Intedis simplifies the vehicle electric system
With integrated flat-conductor systems

Motion Trends,
30th September 2005.

The auto industry's race to reduce waste, weight, complexity, manufacturing / repairs costs and especially operating errors is far from over. Much can still be done better with new materials, new designs, new manufacturing methods and faster processors.

However, the race for better safety and reliability is not always visible.

Take the car electrical system for example. It cannot be compared to evocative designs of a sports car or other emotional objects. Yet, it does hold on its own some key elements to achieve many of the above mentioned targets.

In this regard, integrated flat-conductor systems (in photos) by vehicle electric system specialist Intedis (joint venture between Hella and Leoni) minimize the number of mechanical and electrical interfaces between electronic components and harness in the vehicle electric system.

Integrating lighting or electronic components, the flat conductor is at the same time wiring and circuit carrier and provides a wide range of new options for the use of actuators and sensors.

Moreover, flat-conductor systems save weight and package space and also increase the degree of automation both in the supplier’s and the car manufacturer’s production. They also give the automobile manufacturer considerably more design freedom.

Since Intedis focuses on the overall vehicle electric system, interactions between electronics and electrical installations can be used and undesirable side-effects can be reliably ruled out. As a rule, changes are combined and made simultaneously in wiring and control units. This yields fully developed solutions even from the outset, saving valuable development time as well as resources and costs.

To further optimize the vehicle electric system, Intedis continues to develop flat-conductor technology and the further integration of electronics on flat conductors.

There is even more, since additional potential can be tapped with new functions.

For example, integrated flat-conductor systems (IFS) may be used for heating applications or as contacting and capacitive switches and also for ambient interior lighting.

Looking at the example of a seat, the advantage becomes clear: comfort functions such as seat longitudinal and armrest inclination adjustment or a trap stop are realized either by capacitive, contactless proximity sensors or by capacitive, mechanical pressure sensors.

The capacitive, contactless proximity sensors measure the clearance between body and seat without contact and without the action of force. The capacitive mechanical pressure sensors react as soon as someone sits down or touches the seat and measures the resulting upholstery deformation.

It is a “closed“ sensor system which functions without being influenced by the surrounding electric field. The sensor concepts are cost-effective sensor systems based on integrated flat-conductor systems. Thus, various sensor elements can be realized as capacitive structures on foils.

The benefit: minimal interference due to favourable spatial arrangement of sensor elements and electronics.

Two different types of flat conductors are used: the Flexible Flat Cable (FFC) and the flexible printed circuit (FPC).

Functional elements or components can be integrated on both. Moreover, the principle of flat-conductor integration can be flexibly adapted to different types of installation space. The units are completely assembled and ready for testing without the need of neither plugs nor connections.

Established in 2001, Intedis (Integrated Electronic Distribution Systems) connects Hella's expertise in lighting and body electronics with Leoni’s vehicle electric system competence. Based in Würzburg, Germany, the Intedis joint-venture provides auto manufacturers with complete solutions for the vehicle electric systems. Thanks to an integral view of the system, consisting of control units, cable sets and lighting, the aim of cost and weight reduction (e.g. via fewer interfaces) is pursued while maintaining high levels of reliability and functionality.