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R & D Review


No.103 October 2006

Application of Low Compression Force Metal Seals "SUNLIMES®I"

Requirements for seals have become server with the development of various high performance instruments. For low gas permeability and heat or chemical resistance, metal seals have been required to replace various rubber or resin seals. However, these replacements have not been easy because metal seals have higher torque and are difficult to handle. Mitsubishi Cable Industries has developed the SUNLIMES® series metal seals to improve these problems and offers solutions for the above requirements. In this report, some of the latest examples of the development and installation of SUNLIMES®I are introduced.
[Key words] Metal Seal, Low Compression Force, SUNLIMES I

Development of Anti-Electric Wave Interference Products for Wireless LAN

Jamming, interference and leakage of electric waves are becoming serious problems in wireless LAN systems because only limited channels in 2 .45 Ghz and 5 .2 GHz bands are used in most of the systems. Recently, "voice over internet protocol (VoIP) systems" are used in many offices, and the above problems interfere the connection and transmission of wireless IP telephones. In order to resolve these problems, Mitsubishi Cable Industries has developed various frequency selective shielding materials (FSS; Frequency Selective Surface), and are proposing the solution for improving electromagnetic environment using the combination of FSS and electric wave absorbers. In this report, various FSS products and some examples of their application and installation are introduced.
[Key words] Wireless LAN, Dual Bands, Waveabsorber, FSS, Transparent, Print

Introduction and Improvement for High-Performance Plastic Mandrels for Hose Manufacturing

The core mandrel for hose manufacturing is one of the most important tools for producing various hoses for heavy-duty application. It is particularly necessary to maintain a precise inner hole surface and stable I.D. dimensions. We have produced and supplied plastic mandrels over 20 years and have obtained good reputations from our customers. The plastic mandrels are used with optimum materials to meet various conditions of hose manufacturing processes such as thermoplastic resins of polymethylpentene, which the registered trademark is DAITEPIC®, polyester-elastomer, polyamide and others. In addition, the mandrels are produced by our original "Long-Land Die" extrusion procedure which is able to maintain superior outer diameter accuracy and dimensional stability under repeated hose production. These performances indicate a longer endurance of mandrel tools for hose manufacturing processes.
This report describes the outline of our mandrel characteristics and its recent development results for higher technology requirements.
[Key words] Mandrel, Hose, Polymethylpentene, Polyester-elastomer, Extrusion, Dimensional Stability

Development of the Super-Small Multipole Sealed Connector

As electrical apparatuses for vehicles have become diverse and multifunctional in recent years, various types of ECU have been adopted and increased in numbers. From the view point of space utility and designing trend of location, the ECUs have been shifted from the vehicle compartment to the engine compartment. As the circumstances of engine compartment are more intensive than the vehicle compartment, the requirement of endurance performance has become harsh not only for ECUs but also connectors that mate with ECUs. Our newly developed super-small sealed connector is designed to conform to these requirements, and shows superior seal performance compared to conventional connectors. This performance has been achieved through the adoption of independent wire seals that was unachievable in the past due to designing difficulties to fit the connectors in the limited space of connector housings.
[Key words] Connector, Wire Harness, Multipole Sealed, Low Insertion Force, Super Small, Weight Reduction, Laborsaving, Strength, Reliability

Development of a New Junction Box using the Flexible Flat Circuit (FFC) Technology

We have started bench marking conventional junction boxes (JB) in the market as it is a part of the core component of the electrical distribution system equipped in vehicles, but there are few types of JB which satisfies various requirements of the system.
There are two types of conventional JBs, the types using Busbar and PCB, but both have merits and demerits. As the circuit system of the vehicle became more diverse, the requirements for ECU and JB have become more multifunctional.
We have built the concept of our new JB from this point of view, and developed an original new JB by using our FFC® technology. By using this new concept we have succeeded in lowering the mold cost and establishing flexibility to adopt design change, and simultaneously realized a solderless terminal for large current circuits.
[Key words] Junction Box, Wire Harness, Lighten ,Confidence, Plant

Development of Terminal Connection Technologies for Automotive Aluminum Conductor Cables

Light-weighted aluminum is attracting attention as the cable conductor for aluminum cables used in automobiles. However, when aluminum is adopted for cables in automobiles, the establishment of the terminal connection technology is important from the viewpoint of the contact resistance between the cable conductor and the terminal. In this report, we introduce the terminal connecting technologies to various conductor diameters, long-term reliability, and performances of battery cables that uses the connecting technology.
[Key words] Automobile, Aluminum Cable, Terminal Connection, Ultrasonic Welding, Solder Covering, Contact Resistance

The Extension of the Rigid Trolley Wire System of the New Transit Port Island Line in Kobe

The KNT/Port Island line which started business in February, 1981 , will be access to the newly founded Kobe Airport. We participated in the rigid trolley wire line extension project and controlled power supply to design, production and execution.
Rigid trolley wire line length that we installed this time was 11 .7 km by line increase by a double line between Nakakouen station - Shiminhiroba stations and repair, the sum total of extension of Shiminhiroba stations - Kobe Airport station.
Rigid trolley wires are stronger than existing lines and can cope with speedup of the train. We adopted the Rokko Island line establishment method and made function improvements such as stretch and electricity and we also improved execution and maintenance.
[Key words] Unit Type Rigid Trolley Wire, Support Insulator Device, Rigid Trolley Wire System Installation

Development of Trolley Wire Made of New Copper Alloy (Cu-Fe-P-Sn)

Trolley wires must be exchanged sequentially with the progress of abrasion, worn by mechanical contact with pantographs.
However, exchanging trolley wires is expensive and time consuming. The main problem in trolley wire maintenance is wear-out, and therefore, abrasion resistant and economic trolley wires are in need.
Therefore we developed wires which used Cu-Fe-P-Sn alloys that are superior to Cu-Sn alloy trolley wires in abrasion resistance, easy to mass produce and versatile as a material.
This report describes the basic characteristic and the performance evaluation results of this Cu-Fe-P-Sn alloy trolley wire.
[Key words] Trolley Wire, Copper Alloy, Abrasion Resistance

Pilot Experiment of Broadband in Rural Areas of Mongolia using Long-Distance Wireless LAN Bridge System

We have obtained the certification for Technical Regulation Conformity based on "Relaxization of antenna gain regulations for power- saving data communication systems (wireless LAN)" stipulated by revision of the Radio law.
From 2002 , We has sold Wireless LAN Systems that realized 40 km long distance communication combined with high gain antennas and high quality cables in the 2 .4 GHz band based on IEEE802 .11 b.
Mitsubishi Cable Industries,Ltd.and Nippon Telegraph and Telephone East Corp. (NTT East) performed a pilot experiment for wireless broadband in a rural area of Mongolia from Nov. 2005 to Apr. 2006 supported by The Asia Pacific Telecommunity (APT). This experiment conducted in Baganuur (provincial city) and Mungunmorit (a small village 50 km from Baganuur), connected the two sites using three wireless relay stations. Two important results were confirmed in this experiment. One is the availability of long distance transmission such as over 40 km, and the other is the running stability in a strict environment of under -50°C in the winter seasons. The success of our Wireless LAN System experiment is promising for establishment of broadband environment in rural areas. It expected to be adopted in other areas of similar conditions in the immediate future.
[Key words] Long-Distance Wireless LAN, IEEE802 .11 b, Bridge, Wireless, Broadband, Internet

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