed. We have developed a new seal ring which has suitable oil leakage stability under wider applicable temperature ranges and excellent durability against soft metal alloy by applying high performance Vespel®SP parts and a new design. The combination of these technologies has higher potential to satisfy severe using conditions and reduction of oil leakage on automatic transmission. This paper describes the newly developed Vespel SP compounds, micro-cut seal ring using such compounds and their functional properties.
[Key words] Automatic transmission, Seal ring, Vespel®SP, Micro-cut, Low coefficient of thermal expansion

Development of Grip Heaters for Motorcycles

In recent years, the global market of motorcycles has reached 28 million units per year and as a protection measure against the cold, the demand for grip heaters are also increasing. We, Mitsubishi Cable Industries, Ltd. and Ryosei Electro-Circuit Systems,Ltd. have successfully developed a new type of grip heater which was realized from our cultivated production technologies in the automotive industry such as the wiring system, electrical components and FFC®(Flexible Flat Circuit).
The grip heater is highly praised for its technological excellence and potential variety for mass-production for products such as "Partial heater core" grip heaters. We are also engaged on the development of new-types of grip heaters such as "Full heater core" and "Horse- back riding style motorcycles".
[Key words] Motorcycle, Grip, Heating element, Partial heater, Full heater, SUS material

Application of Computer Aided Engineering for Automotive Products

Recently CAE (Computer Aided Engineering) technology has made remarkable advances in the manufacturing industry, and has been applied to various products and scopes. We have actively adopted several CAE technologies (structural finite element analysis, vibration analysis, computational fluid dynamics, and plastic injection molding analysis) and have established the methods to analyze the behaviors of our automotive products accurately. As a result, we have been able to reduce the development time and lead time to start mass-production.
[Key words] Computer aided engineering, CAE, Finite element analysis, FEA, Computational fluid dynamics, CFD, Plastic injection molding analysis

Management of Substances of Concern Defined in ELV and RoHS
- Our Recent Technology for the Analysis of Hazardous Substances-

In response to requests by our customers to submit certificates indicating that the banned substances Cd, Pb, Hg and Cr (IV) (defined in ELV and RoHS) and Polybromobiphenyl (PBB), and Polybromodiphenylether (PBDE) (defined in RoHS) are not contained, we have established technologies to evaluate the substances and have completed an evaluation system for ELV/RoHS.
[Key words] ELV, RoHS, Environment, Substances of Concern, Cd, Pb, Hg, Cr (VI), Polybromobiphenyl, Polybromodiphenylether, Evaluation System

Photonic Crystal Fibers(3) - Application to Supercontinuum Light Sources-

Research and development of photonic crystal fibers has greatly advanced for characteristics that could not have been achieved by conventional fibers. Among nonlinear phenomena generated in the fiber, broadening the spectrum by the self-phase modulation and four wave mixing is especially drawing attention as an application to supercontinuum light sources. In this paper, we describe supercontinuum generation utilizing the high nonlinearity characteristics of photonic crystal fibers and their applications.
[Key words] Photonic crystal fiber, High nonlinearity, Supercontinuum light source, Optical comb, Optical frequency measurement

Waveabsorbers and Frequency Selective Surfaces for Wireless LAN

As we enter the IT and ubiquitous age, wireless LAN systems will be in greater demand. More importance will be placed on ensuring communication quality and security in such systems. This report describes the outline of our new waveabsorbers and FSS (Frequency Selective Surfaces) as one of the smart solution items for improving electromagnetic environment of such systems.
[Key words] Wireless LAN , IT , Ubiquitous , Dual Bands , Waveabsorber , Frequency Selective Surfaces, FSS , Jerusalem Cross

Development of the Optical Thin Film having Highly Damage Resistances and Environmental Stabilities

Nowadays, there is a great demand for high power laser. It is requested to supply optical components coated by the thin films (anti- reflection (AR) coating and high-reflection (HR) coating etc.) having high damage resistances.
We have developed the optical thin film having high damage resistances and an environmental stabilities. The damage threshold of an AR coating for YAG laser deposited by electron beam (EB) using the thermal evaporation method was, with a pulse laser, 15 .9 J/cm2 and, with a CW laser, 10 kW/mm2 . Furthermore, an AR coating deposited using ion-assisted deposition (IAD) showed excellent environmental stability and display no spectral changes even under conditions of high heat and humidity (49°C× 95 %RH). The laser-induced damage threshold of AR coatings deposited by both methods showed no decline under these conditions [Key words] Anti-reflection coating, High power laser, Ion-assisted deposition, Damage threshold, Environmental stability

Development of Laminate Type Lithium-Ion Rechargeable Batteries

Recently, as minimization of their weight has become possible, lithium ion rechargeable batteries have been used in various portable applications. However, they are not used in large-sized applications such as EV etc. as, compared with lead storage batteries or Ni-MH batteries, they are expensive and not as safe.
Based on our experience with producing lithium ion rechargeable batteries, we have succeeded in producing a laminate-type lithium ion rechargeable battery, the ML4275155 , with superior performance even in low temperatures, and proven safety.
[Key words] Lithium ion rechargeable battery, Large equipment application, Laminate type, High performance, Low temperature performance, Safety

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