Cable Product Group Overview

Molex IPD Cable Assembly Plants

o
o

DEVELOPMENT
Hubs
Little Rock (Cable)
Dongguan (Thermal/PCBA)
Satellites
MIG
Dongguan

MANUFACTURING
Volume
Dongguan
Guadalajara
Specialized
oMaumelle (Cable)
oBangkok (Cable)
oMoltech (Shared)

Molex Little Rock

Maumelle, Arkansas
High Performance Cable
Assembly Business Unit
(HPC) formed in July,
1994
2 Shift Operation
Quality ISO 9001/2000
accredited.
New Product
Development

Molex Moltech
Poland Plant
Acquired by Molex in 1998
2-3 Shift Operations
1230 Employees
Total plant area 18730 sqm
Types of Harnesses:
Patch Cords (customized)
Flat Ribbon Cable (customized)
Board Jumpers (customized)
Wiring Harnesses (customized)
Mechanical Line Cords (customized)
Notch Cable
ISO 9001-2000, UL/CSA Certification
for harness cable assemblies and
connectors,
ISO 14001, ISO TS 16949
Green Partner for SONY,

Molex Dongguan IPD 1

Began Operation in China from 1988.
Design & Manufacturing Center for Harness &
Cable Assembly including:
Automotive Harnesses
I/O Cable Assemblies
Custom Overmold Cable Assy.
Ganged RF Cables
High Performance Cable Assy.
Fiber Optic Cable assy
About 2000 operators, run 24 hours per day
Total Area: 12,500 sq. meters
TS16949, ISO14001 ISO9001 certified

Molex Dongguan DG 2 IPD2

Commencing 2002
2000 employees
Manufacturing, Product &
Process Design Center for:

Heatsink
Fiber Optic
Rigid & Flex PCA
Membrane Switches
Total area of 25,000 sq.m.

Molex Thailand
Date of Incorporation into Molex 18th November 1988
Thailand are currently looking to support the High Mixed medium
to low volume Opportunities
Also Manufacturing Simple to Complex Wire Harnesses and other
IP along with Round conductor flat cable (bulk and custom made
Harnesses).
Discrete Wires & Flat Cable MOV 10k USD, ( unless raw material
MOQ constraint ),
OR 25k USD per program / year to suit high mix - medium to low
volume
Total Manufacturing Area: 4122 Sqm
Plant Certificated to ISO 9001 : 2000, ISO 14000 : 1996,
ISO/TS 16949 :2002

Quality
We are Building on Our Total
Quality Management Philosophy

Lean Six Sigma Will Become the

Way We Think and Work
Part of Our

Part of Our

Way of

Culture

GLSS
Part of Our Way of Working

Thinking

Automotive Focal product

Harness for Power Train

Engine control unit

Engine cooling system
Fuel system
Transmission system

Harness for Audio/Video

Convenience

Radio/LCD display
GPS
Air control module
CD changer and mobile
phone
Entertainment

Harness for Other

Applications

Mirror system
Lighting systems
Doors
Seating systems
Safety system (seat belts
Roof system
Airbag Cables
Passenger Detection
Cables

Automotive Customers
Autoliv
Ford
Hella
Automotive Lighting
Jaguar
IEE
Panasonic
Sony
Cobra
Wabash
TH Bury

MOLTECH

Harness Wire BUS

CUSTOMER :
VOLVO Poland,Finland,Sweden
SCANIA
Poland,Sweden
MAN
Poland,Germany

New Product Launch

Squib AK-2
GPM Frank Sebold

SRS applications

Airbags and belt

pretensioners
Possible number of squib connectors in a well equipped
middle class passenger car:
2 x driver airbag + 2 x passenger airbag + 2 x side airbag front
+ 2 sidebag rear + 2 x curtain airbag + 5 x belt pretensioner
= 15 squib connectors

Markets and Applications

How does an inflator work:

Piletts that
generate gas
while burning

Initial load igniting

the main load

Vent-holes
allowing the gas
to blow up the
airbag

Pins to be
contacted by
squib connector
terminal

Source: Autoliv

Ignitor holder
holds the retainer

Background
Current Molex squib connector capability:

Many years of experience

11mm AK1 (VDA) squib connectors and pigtail assemblies
Ferrite and coil capable
Designs available fulfilling virtually any OEM specification
Dedicated and experienced squib connector Engineers
Active participant in standardization committees
Excellent quality records related to our existing squib product
line

Design Overview AK-2

Code 1:

Code 2:

Code 3:

Squib
AK-2
90

Retainer

Design Overview AK-2

Actuator

Cover
CPA

Housing

Design Overview AK-2

Assembly of components (simplified):
1. Preparation of wires for welding
Wires are unjacketed and de-twisted
Insulation is removed and wires are
compressed to a square
shape=compacting
Final wire cutting
2. Assembly of ferrite onto wires

Ferrite is assembled over the wires

3. Welding

Wires are resistance

welded to terminals

Design Overview AK-2

Assembly of components (simplified):
4. Sub-assembly placed into housing

7. Final testing and printing

5. Assembly of cover

Final Assembly bottom view

6. Assembly of actuator and CPA

Design Overview AK-2

Basic Dimensions:

Features and Benefits

Features

Benefits

Mates with AK-2 interface

Scoop proof/kojiri safe

No changes to igniters

Developed to meet harsh

transport environment

Improved handling

Ferrite and welded

contacts

Robust and compact

design (cost effective)

Full automated and

controlled line

High quality standard

and aggressive costing

Pre-Locked active CPA

feature

Serviceable, enhanced
worker control
Reliable opening of
shorting bars

Specifications (technical performance)

Specifications
Application specification available

Specifications
Packaging specification available

Specifications
Drawings available

Equipped Cars at

Latest Awards at
2009/2010 P415 - Ford F150 Pickup Truck Side Air Curtains

2009/2010 D385 Lincoln MKS Sedan Side Air Curtains

Latest Awards at
2011 U38X Ford Edge/Lincoln MKX Side Air Curtains

2011 U502 Ford Explorer/Mercury Mountaineer Side Air Curtains

Latest Awards at
2011 B299 Ford Fiesta Seat Pretensioner

Product Strategy
Guidline to understand and identify your
customer needs:

Understand if the squib connector is under OEM responsibility

Understand on which interface your customer is working on
Understand which EMI fiter is specified
Understand if the customer prefers squib pigtails we are not
promoting kit versions
Understand if the customer is looking for a 90 or 180 version
or both
Understand which wire type is specified for SRS applications
Understand the wiring strategy mating on the carline or at the
module maker
Understand which module suppliers are nominated
Understand which harness makers are involved

Product Marketing
Use the guideline to understand what your customer is
looking for
Understand if your customer has the sole power to
determine the connection system or if other parties are
involved
If other partners are involved use the Molex sales
network to access those
Use the engineering expertise we have on squib
connectors
Promote our existing product line while being aware
that Molex has the capabilities to adopt if required to
customer specific needs
Open your mind for other SRS applications

Product Marketing
SD-drawing
Application spec
Packaging spec
Product spec
Technology Release
Sample Kits

ready
ready
ready
in work, available Q1/FY09
in work, available Q1/FY09
in work, available Q1/FY09

=> Samples are available, please request Frank Sebold

Product Standards

TP cable 0,35mm feasible with tool changes;

not tested yet
TP cable 0,75mm feasible with tool changes;
not tested yet;
needs a new ferrite
Jacketed cable needs a new strain relief (if jacket to be
clamped)

Cost impact

Molex standard
TP cable 0,5mm; 130 - 6.750mm length
Isolation diameter 1,50,1mm
FLRY-A 19-strands or FLRY 7-strands

Additional Harness Examples

Cable Assemblies Types

Harness vs. Jumper
Jumper is a point-to-point assembly
Harness can have multiple branches

Discrete Wire Harness Assemblies:

Independent discrete wire interconnect
system.

Jumpers

Discreate Wire

Twisted Pair Harness Assemblies:

Cable assembly with twisted wires
Twisted Pair

Cable Assemblies Types

Ribbon Cable Assemblies: Wire
assembly that has flat ribbon cable

Ribbon Cable

Power Harness Assemblies: Assembly

that will carry high current

Body Harness: Integrated Interconnect

wire assembly for the entire Automobile

Power Harness

Body Harness

Cable Assemblies Types

STP (Shielded Twisted Pair): Cable
assembly with shielded twisted wires

Automotive Grade: Assembly that meets

automotive standards
Chemical Resistant
High Temperature

Automotive Grade

Automotive Cable Assy.

Pump Harness

Lamp Harness

Speed Sensor Harness Cooling Fan Harness

Gear Box Harness

Oxygen Sensor
Harness

Custom Headers
Develop to provide customer with the source from for both high volume to small
volume prototype needs
Custom made to fit customer need with full functionality test
Options

Benefit

Pin Length

Variety of pin lengths for every application, including first

make last-break

Kinked Tails

Additional board retention prior to final soldering

Voided Circuits

To meet specific header orientation ad polarization

requirements

Dual body

Ideal for board stacking application

Peg

Board retention

Plating

Selective plating to fit the need

Cover

Fit where application required

Packaging

Per customer specific requirements to fit all processes

Custom Headers For Automotives

Applications

Sub-Harness for Automotive

NECTEC NGV (Natural Gas Vehicle) Conversion

Delphi Pump Harness

CPG Overmolding Capabilities

Capabilities I/O and Overmolded

Products
In-house mold and product design
capabilities.
In-house tooling and test fixtures
design and assembling.
Electrical characterization for High
speed applications.
Application tooling to support all
Molex I/O Connector systems.

Capabilities I/O and Overmolded

Machines
Molex Has 54 Overmolded Machines
10x Capacity of 35 tons (8.8 cubic inches)
1x Capacity of 80 tons (15 cubic inches)
38x Capacity of 45 tons
(Barrel 2.5~3.5 oz)
For PVC, PU, PE, PBT resin
overmolding
4 x 5.5-ton Insert Molding
1x Low Pressure molding

I/O Cables
USCAR USB Infotainment Data Bus (IDB)
HSAutoLink meets 1394Cu and USCAR
rugged automotive requirements
Will bring USB and other technologies into
the information and entertainment systems
in vehicles
Supports USB 2.0 requirements
S400 Performance up to 10 meters in a
single link
Features and Benefits
USCAR USB, 1394 and LVDS Cable Assemblies
Shrouds and latches standard

Rugged connectors meet USCAR

requirements

Full-length cable shielding

Superior signal performance and

reduced EMI

Standard Molex automotive and

USB connector components used

Provides ease-of-use and

simplified assembly process

USCAR-30 compliant

Provides qualified and market

tested USB electrical performance

Applications
Automotive
Motorcycle
Water craft
Farm Equipment
All terrain equipment
Aircraft

Micro-Fit/Mini-Fit Overmolded
Overmolded Micro-fit cables were
designed to provide an external
solution for power cable assemblies
need.
Features and Benefits:
1-5 amp capability.
Customizable in terms of cable awg,
jacket, lengths and circuit sizes.
Plug/Unplug friendly with anatomic
overmold.
Positive latched connector, that
prevents accidental disconnect.
Polarized housing.
Dual row 2, 4, 6 & 10 ckt sizes Samples
available, series number 79516.

Applications:
Personal computers
Computers and Workstations
Handled devices
Fan tray assemblies
Gaming and vending
Cellular phones
AC power line cords
Fax machines
Exercise equipment

Overmold Custom Cable Products

Muscle Tuning
Belt Cable Assy

Custom Combo Cables

DVI Cables

LFH Cables

DMS-59 Adaptor
Cables

Thank you